Basic Automotive

1
Copy Right® Reserve Akademi Saga / Eon Berhad

TECHNICAL COURSE
BASIC AUTOMOTIVE
FOR
CUSTOMER SERVICE
AT
AKADEMI SAGA
18 JULY 2005 2
INTRODUCTION OF AUTOMOBILE
3
WHAT IS PERIODIC MAINTENANCE
MONTH 6 12
MILEAGE X 1000 km 1 10 20
DRAIN ENGINE OIL x x x
REPLACED OIL FILTER x
4
VEHICLE DESIGN
ENGINE CHASSIS ELECTRICAL
AIR
POWER TRAIN
CONDITIONING
Construction Suspension Body Chassis

Lubrication Steering Electrical
Cooling Braking
Tire And Wheel
Manual Transmission Heating

Automatic Transmission And Ventilation
5
LUBRICANTING SYSTEM
6
PURPOSES OF LUBRICANTS
OILS GREASES
LUBRICATION
COOLING
CLEANING
POWER TRANSMISSION FUNCTION

7
LUBRICANTS CHARACTERISTICS
To Reduce Friction and Prevent Wear And Seizure
To Lessen Temperature Rise
To Keep Air Tightness and Prevent Entry of Foreign Substances
To Remove Foreign Substance And Accomplish Cleaning Function
To Prevent Rust And Corrosion
To Ease Shock
8
TYPES OF LUBRICANTS
SOLID
LUBRICANTS GREASE
LUBRICANTS
Engine Oil Chassis Grease Graphite
Gear Oil Wheel Molybdenum

Bearing Dioxide
Automatic Grease
Transmission
Fluid
9
ENGINE OIL
Roles Of Engine Oil
To Reduce Wear Parts
To Remove Heat Generated By Moving Parts
To Be A Sealing
To Clean Deposits in the Engine
To Prevent Corrosion
10
TYPES OF ENGINE OIL
MINERAL OIL SYNTACTIC OIL
VISCOSITY SAE/API
VISCOSITY GRADE
11
VISCOSITY CLASSIFICATION
Society of Automotive American Petroleum

Engineers / SAE Institute / API
Classification By
Single & Multi Grade
Alphabetical
SAE 20 W - 40 SA-SL / CA-CE / GL
12
VISCOSITY CLASSIFICATION
SAE 20 W - 40
Viscosity at high Temperature
Winter Grade
Viscosity at Low Temperature
S Primarily for Gasoline Engine
C Primarily for Diesel Engine
G Primarily for Gear Oils
13
SYNTHETIC LUBRICANTS
Synthetic Lubricants Are Made by Mixing Various Type of Chemical

14
ADVANTAGES SYNTHETIC OILS
Increased Thermal and Oxidation Stability
Less Viscosity Change With Temperature
Improved Fuel Mileage
Reduce Oil Consumption
Better Clean Engine Parts
Not Affected By Fuel Contamination
15
DISADVANTAGES SYNTHETIC OILS
Poor Break In Characteristics
Ineffectiveness in older engine
Higher Cost
Inability to be Mixed
16
AUTOMATIC TRANSMISSION FLUID
Characteristics
Transfer Of Energy
Lubrication
Friction
Types Of ATF
Proton SP III
Mitsubishi DIA QUEEN SP III
17
BRAKE FLUID
Advantages
• Maintain viscosity and

DOT 3 fluidity at the operating
temperature
Types Of Fluid
Used By Proton Cars • High Boiling Point
DOT 4
• Lubricating Ability
• Non Corrosive
• Water Tolerance or able

to absorbing and retain
moisture
18
COOLANT CHARACTERISTIC
ANTIFREEZE
REDUCE
FREEZE POINT BOILING POINT
CORROSION
100% Water 0°c 100% Water 100°c

Add
25% Coolant - 12°c 50% Coolant 107°c Ethylene - Glycol
40% Coolant - 68°c 70% Coolant 114°c
19
ELECTRICAL SYSTEM
20
BATTERY DESIGN
The Purpose Of the Battery Is Act As A Reservoir For

Storing Electricity
21
SPECIFIC GRAVITY
SPECIFIC GRAVITY
READINGS
FULLY
1.260-1.280
CHARGED
1.205-1.235 ½ CHARGED
POOR
1.140-1.170
CHARGED
1.110-1.140 DEAD
The Condition Of The Battery Electrolyte Can Be Check By

Measured Its Specific Gravity By Hydro Tester
22
CHARGING SYSTEM
23
PURPOSE OF CHARGING SYSTEM
Charging system is used to convert the mechanical energy of the engine to

electrical energy
Electrical Energy is Used to Operate the vehicle during normal driving and
charge the battery 24
STARTING SYSTEM
25
PURPOSE OF STARTING SYSTEM
The Starter Motor Is Used To Convert Electrical Energy From The

Battery To Mechanical Energy To Crank The Engine
26
ENGINE DESIGN
27
ENGINE PRINCIPLE
The Component In An Automobile that power the vehicle is Called the

Engine
It is designed to convert energy in fuel into power so the vehicle can

be moved.
28
INTERNAL COMBUSTION ENGINES
Explosion
In An Internal Combustion Engine the combustion of

gases occurs inside the engine.
29
COMBUSTION REQUIREMENT
STRONG
SPARK
GOOD
COMBUSTION
SUITABLE
ENOUGH A/F RATIO
COMPRESSION MIXTURE
30
CONSTRUCTION ENGINE
Rocker Arm Rocker Cover
Camshaft
Cylinder Head
Valve
Combustion
Chamber Exhaust
Manifold
Piston
Flywheel
Connecting Rod
Cylinder Block
& Crankshaft
31
BASIC ENGINE TERMINOLOGY
Cylinder Block
It Is Defined As The Foundation of the Engine
All Other Parts are Attached to The Cylinder Block

32
4 STROKE CYCLE ENGINE
Intake Stroke Compression Combustion Exhaust

Stroke Stroke Stroke
33
ENGINE DISPLACEMENT
BORE
TDC
STROKE
BDC
Displacement
= 0.785 x Bore² x Stroke x No Cyl
34
ENGINE PERFORMANCE
The Purpose of Engine Performance Is To Measure The Maximum Power or

Maximum Torque on Certain Speed That Engine Can Produce.
MAX POWER (bhp/kw) MAX TORQUE (Nm)
147 bhp at 5800 rpm 203 Nm at 4000rpm
109.6 kw at 5800 rpm
1 hp = 0.7457kw
1 kw = 1.341 hp 35
Cylinders
Cylinder Are Defined As Internal Holes in the cylinder block

36
Pistons
Pistons Are Defined As The Round Object That Slides Up

And Down In A Cylinder
37
Connecting Rod & CrankShaft
The Main Purpose is To

Attach The Piston To A
Device Known As The
Crankshaft
The Crankshaft is Used

To Change The
Reciprocating Motion.
38
Cylinder Head 1
The Cylinder Head Is The part That Fits Over The Top Of The
Cylinder Block
It Usually Houses the Valve Cover¹, Valve², Spark Plug, Cam

Shaft ³ and Combustion Chamber 39
Combustion Chamber
The Combustion Chamber Is Where the Combustion Takes

Place Inside The Cylinder
40
Valve
Valves Are Placed Inside The Cylinder Head To Allow Air And
Fuel To Enter and Leave The Combustion Area 41
Camshaft
The Camshaft is Used To Open And Close The Valves At The

Correct Time 42
Flywheel
The Flywheel is Located On The End The CrankShaft
Its Design To Act As A Weight To Keep The Crankshaft

Rotating Once Power Has Been Applied To The Piston
43
OPERATION OF LUBRICATING SYSTEM
Oil Pump
- Driven By Crankshaft
- The oil is then pressurized and
send into the engine.
Oil Filter
-Purpose is to remove harmful

particles from the oil.
Oil Pan
- Serves as a reservoir for oil
44
OPERATION OF LUBRICATING SYSTEM
45
OIL PRESSURE INDICATOR LIGHT
Oil Pressure Switch are used to sense the Pressure in The Main Oil Gallery
Pressure Increases , Oil Indicator Light OFF
Pressure Low, Oil Indicator Light ON 46

COOLING SYSTEM
47
PRINCIPLES OF THE COOLING SYSTEM
To Maintain The Highest and Most

Efficient Operating Temperature
Within the Engine
To Remove Excess Heat From The

Engine
To Bring The Engine Up To Operating

Temperature
48
LIQUID COOLED SYSTEM
In Liquid Cooled System the Heat From The Cylinders Is

Transferred To A Liquid
49
LIQUID COOLANT FLOW
50
COOLING PARTS AND OPERATION
Water Jacket
Water Jacket are

designed to allow coolant
to flow to the right spots
within the engine
51
Water Pump
Purpose of water pump is to circulate the water through the

cooling system 52
Thermostats
It is designed to sense the temperature of the coolant

53
Pressure Cap
Its designed to
Radiators
Increase the
pressure on the
Purpose of the
cooling system
radiator is to allow
fresh air to reduce
Reduce Cavitations
the temperature of
the coolant
Protect the
Radiator Hoses
54
TEMPERATURE INDICATOR
TEMPERATURE TEMPERATURE
GAUGE SENSOR
Purpose to indicate / reads Purpose to indicate / reads

the actual coolant the actual exact
temperature and display temperature inside the
this on the dashboard engine
55
BASIC FUEL SYSTEM
FUEL TANK LINES PUMPS FILTERS
CARBURETORS INJECTORS
Fuel Tank
Fuel Pump
Filter
Fuel Filter
Injector
Pressure
Delivery Pipe Regulator
56
FUEL TANK
The Fuel Tank Is Made To Hold or Store The Excess Fuel
Usually Located In Rear Of the Vehicle

57
FUEL CAP
Fuel Cap Keeps The Fuel Tank From splashing
The Cap Releases The Vacuum Created When The Fuel Is Removed By The
Engine
The Cap Release Pressure When The Fuel Tanks Heats Up and Expand
58
FUEL GAUGE / METERING UNIT
The Fuel Metering Unit Has A Float That Changes Resistance As The Fuel
Level Changes
59
FUEL PUMPS
Mechanical Fuel Pumps Electrical Fuel Pumps
The Mechanical Fuel Pump Is The Electrical Fuel Pumps Work

Used On Many Vehicles That Independently on Electrical
Use Carburetors Current.
60
FUEL FILTER
The Fuel Filter Is Used to Filter Out Small Particles of Dirt and
Rust
The Filter Also Prevent Most Water From Going To The

Carburetor or Fuel Injector
61
CARBURETTOR SYSTEM
62
WHATS IS CARBURETOR
Its Designed To Mix The Air Fuel At The Correct Ratio During
All Engine Operation
63
CONSTRUCTION OF CARBURETOR
Air
Inlet
Auto
Choke
Throttle
Lever
64
CHOKE CONTROL
The Choke Valve Is Used To Restrict The Air Flow Into Carburetor During
Cold Starting Condition
Generally There Is Two Type of Choke
Manually Control
Automatic Controlled 65
FUEL INJECTION SYSTEM
66
WHAT IS FUEL INJECTION
Its Designed To Control The Air Fuel Ratio of the Engine More
Precisely
67
WHAT IS FUEL INJECTION
General
Our previous system use differences name but out system generally is same
Example ;
Multipoint Injection System - Develop by MMC
Engine Management System VDO - Develop by Proton
Injection System - Develop by Renault
Injection System / MPI / EMS System
To control Ignition / Injection & Idle Speed
Must have
Sensor ECU Actuator

68
FUEL INJECTION SYSTEM
ELECTRONIC
SENSOR ACTUATOR
CONTROL UNIT
Sensor ECU Actuator
69
CONTROL SYSTEM DIAGRAM
• Oxygen sensor
• air flow sensor
• intake air temperature sensor
• throttle position sensor • injector
• idle position sensor • purge control solenoid
• TDC sensor valve
• crank angle sensor • idle speed control servo
ENGING
• barometric pressure sensor • EGR control solenoid
• coolant temperature sensor CONTROL valve
• detonation sensor • fuel pump relay
UNIT
• servo valve position • control relay
• power supply • air cond. Power relay
• vehicle speed sensor • engine warning lamp
• air cond. Switch • diagnosis signal
• inhibitor switch • ig. Coil, power transistor
• power steering switch
• ig. Switch ST
70
ADVANTAGES OF FUEL INJECTION
• Improved atomization
(fuel is forced into intake manifold under pressure which
helps break fuel droplets into a fine mist)
71
• Better fuel distribution

- more equal flow of fuel vapors into each cylinder
• Accurate a/f ratio of all speed range
• Good mixture distribution to each cylinder
• Easy correction of air fuel ratio
• Quick response
72
• Improved fuel economy

(high efficiency because of more precise fuel metering,
atomization and distribution)
73
• Better Exhaust Emission ( 0. 5%or Less)

(lean,efficient air fuel mixture reduces exhaust pollution)
74
MANUAL TRANSMISSION
75
PURPOSE OF MANUAL TRANSMISSION
The Purpose of a Transmission is to Apply Different Torque

Force To The Driving Wheels
76
BASIC CONSTRUCTION OF MANUAL MANUAL
TRANSMISSION
Gearbox
Casing
Flywheel
Clutch
Assembly
Gearing
Clutch
Lever
77
PURPOSE OF CLUTCHES
The Clutch is used as A Mechanism To Engage Or

Disengage The Transmission And Driving Wheels
78
PRESSURE PLATE ASSEMBLY
The Pressure Plate is Designed To Squeeze or Clamp the

Friction Disc Between Itself and The Flywheel
79
CLUTCH RELEASE BEARING
The Bearing is Moved By Clutch Pedal And Linkage To

Engage And Disengage The Pressure plate
80
AUTOMATIC TRANSMISSION

81
PURPOSE OF AUTOMATIC TRANSMISSION
The Purpose Of the Automatic Transmission is To Connect The

Rotational Forces
To Provide Correct Torque Multiplication

82
BASIC CONSTRUCTION OF AUTOMATIC
TRANSMISSION
Inhibitor Torque
Switch Converter
Dipstick Gearbox
Casing
Oil Sump
83
SUSPENSION SYSTEM
84
WHAT IS SUSPENSION SYSTEM
The Suspension system of a car is used to

support its weight during varying road condition
It is also used to maintain stability on cornering of

vehicle
The suspension is made of several parts and component e.g
• Spring
• Stabilizers
• Shock Absorber
• Support Arm
• links, etc
85
CHARACTERISTICS OF SUSPENSION
The movements include the front and rear

end motion about the car center of gravity
called pitching.
Pitching
The lateral swaying motion about the car

called rolling
Rolling
The movements up and down motion of

entire car calls bouncing
Bouncing 86
CONSTRUCTION OF SUSPENSION
To Absorb Road Shock
System Must Have
• Spring
• Stabilizers
• Shock Absorber
• Support Arm
• Link etc
87
COIL SPRING
• The Coil Spring are used to support the

vehicle weight
• Also its maintain the car’s stance or

height
Advantage Used Coil Spring :
• Its can absorb road shock and

oscillations condition and return to their
original position.
88
SHOCK ABSORBER
• Shock Absorber are hydraulic devices that help to control

the up, down and rolling motion of a car body.
•The car’s spring support the body, but the shock absorber work with
coil spring to control movement of the car body.
•The shock absorber is equipped to absorb all characteristic vibrations
produce by the spring
89
CLASSIFICATION OF SHOCK ABSORBER
SHOCK ABSORBER
Oil Filled Type Gas Filled Type
• Used at Both Front & • Used at Both Front &

Rear Proton Iswara Rear Proton Wira
• Used At Both Front & • Used At Both Front &

Rear Proton Wira. Rear Proton Waja.
• Used At Proton Perdana

90
STABILIZER BAR
The Stabilizer is torsion bar that support of the vehicle stability due to
centrifugal force while cornering
Advantage :
• To protect body roll during cornering
• Give more Stability control while driving
91
STEERING SYSTEM
92
WHAT IS STEERING SYSTEM
The steering system serves to allow changing the direction in which

the automobile is moving.
93
CLASSIFICATION OF STEERING SYSTEM
STEERING SYSTEM
Manual Steering Type Power Steering

Type
DIFFERENCE
Used Mechanical Support Used Mechanical and

Hydraulic Support
- Steering Shaft -Steering Gear, Shaft And
-Steering Gear Linkage
- Steering Linkage -Pump
- Pressure Hose
- Oil Reservoir
94
POWER STEERING SYSTEM
Power steering is designed to reduce the steering wheel

turning
effort by utilizing hydraulic pressure to the normal torque

develop
by steering box.
Advantage of power steering.
• Less steering effort.
• Higher stability during driving.
95
CONSTRUCTION OF STEERING SYSTEM
Steering Linkage & Gear
Oil Reservoir
Pressure Hose
Pump
Cooler Hose
96
TIRES AND WHEEL
97
WHEEL ALIGNMENT
The Main Purpose of wheel alignment is to allow the wheels to:
a. Roll without Scuffing

b. Dragging
c. Slipping
Advantage if done proper alignment :
a. Better Fuel Economy

b. Less Strain on the Front-end Parts
c. Directional Stability
d. Easier Steering
e. Longer Tire Life
f. Increase Safety
98
IDENTIFYING TIRES
P 185 / 80 R 13
TIRE TYPE ASPEC RATIO RIM DIAMETER
(section height)
P Passenger (Section Width) 13
T Temporary 14
C Commercial 70 15
75
80
SECTION WIDTH CONSTRUCTION
TYPE
(MILLIMETERS) R – Radial
185 B – Bias
195 D - Diagonal
205
ETC
99
CHAMBER
Camber is an angle in degrees from

the center line of the wheel to a
true vertical line.
The main purpose to make sure the

tire is vertical to the road and light
steering controller
Two type of CAMBER
a. Positive Camber
b. Negative Camber
100
CASTER
Caster Angle is distance between the center line of the spindle support arm
and the true vertical line.
Purposely to help front tire return back after cornering.
101
WHAT IS TOE
Toe is define as the difference in the

distance between the front and back
of the front wheel
It prevent side slipping and excessive

wear of the types
Two type of TOE
a. Toe In
b. Toe Out
102
BRAKING SYSTEM
103
BRAKING SYSTEM PRINCIPLE
Brake have been provided to serve the important

function of stopping or slowing down the car when
required to do so.
104
CLASSIFICATION OF BRAKE SYSTEM
Wheel Brake
Classification by Location
Propeller Shaft brake
Hand Brake
Classification by Operation
Foot Brake
Internal Expanding Brake

Classification by Construction
Disk Brake
105
CLASSIFICATION OF BRAKE SYSTEM
Mechanical Type Brake
Hydraulic Type Brake

Classification by Mechanism
Pneumatic Type Brake
Exhaust Type Brake
106
PRINCIPLE OF BRAKE SYSTEM
Dynamic Energy Frictional Force Heat Energy
107
HYDRAULIC PRINCIPLE
Pressure = Force
Area
108
BRAKE BOOSTER
• Booster type brake or Power Brake are designed to have extra

pressure .
• It’s produce vacuum acting as an extra force for the brake pedal
109
CHECK VALVE
• Check valve, which is a one-way valve that only allows air to be

sucked out of the vacuum booster
• It prevents the vacuum from escaping since fluctuation of intake
manifold pressure.
110
MASTER CYLINDER
The Master Cylinder is used to produce the necessary pressure in the

hydraulic system.
The Master Cylinder is to convert the MECHANICAL FORCE to

HYDRAULIC PRESSURE
111
PROPORTIONING VALVE
Rear Left Rear
Right
Front
Right
From Master
Cylinder
Front
Left
• Proportioning valve reduces the fluid pressure to the rear brakes.

• Proportioning valve only lets a certain portion of the pressure
through to the rear wheels so that the front wheels apply more braking
force
112
WHAT IS DISC BRAKE
A Disk Brake system used two pads reacting against a disc

to produce friction and stop the vehicle
113
CLASSIFICATION OF DISC BRAKE
DISC BRAKE
Ventilated Type Solid Type
114

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1

Copy Right® Reserve Akademi Saga / Eon Berhad

DRAIN ENGINE OIL x x x

REPLACED OIL FILTER x

ENGINE CHASSIS ELECTRICAL

Construction Suspension Body Chassis

Manual Transmission Heating

POWER TRANSMISSION FUNCTION

To Reduce Friction and Prevent Wear And Seizure

To Lessen Temperature Rise

To Keep Air Tightness and Prevent Entry of Foreign Substances

To Remove Foreign Substance And Accomplish Cleaning Function

To Prevent Rust And Corrosion

Engine Oil Chassis Grease Graphite

Gear Oil Wheel Molybdenum

Roles Of Engine Oil

To Reduce Wear Parts

To Remove Heat Generated By Moving Parts

To Clean Deposits in the Engine

MINERAL OIL SYNTACTIC OIL

Society of Automotive American Petroleum

SAE 20 W - 40 SA-SL / CA-CE / GL

Viscosity at high Temperature

Viscosity at Low Temperature

S Primarily for Gasoline Engine

C Primarily for Diesel Engine

G Primarily for Gear Oils

Synthetic Lubricants Are Made by Mixing Various Type of Chemical

Increased Thermal and Oxidation Stability

Less Viscosity Change With Temperature

Improved Fuel Mileage

Reduce Oil Consumption

Better Clean Engine Parts

Not Affected By Fuel Contamination

Poor Break In Characteristics

Ineffectiveness in older engine

Mitsubishi DIA QUEEN SP III

• Maintain viscosity and

• Water Tolerance or able

100% Water 0°c 100% Water 100°c

40% Coolant - 68°c 70% Coolant 114°c

The Purpose Of the Battery Is Act As A Reservoir For

The Condition Of The Battery Electrolyte Can Be Check By

Charging system is used to convert the mechanical energy of the engine to

The Starter Motor Is Used To Convert Electrical Energy From The

The Component In An Automobile that power the vehicle is Called the

It is designed to convert energy in fuel into power so the vehicle can

In An Internal Combustion Engine the combustion of

It Is Defined As The Foundation of the Engine

All Other Parts are Attached to The Cylinder Block

Intake Stroke Compression Combustion Exhaust

= 0.785 x Bore² x Stroke x No Cyl

The Purpose of Engine Performance Is To Measure The Maximum Power or

MAX POWER (bhp/kw) MAX TORQUE (Nm)

147 bhp at 5800 rpm 203 Nm at 4000rpm

109.6 kw at 5800 rpm

Cylinder Are Defined As Internal Holes in the cylinder block

Pistons Are Defined As The Round Object That Slides Up

The Main Purpose is To

The Crankshaft is Used