Modern Car Handbook Benas Kundrotas & Algis Jurgis Kundrotas Vilnius 2020 Modern Car Handbook Authors: Dr. Benas Kundrotas Dr. Habil., Prof. Algis Jurgis Kundrotas Annotation The handbook presents innovative technologies of a modern car. Cars with internal combustion engines are mainly overviewed. Hybrid and electric vehicles are presented as well. Great attention is paid to technologies that ensure fuel economy and reduction of gas emissions. The newest internal combustion engine technology is presented and explained. The car passengers and driver safety systems are widely considered. The assist and self-adaptive technology principles for safely ride are reviewed and discussed too. Also, an introduction in the latest technologies that help to protect the surrounding road users and particularly pedestrians is delivered. Car security issues and some recommendations to protect your car from theft are introduced. Car computers elements and its applications for car control and diagnosis are examined. Widely and in details are discussed sensor system which applies in a modern car. Sensors operation principles (physics) and technologies are studied and presented as well. ISBN 978-609-475-496-8 Experimental Version Non-profit edition © Benas Kundrotas, Algis Jurgis Kundrotas Vilnius 2020 Publisher: Benas Kundrotas Vilnius 2020 2 Contents Introduction …………………………………………………………………………….……. 8 Chapter 1. Modern Car ………………………………………………………………...…10 1.1 Introduction to car systems …………………………………………………………….……10 1.2 Car drive wheel configurations ……………………….…………………………………..... 11 1.3 Rear-wheel drive (RWD) and front-wheel drive (FWD) ………….…………………...…... 12 1.4 A four-wheel drive car (4WD) …………………….…………………………… ………..... 15 1.5 All-wheel drive car (AWD) …………………….…………………………………….….… 16 1.6 Symmetrical All-wheel drive car …………….…………………………...…………..….… 18 1.7 All-wheel drive systems ……………………………………………. …..……………...…...19 1.8 Differentials for AWD …………………………………………………………...……….. 21 1.8.1 Torsen differential ………………………………………………….……………. 21 1.8.2 Crown gear differential ………….…………………………………..………...…. 22 1.8.3 Multidisc (multiplate) clutch ………………………………………….……..….... 22 1.8.4 Planetary gear central differential …………………………………….…..…….... 22 1.8.5 Viscous limited slip differential (VLSD) ………………………….……….....….. 23 1.8.6 Haldex limited slip differential …………………….……………..…...……....…. 23 1.9 Short overview of All Wheel Drive systems ………………………………….......……….. 23 1.9.1 Audi Quattro AWD …………………..……………………………….…..…...…. 23 1.9.2 BMW xDrive AWD ……………………………………….………...….….….…. 24 1.9.3 Ford Intelligent (new Disconnect) AWD ……………………………………...…. 24 1.9.4 Honda SH-AWD …………………………………………………….…..…….…. 25 1.9.5 Hyundai HTRAC AWD ……………………………………………..………...…. 25 1.9.6 Kia Dynamax AWD …………………………………………………………...…. 26 1.9.7 Mazda i-ACTIV AWD …………………………………………...………..….…. 26 1.9.8 Mercedes 4MATIC AWD ………………………………...…………..……….…. 27 1.9.9 Mitsubishi Super All Wheel Control S-AWC ……………………………..….…. 27 1.9.10 Nissan ATTESA AWD …………………………………………….…..…….…. 28 1.9.11 Range Rover AWD ………………………………………….……………….…. 28 1.9.12 Subaru Symmetrical AWD (SAWD) ………………………………..……….…. 29 1.9.13 Toyota AWD with Dynamic Torque Control (DTC) …………...…………...…. 29 1.9.14 Volkswagen 4motion AWD ………………………………………….…..…..…. 30 1.10 Car classification …………………………………………………………………..…...…. 30 1.10.1 Car dimensions …………………………………………………….…..…….….. 31 1.10.2 Sedan …...……………………………………………………………..……...…. 33 1.10.3 Convertible or Cabriolet ………………………..………….…………..…….…. 34 1.10.4 Coupe …………………………………………………………………..…….…. 35 1.10.5 Hatchback ………………………………………………………………...….…. 36 1.10.6 Station Wagon, Estate ……………………………………………....…….….…. 37 3 1.10.7 Multi-purpose vehicle ……………………………………..…………...…….…. 38 1.10.8 Sport Utility Vehicle (SUV) …………………………..…………….……….…. 39 1.10.9 Crossover, Crossover Utility Vehicle (CUV) ……………………...…..…….…. 40 1.10.10 Pickup truck …………………………………………………..…………….…. 41 1.10.11 Luxury vehicles …………………………………………………..…...…….…. 42 1.11 Car tire labelling and parameters ……………………...……………………..……..….…. 42 1.11.1 Car tire label ………………………………………………...……..…...…….…. 42 1.11.2 Car tire code ……………………………………………………........……….…. 44 1.11.3 Car tire parameters ……………………………………………….....….....….…. 45 1.11.4 Car tire load index and speed rating ………………….………...…...……….…. 46 Chapter 2. Engine & Fuel …………………………………………………..…..…….…. 48 2.1 Internal combustion engines classification …………………………………….…….….…. 48 2.1.1 Camshaft ……………………………………………………………….……...…. 50 2.1.2 Gasoline (Petrol) fuel injection ……………………………...……………..….…. 51 2.1.3 Diesel engine common rail direct injection (CRDI) system ………………..……. 52 2.1.4 Gasoline (petrol) injectors ……………………………………………….....….…. 53 2.1.5 Diesel engines injectors ……………………………………………..……....…… 55 2.1.6 Turbo charger ………………………………………………………..…..…….…. 57 2.2 Variable valve timing & lift ………………………………………………...……..…….…. 58 2.3 Overview of Variable valve timing & lift systems ………………………..…………….…. 60 2.3.1Audi valvelift system (AVS) ……………………………...……………..…….…. 60 2.3.2 BMW VANOS, Valvetronic …………………………………...…………..….…. 60 2.3.3 Ford Ti-VCT ………………………………………………...…..…………….…. 61 2.3.4 Honda VTEC, i-VTEC …………………………………………..…………….…. 61 2.3.5. Hyundai, Kia CVVT, Dual-CVVT ………………………………..………….…. 61 2.3.6 Mazda S-VT system ……………………………………………………..…….…. 62 2.3.7 Mercedes CAMTRONIC …………………………………………………..….…. 62 2.3.8 Mitsubishi MIVEC …………………………………………….…..………….…. 62 2.3.9 Mitsubishi MIVEC Turbo (gasoline engine) ………………….……..……….….. 65 2.3.10 Nissan N-VTC ………………………………………………..………..…….…. 66 2.3.11 Subaru AVCS & i-AVLS ………………………………….………………...…. 66 2.3.12 Toyota VVT, VVTL, Valvematic ………………………………………………. 66 2.3.13 Volkswagen VVT ………………………………………….……………..….…. 67 2.4 Common rail direct fuel injection systems in diesel engines ………………………………. 67 2.5 Overview of Common rail direct fuel injection systems in diesel engines…………………. 68 2.5.1 Audi TDI …………………………………………………………..……….….…. 69 2.5.2 BMW d, sd …………………………………………………….………..….….…. 69 2.5.3 Ford TDCi ……………………………………………………..…..…………..…. 69 2.5.4 Honda, Acura i-CTD, i-DTEC …………………………………………..…….…. 69 2.5.5 Hyundai, Kia CRDi ………………………………………………….…..…….…. 70 2.5.6 Mazda MZR-CD, Skyactiv-D ……………………………….…..…………….…. 70 2.5.7 Mercedes d, CDI ……………………………………………..…….………….…. 70 4 2.5.8 Mitsubishi Di-D, Di-DC ………………………………….…………..……….…. 71 2.5.9 Nissan dCi ……………………………………………………..……… .…….…. 71 2.5.10 Subaru d, TD ………………………………………………….…………..….…. 71 2.5.11 Toyota D-4D …………………………………………………….……..…….…. 72 2.5.12 Volkswagen TDI ………………………………………………...……..…….…. 72 2.6 Engine fuel ………………………………………………………………………...…….…. 72 2.7 Energy losses in a vehicle ……………………………………………………………….…. 76 2.8 Automatic Stop-Start system …………………………………………………………....…. 77 Chapter 3. Driving & braking …………………………………….……………..….…. 81 3.1 Gear box (transmission) ……………………………………………….……………..….…. 81 3.1.1 Automated manual transmission (AMT) ………………………………..…….…. 83 3.1.2 Automatic transmission (AT) ………………………………….…………..….…. 84 3.1.3 Front-wheel drive (FWD) manual transmission ………..……...…………..….…. 88 3.1.4 A continuously variable transmission CVT………………………….………...…. 89 3.2 Steering systems ………………………………………………………….……..……….…. 94 3.3 Power assisted steering systems ……………………………………….…………..…….…. 95 3.4 Anti-lock braking system (ABS) ……………………………………...………………...…. 99 3.5 Brake assist system …………………………………………………………………….…. 102 3.6 Electronic brake distribution (EBD) …………………………………..……………….…. 102 3.7 Electronic stability control (ESC) …………………………………………..………….…. 104 3.8 Traction control system .……....…………………………………………………..………. 105 3.9 Hill Start Assist HAS …………………………………………………………….…….…. 106 3.10 Indirect tire pressure monitoring ……………………………………..……………….…. 107 Chapter 4. Electrical and Electronic systems ……………...…………..……….…. 109 4.1 Introduction to Car Electrical System .…………………………………..…………….…. 109 4.2 Battery ………………………………………………………………………………….…. 110 4.2.1 Conventional Battery …………………………………………..…………….…. 111 4.2.2 Battery for Stop Start systems ……………………………………….……….…. 112 4.2.3 Battery for Hybrid Electrical Vehicles …………………...………………….…. 113 4.2.4 Battery for electric vehicles ………………………………………………….…. 114 4.3 Starter. Restarting engine ……………………………………………...……………….…. 115 4.4 Modified alternator and regenerative-breaking …………………………….………….…. 116 4.5 Other important electrical system elements …………………………...……………….…. 117 4.6 Electronic systems. Introduction ……………………………………………………….…. 117 4.7 Car computer …………………………………………………………….……………..…. 118 4.8 Controlling the engine ………………………………………………………………….…. 120 4.9 In-Vehicle Networking (IVN) and Protocols…………………………..……………….…. 120 4.9.1 LIN (Local Interconnect Network) ………………………………………….….. 121 5 4.9.2 CAN (Controller Area Network) …………………………………………….…. 121 4.9.3 FlexRay high speed network …………………….……………………………… 122 4.9.4 MOST bus …………………….………………………………………………… 122 4.10 Car Communication ports and their functions …………………….…………………….. 123 4.11 On-Board Diagnostics (OBD) …………………….……………………………………... 124 4.12 On-Board Diagnostics and parameters identification …………………….……………... 126 4.13 Diagnostic and erasing trouble codes …………………….……………………………... 129 4.13.1 Understanding diagnostic trouble codes……………………………………….. 129 4.13.2 OBD-II scan tools …………………….……………………………………….. 130 4.13.3 Cheap OBD-II scan tools …………………….………………………………... 133 4.13.4 The risk of using OBD-II scan tools …………………….…………………….. 135 Chapter 5. Safety, Security & Comfort …………………….………………………. 139 5.1 Car Safety introduction …………………….……………………………………………... 139 5.2 Safety systems …………………….………………………………………………………. 141 5.3 Security systems …………………….…………………………………………………….