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1、Range Rover Sport,动力总成 V8 自然吸气/机械增压 发动机,学员手册第8部分第5 71页,由中汽南方蒋凤石翻译,Powertrain V8 Engines N/A and S/C,Workbook section 8Pages 5 71,目的(动力传递部分),注意：本课程与另外一门课程（Denso发动机管理系统）共同组成发动机部分的完整介绍。描述4.4 NA和4.2 SC发动机的结构特性介绍各种发动机技术参数按照路虎公司政策进行发动机维修正确使用专用工具,Objectives(Powertrain),Note:this course is designed to run a
2、long side the Denso Engine management training programmeDescribe the Features of the naturally aspirated 4.4 litre and the 4.2 litre supercharged engineDescribe the technical specification for all enginesCarry out engine repairs in line with Land Rovers PolicyUse special tools correctly.,概述,Page 9,G
3、eneral,Page 9,V8 汽油机,90 V型铝制缸体铝制汽缸盖 每缸4气门无垫片，挺杆直接作用可变气门正时(VVT)机械增压版上未安装初级、次级链式驱动 铝制缸床(阶梯型结构)碎裂式连杆两根V型驱动皮带电控EGR(机械增压版未装)引入机械增压在Bridgend的发动机厂组装,Page 9,V8 Petrol Engine,90 Vee Aluminium cylinder blockAluminium cylinder heads-Four valves per cylinderShim-less,tappet bucketsVariable valve timing(VVT)not
4、on superchargerPrimary and secondary chain drives Aluminium bedplate(ladder frame)Fracture split connecting rodsTwin multi-vee drive beltsElectronic EGR(no EGR on supercharger)Supercharger introducedBuilt at the Bridgend engine plant.,Page 9,Base Engine,AJ-41 V8 NA 发动机是 AJ-33 V8 NA 的改良版新型 AJ-41/43 V
5、8 发动机将投放所有市场变更要点：深式油底壳修正FEAD(发动机驱动风扇)排放标准达到欧4 US LEV II修正EGR15,000 英里机油保养(欧洲),7,500英里换机油(美国)无回油管路系统修正冷却水出口控制(throttle to different side of vehicle)无垫片,Base Engine,AJ-41 V8 NA Engine is modified version of AJ-33 V8 NA The new AJ-41/43 V8 will be launched into all markets.Key V8 engine changes over th
6、e Jaguar version:-Deep SumpRevised FEAD(engine driven fan)Tail pipe emissions Europe&ROW Stage 4 US LEV IIRevised Exhaust Gas Recirculation(EGR)15,000 Mile Oil Service(Europe),7,500 miles oil change in USAReturnless Fuel SystemRevised water outlet(throttle to different side of vehicle)Shim-less tapp
7、ets.,AJ41 V8 NA,发动机线束,加油管高度增加,改进的缸盖改良水套,排气歧管,缸床,深式油底壳,初级FEAD皮带,具有滤清的油冷却器,次级发动机前发动机辅助驱动皮带（FEAD）,改进的节温器支架以适应节气门,节气门体,发动机罩盖安装支架,AJ41 V8 NA,Engine Harness,Oil Fill tube,Height increased,Modified Cylinder Head,improved ports and water jacket,Fabricated LogExhaust Manifolds,Structural bedplate,Deep sump,P
8、rimary FEAD drive,Oil Cooler with filter head,Second FEAD drive,Modified Thermostat housing to suit throttle elbow,Throttle Body and elbow,Engine cover mounting brackets,AJ41 V8 NA,修正的EGR管,变矩器连接处,起动机,AJ41 V8 NA,Revised EGR pipe,Torque converter access,Starter Motor,功率/扭矩数据L319-L320-L322,Power/Torque
9、 Figures L319-L320-L322,缸体,铸铝中缸，干式的钢质气缸内衬套，和4.4L NA发动机类似。缸径尺寸由88mm改为86mm 机械增压款发动机加装了活塞机油喷射冷却装置。（在主油道上装有放油口，喷射冷却装置通过螺纹拧紧到放油口上。）该喷油装置位于活塞冠部下方。共四个喷油装置，每个有两个喷嘴。在4.4L NA发动机上的放油口没有精加工（因为没有必要使用机油喷射冷却装置）。,Page 14,Cylinder Block,Aluminium casting with iron dry liners similar to 4.4L NA;Cylinder bore size is
10、86mm instead of 88mm Piston cooling jets are bolted into tapings into the main oil gallery directed at the underside of piston crown.Four jets each have two nozzles.Tapings are left unmachined for 4.4L NA.,Page 14,缸号/发动机数据,*SLHPT*CBBC*22222211*KMKMK*000823 0756,曲轴轴颈等级,曲轴曲柄销等级,缸镗等级,日期/时间,曲轴轴承孔,发动机数据
11、左侧,Page 15,Cylinder numbering/engine data,*SLHPT*CBBC*22222211*KMKMK*000823 0756,Main crankshaftjournal grades,Crankshaft pin Grades,Cylinder bore Grades,Date/time,Main Crank bores,Engine data left hand side,Page 15,发动机数据 3个位置,发动机缸体上有两个 另外一个在发动机前盖上如 0408232319AA04=年08=月份23=日期2319=时间AA=自然进气SA=机械增压,En
12、gine Data 3 Locations,Two locations on cylinder block One on engine front coverExample of coding 0408232319AA04=200408=August23=Day2319=TimeAA=Naturally AspiratedSA=Supercharged,曲轴,活塞铸造深式活塞(压缩比 9.1:1)，活塞销22mm(NA发动机21mm)活塞销固定卡簧和连杆小端轴承设计和4.4L NA 发动机一样 例如活塞销在飞溅润滑的铜套中浮动和4.4L NA发动机一样镗缸有三个等级可靠的油环（最底端的活塞环）
13、控制(4.4L NA发动机是相互分离的三活塞环设计).连杆22mm的连杆销直径与4.4L NA发动机不同；将来会有两个连杆供应商，标记符号方面可能会有不同。曲轴、曲轴轴承、连杆大头轴承 与NA发动机相同(90.3mm行程),Page 16,Crankshaft,PistonsForged deep dish piston(CR 9.1:1)with 22mm pin diameter.(21mm for NA)Design of piston pin retention(circlips)and little-end bearing same as 4.4L NA i.e.floating p
14、in in splash-fed bronze bush.Three grades as 4.4L NA.Solid oil control(bottom)ring(4.4L NA is three piece segmented).Con rodsDifferent to 4.4L NA due to 22mm pin diameter.(Two rod suppliers in future transparent to service but some markings may differ).Crank,Main and Big-End Bearings,Same as NA engi
15、ne(90.3 Stroke),Page 16,汽缸盖,铸造、加工及组装同 4.4L 自然进气式包括阀座、气门导杆、凸轮轴盖及油堵头(Avdel Plugs)注意：对于机械增压发动机，每个缸盖均需一个额外的油堵头以堵住未用的VVT出油口。气门、气门弹簧、气门琐销同 4.4L 自然进气式凸轮轴不同的进、排凸轮轴，SC发动机气门叠开角度更小，对正时可采用相同的凸轮轴固定工具。,Cylinder Heads,Head Casting and Machining&Sub AssemblySame as 4.4L NAIncludes valve seats and guides,cam caps,ga
16、llery plugs(Avdel Plugs)NB:One extra Avdel plug is required per head to blank off VVT feedValves,springs,colletsSame as 4.4L NACamshaftsDifferent intake and exhaust cams.Duration and timing(less overlap for SC engine).Timing flats positioned appropriately so same service tools used for timing.,4.2.S
17、C 正时链/齿调整,上图为不带VVC装置的 4.2 SC 正时链调整下图为4.4 N/A 带有VVC装置的正时调整,4.2.SC Timing Chain/Gear Arrangement,Top image shows 4.2 SC gear arrangement with no VVCLower image shows 4.4 N/A gear arrangement with VVC,4.2.SC 正时链/齿调整,上图为 4.2 SC 不带VVC装置的正时调整注意：没有安装VVC装置的汽缸盖上供油孔是空的。下图是 4.4 N/A带有VVC装置的正时调整注意到VVC装置的油孔是清晰可见的
18、注意点：当安装4.2 SC发动机新的缸盖时确保油口堵死。,4.2.SC Timing Chain/Gear Arrangement,Top image shows 4.2 SC gear arrangement with no VVCNote:oil feed in cylinder head is blanked off as no VVC housing is fittedLower image shows 4.4 N/A gear arrangement with VVCNote oil feed to VVC housing is clearly visible Care point!
19、When fitting new cylinder head to 4.2 SC engine make sure redundant oil feed gallery is plugged to prevent loss of oil pressure and oil starvation to cylinder head components,4.2.SC 正时链/齿调整,4.2.SC Timing Chain/Gear Arrangement,凸轮轴链条驱动,链条驱动此系统全部与4.4L NA相同。两个主链条驱动每边的进气凸轮轴，排气凸轮轴由进气凸轮轴通过次级驱动链驱动，液压涨紧器全时使
20、用。对正时步骤同Discovery 3/LR3可变凸轮轴正时(部件安装于进气凸轮轴)没有安装在 SC 发动机上(很可能安装在MY07上)进气凸轮轴为普通链轮齿删除VVT供油支架及电磁阀缸盖油道供油需要用油堵（Avdel plug）堵住！此操作在维修时需要特别注意！,Page 29,Camshaft Chain Drive,Chain DriveSame overall system as 4.4L NA.Two main chains drive inlet cams for each bank.Exhaust cams then driven from each intake cam wit
21、h small secondary chains.Hydraulic tensioners used throughout.Timing process identical to Discovery 3/LR3Variable Camshaft Timing(unit on intake cams)NOT fitted to SC engines.(But is likely to come in for MY07)Intake camshaft sprockets are therefore conventional“disc”sprocket.VVT oil feed“spider”bra
22、cket and solenoid unit therefore deleted.Oil feed from cylinder head gallery requires blanking off with Avdel plug.This operation will be required in service?,Page 29,4.2 SC 发动机特点,汽缸内径由 88mm 减少到 86mm活塞冷却喷嘴铸造活塞/新型油环新型连杆新型凸轮轴无VVT装置-新型凸轮轴盖空气进入中冷器 具有独立的冷却回路无EGR,Features for 4.2 SC engine,Bore size reduc
23、ed from 88mm to 86mmPiston cooling jetsForged pistons/new oil control ringNew connecting rodsNew camshaftsNo Variable Valve Timing-New camshaft coversAir to water intercoolers with separate cooling circuitNo EGR,其他详细差异：-RFI suppressor 安装在B-Bank中冷器后部-美观降噪塑料盖板 中冷器上有长的固定螺栓-净化系统，碳罐电磁阀安装在外壳支架上-在“眼镜蛇”进气管的
24、下方有一个控制噪音的黑色T型塑料袋（内装降噪材料）-无EGR-凸轮轴盖 如果部件或系统没有提及，则为相同的，主要有：点火系统(火花塞和点火线圈)发动机支架及固定螺栓正时链条盖润滑系统(油底壳、集滤器、机油泵、机油尺、管路等),细节/共同性,Other detail differences;-RFI suppressor mounted at rear of B-Bank intercooler-Styling cover mountings long pillar studs fitted to intercoolers-Purge system.Purge valve mounts to b
25、racket on bell housing-NVH“stuffer”under cobra duct(Black T-shaped pad).-No EGR-Camshaft covers If a part/system hasnt been mentioned yet then it is common.These include;Ignition system(Spark plugs and coils)Engine mounting brackets and boltsChain drive coverLubrication system(sump,oil pickup,oil pu
26、mp,dipstick and tube).,Details/Commonalities,机械增压,Supplier-Eaton Model-M112-4H33 6F066 BAPerformance gain approx 60KW(80HP)0.8 bar inlet pressure(gauge)1.8 bar absolute,Page 37,Supercharging,Supplier-Eaton Model-M112-4H33 6F066 BAPerformance gain approx 60KW(80HP)0.8 bar inlet pressure(gauge)1.8 bar
27、 absolute,Page 37,机械增压,发动机动力取决于可消耗的空气量 通常方法是靠大气压力提供发动机进气 如果空气在高压情况下进入汽缸就可以获得更多的进气量，这就是：机械增压,Page 38,Supercharging,Power of the engine depends upon mass of air it can consume Normal method allows atmosphere to force air into the engine If the air is forced into cylinders under pressure higher than at
28、mospheric,a greater mass of air will enter the cylinder and the engine will be:Supercharged,Page 38,中冷器,经过增压单元压缩后进气温度通常超过160每侧都有单独的水冷空气散热器。这种近距离的小体积散热器有利于减小“增压延迟现象”。为获得最大的冷却效果，中冷器冷却回路与发动机冷却水路是分开的(中冷器冷却有自己的水泵，是独立的回路)气流由上部大出口流出，分成A、B两部分支流，然后通过两个喉管再进入各自的中冷器。,Intercoolers,After compression in the superc
29、harger unit,the intake air temperature often exceeds 160 degrees C.Separate air to water heat exchanger matrices for each bank.Close coupled small volume heat exchangers minimise boost“lag”.Cooling circuit for intercoolers is separate to engine system for greatest cooling effect.(Separate pumped cir
30、cuit)Airflow exits supercharger from one large port on top surface flow then diverges into A-bank and B-bank streams(“wing duct”)before entering each intercooler.,分解图,驱动齿轮,齿轮外科/油底壳,叶片,驱动皮带轮,支撑轴承,构造:,输入轴,Exploded View,Gear drive,Gear housing/sump,Vanes,Drive pulley,Supportbearing,Construction:,Input
31、shaft,机械增压,Supercharger,机械增压,组成:转子安装于钢轴上轴在前部滚子轴承上运转（后部为滚针轴承）螺旋齿被压向前部钢轴螺旋齿轮由润滑油密封(油池,全合成润滑油)不要进行维修驱动皮带盘安装在钢轴上，与斜齿轮柔性耦合连接,Supercharger,Assembly:The rotors are mounted on steel shaftsThe shafts run on bearings(needle roller rear)deep groove ball bearing frontHelical gears are pressed onto the front of
32、the steel shaftsThe helical gears are lubricated(oil bath,fully synthetic PTFE based)sealed for life DO NOT TOP UP IN SERVICEDrive pulley is mounted on the steel shaft and is connected to the driver helical gear via a torsion soft coupling,机械增压器,Supercharger,机械增压,中冷器,机械增压,节气门体,旁通阀,机械增压系统,Intercooler
33、,Supercharger,Throttle body,By-pass valve,Supercharged System,中冷器,水冷铝制结构每侧一个,连接水管,来自机械增压,Page 39,Intercooler,Water cooledAluminium construction1 Per bank,Water connections,From supercharger,Page 39,中冷器,散热片管路实现气液热交换,Intercoolers,Fin and tube air-to-liquid heat exchangers,压力控制阀,进气,机械增压,压力控制阀,在机械增压上利用旁
34、通空气控制压力,Pressure control valve,Air intake,Supercharger,Pressure control valve,By-passes air to controlPressure in supercharger,压力控制阀,真空操作旁通阀（真空管在节气门体下游控制）怠速及巡航条件下旁通阀全开提供最大的旁通进气量以获得最佳的燃油经济性。当节气门打开时旁通气阀逐渐关闭以减少旁通气流增加空气供给压力，从而获得发动机的最佳动力输出。,Page 40,Pressure control valve,Vacuum operated bypass valve.(Vac
35、uum pipe downstream of throttle body to actuator unit).Idle and most cruise conditions the bypass valve is fully open to provide maximum bypass and optimum fuel economyAs the throttle opens the bypass valve progressively closes to reduce bypass flow and increase the pressure of the air supplied to t
36、he engine for optimum power output.,Page 40,旁通阀,旁通阀,真空阀,阀连接,Bypass valve,Bypass valve,Vacuum valve,Valve linkage,压力控制阀,严禁在压力控制阀不连接的情况下着车，否则将会导致严重的发动机损坏 这是因为机械增压过热、疲劳卡死，甚至达到疲劳极限注意:如果在维修过程中压力控制阀损坏，会导致发动机运转时机械增压严重的损坏,真空阀,Pressure control valve,NEVER RUN the engine with the pressure control valve discon
37、nected otherwise severe engine damage will result This will cause the supercharger to overheat and seize,even if running was for a limited periodNote:If pressure control valve fails in service serious damage is caused to the supercharger,Vacuum valve,机械增压维修,密封部件-只能换件：机械增压部件应该运转自由-没有明显受限在发动机运转情况下不要执行
38、以下操作：拆除驱动皮带情况下检测机械增压拆卸真空管,Supercharger Servicing,Sealed component-REPLACEMENT ONLY:The supercharger should be free running without noticeable restrictionDo not conduct any of the following with the engine runningTest supercharger with drive belt removedDisconnect vacuum pipes,机械增压诊断,扭转耦合:拆除任节气门肘或机械增
39、压出口用手抑制转子的运动（不要使用工具）无负载情况下用手旋转驱动皮带，原设计是大约30度注意:这种运动是正常的并且可消除怠速异响,Supercharger Diagnostics,Torsion coupling:Remove either throttle elbow or supercharger outlet housingRestrain rotor movement with hand(DO NOT use tools)Rotate drive pulley by hand,approx 30 degrees total movement in unloaded condition
40、is the design conditionNote:This movement is normal and is required to eliminate idle speed gear chirp,机械增压诊断,Supercharger Diagnostics,机械增压诊断,外观检查：转子具有明显磨损（磨光）是可以接受的当磨掉特殊镀层(允许保持转子和壳体最小间隙)时会看到磨光的情况严重划痕情况，例如转子上磨损可见铝制材料是不可接受的(不要与磨光混淆)严重的划痕可能导致外物进入机械增压,Supercharger Diagnostics,General Visual examination
41、:Evidence of polishing on the rotors is acceptableThis occurs as a result of removal of high spots of special coating(this allows minimum clearance to be maintained between rotors and casing)Heavy scoring i.e.Aluminium base material becomes visible on rotors is not acceptable(do not confuse with pol
42、ishing)Isolated or random heavy scoring is generally a result of foreign body ingress into the supercharger,可变气门正时,工作原理油经过三角支架总成进入各个VVT执行器，三角支架总成包括VVT电磁阀、油道及正时链导向机构发动机管理系统通过安装在三脚架顶部的电磁阀来控制凸轮轴的提前或滞后。,Page 45,Variable Valve timing,Operating principal Oil is fed to the front of each VVT actuator via th
43、e spider bracket assembly which contains the VVT actuator solenoid,supply oil galleries and timing chain guide.Oil pressure advances and retards the camshaft timing which is controlled by the engine management system via a solenoid valve mounted in the top of the oil feed spider assembly.,Page 45,可变
44、气门正时,凸轮轴正时Camshaft timing:依据发动机转速、负载及油压进行调整,Page 46,Variable Valve timing,Camshaft timing:dependant on engine speed,load and oil temperature.,Page 46,SC 发动机需要对机油进行外部风冷，从冷却器供油回油到发动机油底壳前滤网的油道前部滤网包含一个温度调节装置，防止油温低于103,机滤,Page 49,SC engine requires external air blast oil cooler.Pipe work to feed and retu
45、rn from this cooler plumbs into the engine oil galleries in the oil filer housing on the front of the sump.This filter head contains a thermostatic valve which prevents oil flow below 103 degrees C oil temp.,Oil Filter Head,Page 49,冷却系统,冷却系统 Page 53,Cooling,Cooling Systems Page 53,S/C 冷却回路,用水冷却空气此处连
46、接使得层压器冷却水路和发动机冷去水路相连，但在系统工作时两个水路的冷却水是不互相传热（流通）的。通过BOSCH电子泵驱动，通过塑料支架和销子安装在散热器边侧,S/C Coolant Circuit,Water charge air coolingVortex connection to top hose,providing single point for fill/degas but remains thermally decoupled.Driven by Bosch electric pump,mounted to radiator end tank with push fit plas
47、tic bracket and pin.Service fill screw in brick feed T piece(deleted from bricks),S/C 冷却水管,加热管，快速接口发动机和防火墙无辅助加热选项散热器到发动机有排气管排水管由膨胀箱到快速接口再到发动机,Coolant Hoses S/C,Heater pipes,quick fit to bulkhead and engineNo auxiliary heater option Bleed hose from radiator and engine.Drain hose from expansion tank,q
48、uick fit to engine.,S/C 机油冷却器及管路,两个油冷却器并联，均来自发动机节温器出水口。片装水冷器安装在底盘横梁上。冷却器上装有快速连接油管。到冷却器的冷却水从水管的两个T型连接处引出。,S/C Engine Oil Coolers and Pipes,Two oil coolers in parallel,fed from engine thermostat port.Plate water oil cooler mounted off cross member,Oil hoses quick fitted to cooler stub pipes.Coolant fe
49、d from radiator return hose via double T,Velocity Head Scoop.,S/C 机油冷却器及管路,空气冷却器安装在右翼子板后方，轮眉上方风口处。冷却器上装有油管的快速接头。,S/C Engine Oil Coolers and Pipes,Air blast oil cooler mounted in offside wing,with vented wheel arch liner.Fixings to bumper armature,and body mount,Oil hose quick fits to oil cooler,with
50、 single release tool supplied on pipes backwards(one per cooler),前发动机辅助驱动皮带FEAD,初级FEAD皮带与4.4L NA相似。例如V型皮带驱动空调压缩机、动力转向、水泵和发电机L320的不同点在于这条皮带同时也带动动态反应泵，因此皮带较长，且带有一个额外的堕伦。所以机械增压发动机都标配动态反映泵，自然吸气发动机是选配。次级FEAD皮带内外均有棱纹，与NA发动机上的风扇驱动的布置相同，但是向上部延展以驱动机械增压。风扇驱动皮带盘为左侧螺纹，因为风扇旋转方向相反。塑料保护外壳有颜色代码。,Page 59,FEAD belt s
