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CHAPTER 1 AUTOMOTIVE BASICS1

1.1 BODY AND FRAME1

1.2 BASIC ENGINE2

1.3 DRIVE LINES AND RUNNING GEAR4

1.4 SUSPENSION SYSTEM4

New Words5

CHAPTER 2 ENGINE CLASSIFICATIONS7

2.1 CLASSIFIED BY THE LOCATION OF THE COMBUSTION7

2.2 CLASSIFIED BY THE TYPE OF COMBUSTION8

2.3 CLASSIFIED BY THE TYPE OF INTERNAL MOTION8

2.4 OTHER CLASSIFICATION METHODS9

2.5 CLASSIFICATION OF ENGINES USED IN AUTOMOBILES10

New Words10

CHAPTER 3 BASIC ENGINE TERMINOLOGY11

3.1 CYLINDER BLOCK11

3.2 CYLINDERS11

3.3 PISTONS11

3.4 CONNECTING ROD AND CRANKSHAFT12

3.5 CYLINDER HEAD12

3.6 COMBUSTION CHAMBER12

3.7 VALVES13

3.8 VALVE AND CYLINDER HEAD ARRANGEMENTS14

3.9 CAMSHAFT14

3.10 FLYWHEEL15

3.11 INTAKE AND EXHAUST MANIFOLDS15

3.12 CARBURETOR16

3.13 FUEL INJECTORS16

New Words16

CHAPTER 4 ENGINE DESIGN AND SYSTEMS18

4.1 FUEL SYSTEM18

4.2 IGNITION SYSTEM19

4.3 STARTING AND CHARGING SYSTEM19

4.4 LUBRICATION SYSTEM20

4.5 COOLING SYSTEM21

4.6 AIR INTAKE AND EXHAUST SYSTEMS21

4.7 POLLUTION CONTROL SYSTEM22

New Words23

CHAPTER 5 GASOLINE ENGINE PRINCIPLES25

5.1 COMBUSTION REQUIREMENTS25

5.2 FOUR-STROKE ENGINE DESIGN28

New Words32

CHAPTER 6 OTHER POWER SOURCES33

6.1 DIESEL ENGINE PRINCIPLES33

6.2 TWO-STROKE ENGINE DESIGN36

6.3 ROTARY DESIGN(WANKEL)38

6.4 HYBRID POWER SOURCE38

6.5 FUEL CELLS41

New Words43

CHAPTER 7 BASIC ENGINE CONSTRUCTION45

7.1 CYLINDER BLOCK45

7.2 CRANKSHAFT ASSEMBLY46

7.3 PISTON AND ROD ASSEMBLY51

New Words58

CHAPTER 8 CYLINDER HEADS AND VALVES60

8.1 CYLINDER HEAD60

8.2 VALVE ASSEMBLY62

8.3 CAMSHAFT ASSEMBLY64

8.4 VALVE DRIVE MECHANISM65

New Words68

CHAPTER 9 LUBRICATION SYSTEM70

9.1 OIL FLOW70

9.2 OIL PAN71

9.3 OIL PUMPS71

9.4 OIL PRESSURE REGULATING VALVE72

9.5 OIL FILTERS73

9.6 OIL COOLERS74

9.7 OIL SENSORS AND GAUGES74

New Words75

CHAPTER 10 COOLING SYSTEM76

10.1 TYPES OF COOLING SYSTEMS76

10.2 COOLING SYSTEM PARTS77

New Words83

CHAPTER 11 FUEL DELIVERY SYSTEMS84

11.1 TOTAL FUEL FLOW84

11.2 FUEL TANK86

11.3 FUEL PUMPS87

11.4 FUEL FILTERS90

11.5 ELECTRONIC FEEDBACK CARBURETORS90

11.6 GASOLINE FUEL INJECTION SYSTEMS91

New Words93

CHAPTER 12 AIR INTAKE AND EXHAUST SYSTEMS94

12.1 AIR INTAKE SYSTEMS94

12.2 EXHAUST SYSTEMS95

12.3 TURBOCHARGERS AND SUPERCHARGING SYSTEMS96

New Words97

CHAPTER 13 IGNITION SYSTEMS98

13.1 CONVENTIONAL IGNITION SYSTEM98

13.2 ELECTRONIC AND COMPUTERIZED IGNITION SYSTEMS100

New Words105

CHAPTER 14 CHARGING SYSTEMS AND STARTING SYSTEMS107

14.1 AUTOMOTIVE BATTERIES107

14.2 CHARGING SYSTEMS107

14.3 STARTING SYSTEMS108

New Words111

CHAPTER 15 EMISSION AND CONTROL SYSTEMS112

15.1 TYPES OF POLLUTANTS112

15.2 POSITIVE CRANKCASE VENTILATION(PCV)SYSTEM113

15.3 EVAPORATIVE EMISSION CONTROLS113

15.4 HEATED AIR INTAKE114

15.5 EXHAUST GAS RECIRCULATION(EGR)114

15.6 CATALYTIC CONVERTERS115

New Words116

CHAPTER 16 COMPUTERIZED ENGINE CONTROL SYSTEMS118

16.1 ENGINE COMPUTER SYSTEM118

16.2 INPUT COMPONENTS(SENSORS)119

16.3 OUTPUT COMPONENTS(ACTUATORS)126

New Words127

CHAPTER 17 AUTOMOTIVE CLUTCHES128

17.1 PRESSURE PLATE ASSEMBLY128

17.2 FRICTION DISC129

17.3 MULTIPLE DISC CLUTCHES129

17.4 CLUTCH RELEASE BEARING(THROW-OUT BEARING)130

17.5 CLUTCH LINKAGE130

17.6 FLYWHEEL DESIGN132

New Words133

CHAPTER 18 MANUAL TRANSMISSIONS134

18.1 MAIN GEARS AND SHAFTS134

18.2 TYPES OF TRANSMISSIONS135

18.3 SYNCHRONIZERS136

18.4 TRANSMISSION CASE AND LUBRICATION136

18.5 SHIFTING FORKS137

18.6 SHIFT MECHANISMS139

New Words139

CHAPTER 19 AUTOMATIC TRANSMISSIONS140

19.1 MAJOR PARTS OF THE AUTOMATIC TRANSMISSION140

19.2 TORQUE CONVERTER140

19.3 PLANETARY GEAR SYSTEM143

19.4 CLUTCHES,BANDS,AND SERVO PISTONS145

19.5 HYDRAULIC SYSTEM148

19.6 TRANSMISSION CONTROLS150

19.7 ELECTRONIC AND COMPUTER-CONTROLLED TRANSMISSIONS150

19.8 CVT152

New Words153

CHAPTER 20 DRIVE LINES,DIFFERENTIALS,AND AXLES154

20.1 REAR-WHEEL DRIVE SHAFTS AND OPERATION154

20.2 FRONT-WHEEL DRIVE SYSTEMS157

20.3 DIFFERENTIALS AND AXLES159

New Words161

CHAPTER 21 FOUR-WHEEL/ALL-WHEEL DRIVE SYSTEMS162

21.1 PRINCIPLES OF FOUR-WHEEL/ALL-WHEEL DRIVE SYSTEMS162

21.2 FOUR-WHEEL DRIVE COMPONENTS164

New Words165

CHAPTER 22 BRAKING SYSTEMS166

22.1 COMMON BRAKING SYSTEM PRINCIPLES166

22.2 COMMON BRAKING SYSTEM COMPONENTS AND OPERATION168

22.3 POWER BRAKES171

22.4 ANTILOCK BRAKE SYSTEMS(ABS)173

New Words178

CHAPTER 23 SUSPENSION SYSTEMS179

23.1 FRONT SUSPENSION179

23.2 REAR SUSPENSION183

23.3 SHOCK ABSORBERS185

23.4 COMPUTER-CONTROLLED SUSPENSION SYSTEMS190

23.5 MACPHERSON STRUT SUSPENSION192

New Words193

CHAPTER 24 STEERING SYSTEMS194

24.1 STEERING SYSTEM PARTS194

24.2 FRONT END GEOMETRY AND ALIGNMENT197

24.3 POWER STEERING200

New Words202

CHAPTER 25 TIRES AND WHEELS203

25.1 TIRES203

25.2 WHEELS AND RIMS205

New Words207

REFERENCE208