Table of Contents

2............................................................................................... Introduction :
3........................................................................................................ History:
4................................................................................................... Over view:
7........................................................................................................ Engine:
21................................................................................ Manual Transmission:
31..................................................... Electrical & Electronic Systems Basics:
45.................................................................................. Suspension system :
51...................................................................................... Steering system :
53....................................................................................... Breaking system:

: Introduction-1
. This report is about our training in Mercedes Benz
In this report we are going to talking about the
: following

-1
:History
The history of company ,how it start and who are
.the founding
: over view-2
Over view on the classes, air metering, systems of
.diagnoses
:engines -3
More specific view on the engines, it`s function and
.how is it work
:manual transsimision-4
There are two types of transmission systems
:the manual transmission and the automatic
one. In the this report we will talk about the
. manual transmission
:electricity system -5
About the electricity system, now days every
car had it`s electricity system . the electricity
system contains control units, sensors and
.actuators

:chase system-6
. it contain the suspension and breaks

:History .2
Karl Benz-2.1
Was a German engineer , made his first car in
.1886
:Gottlieb Daimlar-2.2
Was a German engineer , his slogan was " the best
" or nothing
Made the first Mercedes in 1886 . the name "
Mercedes " back to the daughter of business man
that order from Daimlar to made a group of cars
.spicily for hem

:Wihlem Maybach -2.3

.The king of constructor

: The Merge -2.4

The merge happened in 1926 and the company

"called "Mercedes Benz

Mercedes from Daimlar car`s and Benz from Karl

.Benz

:Over view-3

-calssfication3.1:
The classification in Mercedes contains a liter and
numbers, the litter for model and the number for
"cc "engine Capacity
: Here are some of classification

W203> saloon

Cl203>sports coupe

"S203>estate "station

V203>long

systems of

:
diagnoses3.2

Before 1996 the OBD "on bored diagnoses" was not

,in all cars
This system in first place watching everything
happened in injection and exhaust system. This
.system was in the cars not in the workshop

These system "das, wis" are in the work shop and

use to locate and discover the flutes and some
. time helps to solve the problems

These system work on a special computers such as

:
Star (basic)Compuct( das)Compuct 2(wis)Compuct3-

Compuct4-

air metering3.3 :
It is advice used to calculate the percentage of air
. and then inject the fuel
: There are some types of it

HFM: hot flam air massing

ME: engine electric system

SIM: Siemens engine electronic

gine :ne4
There are two types of engines: four stroke and two
. stroke
The four stroke is used in the cars while the two
.stroke is used in motorcycles and some machines

: engine two strokes 4.1

It is not so perfect in exhaust system and affected
by the condition of operation ,also it is less
.Efficiency from the four strokes engine

: Strokes

(induction +compression)-

(exhaust + power)-

Four strokes : nginee4.2

:the strokes 4.2.1

:indution stroke-1
Start when the piston at top
died center and finished when
the piston at bottom died
center. Also at the beginning
the inlate valve open to llet the
. air and the fuel goes on

:copmerssion stroke -2
The valves closed, and start when
the piston at bottom died center
and finished when it at top died
.center

: power -3
The same stroke of induction but the piston moves
.dwon by power

: exhaust -4
As the piston moves up, the exhaust gases are
.expelled into the exhaust system
At the end of the stroke, the exhaust
valve closes, ready for the inlet valve
.to open and the cycle to repeat

t:
engine compnen2.2.4

:Cylinder block-1
The cylinder head is ussually made from cast iron
.or al
The underside of the cylinder heda house the crank
.shaft and main bearing
A gasket and high
tensile bolts complete
the seal between the
cylinder block and
.cylinder head

:cylinder sleeve -2

They are usually made of cast iron or steel, and

may also be used to repair badly damaged cylinder
.walls in cast-iron blocks
Dry sleeves are thin and supported by the cylinder
block material. They are not in direct contact with
the coolant and are generally pressed into
the block

Wet sleeves are directly exposed to the

coolant and are thicker to account for the
.lack of structural support from the block

:block gridle-3

A block girdle, or main bearing bedplate, is a onepiece (unit main) cap that fits over the whole of the
.bottom of the block, for added strength
The block girdle replaces
individual main bearing
caps and is more
common on aluminium
.blocks

:cylinder head -4
The cylinder head is housing the
. valves

Water jacket holes in the cylinder head match

those in the cylinder
block, providing coolant
passageways from the
.block to the head

:cylinder head component 4.1

The cylinder head contains many components
.

Valve mounts
consist of springs,
guides, seats, seals,
retainers and
cotters
.
In the case of the
OHV layout shown,
the valves are
opened by pivoted
rocker arms moved
by push-rods from a camshaft mounted in the
block

:pistons and crank shaft-5

:pistons 5.1
Most pistons are forged or cast from an
aluminium alloy for light weight and
.strength
The piston must be able to withstand
rapid changes of speed and direction
.over a very short distance
Connecting rods link the pistons to the
.crankshaft
The part of the piston below the pin hole
.is known as the skirt
:piston ring 5.2

Compression rings are generally made from cast

iron and prevent Blow-by (pressure leakage into
.the crankcase)
There are generally two
compression rings, both
acting as gas seals.
Designs may vary from
.engine to engine
The lower ring is an oil ring
which is used to wipe oil
from the cylinder wall,
limiting oil seepage to the
combustion chamber.
Compression ring

:connecting rod 5.3

The connecting rod is typically made of ductile
steel to withstand the high
loads, and incorporates
bearing shells and may have
.a bush for the gudgeon pin
The big end is connected to
the crankshaft and normally
has bearing inserts called
.bearing shells

The small end may have a bronze bush for the

.gudgeon pin in full-floating operation

: crank shaft -6

The crankshaft offset is the

distance between the
centre of the crankshaft
and the centre of the
journals. Twice the offset is
.the distance that a piston travels in one stroke
:oil holes and groves -7
The crankshaft rotates in the
bearings between the
cylinder block and the caps.
Because the crankshaft
operates at high load and
speed, a large amount of
friction and heat is generated
that could lead to damage.
Therefore, lubrication is necessary to both remove
heat energy, and create a hydrodynamic film of oil
.between the two surfaces to minimize wear
:blancer shaft-8

Balancer (silencer)
shafts are fitted on
either side of the
cylinder block and are
used to reduce
vibration forces and
noises caused by
piston, connecting rod
and crankshaft
.movements
Balancer shafts are commonly chain driven at
twice the crankshaft speed. The balancer shafts
are typically rotated in opposite directions and are
.timed to the crankshaft

:Cam Shaft -9
Camshafts are used to control the opening and
closing of the inlet or exhaust valves. They are
made from cast or forged steel and precision
.ground

Camshafts can either

be belt or chain
driven from the
crankshaft. For a four-

stroke engine, for every two revolutions of the

.crankshaft, the camshaft rotates once

A camshaft opens and closes the valves by the use

of cams (also known as lobes). The surface area of
the cams are hardened, in order to withstand
.wear

:cooling system 4.2.3

Air cooling requires a large volume of air flow around the
.engine
The cylinder has cooling fins to improve radiation of heat.
The large surface area of the fins, transfers heat to the
.surrounding air
With water cooling, the coolant circulates around a water
.jacket to absorb the heat energy
The coolant is a mixture of water and antifreeze and
.anticorrosion additives
Water cooling provides better control and stability of the
.engine temperature

Water cooling

air cooling

:water pump -1
The water pump forces
coolant through the
engine cylinder block and
.head channels
Coolant is drawn into the
centre of the water pump
via the lower hose of the
.radiator
Centrifugal force, due to
the rotation of the water pump impeller, throws the liquid
.out at the edge and into the cylinder block
If a mechanical cooling fan is used, it may often be
.attached to the water pump hub

:water flow -2
Conventional coolant flow is
upward past the cylinders (hot
.liquid rises)
Coolant then flows out from
the cylinder head to the
radiator via its top hose. The
hot coolant is then cooled as it
.travels through the radiator
The water pump draws
coolant from the bottom of the radiator and forces it back
.through the cylinder block
Reverse flow cooling is unusual, but is in the opposite direction from that
described above

:electric cooling fan-3

Electric fans use DC (direct current)
motors coupled to a thermostat switch.
The fan is operated to prevent
overheating when the coolants
temperature increases beyond its
.optimum value

Lubrication System 4.2.4

The reservoir of oil is
held in the sump
(deep part of the oil
.pan)
The oil is drawn into
the engine through a
.pickup
Oil is forced round the
.system by a pump
The system is protected from over high pressure, by a
.pressure relief valve

.Particulates are strained out by a filter

The oil is circulated around in galleries within the head
.and block

Lubrication System Components -2

Oil Filter -3
They are usually a spinon fitting with an O-ring
.seal to prevent leakage
The outlet tube is at the
.centre
Several input feed holes
are arranged directly into
.the filter element
The paper element traps small metal, rust, carbon or dirt
.particles
This keeps impurities out of the engine to prevent damage
.to working surfaces

1. Manual transmission
Clutches are required in vehicles that use a manual
transmission system.
They are used to provide a drive link between the engine and
the transmission system and are also used to separate this
link (disengage the transmission).
Clutches allow a smooth take up of drive so that the vehicle
can be gradually moved away from rest. This is done by
moderately slipping the clutch, as the engine speed is
increased.
The clutch also allows for a brief disengagement between the
engine and gearbox for gear changing, when in motion. This
must be done when changing up or down through the gears.
The clutch also has to give a temporary disconnection when
the vehicle is stopped in gear. This situation may arise when
waiting at traffic lights or at a road junction.

clutch action :
The action of a clutch can be simply demonstrated by the use
of two discs.

One disc (drive disc) is attached to the engine and is rotated

by its action. The other disc (driven disc) is attached to the
transmission input shaft.

2.1 clutch system parts:

The clutch system consists
of five major components:
the Flywheel, Clutch
(Friction or Driven) Plate,
Pressure Plate Assembly,
Release (Throw-Out) Bearing
and Clutch Fork.
As the clutch system is
situated between the engine
and the transmission, a clutch housing is used to join the
transmission to the engine and protect the clutch components
from the outside elements.
2.1.1clutch plate:
Also known as a clutch (or friction) disc, the clutch plate is
found between the flywheel & pressure
plate and provides the friction material
required between these two components.
The splines in the centre of the clutch
plate mesh with the splines of the
transmission system's input shaft.
The diagram shows two discs of frictional
material. These are riveted to the
cushion spring plate on either side of the
friction ring. The friction discs sometimes
have grooves cut into them to aid cooling
of the material.
The friction material is riveted to cushioning springs that have
a slight curve in them. These springs cushion the force as the
pressure plate pushes the clutch plate onto the flywheel.
The torsional (damping) springs soften the torsional load
applied to the clutch plate as it first begins to turn, so allowing
a smooth take up of drive. If this did not occur, a juddering
effect may be felt in
the vehicle.
The friction material is riveted to cushioning springs that have
a slight curve in them. These springs cushion the force as the
pressure plate pushes the clutch plate onto the flywheel.

The torsional (damping) springs soften the torsional load

applied to the clutch plate as it first begins to turn, so allowing
a smooth take up of drive. If this did not occur, a juddering
effect may be felt in
the vehicle.
Cover

pressure plate

2.1.2pressure assembly :
The pressure plate assembly
is
the component used to push
the
clutch plate onto the
flywheel.
There are two types of
pressure plate: Coil Spring
and Diaphragm Spring. Both
types of plate assembly
have a pressure plate, which
is
the part that presses on to
the
clutch plate, and is housed within a cover.
The coil spring type uses a number of coil springs in order to
push the pressure plate against the clutch plate. The
diaphragm spring pressure plate assembly uses a single dishshaped spring that is made of several fingers.

The diaphragm spring pressure plate

assembly uses a single dish-shaped
spring that is made of several fingers.
Diaphragm spring

2.1.3 release bearing and

clutch fork:

The release (throw-out) bearing and clutch fork are

components used to move the pressure plate back
and forth. As the clutch fork moves, it pivots and
pushes the release bearing against the
diaphragm spring of the pressure plate. This
disengages the pressure plate from the clutch
plate and drive is removed from the gearbox
(transmission) input shaft.
As the clutch fork moves in the other direction, the
release bearing removes pressure from the diaphragm spring
and the clutch plate is engaged.

the

Release bearing and clutch fork move pressure plate. As clutch fork
moves, it pushes release bearing and disengages
pressure plate from clutch plate. As clutch fork
moves in the other direction, release
bearing engages clutch plate.

2.2.1 clutch operation mechanismsmechanical :

The mechanically operated clutch uses a
multi-stranded steel wire cable that is
connected between the clutch fork and
clutch foot pedal. The wire is protected by
a flexible outer sheath, which is typically
made of plastic.
As the clutch foot pedal is depressed it
pivots and pulls the wire, which in tu rn
pulls the clutch fork. The clutch fork activates the release bearing
and the clutch is disengaged. The return spring helps the clutch fork
to return to its rest position when the clutch foot pedal is released.

2.2.2 clutch operation mechanisms-hydraulic:

The hydraulically operated clutch has a pipe

for fluid (usually brake fluid) connected
between the foot pedal and clutch fork. It
uses two cylinders. At the clutch pedal is
the master cylinder, which incorporates a
fluid reservoir and at the clutch fork is the
slave cylinder. As the clutch pedal is
depressed, the master cylinder builds a
pressure in the system, activating the slave
cylinder. When the clutch pedal is released,
springs in the cylinders and on the clutch
pedal
(or clutch fork) help to return the system to its rest position.

2.3 automatic clutch system(ACS):

The automatic clutch system (ACS) is a
system for automatic clutch operation when
starting, gear changing and stopping.
the shift direction angle of rotation sensor
and selected direction angle of rotation
sensor ,serve to recognize the gear selected.
the shift bracket angle of rotation sensor
serve to recognize the shift intention.
Other than these signals, the control unit
of the ACS requires further signals from other systems, which can
be called up over the CAN-data bus.

3-manual transmission:
1- gears type:
Spur gearing has teeth that are cut parallel to the
rotating axis. These are noisy when operating at high
speeds .

Helical gearing has teeth cut at an angle to the

rotating a xis. This provides more tooth surface area,
allowing the gearing to run quieter.

Double helical gearing incorporates two sets of helical teeth

on one gear. Very quiet operation, although expensive to
manufacture .

2-gear ratio :
If the driver gear is smaller than the driven gear,
this is known as an underdrive gear
arrangement.
Underdrive gears are the lower transmission
range on a vehicle and are used for low speed
and high torque (1st , 2nd or 3rd ).
If the driver gear is larger than the driven gear,
this is known as an overdrive gear
arrangement.
An overdrive gear is normally the high gear (5 th or 6th). It is used for high
vehicle speeds and improved fuel economy.

3- Counter (Lay) Shaft Construction:

Input shaft
Output
shaft
Thrust
Thrust
washer

Counter shaft

4-revarse shaft construction:

When selecting reverse, the direction of drive is
changed. This is achieved by using an idler gear.
The idler gear is meshed between a counter shaft
gear and an output shaft gear.
Construction is generally a gear on a fixed shaft,
which is supported by bushes or roller/needle
bearings.

5-Output shaft construction:

The output shaft, also called the main shaft, is connected to the drive
shaft. Casing supports, used in conjunction with bearings, hold the shaft in
place.

Different sized gears are mounted on the output

shaft.
These gears rotate freely on the output
shaft, and are meshed with the gears of
the counter shaft.

6-Synchronizer
Components
As the driver selects a gear, the outer sleeve of a synchronizer slides over
its hub and toward the
required gear on the output
shaft.
In doing so, it pushes a
blocking ring against the
gears cone, producing
friction between the two.
When the synchronizer,
blocking ring and gear are
all rotating at the same speed, the gear is said to be synchronized.
The synchronizer sleeve now slides over the gear, the inner teeth of the
sleeve engaging with teeth on the gear.
This locks the gear to the synchronizer hub, and therefore to the output
shaft.
Power is now transferred from the counter shaft to the output shaft.

7-gear lever:
The gear lever is what the driver uses to manually change gear.
Gear levers are typically located on the steering wheel column or between
the two front seats.
Modern variations of gear levers include finger tip buttons on the steering
wheel, short shift and Tiptronic levers on the dashboard.

8- gear linkage:
There are two main types of linkages: external and internal. These
connect the drivers gear lever to the selector rods and forks.

Various configurations of linkage are used depending on the position of

the transmission in relation to the lever (for example, rear wheel drive or
front wheel drive vehicles).
The diagram above shows a single rail selector that uses one selector rod.
The rod has fixed pins to move the selector forks. The gate is formed by
extensions of the selector forks. To select a gear, the rail is rotated until
the selector pin aligns with the required selector fork and then moved
backwards or forwards.

9- multi-rail selector:
Multi-rail selection uses selector rods sliding in the gearbox housing.
Sliding with these rods are
the selector forks, which fit
onto the synchronizer
sleeves.
Pushing a selector fork will
move the outer sleeve of the
synchronizer hub to engage
the The lower end of the gear
lever moves between the
three selector gates to align
with one rod. When the gear
lever is moved forward or
backward, the selector rod and fork move laterally.

10- Retainers:
Retainers are spring-loaded balls or plungers, which locate in grooves in
the selector rods to hold the rods in their selected position.
When a rod is shifted it must be retained in the gear position, or neutral,
to give a positive feel and help prevent it jumping in or out of gear.

Neutral
Position

Gear
Engaged

11-Interlock

If two selector rods were

moved at the same time by the gear lever, two gears would be engaged
and cause the gearbox to lock up. To prevent this, an interlocking device
may be used.

A Ball and Plunger interlock (as shown in the diagrams) uses a pin sliding
in a hole drilled through the central rod. The rods on each side have single
grooves facing the middle. Holes in the casing hold two balls.
When an outer rod is moved, the ball is forced out of the groove and
pushes the plunger across to hold the other two rods. When the centre rod
is moved, both balls will drop into the grooves of the outer rods to lock
them.

12-Transmission Power Flow:

Frist gear

Scend gear:

Reverse Gear

Electrical & Electronic Systems Basics

Current, Voltage, Resistance

Current:
The movement of electrons in a circuit = The flow of electricity
Current is measured in units known as amperes or amps (A).
Amp = how many electrons are moving through a circuit at a given time.

(6.28 billion billion electron/sec)

Conventional Current Flow theory:

Current flow from the positive terminal to the negative terminal.
Electron Theory:
current flows from the negative terminal to the positive terminal.

Current I):
Direct current (DC): is best described as a direct, or continuous, flow of
electrons in one direction. Most automotive systems use DC. The
advantage of DC is it can be stored electro-chemically in a battery.

Alternating current (AC): is best described as an alternating, or back

and Student Workbook forth, flow of electrons. Automotive generators
produce AC potential. AC is easier to produce in a generator due to the
laws of magnetism, but it is extremely difficult to store.

Voltage (V, E, U): Electromotive force

Electrical pressure or electrical potential that drives electron flow.

Voltage is measured in volts (V)
12 v for passenger cars & 24 v for commercial cars
12000 v to 40000 v in the ignition system (ignition coil)

Resistance (R):
Resistance is the opposition to the movement of electrons, or current flow.
Resistance is measured in units called ohms ().
Resistance Factors:
Length: The longer the conductor, the higher the resistance.
Cross-sectional area: The larger the cross-sectional area of a conductor,
the lower the resistance (a bigger pipe flows more water).
Temperature: For most materials, the higher the temperature, the higher
the resistance(PTC). There are a few materials whose resistance goes
down as
temperature goes up(NTC).

Wanted/Unwanted Resistance:
Resistance is useful in electrical circuits.
We use it to produce heat, make light, limit current, and regulate
voltage.
Resistance in the wrong place cause circuit fault
[component failure, limit component operation, etc.]

Resistors:

Two basic types of

mechanically
operated variable resistors
are

Potentiometer
A three terminals variable
resistor
Current distributes
[TPS]

Rheostat
Two terminals variable
resistor
Current does not distribute
[Dash light dimmer control]

Practical Time

What is DMM?
Three things about DMM you need to know:
1. What does a DMM indicate for DC voltage?
It indicate the difference in voltage between the probe tips
[Connect the COM of ground to - BAT]
2. DMM accuracy is important [ check owner's manual, should be equal or
less than 0.05 %]
3. A good 9V battery in your DMM is important. [when the battery symbol
appears that means the accuracy decrease]

How can you measure current, voltage, and resistance ?

1. Measuring Resistance
a. power must be off
b. select ohm position
c. meter leads are placed across the component
d. make sure your fingers are not touching the leads of the meter

2. Measuring Voltage
a. Apply power to the circuit
b. select V(DC) position
c. meter leads are placed across the component
3. Measuring Current
a. select mA/A position
b. create break in the circuit

c. Apply power to the circuit

Sources of electricity
1. Friction ----------- Static electricity ESD [ vehicle tire rolling]
2. Heat --------------- Thermocouple [ very small current use to measure
temperature]
3. Light --------------- Photo electricity [ some of the light energy is
transferred to the free electrons of the metal, so electron can loss
from the surface]
4. Pressure ---------- Piezoelectricity [ the crystals of material under
cretin pressure create potential difference] (Knock sensor)
5.

Chemistry --------- electrochemistry [when two different metal

placed in
a conducting and reactive chemical solution, create a potential
difference]
(Automotive battery)
6. Magnetism --------- If an electrical conductor is moved through
a magnetic field, a voltage is induced in it.

BASIC CIRCUIT CONSTRUCTION

1. Power Source (Battery)
2. Protection Device (Fuse,Circuit Breaker)
3. Load Device (Lamp, Motor, Winding, Resistor, etc.)
4. Control (Switch, Relay, or Transistor)
5. Conductors (A Return Path, Wiring to Ground)

Series circuit

Parallel circuit

Basic Circuit Faults

There are several ways that a circuit can malfunction:
1. Open
2. Too much resistance
3. Too little resistance
4. Short to ground
5. Short to voltage

Dangers of Electricity
As shown in the illustration, a person touches a voltage source with an AC
voltage of 220 V.
Calculate which current flows through the body.

W
hat effect does the following
current have on the person?
Current in
mA

Consequence
for the
person

0.3

Sensitivity
limit

Shock

10

Muscular
cramp

30

Stunning

50

Ventricular
fibrillation,
death

Protection devices
1. Fuses
2. Circuit breaker
3. PTC circuit protectors

1. Fuses
Protect the wiring from overheating and damage by excessive
current flow as a results of:
a. Short circuit
b. Other malfunction
Fuses are protect one or more circuit.
Each fuse has amperage rating classify by color.
Test fuses
a test light should light on both sides.

Can be checked for failure by measuring for continuity across the

end terminals of the fuse or breaker.

2. Circuit breaker

Prevent harmful overload (excessive current)

It is mechanical unit made of two different metals (bimetallic) which

deform when heated and open a set of contact point.
When the excessive current stop the bimetallic cooled and contact
again.
[safety of passenger as power seats, door locker, window ]

Can be checked for failure by measuring for continuity across the

end terminals of the breaker.

3. PTC circuit protectors

Positive temperature coefficient

PTC is installed in series in the circuit
If excessive current cause temperature increases, so resistance
increases, and the current go down again
PTC may cause the electrical component in the circuit not to
function correctly [power window circuit operates slow when
temperature goes up]

Control devices
1. Switches
2. Coils
a. relays
b. solenoids

Switches
uses in the circuit as ON/OFF, Selection, or Dimer controler.
Classification:

1. according to function:
Normaly open Normaly closed 2 way
2. according to how they are actuated:

Relays
control high current by using small
current.
1. Normally open
2. Normally closed

relays location

Operation of solenoid valves

sensors and actuators:

Sensors :
In order to be able to perform all the functions relevant to the engine
managements the control unit depends on input signals like :
1- throttle valve actuator and accelerator pedal with pedal position sensor.
2- intake pipe pressure sensor and hot-film air-mass sensor with
integrated temperature sensor for intake air.
3-camshaft hall sensor and crankshaft
S position sensor.
4- knock sensor and lambda probes
1-throttle valve actuator and accelerator pedal with pedal position sensor:

it has an opening angle to determine the amount of air in the intake

pipe and how much petrol should be injected in the cylinder for
combustion
the throttle is no longer activated mechanically
in engines control unit assesses the position of the accelerator
pedal electronically and controls the opening of accelerator valve
called EGAS
the throttle valve actuator sensors indicates load conditions and
makes idling and over run operation detectable

2- intake pipe pressure sensor and hot-film air-mass sensor with

integrated temperature sensor for intake air:
The air mass :

determine the engine load

is the output variable for the amount of petrol to be injected

hot-film air mass sensor :

the cooling of the hot-film is done by the flowing air

the calculation of air-mass is from measuring the voltage

air temperature :

the hotter the air is the more it will expand

less oxygen molecule per volume unit for air

greater air supply

the intake pipe pressure :

vacuum and injected pressure are added together

the engine central system combusts for the effect with a shorter
opening time
the stronger the vacuum is in the intake pipe is the shorter the
injection valves opening time will be.

3-camshaft hall sensor and crankshaft position sensor.

A. Crankshaft position sensor :
Its used in
1. measurement of engine speed
2. optimization of :
injection timing
ignition timing
injection period

B. camshaft hall sensor :

its aim is to synchronization of injection timing and ignition timing
.according to gas exchange
4- knock sensor and lambda probes :
Knock sensor :

measure cylinder vibrations

optimizes ignition timing

lambda sensor :

measure residual oxygen content in the exhausted gas

optimize mixture of cremation

Actuators :
The engine control unit is basically control engine running by the use of 3
actuators
1. the throttle valve
2. injection valve
3. ignition coil \spark plug

1the throttle valve :

Implements the drivers output demands
Opening and closing releases The air path \ makes the air phase
narrower
More petrol Is added as the air-mass increases
2- injection valve :

The injection of finely sprayed petrol creates a mixture

Output variable is used in following air-mass
Injection valves are responds to the air-mass value connected to
the sensors of the throttle valve and he intake pipe pressure
the engine control unit controls:
valve opening time .1
injection timing .2
constant injection pressure .3
synchronization of injection timing and ignition timing

3- ignition coil \spark plug :

ignition timing is determined by the engine control unit

ignition voltage is determined by the design of the ignition point
the combustion period is determined by the homogeneity of the
mixture
the ignition time is moved farther forward before the top dead
center as the speed increases

: Suspension system
: the main purpose of the suspension system -1

.keep tyres in firm contact with the road at all times and conditions .prevent body squat (tilting down at rear) when accelerating
.prevent body dive (tilting down at front) when braking
.allow front wheels to turn for steering

:The main motion of the vehicle -2

.A-yaw motion : happened when the car turn on a high speed
B-roll motion : happened when the
. car turn right or lift
C-pitch motion: happened when
the car apply the breaks or
. accelerate

: Types of suspension
:depentant suspension -1
.Solid axle - tilts with road bumps, Both wheels tilted

-2
: indepentant suspension
.one wheel moves without affecting other
Control arm pivots, this
helps to keep the wheel
.upright
Preferred system
for modern
.vehicles

the main types of spring that in common 2.1

:used
.coil spring -1
.leaf spring-2
.torsion bar-3
.air spring-4

:A-coil spring
.This consists of a spring-steel rod wound into a coil
.It is ideally suited to independent suspension
This is the most common type of
.spring used by modern vehicles

:B-leaf spring
.Flat plates of spring steel are bolted together
The front end of the spring is bolted directly to the
.frame
A swinging shackle at the rear permits the length of the
.spring to change when it is flexed

.U-bolts and plates clamp spring to axle housing

This type used to be common but is now only used on a
.systems
few rear suspension

:C-torsion bar
One end of the torsion bar is fixed to the vehicle
frame .The other end of the torsion bar is attached to
the control arm so that it twists as the control arm
.moves up or down
A strut rod prevents
front or rear
movements of the
.control arm
When the control arm is
moved by the suspension, the
twisting motion of the
torsion bar
.resists the movement

: D-air spring
This is normally a two-ply rubber cylinder filled with
.compressed air
It has similar rebound reaction
.to a coil spring
The air spring is much lighter in weight,
compared with its steel sprung equivalent,
resulting in increased economy and an
.adjustable controllable ride
Rebound (expansion) allows the control arm to
move down when there are hollows in the
.road surface
This is especially adaptable to automatic
.levelling systems

the main component of the independent 2.2

: suspension

: A-control arm
A control arm holds the steering knuckle, bearing
.support or axle housing
The control arm is free to
move up and down with the
.suspension

:B-shock absorber
The function of a shock absorber is to reduce spring
oscillations (up and down movements) following a road
.shock
The upper end (top mount)
is attached to the frame
and the lower end (bottom
mount) to the suspension
.unit
A piston and valve
assembly moves in an oilfilled cylinder. Movement is
.controlled by the valve, rate-of-flow, restriction
A pressurized gas chamber is sometimes added to
.prevent air bubbles in the oil causing foaming
.The cylinder is enclosed in a dust cover

:C-stabilizer bar
The purpose of the stabilizer bar is to prevent
.excessive body leaning when turning

Links both the lower

control arms
.together
When one end of the
bar is deflected in
either direction (up or
down), the bar tries
to pull the other side
in the same direction,
this has the effect of
stabilizing and
controlling the
.suspension
When cornering, the outside of the body tends to drop,
.which twists the bar and limits the amount of the sway

:D-panhard rod
A panhard
rod
prevents
side-toside rear
axle
movement
when
.cornering
One end of
the
panhard rod is fastened to the axle, the other end to
.the frame on the opposite side of vehicle

: 2.3the main types of independent suspension

: woshbon suspension-1
The upper wishbone is
short and the lower
.wishbone is longer
both wishbones pivot
points and lengths
are calculated to
provide the best
operating angle
for a given
suspension
.movement

: Advantage
good control good handling : Disadvantage
hard uncomfortable -

: mapherson suspension-2
The top of the strut is bolted to a reinforced section of
.the frame structure
The lower end of the
strut is attached to a
.steering knuckle
The control arm is also
attached to the
.steering knuckle
The control arms are
mounted on
a cradle section of the
.frame
An anti-roll bar links
the two control arms
together to reduce
.sway (body roll)
: Advantage
softcomfortable-

:Disadvantage
unstableless control-

:multilink suspension-3
The multilink suspension is between the Macpherson
and wishbone
suspension , so it
collect between the
softness ,comfort and
the stability ,
. controlling

: air spring-4
This system is used to assist a conventional suspension
.system
Special shock absorbers are used with separate air
.chambers
Height sensors are mounted on the frame and linked to
the
axle
housi
ng to
chec
k the
heigh
t of
the
vehic
.le
A
comp
resso
r
.supplies air pressure to power the system

.This is electrically controlled via cables and harness

If the load increases, the sensor can turn the
compressor on, increasing pressure, or release air from
.the system if the load reduces

Active Suspension System -5

.This uses hydraulic cylinders in place of the springs
.A hydraulic pump supplies the cylinders with pressure
Pressure sensors send
signals to an electronic
.control unit (ECU)
When a wheel
goes down, the
inlet valve is
opened to
increase pressure in
.the cylinder
When a wheel
moves up, the outlet valve is
.opened to reduce pressure
.The system response is very fast
A back-up pressure reservoir/accumulator is normally
.incorporated

: Steering system
: Basic steering system

There are two main types of

steering
:linkage -1
Linkage or Conventional
,type
Also known as )
(Parallelogram
.and rack-and-pinion type
Linkage type uses a worm
gear inside the steering
gear/box, this operates the
drop arm, then couples to a
centre link, idler arm, track rods and the steering
.knuckles

:rak-and-pinion-2
Rack-and-pinion type
uses a pinion gear that
turns on a toothed rack
to move a steering bar
horizontally. Track rods
couple the bar to
.steering knuckles

: Steering shafts and columns

Nearly all steering systems use a steering column or
shaft to link the driver (steering wheel) to the steering
.rack or gear/box
Nearly all steering systems use a steering column or
shaft to link the driver (steering wheel) to the steering
.rack or gear/box

Universal joints allow

steering shaft angles to
.change
Most steering columns
are
designed with a
collapsible section
that helps prevent
forces generated in a
collision being
transferred to the
.driver
The bottom of steering column
normally has a master spline where
it mounts onto the steering
rack-and-pinion or steering gear/box, ensuring correct
.alignment

: Basic power steering system

Power steering uses hydraulic fluid pressure to assist
.steering movement
There are three
:main types
.Rack and pinion
.Integral piston
.External cylinder
All systems require a reservoir,
pump, hoses, control valve,
pressure relief valve and a
.hydraulic cylinder

Breaking system
.The brakes are controlled by the driver pressing on the brake pedal
The master cylinder and brake servo assist in applying pressure to
hydraulic fluid in the
.brake pipes

Pressurized fluid in the

brake pipes feeds the brake
components at each of the
.individual wheels
The brakes respond equally
(on the same axle) to the pressure to
.slow the vehicle
A separate manually operated
handbrake doubles as an
emergency brake in the event of
.failure of the main braking system

:Hydraulic Fluid Specification

Automobile brake fluid must meet SAE (Society of Automotive
Engineers) and DOT (Department of Transportation) specifications
:for
-.Lubrication - to reduce wear on pistons and cups
High boiling point - remains liquid at the highest operating
-.temperatures
-.Low freezing point - does not solidify in cold weather

: Action of breaking system

Master cylinder applies the force from the pedal to the brake pipe
.fluid
Drum brakes are common
.on the rear wheels
Disc brakes are most
commonly used on the
front wheels, but are also
used on the rear of some
.modern vehicles
In early hydraulic systems a
single brake pipe was used
to feed fluid from the
master cylinder to all four
.brakes
All modern vehicles use a
.dual circuit braking system
Action of the Master Cylinder
When pressure is applied at the pedal push rod, the primary seal
.covers the compensating port

Pressure can then build up in the

.brake pipes to apply the brakes
When the brake pedal is released, the
.return spring pushes the piston back
Low pressure appears in the cylinder
if the piston moves back too quickly.
To overcome this, holes are drilled in
the piston head to allow fluid to
.flow through

Vacuum Brake Servo Principles

As pressure is applied to the brake pedal, the atmosphere valve
opens allowing a pressure
.differential across the diaphragm
This pressure assistance increases
as the vacuum
.valve closes
A combination of the vacuum
acting on the diaphragm and the
direct pressure of the brake pedal
push rod, pushes the master
cylinder push rod to pressurize the
.brake pipes and apply the brakes

There are two types of breaking system

a-disc break
b-drum break

: A-disc break
Fixed Disc Calliper -1
The brake calliper is bolted directly to the front steering knuckle
.and remains rigidly mounted
Brake fluid feeds
.both pistons
Each friction pad has its own
.operating piston
The brake pads are squeezed
in towards the disc from both
.sides, in a clamping action
This type is very common on
modern high performance
.vehicles
A ventilated disc
construction allows internal
.cooling

Floating Disc Calliper -2

.In this type, the calliper is free to slide, or float, on its mounting
As the calliper can move across the disc, the friction pads apply
.even pressure to both sides of the disc
One brake pipe feeds the single piston. Only a single piston is
.required to apply the pressure
.The disc may be solid or ventilated
The elasticity of the hydraulic seal pulls the
piston away from the pads when fluid
.pressure is released

: B- drum break
Most have two pistons in
.one cylinder

When brake pressure is applied,

the pistons are both forced
.outward with equal pressure
When brake pressure is released,
retractor springs pull the brake
.shoes away from the brake drum
On installation the bleed screw
allows unwanted air to be
removed from the brake pipes
.and cylinder
The wheel cylinder pistons push
.outwards onto both brake shoes
The primary shoe is leading
and is the front shoe, this
normally has a smaller and
.thicker frictional lining area
Retracting springs pull the brake
shoes away from the drum when
.pressure is released
The secondary shoe is trailing and is the rear shoe, this normally
.has the largest but thinnest frictional lining area

The purpose of the drum is to provide a friction surface for the

brake linings, to dissipate the heat, and in some
cases provide hub
bearing or wheel
.location
The drum fits over the
wheel hub or the
.drive flange
The wheel and drum
are bolted together
.and turn as one unit
Drums sometimes have
.fins to aid cooling

:Hand breaks
The handbrake doubles as an emergency brake and is manually
.operated
.Lever has a ratchet system with a spring-loaded release button
A cable/rod links the brake
lever to the rear-wheel
.brakes
There is a pressure equalizer
and brake adjuster coupling
.the cable links together
Left and right flexible cables
link the operation to the
.wheels