Peter Ashraf Gendy

AUTOMOTIVE
REPORT
32012237
MCV Car Services

Dr. Adel El
Shabrawy

TABLE OF CONTENTS
CHAPTER 1
SECTION 1.1
SECTION 1.2
SECTION 1.3
CHAPTER 2
CHAPTER 3
SECTION 3.1
SECTION 3.2

1. Component parts of internal

combustion engines

1.1

Combustion chambers:

Internal combustion engines can contain any

number of combustion chambers (cylinders), with
numbers between one and twelve being common,
though as many as 36 (Lycoming R-7755) have
been used. Having more cylinders in an engine
yields two potential benefits: first, the engine can
have a larger displacement with smaller
individual reciprocating masses, that is, the mass
of each piston can be less thus making a
smoother-running engine since the engine tends
to vibrate as a result of the pistons moving up
and down. Doubling the number of the same size
cylinders will double the torque and power. The
downside to having more pistons is that the
engine will tend to weigh more and generate
more internal friction as the greater number of
pistons rub against the inside of their cylinders.
This tends to decrease fuel efficiency and robs
the engine of some of its power. For highperformance gasoline engines using current
materials and technology, such as the engines
found in modern automobiles, there seems to be

a point around 10 or 12 cylinders after which the

addition of cylinders becomes an overall
detriment to performance and efficiency.
Most car engines have four to eight cylinders,
with some high-performance cars having ten,
12 or even 16, and some very small cars
and trucks having two or three.
Small portable appliances such as chainsaws,
generators, and domestic lawn mowers most
commonly have one cylinder, but two-cylinder
chainsaws exist
Motorcycles commonly have from one to four
cylinders, with a few high-performance
models having six; although, some 'novelties'
exist with 8, 10, or 12.

1.2 Ignition system:

The ignition system of an internal combustion
engines depends on the type of engine and the
fuel used. Petrol engines are typically ignited by a
precisely timed spark, and diesel engines by
compression heating.

Spark: The mixture is ignited by an electric

spark from a spark plug the timing of which
is very precisely controlled. Almost all
gasoline engines are of this type.

 Compression:
Ignition occurs as
the temperature of the fuel/air mixture is
taken over its auto ignition temperature, due
to heat generated by the compression of the
air during the compression stroke.

1.3 Fuel systems:

Fuels burn faster and more efficiently when they

present a large surface area to the oxygen in air.
Liquid fuels must be atomized to create a fuel-air
mixture,
traditionally this
was done with a
carburetor in
petrol engines
and with fuel
injection in diesel
engines. Most
modern petrol
engines now use fuel injection too though the
technology is quite different. While diesel must
be injected at an exact point in that engine cycle,
no such precision is needed in a petrol engine.
However, the lack of lubricity in petrol means that
the injectors themselves must be more
sophisticated.
Carburetor: Simpler reciprocating engines
continue to use a carburetor to supply fuel
into the cylinder. Although carburetor
technology in automobiles reached a very
high degree of sophistication and precision,
from the mid-1980s it lost out on cost and
flexibility to fuel injection. Simple forms of
carburetor remain in widespread use in small

engines such as lawn mowers and more

sophisticated forms are still used in small
motorcycles.

Fuel injection: Larger gasoline engines

used in automobiles have mostly moved to
fuel injection systems (see Gasoline Direct
Injection).

Fuel pump: Most internal combustion

engines now require a fuel pump. Petrol fuel
injection delivers into the inlet tract at
atmospheric pressure (or below) and timing is
not involved, these pumps are normally
driven electrically.

 Superchargers and chargers: A

supercharger is a "forced induction" system
which uses a
compressor powered
by the shaft of the
engine which forces
air through the valves
of the engine to
achieve higher flow.
When these systems
are employed the
maximum absolute pressure at the inlet valve
is typically around 2 times atmospheric
pressure or more.
Turbochargers are another type of forced
induction system which has its compressor
powered by a gas turbine running off the
exhaust gases from the engine.

1.4 Parts:

For a four-stroke engine,

key parts of the engine
include the crankshaft,
connecting rod, one or
more camshafts, and
valves.
For a two-stroke engine,
there may simply be an
exhaust outlet and fuel
inlet instead of a valve
system. In both types of
engines there are one or
more cylinders, and for each cylinder there is a
spark plug, a piston, and a crankpin. A single
sweep of the cylinder by the piston in an upward
or downward motion is known as a stroke. The
downward stroke that occurs directly after the
air-fuel mix passes from the carburetor or fuel
injector to the cylinder (where it is ignited) is
also known as a power stroke.
Valves: All four-stroke internal combustion
engines employ valves to control the
admittance of fuel and air into the combustion
chamber. Two-stroke engines use ports in the
cylinder bore, covered and uncovered by the

piston, though there have been variations such

as exhaust valves.
Piston engine valves: In piston engines, the
valves are grouped into 'inlet valves' which
admit the entrance of fuel and air and 'outlet
valves' which allow the exhaust gases to
escape. Each valve opens once per cycle and
the ones that are subject to extreme
accelerations are held closed by springs that are
typically opened by rods running on a camshaft
rotating with the engines' crankshaft.
Control valves: Continuous combustion
enginesas well as piston enginesusually
have valves that open and close to admit the
fuel and/or air at the startup and shutdown.
Some valves feather to adjust the flow to control
power or engine speed as well.
Exhaust systems: Internal combustion
engines have to effectively manage the exhaust
of the cooled combustion gas from the engine.
The exhaust system frequently contains devices
to control pollution, both chemical and noise
pollution. In addition, for cyclic combustion
engines the exhaust system is frequently tuned
to improve emptying of the combustion

chamber. The majority of exhausts

also have systems to prevent heat
from reaching places which would
encounter damage from it such as
heat-sensitive components, often referred to as
Exhaust Heat Management.
Cooling systems: Combustion generates a
great deal of heat, and some of this transfers to
the walls of the engine. Failure will occur if the
body of the engine is allowed to reach too high
a temperature; either the engine will physically
fail, or any lubricants used will degrade to the
point that they no longer protect the engine.
The lubricants must be clean as dirty lubricants
may lead to over formation of sludge in the
engines.
Piston: A piston is a component
of reciprocating engines. It is
located in a cylinder and is made
gas-tight by piston rings. Its
purpose is to transfer force from
expanding gas in the cylinder to
the crankshaft via a piston rod and/or
connecting rod. In two-stroke engines the piston
also acts as a valve by covering and uncovering
ports in the cylinder wall.

 Crankshaft: Most
reciprocating internal
combustion engines end up
turning a shaft. This means
that the linear motion of a
piston must be converted
into rotation. This is typically
achieved by a crankshaft.
Flywheels: The flywheel is a disk or wheel
attached to the crank, forming an inertial mass
that stores rotational energy. In engines with
only a single cylinder the flywheel is essential to
carry energy over from the power stroke into a
subsequent compression stroke. Flywheels are
present in most reciprocating engines to smooth
out the power delivery over each rotation of the
crank and in most automotive engines also
mount a gear ring for a starter. The rotational
inertia of the flywheel also allows a much slower
minimum unloaded speed and also improves the
smoothness at idle. The flywheel may also
perform a part of the balancing of the system
and so by itself be out of balance, although
most engines will use a neutral balance for the
flywheel, enabling it to be balanced in a

separate operation. The flywheel is also used as

a mounting for the clutch or a torque converter
in most automotive applications.
Starter systems:
All internal
combustion engines
require some form of
system to get them
into operation. Most
piston engines use a
starter motor
powered by the same battery as runs the rest of
the electric systems.
Heat shielding systems: These systems
often work in combination with engine cooling
and exhaust systems. Heat shielding is
necessary to prevent engine heat from
damaging heat-sensitive components. The
majority of older cars use simple steel heat
shielding to reduce thermal radiation and
convection. It is now most common for modern
cars are to use aluminum heat shielding which
has a lower density, can be easily formed and
does not corrode in the same way as steel.
Higher performance vehicles are beginning to
use ceramic heat shielding as this can withstand

far higher temperatures as well as further

reductions in heat transfer.
Lubrication systems: Internal combustions
engines require lubrication in operation that
moving parts slide smoothly over each other.
Insufficient lubrication subjects the parts of the
engine to metal-to-metal contact, friction, heat
build-up, rapid wear often culminating in parts
becoming friction welded together e.g. pistons
in their cylinders. Big end bearings seizing up
will sometimes lead to a connecting rod
breaking and poking out through the crankcase.

Control systems: Most engines require one

or more systems to start and shut down the
engine and to control parameters such as the
power, speed, torque, pollution, combustion
temperature, and efficiency and to stabilize the
engine from modes of operation that may
induce self-damage such as pre-ignition. Such
systems may be referred to as engine control
units.

Many control systems today are digital, and

are frequently termed FADEC (Full Authority
Digital Electronic Control) systems.
Diagnostic systems: Engine On Board
Diagnostics (also known as OBD) is a
computerized system that allows for electronic
diagnosis of a vehicles' power plant. The first
generation, known as OBD1, was introduced 10
years after the U.S. Congress passed the Clean
Air Act in 1970 as a way to monitor a vehicles'
fuel injection system. OBD2, the second
generation of computerized on-board
diagnostics, was codified and recommended by
the California Air Resource Board in 1994 and
became mandatory equipment aboard all
vehicles sold in the United States as of 1996.

2. Disc brake
A disc brake is a wheel brake that slows rotation of
the wheel by the friction caused by pushing brake
pads against a brake disc with a set of calipers. The

brake disc (or rotor in American English) is usually

made of cast iron, but may in some cases be made of
composites such as reinforced carboncarbon or
ceramic matrix composites. This is connected to the
wheel and/or the axle. To stop the wheel, friction
material in the form of brake pads, mounted on a
device called a brake caliper, is forced mechanically,
hydraulically, pneumatically, or electromagnetically
against both sides of the disc. Friction causes the
disc and attached wheel to slow or stop. Brakes
convert motion to heat, and if the brakes get too hot,
they become less effective, a phenomenon known as
brake fade.

The brake disc is the component of a disc brake

against which the brake pads are applied. The
material is typically grey iron, a form of cast iron. The

design of the disc varies somewhat. Some are simply

solid, but others are hollowed out with fins or vanes
joining together the disc's two contact surfaces
(usually included as part of a casting process). The
weight and power of the vehicle determines the need
for ventilated discs. The "ventilated" disc design
helps to dissipate the generated heat and is
commonly used on the more-heavily-loaded front
discs.

Many higher-performance brakes have holes drilled

through them. This is known as cross-drilling and was
originally done in the 1960s on racing cars. For heat
dissipation purposes, cross drilling is still used on
some braking components, but is not favored for
racing or other hard use as the holes are a source of
stress cracks under severe conditions

Discs may also be slotted, where shallow channels

are machined into the disc to aid in removing dust
and gas. Slotting is the preferred method in most
racing environments to remove gas and water and to
deglaze brake pads. Some discs are both drilled and
slotted. Slotted discs are generally not used on
standard vehicles because they quickly wear down
brake pads; however, this removal of material is
beneficial to race vehicles since it keeps the pads
soft and avoids verification of their surfaces

As a way of avoiding thermal stress, cracking and

warping, the disc is sometimes mounted in a half
loose way to the hub with coarse splines. This allows
the disc to expand in a controlled symmetrical way
and with less unwanted heat transfer to the hub.
On the road, drilled or slotted discs still have a
positive effect in wet conditions because the holes or
slots prevent a film of water building up between the
disc and the pads. Cross-drilled discs may eventually
crack at the holes due to metal fatigue. Cross-drilled
brakes that are manufactured poorly or subjected to
high stresses will crack much sooner and more
severely.

3. Car Services:
1.
2.

Malfunctions Car Services.

Periodic Car Services

3.1 Periodic Car Services:

Car services being operated on the car
depending on the model and the developer
every certain distance.

E.g.: Hyundai and Daewoo cars

Hyundai Cars (Verna in specific)

1000 Km Services:
a.Changing Engine's Oil
b.Car Chassis' Check
c. Car Fluids Check

5000 Km Services:
a.
Changing oil filter and oil
b.
Car fluids check
c.Car chassis' check
d.
Brakes check
e.
Front and Rear Lights Check
f.Air conditioning system check
g. changing oil filter

10,000 Km Services:
a. Changing oil filter and oil
b. Car fluids check
c. Car chassis' check
d.Brakes
Check

e.Front and
Check

f.

Rear

Lights

Air conditioning system check

g. Changing car spark plug

h. Changing air filter
i.

Changing fuel filter

40,000 Services:
a.

b.
c.

d.
e.
f.
g.
h.

Changing oil filter and oil

Car fluids check
Car suspension check

Brakes check
Front and Rear Lights Check
Air conditioning system check
Changing car spark plug
Changing air filter

i. Changing fuel filter

j. Belt time change
k. Changing belts
l. Brake check and change
if necessary

3.2 Malfunctions Services:

Not related to distance or time but it
depends on malfunctions and car
owners' requests.
Front light not working;
Light check and changing 2 lamps.

Knocking sound in the car while driving

through bumps;
Car checked on the road and sound found, then
the car is lifted on the lifter and tighten the
screws of the suspension
(Driving wheel bars Driving wheel rod).

 Engine is not stable;

Engine Checked and Spark

plugs changed.

Air conditioning system is

weak;
- Air conditioning system checked, High
and Low pressures measured;

- Freon is
added.

Car wont
start;
Starter system checked and found
malfunctioned, and then changed.