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Unit 1

VEHICLE STRUCTURE AND ENGINES


ENGINE:
Engine block assembly

Very sophisticated casting.

Made of cast iron or aluminum with cast iron cylinder liners.

A great deal of machining involved in the process of manufacturing.

Becomes the frame of the engine.

Bottom end parts:

Block Crankshaft

Connecting Rod

Pistons, Rings, & Wrist Pin Bearings (Main and Connecting rod)

Caps (main and Connecting Rod)

Fly Wheel and nuts and bolts Cylinder block configurations:

Common cylinder configurations:

Vee,

inline,

Opposed

slant.

Number from farthest front backwards Crankshaft:


Converts reciprocating motion into rotary motion.
Made of either nodular iron, forged steel, or billet steel

Crankshaft bearings:
Known as friction or precision insert bearings.

Uses a steel backing with soft metal on crankshaft side.(lead, tin, copper, silver,
cadmium)

Oil clearance between crankpin and bearing very critical. (.001)


Oil Clearance measured with plastigauge.

The flywheel (known as the flex plate when used with an automatic transmission)
carries the engines inertia in between power strokes.
It is the powers take off for the engine. The clutch or torque converter bolts to it. Lastly

it has the starter motors ring gear.

Vibration damper:
The vibration damper smoothes the vibrations caused by the power strokes. It has
a pulley on it the run auxiliary systems.
It may contain timing marks or crankshaft timing sensors.

Balancer shafts:
Used to counteract the normal vibrations inherent to piston engines. Found
on 4 cylinder and 6 cylinder engines mostly.

Cover and pans:


Made of steel metal, aluminum, or plastic materials.
Usually use gaskets or seals

Gaskets seals and sealers:


Gaskets seal two stationary surfaces. Seals do it when one surface moves.
Many types of materials: rubber, paper, aluminum, steel, cork and more.Sealers adhere
gaskets to one of the surfaces.

Pistons:

Pistons harness the energy of the power stroke and transfer the force toward the
crankshaft.

Head or crown

Ring grooves

Ring lands

Oil return holes

Skirt

Pin hole

Pin boss

Pin offset

Piston rings:
Rings seal the compression in the combustion chamber and the motor oil in the crankcase.
Automotive engines use 3 rings: 2 compression and 1 multi-piece Oil Ring

Types:
Rings are usually made of cast iron can be plated with chrome or molybdenum.
Help seal the ring to the cylinder wall.
Shapes of the ring vary to also help the ring seal better.

Piston Pin:
Hollow polished steel pin.
Attached in a variety of ways.
Pinned to piston.
Clamped to rod small end.
Snap ring free floating.
Press fit.
Connecting rods:

I-beam style rod use to transfer the pistons force to the crankshaft.
Small end contains the piston pin and the big end has a removable cap to
install it to the Crank.
Nuts and bolts are usually of a very high quality.
Installation of pistons:
Cylinder number
Piston number
Notch to the front
Position ring gaps
Remove rod cap check bearing inserts
Cover bolts with fuel line if needed
Crankshaft at TDC or BDC
Install ring compressor
Oil piston, cylinder wall, & crank journal
Carefully tap in piston with hammer handle.
Properly replace rod cap
Automotive chassis:
Introduction of Chassis Frame: Chassis is a French term and was initially used to
denote

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