vehicle body pt 2

vehicle body

Relays

battery

indicator light circuit

Brake light circuit

steering and suspension

wheels and tyres

car battery

basic electrics

multimeters

properties of metals

Engineering tools

petrol electronic fuel injection

engine data 11 cars

Subaru Impreza WRX STI Spec R 2010

Type of engine – DOHC Subaru Boxer engine

Power - 305 Hp

Torque - 290 lb-ft

Engine size - 2.5 litre



Aston Martin V12 Vantage 2010

Type of engine – DBS sourced V12

Power - 510 Hp

Torque - 420 lb-ft

Engine size - 6.0 litre



Mazda RX 8 2010

Type of engine – Rotary engine

Power - 231 Hp

Torque - 211 lb-ft

Engine size - 1.3 litre



McLaren Mercedes F1 2009

Type of engine – V12

Power - 627 Hp

Torque - 479 lb-ft

Engine size - 6064cc



Ford Focus 2.0L 2010

Type of engine –

Power - 130 Hp

Torque - 183 lb-ft

Engine size - 1988cc



Land Rover Discovery TDV6 2010

Type of engine – v6

Power - 241Hp

Torque - 443 lb-ft

Engine size - 3000cc



Toyota Hybrid Camry 2010

Type of engine –

Power - 147Hp

Torque - 138 lb-ft

Engine size - 2.4 litre



Nissan Skyline R35 2010

Type of engine – DOHC v6

Power - 474Hp

Torque - 434 lb-ft

Engine size - 3 litre



Ford Falcon xr 6 Turbo 2010

Type of engine – DOHC D1-VCT Turbo16

Power - 394Hp

Torque - 533 lb-ft

Engine size - 4.0 litre



Holden Commodore SSV 2010

Type of engine – v8

Power - 260Hp

Torque - 517 lb-ft

Engine size - 6.0 litre



Lotus Exige s240 2010

Type of engine –

Power - 240Hp

Torque - 170 lb-ft

Engine size - 1.8 litre

written report

Safety is ensuring you and your work mates around you are safe from the dangerous things around the workshop. Fire and hazardous substances can cause burns, irritations and it also can be lethal. Many people have lost their lives when dealing with fires and different kinds of hazardous substances.



Fire can be caused when the three essentials of making a fire come together. Injuries from hazardous substances are common because of carelessness. These things can be prevented. Isolating heat, fuel or oxygen and the fire won’t be made. Storing hazardous substances properly and clearly labelling what the chemical is. If not prevented they could be minimised.



Wearing the correct clothes for the right kind of job is called Personal Protection Equipment (PPE). These equipments include face masks, hand gloves, overalls, ear muffs, helmets and steel capped toe boots. When handling chemicals it is a good thing to wear non corrosive PPE as most chemicals are corrosive.



When putting out a fire, it is essential to have the kind of fire extinguishers in the workshop. There are different kinds of fire extinguishers: Water-red, Foam-blue, dry chemical-white, wet chemical-brown and Carbon dioxide-black. There are also different classes of fires, using these classifications we can assume which fire extinguisher to use. The classes are: Class A- wood, paper, textiles, plastic, Class B- petrol, kerosene, alcohol, oil, paint thinners, plastic, Class C- LPG, butane, acetylene, hydrogen, natural gas, methane, Class D- potassium, sodium, lithium, aluminium, magnesium, swarf and Class E- live electricity, energised electrical equipment. It is essential to use the correct coloured fire extinguisher for the right class of material that has caught on fire.

When dealing with an unknown substance, we could use an M.S.D.S (material Safety data sheet). A material safety data sheet (MSDS) is a form containing data regarding the properties of a particular substance. An important component of product maintenance and workplace safety, it is intended to provide workers and emergency personnel with procedures for handling or working with that substance in a safe manner, and includes information such as physical data (melting point, boiling point, flash point, etc.), toxicity, health effects, first aid, reactivity, storage, disposal, protective equipment, and spill-handling procedures. MSDS formats can vary from source to source within a country depending on national requirements.

MSDS (material safety data sheets) are a widely used system for cataloging information on chemicals, chemical compounds, and chemical mixtures. MSDS information may include instructions for the safe use and potential hazards associated with a particular material or product. These data sheets can be found anywhere where chemicals are being used.

Modern occupational safety and health legislation usually demands that a risk assessment be carried out prior to making an intervention. It should be kept in mind that risk management requires risk to be managed to a level which is as low as is reasonably practical. This assessment should: Identify the hazards, Identify all affected by the hazard and how, evaluate the risk and Identify and prioritize appropriate control measures.

When working at a workshop, u must know some form of first aid and have a current first aid certificate. The employee must be educated enough to know first aid because it will come in handy if any of your work mates or even yourself could end in up in a situation. This could mean saving lives of others, if you do not know what to do in a situation like this then simply follow the instructions. It could take just seconds for you to lose your life.



To summarise, fire safety is so important because in a second it could mean life and death. Do not attempt to put out a fire that is out of control. Using material safety data sheets you can minimise accidents from hazardous substances such as petrol, oil, gas, chemical wastes and poisonous fumes.







By: Shridhaant Kumar

fire safety presentation done by zero traction ages ago

ignition system

fault diagnosis sheet - spark plugs

Appearance of a used spark plug tells a lot about the operating conditions of the engine and the plug. Thus the analysis of a plug plays an important role in the maintenance of a car.



1 : Carbon Fouling
Carbon fouling is the most common spark plug related failure, but is not a spark plug fault. Carbon deposits are conductive, and as they accumulate along the insulator nose they reduce the insulation resistance of the spark plug. As electricity always takes the path of least resistance a misfire may occur if a significant amount of carbon deposits accumulate. A spark will not form as electricity can track along the conductive carbon deposits to the metal shell (as shown in red below) rather than forming a spark across the electrode gap which has a very high resistance.



As mentioned the optimal operating temperature range for a spark plug is 450 – 870°C, 450°C is the spark plug self cleaning temperature at which point carbon deposits will burn off. However, if too cold a spark plug is used and this temperature is not achieved carbon fouling will occur. This is the most common reason for carbon fouling.



Other causes for carbon fouling include:

Causes

Corrective actions

Air/fuel mixture (A/F) too rich
==>
It is necessary to service the carburetor, the auto choke system or the fuel injection system.

Incorrect adjustment of carburetor


Faulty auto choke system


Faulty fuel injection system


Faulty electrical system
==>
It is necessary to service the electric system.

Poor connection of the high tension cables


Inadequate running conditions
==>
It is necessary to run at higher speeds (about 80 km/h) from time to time.

Prolonged idling


Continuous low speed driving


Too cold a spark plug
==>
Use a hotter spark plug
(Example: BK R6E-11 --> BK R5E-11)

Air cleaner contaminated



As carbon builds up, the insulation resistance of the spark plug drops and the voltage generated by the ignition coil is reduced. When the generated voltage becomes lower than the required voltage of a spark plug (the voltage needed to cause sparks at the spark gap), sparking is suppressed and mis-firing occurs.

2 : Terminal Nut Wear
Excessive vibration of the engine may led to abnormal wear of the terminal nut. As a result, the cover may come off the plug. For vehicles whose engines vibrate more than others, such as watercraft and snowmobiles, solid post terminal plugs with excellent vibration resistance and wear resistance are recommended.

Solid post terminal plugs are currently available with five part numbers: B7ES, B8ES, and BR9ES. A special package has been made for solid post terminal plugs.

3 : Flash-Over - Spark leakage from terminal to metal shell

Flash-Over When the spark gap has widened due to wear of the electrodes, a higher voltage is required. The flash-over occurs when the required voltage between the plug electrodes is higher than the voltage flying between the terminal and metal shell.
The plug cable material hardens as time elapses, which in turn reduces the tightness of the cover and insulator, lowering the preventive power for flash-over.

As a higher voltage is required for a turbo charged engine, flash-over is more likely to occur. It is important to recognise that a plug cable is a consumable part which needs to be replaced periodically. When there is no spark after washing the car or the engine room, check whether water has entered the plug cover or not.




Corona Stain A removed spark plug sometimes has discolouration around the insulator surface which looks like gases have leaked between the insulator and the shell. This discolouration is generally called " Corona stain" and is caused by the fact that oil particles in the air around the insulator surface are attracted by the corona discharge, are charged, and then adhere to the insulators surface. The corona stain causes no deterioration of the function of the spark plug.


4 : Metal shell - Rust, breakage at caulked portion

Rust
The Caulked Portion
When water has entered the plug hole due to water resistance of the plug cover or, in the case of a motorcycle, when water has accumulated due to the inadequate draining through the plug hole, the metal shell may rust.

The rusting of the metal shell causes no deterioration of the function of the spark plug. Note, however, that water inside the cover may prevent sparks from being generated.

If the plug is forced to remove when the returning torque is abnormally high due to some causes such as plug thread seizure, the plug may break at the caulked portion of the metal shell.

When returning torque is high, the engine should be first warmed up. Then, by spraying penetrating liquid around the plug thread and leaving it for a while, the plug can sometimes be removed more easily.

5 : Firing End - Broken ceramics, melted electrodes, deposits

Broken Ceramics Melted Electrodes Deposits
When the firing end of the plug has overheated, the ceramics may break or the electrodes may melt.
Under usual engine condition, the plug does not overheat. Note, however, that it gets extremely hot in the case of abnormal combustion (ex. high - speed knocking, pre - ignition).

When the A - F setting is lean due to a faulty fuel system, the combustion temperature may rise, resulting in abnormal combustion. The engines cooling system may be faulty. When the spark timing is too early, the combustion temperature may rise, resulting in abnormal combustion. When deposits (generating from combustion) are accumulated in the combustion chamber, the combustion temperature may rise, resulting in abnormal combustion.

When deposits have accumulated on the firing end of the plug, deposits may overheat, causing abnormal combustion. Especially in a two - cycle engine, oil gets burned and remains in the combustion chamber as deposits, accumulating on the plug as well. It is necessary to remove these deposits periodically.

In engines that consume larger amounts of oil, oil may enter the combustion chamber. It is necessary to check the amount of deposits during inspection of the plug. Burning of oil can also be detected by visible white exhaust gas emitted from the tail pipe.

6 : Dry and wet fouling
Wet fouling is fundamentally similar to carbon fouling. Although the root cause may vary due to a number of reasons, in essence the insulation resistance is reduced allowing a spark to track along the insulator nose and earth to the metal shell rather than forming a spark across the electrode gap as desired. Please see 1. Carbon Fouling

7 : Insulator - Breakage at the corrugation and caulked portion

Corrugation
Caulked portion
When removing or installing the plug, the plug wrench may slip or be tilted and may hit the corrugation of the plug against the inside, breaking the insulator.
Depending on the type of plug wrench, the plug may break at the caulked portion of the metal shell. This may not be noticeable from the outside appearance.

Slipped wrench leaves a mark on the hexagonal portion of the metal shell. A plug wrench with a definite hexagonal shape should be used. A rounded or loose wrench should be either avoided or used with special care.

8 : Gasket too loose, too tight

Too loose
Too tight
When the plug has not been tightened enough, the combustion gas leaks out the thread portion. This reduces the radiation of the plug, causing the metal shell to be heated, resulting in discolouration of the metal shell plating. If the metal shell continues to overheat the plug temperature may rise and abnormal combustion may result.
When the plug has been tightened too much the thread neck portion of the metal shell will be lengthened. When the threaded neck portion is lengthened, the insulator and metal will not seal tight enough, causing the combustion gas to leak. When the gas continues to leak, the plug will be overheated and abnormal combustion may result.
The plug should be tightened to the following recommended torques and turning angles.

is it fair?

paying 1 billion over 5 years is not fair and is not the 50:25:25 ratio

why would a home owner pay 50 percent of the problem he or she didnt create. although its a improvement from the 65 percent from last year it still a bit too much.

the leaky home only applies to the people whose house were built within 10 years so wat would happen to the other home owners whose house are built more then 10 years? who will pay for there leaky home? this isnt fair because they are paying for someone else.

workshop management

lubrication pt2

lubrication pt1

Turbochargers and Superchargers

What is the simple principle behind modern turbocharging?
If the air entring a n engine is pressurised and more oxygen is forced in then by adding more fuel the result is higher engine torque and power.

Describe the terms engine torque and power!
engine torque: torque is the amount of rotational force the engine generates.
power: Engine power is measured at the engine flywheel at the crankshaft output. it can be increased by variable valve timing and turbochargers.

how much oxygen is at sea level?
.016 lbs of oxygen per cubic foot at sea level.

at altitudes what difficulties are faced by an engine?
it becomes more difficult for the engine to obtain the mass of oxygen it needs to generate it required power.

define the term naturally aspirated?
a car that is not running on a supercharger or turbocharger.

when fuel is mixed with insufficient oxygen what happens to the fuel?
the fuel is only partially burned and some escapes out if the exhaust as black smoke.

simply put how does a turbocharger helps to supply air?
it helps to suplly air by forcing the air into the combustion chamber under pressure.

why is a turbo engine able to maintain the same air fuel ratio as at sea level?
it is able to this since the needed atmoshperic pressure makes the turbine stage more efficient.

how are mechanicle superchargers driven?
it is used as a mechanicle pump driven directly from the engine.

why is the supercharger described as an engine parasite?
it uses a large proportion of the potential power increase to drive itself.

give an example of how much power the supercharger takes from the engine?
a engine with 220 horse power is fitted wwith a supercharger which has a potential of 370 horse power but 50 horse power is taken to drive the supercharger so the final power of the engine is 320 horse power.

why is the turbocharger considered to be far more efficient?
because it is able to utilise both the pressure and the heat energy of the engine exhaust gases without taking power from the engine.

inside the turbo where is the exhaust gas chanelled?
turbine housing

what happens next to the exhaust gases?
it enters the turbine wheel.

the gas enters the turbine wheel, what happens to the speed of the gas?
slows down releasing energy.

which two components are connected by the common shaft?
turbine wheel and compressor wheel

during the turbo process what is the compressor wheel doing?
draws filtered air to the compressor housing raising both its pressure and density, and forces it into the engine.

a turbo housing contains fully floating bearings use the internet to describe the bearing types.
the floating bearings sit on oil which makes less friction between the bearing and the common shaft

what other names are turbo oil seals known as?
split ring seals
piston ring seals

what is a thrust bearing?
a thrust bearing is a particular type of rotary bearing, like other bearings they permit rotation between parts, but they are designed to support a high axial load while doing this.

what governs the rate of airflow?
the design of both the wheels and the housings and by the speed of the turbo.

turbo diagnosis

A turbocharger has been removed. Describe the checks which a technician should perform?
they could be poor throttle adjustment, blocked airflow or exhaust need to check for airflow blocks or exhaust leakage making sure the wastegate actuator is working properly

24)check that the turbine spins freely then check that the clearences are inside the munufactures tolerences

25)axial is a geometry term for down the middle of a axis and radial is the radius of a object

26)apply three bar air pressure to your wastgate

27)cyclic knock or surge, high pitched squeal squeak or howl

turbo or super you decide?
i decide on a turbo because unlike a supercharger it doesnt act like a parasite when operated.

wastegates

1)a wastegate is a little port in a turbocharger with a covering flap operated by a actuator arm

2)a wastegate is there to let off boost pressure when it is either no longer needed or to keep the turbo at a predefined speed without going over

3)it has a spring set to a desired pressure then a diaphram conected to a valve when the exhaust gasses that go past it reach enough pressure to push the spring up and open the valve and the excess gasses get channeled back to the exhaut system

4)turbo intercooled means that the car has a turbocharger run off exhaust gasses to increase power the extra air preduced by the turbo is also forced through a intercooler to make sure the air going into the engine is as cool and as dense as possible

5)the wastegate makes a huge difference in performance because it lets extra boost pressure off and so it can drop performance if it dumps to much boost but if it isnt there the turbo could overspeed and also damage engine and so depending on what strength spring you have you can have your turbo run at the performance you want.

cooling system

saker

car debate