What is 5S principle?
The large rear door allows easy access
- 5S is a philosophy and a way of
organizing and managing the
workspace and work flow with the
intent to improve efficiency by
eliminating waste, improving flow and
reducing process unreasonableness.
- is a systematized approach to
organize work areas, keep rules and
standards, and maintain the discipline
needed to do a good job.
- It is for improvement of working
environment
Automobile
- Derived from the Greek word autos,
which means self.
- Derived from the French word mobile,
which means moving
- can be operationally defined as a land
vehicle or carriage, moving along the
road or highway through its wheels
and used to transport or transfer
people, goods and merchandise from
one place to another.
AUTOMOBILE MAJOR COMPONENTS
Body
- Provides enclosures or compartments
for the engine, passengers, and
luggage or cargo.
- Made of steel, aluminum, fiberglass,
plastic, or composite materials
- Forms the outside of the vehicle
- Serves as an attractive covering for
the chassis
Automobiles are available in several body
types, including:
- Sedan
Uses center body pillars, or “B” pillars,
between the front and rear doors. A hardtop
does not use “B” pillars.
- Hardtop
- Convertible
Uses a vinyl or cloth top that can be raised
and lowered
- Hatchback
when hauling items
- station wagon
Provides a large rear interior compartment
- minivan
Has a higher roofline for more
headroom and cargo space
- sport-utility vehicle
Provides the comfort of a passenger car, the
interior space of a station wagon, and the
durability of a truck.
Engine
- An engine, or power plant, that
produces power to move the vehicle.
- Provides the energy to propel the
vehicle and operate the other systems
- Most engines burn gasoline or diesel
fuel
- The fuel burns to produce heat
- The heat causes gas expansion,
creating pressure
- The pressure moves the internal
engine parts to produce power
Power Train/Drive Train Systems
A.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
B.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
C. 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
D. 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
Transaxle
- Used with front-wheel-drive vehicles
- Both manual and automatic transaxles
are available
- Consists of a transmission and a
differential in a single housing
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
Suspension System
- A suspension system, that absorbs the
shock of the tires and wheels meeting
bumps and holes in the road.
- 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
- Various springs, bars, swivel joints,
and arms make up the system
Steering System
- A steering system, so the driver can
control the direction of vehicle travel.
- Allows the driver to control vehicle
direction by turning the wheels right
or left
- Uses a series of gears, swivel joints,
and rods
Brake System
- A braking system, so the driver can
slow and stop the vehicle.
- Produces friction to slow or stop the
vehicle
- When the driver presses the brake
pedal, fluid pressure actuates a brake
mechanism at each wheel
- Mechanisms force friction material
against metal discs or drums to slow
wheel rotation
Electrical System
- An electrical system, to provide
electricity for cranking the engine,
charging the battery, and powering the
lights and other electrical equipment.
Accessory Systems
Common accessory systems include:
- air conditioner
- sound system
- power seats
- power windows
- rear window defogger
Safety Systems
Common safety systems include:
- seat belts
- air bags
- security systems
Internal Combustion Engine Design and
Construction
Engine Design and Construction
- Automotive engines are usually
mounted in front of the vehicle under
the hood and are installed in line with
the body. There are still automotive
cars with engines at the rear end of the
vehicle. The location of the engine
 depends on the design of the body for
which the vehicle is made of. In
general, automotive engines are
usually made up of cast iron and
aluminum alloy metals. There are
however parts which are made up of
steel like the crankshaft, camshaft,
connecting rod and valves. Aluminum
alloy is used in the pistons, cylinder
head and cylinder block of some
engines.
Vehicles can be classified by the
position of the engine and drive
wheels, and the number of drive
wheels.
FF (Front-engine, Front-drive)
- Because a FF vehicle does not have a
propeller shaft, a spacious interior
can be realized, thus achieving
excellent comfort.
FR (Front-engine, Rear-drive)
- Because a FR vehicle has a good
weight balance, it excels in
controllability and stability.
MR (Midship-engine, Rear-drive)
- Because a MR vehicle has a good
weight balance on the front and rear
axles, it excels in controllability.
4WD (4-Wheels Drive)
- Because a 4WD vehicle drives with
four wheels, it can operate under poor
conditions in a stable manner. Its
weight is greater than that of other
types of vehicles.
Engine Classification
Classification of Engines
Internal combustion engine- burns its fuel
inside the engine in the combustion chamber.
External combustion engine- fuel used is
burned in a separate compartment outside
the engine.
Internal combustion engines can be
classified into several groups using
features as characteristic:
1. Type of combustion fuel used
2. Method of cooling
3. Number and arrangement of cylinders
4. Position of valves
5. Method of ignition
6. Cycle of operation
Two classifications of engines according
to fuel used:
1. Gasoline engine
These are engines using gasoline as fuel
which is mixed with air in correct proportion in
the carburetor to change it into vaporized
form before admittance to engine cylinder
where it is charged and later on burned at the
combustion chamber by means of electric
spark from the spark plug.
Gasoline engine is a spark ignition engine
This type of vehicle runs on an engine that
uses gasoline fuel. Because gasoline engines
produce high power yet come in a compact
package, they are widely used in passenger
vehicles.
EFI-ELECTRONIC FUEL INJECTION
An EFI system consists of a fuel pump, fuel
injectors, sensors and an Engine Control Unit
(ECU). Fuel gets pumped up from the tank
via a fuel pump out to a fuel injection rail,
then into individual injectors which are
inserted directly into the intake manifold. The
fuel injectors are controlled by the ECU.
STOICHIOMETRIC RATIO
The stoichiometric mixture for a gasoline
engine is the ideal ratio of air to fuel that
burns all fuel with no excess air. For gasoline
fuel, the stoichiometric air–fuel mixture
is about 14.7:1 i.e. for every one gram of fuel,
14.7 grams of air are required.
Diesel engines
These are engines using diesel fuel oil or
crude oil as fuel which are more viscous than
gasoline. This fuel is injected in atomized
form to the combustion chamber inside the
engine by means of the injection pump and
nozzle which is ignited by high compression
pressure and temperature of compressed air
of about 500 psi and 1000 degrees
Fahrenheit respectively. There are no spark
plugs but pre-heating devices called glow
plugs.
Diesel engines are compression ignition
engines
This type of vehicle runs on an engine that
uses diesel fuel. Because diesel engines
produce large torque and offer good fuel
economy, they are widely used in trucks and
SUVs.
Methods of Cooling
Common types of cooling system used in
automotive engines:
Indirect cooling system – a type of cooling
system are also called water cooled engine.
Water serves as the coolant or the cooling
which circulates in the water jacket to absorb
the heat of the engine.
- Thermostat
- Bypass
- Radiator
- Water pump
Direct cooling system – a type of cooling
system are also called air cooled engine. Air
is drawn by a blower leading to air metal fins
or shrouds around the cylinders through air
ducts.
Cylinder Arrangement
1. Vertical or in line engines- These are
engines with vertical center lines of the
cylinders.
2. Horizontal engines- These are engines
with horizontal center lines. Cylinder are
arranged horizontally opposing one another
so that the pistons move toward and away
from each other during engine operation.
3. V-type engine- the engine block
resembles the shape of letter “V”. These are
engines where the cylinder axes are located
in two intersecting planes which permit the
pistons of each cylinders to act upon the
same crank.
According to number of cylinders
Automotive engines may be either be
single or multi-cylinder engines. A motorcycle
usually has one or two cylinders. The minica
has 3-cylinder engines while light cars and
jeepneys usually have 4-cylinder engines.
There are also big automobiles with 6, 8, 10
and 12 cylinder engines.
Technical terms:
1. Cycle- this is a series of events repeated
in the same regular order. Events for instance
that are completed in a cycle are Intake,
Compression, Power and exhaust stroke.
2. Stroke- This refers to the distance
travelled by the piston from top to bottom or
bottom to top.
3. Top Dead Center (TDC)- This refers to the
topmost part reached by the piston during its
upward motion.
4. Bottom Dead Center (BDC)- This refers
to the lowermost part reached by the piston
its downward motion.
5. Combustion- This is a chemical reaction
in which certain elements of the fuel combine
with oxygen, causing an increase in
temperature of the gases.
6. Revolution- This refers to one complete
rotation at an axis as in the crankshaft and
camshaft equivalent to 360 degrees.
7. Compression Ratio- is the measure of
how much the air-fuel mixture is compressed
during the compression stroke. Compression
ratio is found by dividing the volume of the
cylinder and combustion chamber when the
piston is at BDC by the volume when the
piston is at TDC.
 Since Petrol is very volatile, the
'Compression Ratio' for Petrol engines
is typically lower. Thus, it varies
from 10:1 to 14:1. The petrol engine
compresses the air & fuel with a ratio
between 10:1 to 14:1. The petrol
engine mixes petrol with air &
compresses this mixture in the
combustion chamber.
  In the diesel engine, only air is initially
introduced into the combustion
chamber. The air is then compressed
with a compression ratio
typically between 15:1 and 23:1. This
high compression causes the
temperature of the air to rise.
8. Suction- This is the drawing in of fuel-air
mixture or air into the engine cylinder due to
the downward movement of the piston and
the vacuum created in the combustion
chamber.
9. Piston Displacement- This is the volume
the piston displaces as it moves from BDC to
TDC.
 The equation for calculating
displacement is: Engine displacement
= πx bore² x stroke number of
cylinders. Displacement is usually
measured in liters (L), cubic
centimeters (CC), or cubic inches (CI).
10. Firing Order- This is the sequential firing
or combustion of the fuel charge inside the
engine in the combustion chamber. 1-3-4-2
four cylinder 1-5-3-6-2-4 six cylinder 1-5-4-8-
6-3-7-2 eight cylinder.
11. Running Mate- This refers to two pistons
moving at the same time in the same
direction but performing different strokes.
Engine running mate:
1-4
2-3
FOUR STROKE CYCLE ENGINE
INTAKE STROKE- The intake valve is open
and the piston inside the cylinder travels
downward, drawing a mixture of air and fuel
into the cylinder. The crankshaft rotates 180
degrees from top dead center (TDC) to
bottom dead center (BDC).
COMPRESSION STROKE- as the engine
continues to rotate, the intake valve closes
and the piston moves upward in the cylinder,
compressing the air-fuel mixture. The
crankshaft rotates 180 degrees from bottom
dead center (BDC) to top dead center (TDC)
and the camshaft rotates 90 degrees.
Exhaust valve also closed.
POWER STROKE- When the piston gets
near the top of the cylinder, the spark at the
spark plug ignites the air-fuel mixture, which
forces the piston downward. The crankshaft
rotates 180 degrees from top dead center
(TDC) to bottom dead center (BDC) and the
camshaft rotates 90 degrees. Both valves
closed.
EXHAUST STROKE. The engine continues
to rotate and the piston again moves upward
in the cylinder. The exhaust valve opens and
the piston forces the residual burned gases
out of the exhaust valve and into the exhaust
manifold and exhaust system. The crankshaft
rotates 180 degrees from bottom dead center
(BDC) to top dead center (TDC) and the
camshaft rotates 90 degrees. Intake valve
closed.
Graphing Four stroke cycle Gas and
Diesel engine
- In graphing the engine cycle of
operation, it would be helpful to review
the four events, piston motion, valve
action and degrees of crankshaft
rotation.
Also it is important to know the meaning
of the following terms:
Firing Order- this is the sequential firing or
the combustion of the fuel charge inside the
engine in the combustion chamber.
Running Mate- this refers to two pistons
moving at the same time in the same
direction but performing different strokes.
Overlapping Piston- this refers to pistons
performing the same strokes being performed
earlier by other pistons.