CHAPTER 1 AUTOMOTIVE BASICS 1
1.1 BODY AND FRAME 1
1.2 BASIC ENGINE 2
1.3 DRIVE LINES AND RUNNING GEAR 4
1.4 SUSPENSION SYSTEM 4
New Words 5
CHAPTER 2 ENGINE CLASSIFICATIONS 7
2.1 CLASSIFIED BY THE LOCATION OF THE COMBUSTION 7
2.2 CLASSIFIED BY THE TYPE OF COMBUSTION 8
2.3 CLASSIFIED BY THE TYPE OF INTERNAL MOTION 8
2.4 OTHER CLASSIFICATION METHODS 9
2.5 CLASSIFICATION OF ENGINES USED IN AUTOMOBILES 10
New Words 10
CHAPTER 3 BASIC ENGINE TERMINOLOGY 11
3.1 CYLINDER BLOCK 11
3.2 CYLINDERS 11
3.3 PISTONS 11
3.4 CONNECTING ROD AND CRANKSHAFT 12
3.5 CYLINDER HEAD 12
3.6 COMBUSTION CHAMBER 12
3.7 VALVES 13
3.8 VALVE AND CYLINDER HEAD ARRANGEMENTS 14
3.9 CAMSHAFT 14
3.10 FLYWHEEL 15
3.11 INTAKE AND EXHAUST MANIFOLDS 15
3.12 CARBURETOR 16
3.13 FUEL INJECTORS 16
New Words 16
CHAPTER 4 ENGINE DESIGN AND SYSTEMS 18
4.1 FUEL SYSTEM 18
4.2 IGNITION SYSTEM 19
4.3 STARTING AND CHARGING SYSTEM 19
4.4 LUBRICATION SYSTEM 20
4.5 COOLING SYSTEM 21
4.6 AIR INTAKE AND EXHAUST SYSTEMS 21
4.7 POLLUTION CONTROL SYSTEM 22
New Words 23
CHAPTER 5 GASOLINE ENGINE PRINCIPLES 25
5.1 COMBUSTION REQUIREMENTS 25
5.2 FOUR-STROKE ENGINE DESIGN 28
New Words 32
CHAPTER 6 OTHER POWER SOURCES 33
6.1 DIESEL ENGINE PRINCIPLES 33
6.2 TWO-STROKE ENGINE DESIGN 36
6.3 ROTARY DESIGN(WANKEL) 38
6.4 HYBRID POWER SOURCE 38
6.5 FUEL CELLS 41
New Words 43
CHAPTER 7 BASIC ENGINE CONSTRUCTION 45
7.1 CYLINDER BLOCK 45
7.2 CRANKSHAFT ASSEMBLY 46
7.3 PISTON AND ROD ASSEMBLY 51
New Words 58
CHAPTER 8 CYLINDER HEADS AND VALVES 60
8.1 CYLINDER HEAD 60
8.2 VALVE ASSEMBLY 62
8.3 CAMSHAFT ASSEMBLY 64
8.4 VALVE DRIVE MECHANISM 65
New Words 68
CHAPTER 9 LUBRICATION SYSTEM 70
9.1 OIL FLOW 70
9.2 OIL PAN 71
9.3 OIL PUMPS 71
9.4 OIL PRESSURE REGULATING VALVE 72
9.5 OIL FILTERS 73
9.6 OIL COOLERS 74
9.7 OIL SENSORS AND GAUGES 74
New Words 75
CHAPTER 10 COOLING SYSTEM 76
10.1 TYPES OF COOLING SYSTEMS 76
10.2 COOLING SYSTEM PARTS 77
New Words 83
CHAPTER 11 FUEL DELIVERY SYSTEMS 84
11.1 TOTAL FUEL FLOW 84
11.2 FUEL TANK 86
11.3 FUEL PUMPS 87
11.4 FUEL FILTERS 90
11.5 ELECTRONIC FEEDBACK CARBURETORS 90
11.6 GASOLINE FUEL INJECTION SYSTEMS 91
New Words 93
CHAPTER 12 AIR INTAKE AND EXHAUST SYSTEMS 94
12.1 AIR INTAKE SYSTEMS 94
12.2 EXHAUST SYSTEMS 95
12.3 TURBOCHARGERS AND SUPERCHARGING SYSTEMS 96
New Words 97
CHAPTER 13 IGNITION SYSTEMS 98
13.1 CONVENTIONAL IGNITION SYSTEM 98
13.2 ELECTRONIC AND COMPUTERIZED IGNITION SYSTEMS 100
New Words 105
CHAPTER 14 CHARGING SYSTEMS AND STARTING SYSTEMS 107
14.1 AUTOMOTIVE BATTERIES 107
14.2 CHARGING SYSTEMS 107
14.3 STARTING SYSTEMS 108
New Words 111
CHAPTER 15 EMISSION AND CONTROL SYSTEMS 112
15.1 TYPES OF POLLUTANTS 112
15.2 POSITIVE CRANKCASE VENTILATION(PCV)SYSTEM 113
15.3 EVAPORATIVE EMISSION CONTROLS 113
15.4 HEATED AIR INTAKE 114
15.5 EXHAUST GAS RECIRCULATION(EGR) 114
15.6 CATALYTIC CONVERTERS 115
New Words 116
CHAPTER 16 COMPUTERIZED ENGINE CONTROL SYSTEMS 118
16.1 ENGINE COMPUTER SYSTEM 118
16.2 INPUT COMPONENTS(SENSORS) 119
16.3 OUTPUT COMPONENTS(ACTUATORS) 126
New Words 127
CHAPTER 17 AUTOMOTIVE CLUTCHES 128
17.1 PRESSURE PLATE ASSEMBLY 128
17.2 FRICTION DISC 129
17.3 MULTIPLE DISC CLUTCHES 129
17.4 CLUTCH RELEASE BEARING(THROW-OUT BEARING) 130
17.5 CLUTCH LINKAGE 130
17.6 FLYWHEEL DESIGN 132
New Words 133
CHAPTER 18 MANUAL TRANSMISSIONS 134
18.1 MAIN GEARS AND SHAFTS 134
18.2 TYPES OF TRANSMISSIONS 135
18.3 SYNCHRONIZERS 136
18.4 TRANSMISSION CASE AND LUBRICATION 136
18.5 SHIFTING FORKS 137
18.6 SHIFT MECHANISMS 139
New Words 139
CHAPTER 19 AUTOMATIC TRANSMISSIONS 140
19.1 MAJOR PARTS OF THE AUTOMATIC TRANSMISSION 140
19.2 TORQUE CONVERTER 140
19.3 PLANETARY GEAR SYSTEM 143
19.4 CLUTCHES,BANDS,AND SERVO PISTONS 145
19.5 HYDRAULIC SYSTEM 148
19.6 TRANSMISSION CONTROLS 150
19.7 ELECTRONIC AND COMPUTER-CONTROLLED TRANSMISSIONS 150
19.8 CVT 152
New Words 153
CHAPTER 20 DRIVE LINES,DIFFERENTIALS,AND AXLES 154
20.1 REAR-WHEEL DRIVE SHAFTS AND OPERATION 154
20.2 FRONT-WHEEL DRIVE SYSTEMS 157
20.3 DIFFERENTIALS AND AXLES 159
New Words 161
CHAPTER 21 FOUR-WHEEL/ALL-WHEEL DRIVE SYSTEMS 162
21.1 PRINCIPLES OF FOUR-WHEEL/ALL-WHEEL DRIVE SYSTEMS 162
21.2 FOUR-WHEEL DRIVE COMPONENTS 164
New Words 165
CHAPTER 22 BRAKING SYSTEMS 166
22.1 COMMON BRAKING SYSTEM PRINCIPLES 166
22.2 COMMON BRAKING SYSTEM COMPONENTS AND OPERATION 168
22.3 POWER BRAKES 171
22.4 ANTILOCK BRAKE SYSTEMS(ABS) 173
New Words 178
CHAPTER 23 SUSPENSION SYSTEMS 179
23.1 FRONT SUSPENSION 179
23.2 REAR SUSPENSION 183
23.3 SHOCK ABSORBERS 185
23.4 COMPUTER-CONTROLLED SUSPENSION SYSTEMS 190
23.5 MACPHERSON STRUT SUSPENSION 192
New Words 193
CHAPTER 24 STEERING SYSTEMS 194
24.1 STEERING SYSTEM PARTS 194
24.2 FRONT END GEOMETRY AND ALIGNMENT 197
24.3 POWER STEERING 200
New Words 202
CHAPTER 25 TIRES AND WHEELS 203
25.1 TIRES 203
25.2 WHEELS AND RIMS 205
New Words 207
REFERENCE 208