to r v e h ic le c o m p o n ents

1 Mo
2 Workshop safety
ces
3 Workshop practi
e
4 Tools and their us king
hec
5 Measuring and c s
F r ic ti o n a n d b e a r ing
6 e alants
a ls , g a s k e ts a n d s
7 Se th e a u to m otive
m e n t a n d
8 The environ
service industry

01 May - Automotive 8e.indd 1 19/5/09 2:55:38 PM

01 May - Automotive 8e.indd 2 19/5/09 2:55:39 PM
 CHAPTER 1 • MOTOR VEHICLE COMPONENTS 3

M e c h a n ic a l a r r a ngements
•
tor vehicle
• Sections of a mo
icles
• Hybrid-drive veh
mbly
• The engine asse
tion
• Vehicle construc
• The drive train
• Transmissions
• Running gear
• Electrical system
ted parts
• Body and associa
nents and parts
• Names of compo
• Technical terms
s
• Review question

01 May - Automotive 8e.indd 3 19/5/09 2:55:39 PM

 4 PART 1 • INTRODUCTION TO MOTOR VEHICLES
A motor vehicle is made up of a large number of parts
which are assembled together during manufacture.
Some parts are large and others are quite small.
Many parts are fitted together to form larger com-
ponents. Some parts are bolted together while
others, such as the body panels and subframes, are
welded together.
Motor vehicles vary greatly in design and body
style, and the term motor vehicle can be used to
include passenger cars, station wagons, vans, utilities,
trucks, buses and coaches. In fact, any wheeled
vehicle that operates on roads can be included.
In this book, most of the information will relate
to passenger vehicles and light commercial vehicles.
However, the basic principles involved apply to all
motor vehicles and, in many instances, to vehicles that
do not usually operate on roads, such as agricultural
tractors and industrial and construction equipment.
Mechanical arrangements
There are two basic arrangements of the major
mechanical components of passenger and light
commercial vehicles: front-wheel drive and rear-
wheel drive. These are shown in simplified form in
Figures 1.1 and 1.2 with their parts identified. While
the main difference is whether the front wheels or
the rear wheels drive the vehicle, this can affect a
2 3 4 5 6 7
1 20 19
Figure 1.1 Skeletal arrangement of a rear-wheel-drive vehicle
1 engine assembly, 2 radiator, 3 alternator, 4 front suspension, 5 front disc brake, 6 steering assembly, 7 torque converter, 8 automatic
transmission, 9 handbrake, 10 propeller shaft, 11 rear suspension, 12 rear brake, 13 shock absorber, 14 rear-axle assembly, 15 fuel tank,
16 final drive, 17 exhaust system, 18 catalytic converter, 19 wheel hub, 20 battery
01 May - Automotive 8e.indd 4
number of other components, such as the mounting
of the engine, the transmission, the drive line and the
suspension.
In addition to these two basic arrangements,
there are also four-wheel-drive vehicles. These have
additional transmission and drive-line components
that carry the drive to all four wheels of the vehicle.
In many four-wheel-drive vehicles, front-wheel
drive is selected by the driver only when it is needed,
but other vehicles, referred to as all-wheel drives,
operate in four-wheel drive at all times.
Sections of a motor
vehicle
A motor vehicle consists of a number of sections which,
for convenience, can be considered as follows:
1 The engine assembly, which is the source of
power.
2 The frame or chassis, which forms the basic
structure to support the engine and the various
mechanical components.
3 The drive train, which has gears and shafts to
connect the engine to the driving wheels.
4 The running gear, consisting of the wheels,
tyres, suspension, steering and brakes, which
enables the vehicle to operate on the road.
8 9 10 11 12 13
14
15
18 17 16
19/5/09 2:55:39 PM

4 5 6 7 8 9
19 3 1 2 18
Figure 1.2 Skeletal arrangement of a front-wheel-drive vehicle
1 manual transaxle, 2 final drive, 3 clutch, 4 radiator, 5 alternator, 6 engine assembly, 7 front disc brake, 8 hub, 9 wheel, 10 steering assembly,
11 exhaust system, 12 rear suspension, 13 rear brake, 14 fuel tank, 15 rear-wheel hub, 16 handbrake, 17 drive shafts, 18 suspension, 19 battery
5 The electrical system, which includes the
battery, wiring, lights, starter, alternator and
other electrical components.
6 The body of the vehicle, which provides seating
for the driver and passengers and, in commercial
vehicles, carries loads.
To service these various parts of a motor vehicle,
it is necessary to know the names of the various
components, their location on the vehicle, and their
purpose or function.
It is also necessary to understand how components
operate and to be familiar with their construction
and design. A knowledge of adjustments and servic-
ing requirements is also important, together with
accepted methods of carrying out repairs.
Hybrid-drive vehicles
Hybrid vehicles have an internal combustion engine
combined with an electric motor to provide the power
to drive the vehicle. The reason for this is to improve
fuel economy and to reduce exhaust emissions. The
engine can be designed so that it is smaller than
normal and as a result is more fuel efficient. The
electric motor produces no emissions.
01 May - Automotive 8e.indd 5
CHAPTER 1 • MOTOR VEHICLE COMPONENTS 5
10 11 12 13
17 16 15 14
The basic hybrid arrangement is shown in
Figure 1.3 on the following page with its main parts
identified. Depending on driving conditions, power
to drive the vehicle is delivered by the engine, by the
electric motor, or by a combination of the engine and
the electric motor.
It has a fuel tank to supply petrol to the engine and
high-voltage batteries to provide power to the electric
motor. The battery is recharged by a generator when
the electric motor is not in use. More information on
hybrid vehicles can be found in Volume 2.
The engine assembly
The engine is the source of power that provides the
torque or turning force which is used to drive the
vehicle. Engines in motor vehicles can be internal com-
bustion, electric or a combination of the two (known
as ‘hybrid’). Internal combustion engines burn the
fuel inside the engine using petrol, distillate or gas.
Electric motors use electricity supplied from storage
batteries fitted to the vehicle. The batteries can be
charged using an internal combustion engine, fuel cell,
solar cell, power regeneration and external charging.
Figure 1.4 on the following page is a drawing of
a basic engine with its main parts identified. This is a
19/5/09 2:55:45 PM
 6 PART 1 • INTRODUCTION TO MOTOR VEHICLES

3 4 5 6 7 8 9

2 1 1 12 11 10

Figure 1.3 Skeletal arrangement of a hybrid-powered vehicle

1 hybrid transaxle, 2 electric-motor assembly, 3 radiator, 4 engine, 5 front brake, 6 front hub, 7 wheel, 8 steering assembly, 9 fuel line,
10 high-voltage battery, 11 fuel tank, 12 power cable

camshaft

timing belt

camshaft exhaust valve

pulley
cylinder head
intake valve
piston rings

piston
flywheel

cylinder

connecting
rod

timing
pulley

crankshaft
pulley

connecting-rod crankshaft
bearing crankshaft
main
oil pan bearing

Figure 1.4 Basic construction of a four-cylinder engine

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 CHAPTER 1 • MOTOR VEHICLE COMPONENTS 7

four-cylinder petrol engine of the type fitted to pas-

senger cars and light commercial vehicles. More details
of an engine of this type can be seen in Figure 1.5.
In operation, burning fuel inside the cylinders of
the engine produces a high pressure which forces
the pistons to move down their cylinders. Piston
movement is transferred to the crankshaft by the
connecting rods, causing the crankshaft to rotate.
This rotary motion is then carried by the drive train
to the driving wheels and used to propel the vehicle
along the road.
The engine assembly includes the engine itself
as well as all the components and systems needed
to make it start and run. These include the starting,
charging, cooling, ignition, lubrication, fuel and the
exhaust systems.
Vehicle construction
Passenger cars have a body of unitised construction.
Reinforced panels and subframes are built into the
body to provide the necessary strength and stiffness.
A body of this type is shown in Figure 1.6 on the next
page.
Subframes for supporting the engine and trans-
mission, the front and rear suspensions and other
mechanical parts are built into the reinforced under-
body panels. Strengthened sections of panels are
used for mounting other components.
The subframes provide mountings for the engine,
the transmission, the suspension and the steering. The
engine has rubber mountings to prevent noise and

Figure 1.5 Four-cylinder engine, sectional view

1 timing belt, 2 camshaft drive pulley, 3 camshaft, 4 intake valve, 5 exhaust valve, 6 oil filler cap, 7 valve rocker gear, 8 cylinder head,
9 piston in section, 10 cylinder block, 11 cylinder, 12 connecting rod, 13 flywheel, 14 connecting-rod big end and crankshaft, 15 oil pan or
sump, 16 oil pump intake, 17 fan belt, 18 pulley on crankshaft, 19 oil pump, 20 water pump, 21 fan MITSUBISHI

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 8 PART 1 • INTRODUCTION TO MOTOR VEHICLES
Figure 1.6 Body structure with different metals used. These provide light weight and strength
vibration being transmitted to the vehicle body. Rubber
bushes between the various parts of the suspension
and the subframe also insulate against the noise and
vibration that originates at the road and tyres.
Some light commercial vehicles are designed with
a cab and chassis. They have a driver’s cab of unitised
construction and a frame, or rear chassis, on which a
tray-type body, or a commercial body of some other
design can be built.
Larger commercial vehicles have a full frame
or chassis to which the body, engine, suspension,
steering and other mechanical components are
fitted. The chassis is made of steel channel or box
section for strength, with the parts being welded or
riveted together. Cross-bracing is provided to make
the frame rigid enough to withstand the shocks,
twists and vibrations that it will be subjected to during
operation.
The drive train
The drive train, also called the power train, includes
all the components that carry drive from the engine
to the driving wheels of the vehicle. Different
arrangements are used for rear-wheel drive and front-
wheel drive (refer to Figures 1.1 and 1.2).
With rear-wheel drive, the drive reaches the rear
wheels through the clutch, transmission, propeller
shaft, final drive, differential and rear axle.
With front-wheel drive, the drive is carried by the
clutch, transaxle and drive shafts to the front wheels
of the vehicle. There are similar components, but
they are arranged differently and are more compact.
Vehicles with automatic transmissions have similar
drive trains to those with manual transmissions,
but they have a torque converter instead of a clutch.
01 May - Automotive 8e.indd 8
Body structure
steel usage
Materials
Low carbon
Medium strength
High strength
Advanced high strength
Ultra strength
Aluminium
COPYRIGHT HOLDEN 2008. USED WITH PERMISSION.
Automatic transmissions for front-wheel drive are
known as automatic transaxles.
Handy hint: The term drive is one that is commonly
used, although what is actually being transmitted is
torque, or twisting force.
Clutch
The clutch is a friction-type coupling that enables
the engine to be connected or disconnected from
the transmission. It consists basically of a large disc
held against the engine’s flywheel by spring force.
The disc is released by the driver pressing down the
clutch pedal. This allows the gears to be engaged and
gearshifts to be made. The clutch also enables the
load to be applied gradually when starting the vehicle
from rest.
A simplified clutch arrangement is shown in
Figure 1.7. The clutch disc is normally held against
the face of the flywheel by the diaphragm spring,
but is released by the movement of the pedal being
transferred through the cable to the release fork.
A mechanically operated clutch is shown. Its
operation depends on the action of levers. Other
clutches are operated hydraulically.
Rear-wheel drive
In rear-wheel-drive vehicles, a drive shaft, called the
propeller shaft, carries the drive from the transmission
to the rear-axle assembly. It has universal joints and
a sliding spline which allows the shaft to change its
length and ‘angle’ so that it can adjust to rear-axle
and suspension movement.
19/5/09 2:56:08 PM
 CHAPTER 1 • MOTOR VEHICLE COMPONENTS 9

the propeller shaft to the rear wheels. The final-drive

2
gears (the crown wheel and pinion) provide a gear
1
3 ratio of about 4:1. They also change the direction of
4
drive 90°, from the propeller shaft to the rear-axle
5 shafts and rear wheels.
The rear axle also houses the gears of the
differential. When the vehicle is travelling in any
direction, other than straight ahead, one rear wheel
must turn faster than the other. The differential allows
this, while still delivering drive to both rear wheels.

6 Information: With a 4:1 gear ratio in the final

drive, the propeller shaft would rotate four times to
7 turn the rear wheels once.

8
9
Figure 1.7 Simplified illustration of a clutch assembly
1 flywheel, 2 clutch disc, 3 pressure plate, 4 pressure plate
cover, 5 pedal, 6 control cable, 7 release bearing, 8 diaphragm
spring, 9 release fork
Rear-axle assembly
The rear-axle assembly of a rear-wheel-drive vehicle
contains the gears and axles that carry the drive from
Front-wheel drive
The arrangement of a front-wheel drive is shown in
Figure 1.8. The engine is mounted transversely, that
is, across the vehicle. Therefore, there is no need to
change the direction of drive before it reaches the
driving wheels. Drive is transferred from the engine
by the clutch to the gears of the manual transaxle,
then through the final-drive gears and differential
(which are in the transaxle housing) and then by the
drive shafts to the front wheels.
The drive shafts have special types of universal
joints, called constant-velocity joints. Apart from
allowing the shafts to adjust to suspension movement,

Figure 1.8 Arrangement of a transaxle and front-wheel drive FORD

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 10 PART 1 • INTRODUCTION TO MOTOR VEHICLES
Figure 1.9 Arrangement of the drive line of a four-wheel-drive vehicle
the outer joints in the shaft must allow the front
wheels to turn for steering.
Four-wheel drive and all-wheel drive
Four-wheel-drive vehicles have a final drive and axle
at both front and rear. Figure 1.9 shows the basic
arrangement of a larger four-wheel-drive vehicle.
There is a propeller shaft from the transmission
to both the front and the rear axles. This has a
secondary transmission, known as a transfer case,
located beside the main transmission. This is used to
manually engage front-wheel drive.
All-wheel drive vehicles operate in four-wheel
drive all the time. They have a centre differential,
or a special silicon coupling that allows for different
speeds at the front and rear wheels. This is in addition
to the differentials in the front and rear axles.
Transmissions
A transmission, commonly called a gearbox, contains
gears and shafts which provide a number of different
gear ratios between the engine and the driving wheels.
Gears are needed because an internal-combustion
engine produces little power when running at low
speeds.
To move a stationary vehicle, a low gear allows
the engine to operate at a fairly high speed while the
driving wheels turn at a low speed. This delivers a high
torque to the wheels so that the vehicle can move
01 May - Automotive 8e.indd 10
TOYOTA
off easily. However, a low gear ratio is unsuitable for
higher road speeds because the engine would have
to operate at speeds far in excess of those at which
it is capable. For this reason, a transmission, with a
number of gears, is used.
Transmissions used in cars may have three, four,
five or even six different gear ratios for forward
movement as well as one for reverse. For light trucks,
five or six gear ratios are often provided. Large trucks
have an even greater number of gears.
In addition to the gear ratios within a transmission,
a gear reduction also occurs in the final drive. In rear-
wheel-drive vehicles, the final drive is located in the
rear-axle assembly, and in front-wheel-drive vehicles,
it is within the transaxle housing.
Information: With front-wheel drive, the
transmission is called a transaxle because it combines
the functions of a transmission with those of an axle.
Manual transmissions
In a manual transmission or a transaxle, the gears are
selected by the driver moving the gear lever. When
selecting or changing gears, it is necessary to isolate
the engine from the transmission by using the clutch.
The overall gear reduction between the engine
and the rear wheels is provided by the gears in the
19/5/09 2:56:13 PM

transmission and also by the gears of the final drive.
For example, if the first gears of the transmission
provide a ratio of 3:1 and the gears of the final drive
provide a ratio of 4:1, the overall effect would be a
gear ratio of 12:1. With this arrangement, the engine
crankshaft would rotate twelve times to turn the
driving wheels once.
Other possible transmission ratios are: second
gear 2:1, third gear 1.5:1, fourth gear 1:1, and fifth
gear 0.5:1. Changing up through the gears enables
the road speed to be increased while maintaining
reasonable engine speeds.
Gears in the transmission are not just used for
road speed, they are used for transmitting torque,
and so lower gears are used under conditions where
the engine is operating under load.
Information: Gear ratios similar to those shown
could be used, but the actual ratios will depend on the
particular make and model of vehicle. An example of a
low ratio is 3.166; even ratios are not used.
Automatic transmissions
Automatic transmissions have a different type of
gears, but they have similar ratios to a manual trans-
mission. Gear shifting is done automatically without
the help of the driver.
Instead of a clutch, vehicles with an automatic
transmission (or an automatic transaxle) are fitted
with a torque converter between the engine and the
transmission (Figure 1.10). This is a hollow flywheel,
full of oil, attached to the crankshaft of the engine.
Drive is transmitted through the converter by fluid
being forced against vanes on the internal parts of
the converter.
welded joint
oil pump drive
Figure 1.10 External view of a torque converter – it has internal
vanes and is filled with oil
01 May - Automotive 8e.indd 11
CHAPTER 1 • MOTOR VEHICLE COMPONENTS 11
At engine idle speed, the fluid in the converter
moves slowly and drive is not transmitted, but when
engine speed is increased, the fluid has sufficient
force to carry drive through the converter to the
transmission gears. There is slip between the parts of
the converter and this can provide a form of gearing
under certain conditions. A clutch in the torque
converter operates automatically in the higher gears
to prevent slip.
Running gear
The running gear of a vehicle includes the
suspension, wheels, tyres, brakes, steering and all the
other chassis components that enable the vehicle to
operate on the road. Separate chapters of this book
are devoted to most of these, but a number of them
will be considered briefly here.
Suspension
The purpose of the suspension system is to support
the body and to reduce the transmission of movement
from the wheels to the body of the vehicle while
keeping the wheels in correct alignment.
The suspension system includes the wheels and
tyres, axles, springs and shock absorbers. It also
includes the arms and linkages which attach them
to the chassis or subframe. There are a number of
different arrangements.
Figure 1.11 on the following page shows a strut-
type suspension unit. The unit consists of a coil
spring mounted on a strut (which is a large shock
absorber) and the axle spindle on which the wheel
hub is mounted. This type of suspension is referred
to as McPherson suspension. It is fitted to many
passenger cars and can be used for both front and
rear suspensions.
Springs
The wheels and axles are isolated from the chassis
or subframe by the springs, which support the
main parts of the vehicle. Springs allow the wheels
to move up and down as the wheels meet holes or
bumps in the road, thereby reducing the movement
that would otherwise be transferred to the body and
passengers.
The action of a coil spring is shown in Figure 1.12
on the following page. When the wheel encounters
a bump in the road, the spring compresses, and
when it meets a hollow, the spring expands. This
enables the wheel to follow the irregularities in the
road. Linkage, or arms, connect the knuckle to
the subframe and hold the wheel in position. There
19/5/09 2:56:19 PM
 12 PART 1 • INTRODUCTION TO MOTOR VEHICLES

would continue to compress and expand (or oscillate),

moving the body of the vehicle up and down. This
repeated up-and-down movement of the body would
not only produce a very rough ride, but would cause
the vehicle to be unstable. The driver would find it
mounting difficult to control, particularly at higher speeds and
on curves.
spring A shock absorber is fitted between the suspension
and the body or frame near each wheel of the vehicle.
Shock absorbers are filled with fluid which provides
the damping action. Separate shock absorbers are
strut
not used with McPherson struts as a shock absorber
shield is built into the strut.
brake disc
Wheels and tyres
Wheels are made of pressed steel or of aluminium
alloy. Aluminium alloy is used because it is lighter
caliper
hub
than steel and also for appearance.
Wheels consist of two sections: a rim and a flange.
The rim provides a mounting for the tyre, while the
flange is provided with holes to allow the wheel to be
Figure 1.11 Strut-type suspension with its wheel hub and disc bolted to the axle hub. Passenger vehicles use single
brake wheels. Light trucks have single wheels at the front
and dual wheels at the rear to increase their load-
carrying capacity.

upper
Tyres
knuckle support suspension The tyres support the vehicle and absorb road shocks
arm
from smaller irregularities in the road surface. Tyres
spring
with a separate inner tube were used for many years,
but passenger cars now use tubeless tyres in which
frame
the air is retained by the airtight casing of the tyre
and its fit on the wheel rim.
Tyres provide cushions of air which enable them
to flex slightly as bumps are encountered and this
provides a smooth ride. The tyres also provide good
frictional contact with the road surface for the driving
wheels and also for braking.

lower Brakes
suspension
arm Brakes are used to slow or to stop the vehicle. With
(spring support)
disc brakes, a disc attached to the wheel hub is
clamped between two brake pads. Drum brakes have
Figure 1.12 The coil spring compresses as the wheel a drum attached to the wheel hub and braking is by
encounters a bump in the road means of brake shoes which are expanded against
the inside of the drum.
Both types are operated hydraulically. Hydraulic
are various arrangements for both front and rear fluid in the system is used to transfer force from
suspensions, which include coil springs, leaf springs the driver’s brake pedal to the brakes at the
and torsion bars. wheels.
The arrangement of a braking system is shown
Shock absorbers in Figure 1.13. The hydraulic system consists of a
Shock absorbers are used to dampen out the action master cylinder, which is operated by the brake
of the springs. Without shock absorbers, the springs pedal, and hydraulic lines and hoses, which connect

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 CHAPTER 1 • MOTOR VEHICLE COMPONENTS 13

master cylinder brake hose

pedal pushrod brake lines

FRONT REAR

park brake
lever

brake line park brake

cable drum brake or
disc brake disc brake

Figure 1.13 Braking system arrangement HOLDEN LTD

the master cylinder to the brake cylinders at the

wheels. The system is filled with hydraulic brake
fluid.
Brakes are power assisted. This reduces the force
that the driver has to apply to the brake pedal. Some
brakes are fitted with an antiskid braking system
(ABS) which prevents the wheels from skidding
when the brakes are forcibly applied.
A parking brake can be applied by a foot- or
hand-operated lever. The park brake applies the rear
brakes by means of cables between the handbrake
lever and the rear brakes.

Steering system
The steering system permits the front wheels and
hubs to be turned to the left and right so that the
vehicle can be steered. The steering wheel is attached
to a shaft which is connected to a steering box. Gears
in the steering box are connected to the steering Figure 1.14 Simple steering arrangement
linkage and this linkage is then connected to the 1 steering column, 2 steering box, 3 track rod, 4 idler arm,
front wheels. This arrangement turns the wheels in 5 steering arm, 6 ball joint
whichever direction the steering wheel is turned.
The steering arrangements in both Figures 1.1 and
1.2 are for a rack-and-pinion steering box. Inside the Most vehicles have power steering, where
steering box, a small gear on the end of the steering hydraulic pressure in the steering box is used to
shaft is meshed with gear teeth of a rack. The rack can assist the driver.
be moved from side to side by turning the steering
wheel and this movement is used to turn the wheels.
This design of steering box is used extensively on
passenger cars. Information: A rack is a bar into which gear teeth
A steering arrangement which is used with a have been cut; a pinion is a small gear; a worm is a
worm-type steering box is shown in Figure 1.14. This spiral shaped gear.
design is likely to be found on some larger cars and
commercial vehicles.

01 May - Automotive 8e.indd 13 19/5/09 2:56:24 PM

 14 PART 1 • INTRODUCTION TO MOTOR VEHICLES
Electrical system
The electrical system includes all the electrically
operated parts of the motor vehicle, such as the
battery, alternator, starter motor, switches, controls,
lights and instruments.
The battery is the source of electrical energy when
the engine is stopped. It is used to operate the starter
motor, the ignition system and the other accessories
which are needed to start the engine. Once the
engine is running, the alternator supplies the system
with electricity. It also recharges the battery; that is,
it replenishes the energy used in starting the engine.
The alternator is fitted with a grooved pulley and
is driven by a belt from a similar pulley attached to the
front of the engine’s crankshaft. Its output increases
with engine speed and so it is fitted with a voltage
regulator.
Electrical wiring installed throughout the vehicle
connects the various parts of the electrical system,
such as the battery, lights, switches, alternator, starter
and instruments.
Electronic controls
Electronic control units (ECUs) now play a major part
in the electrical system of motor vehicles. These are
micro-computers with electronic components and
circuitry that can monitor electrical components and
perform a variety of tasks.
Many vehicles have a power control unit that looks
after various engine functions and also automatic
transmission controls. There is also a body control
unit to control such items as lights, instruments, air
bags, remote locking and entertainment.
Reminder: While it is not necessary to understand
just how electronic components and control units
work, we do need to know why controls are needed
and what the controls do.
Body and associated
parts
The body components include the metal panels
of the body shell, the doors, bonnet (hood), boot
lid, bumper bars, seating, soft trim, glass, body
hardware, ornamentation, sound insulation and
01 May - Automotive 8e.indd 14
paintwork. Figure 1.15 identifies the main external
parts.
Body panels
Body panels, such as the roof panel and door panels,
are made from sheet metal which is pressed to shape
between dies in large presses. The shaped parts
are then welded together before being subjected
to the finishing processes of sanding, priming and
painting.
While most structural parts are of steel, aluminium
alloy is used for panels in some vehicles because of
its lighter weight.
Glass
Windscreens are made of laminated glass. This has
two thin layers of glass with a thin layer of clear plastic
between. If the windscreen is damaged, a layer of glass
will chip or crack, but will remain bonded to the plastic
and the other layer of glass. Visibility is unaffected.
The glass in the rear window and the doors is
made of toughened safety glass. If safety glass is
damaged by being struck by a stone, it will crack into
small pieces across the entire glass, but will usually
remain in position.
Safety tip: Safety glass is used because it breaks
into granules and not into sharp pieces like ordinary glass.
This makes it safer for the occupants of the vehicle.
Body hardware
Body hardware includes items such as door locks,
handles, hinges and window mechanisms. There are
also smaller items like bolts, screws and clips and
various other fasteners.
Interior trim
There are hard trim and soft trim parts. Hard trim
items are metal fittings and plastic mouldings which
are used to finish off sections of the interior of the
vehicle.
Soft trim items include door linings, hood lining,
floor mats, carpet, upholstery, and other vinyl or
fabric trimmings.
Ornamentation
The body is fitted with a number of small ornamental
items such as the name of the vehicle, model badges,
or emblems which provide decoration and also
identify the particular make and model.
19/5/09 2:56:30 PM
 CHAPTER 1 • MOTOR VEHICLE COMPONENTS 15

3 4
2
5

1
6

14
15
12 13
7

11

8
10 16
9

24
17

23
19 18
22 20

21

Figure 1.15 External body parts

1 spoiler, 2 rear window, 3 roof panel, 4 roof moulding, 5 door opening moulding, 6 front mudguard, 7 door moulding, 8 wheel arch,
9 rear quarter panel, 10 rear lamp, 11 emblem, 12 rear bumper, 13 windscreen, 14 centre pillar, 15 rear pillar, 16 rear door glass,
17 rear door, 18 front door glass, 19 front door, 20 sill or rocker panel, 21 front bumper, 22 front lamp, 23 grille, 24 bonnet HOLDEN LTD

Mouldings
Chromed plastic strips are used around window
openings, lights, and the edges of the bonnet or
boot lid and some other panels. Chrome-plated
metal parts are also used, but to a lesser extent than
plastic.
Plastic strips are used along the belt line of the
body on mudguards and doors. These types of strips
are generally referred to as mouldings. They are
partly ornamental but they also provide a finish and
protection for the panels.
Bumper bars
Bumper bars are fitted to the front and rear of the
vehicle. They provide a small measure of protection
for the vehicle against damage from collision, but
only at very low speeds.
Passenger cars have large plastic bumper bars.
These have a skirt, which provides a finish to the
body at the front and rear ends of the vehicle.
Commercial vehicles have bumper bars of steel,
providing more protection than plastic.
Grilles
A grille at the front of the vehicle allows air to reach
the radiator. Some vehicles have a decorative grille,
others have air flow space designed into the front of
the bodywork.
Paintwork
During manufacture, the body panels are given anti-
corrosive treatments. Some body panels are made
from galvanised steel, which resists corrosion, other
panels and parts are sprayed with rust preventative
materials after assembly.
A bead of sealer is applied to joints between panels,
and sound-deadening compound is applied to a number
of places, such as the undersurface of the body and the
inside of the door panels. Folds and seams, which could
trap moisture and dust, are treated with anticorrosive
material that will penetrate between the surfaces.
The exterior of the body undergoes a surface-
preparation treatment before being primed and
then sprayed with its finishing coats of paint of the
required colour.

01 May - Automotive 8e.indd 15 19/5/09 2:56:31 PM

 16 PART 1 • INTRODUCTION TO MOTOR VEHICLES
Names of components
and parts
For identification purposes, all the parts of motor
vehicles have names, and replacement parts also
have part numbers.
The names are given for various reasons. Some
names relate to the location of the part, and the
word upper or lower is often used in conjunction
with the part name. Other part names include the
words left or right, or front or rear. Examples of this
are upper radiator hose and right front wheel.
Some parts are obviously named according
to their function, such as filter, spring or shock
absorber.
The connection of some other parts with
their names is a little harder to find, as they can
relate to the name of a person. For example, the
diesel engine takes its name from Dr Diesel, who
developed the engine.
Names of components and parts can vary
from country to country, as can the spelling. For
example, clutch disc can be spelt disc or disk.
However, with a little thought, the reason for
the names which have been given to various
parts can be understood. This will also assist in
remembering their names.
Larger components
Larger components consist of a number of
small parts: for example, the gearbox can be
considered as a component and the gears
which are fitted inside the gearbox as parts.
Many components that contain other parts are
referred to as housings or boxes, such as the
clutch housing and gearbox.
In other cases, parts can be considered to
form a system, which consists of a number of
components or parts; for example, the fuel
system includes the fuel tank, fuel pump, fuel
lines and fuel injection components.
The diagrams in Figures 1.1 and 1.2 show the
components in simple form and enable various
components which make up the mechanical
section of a motor vehicle to be identified.
Handy hint: The terms components,
parts, units and items are all used in
relation to motor vehicle parts.
01 May - Automotive 8e.indd 16
Technical terms
Motor vehicle, front-wheel drive, rear-wheel drive, four-
wheel drive, all-wheel drive, internal combustion, diesel,
unitised, subframe, chassis, cross bracing, suspension,
drive, drive train, power train, clutch, hydraulic,
transmission, gear, gear ratio, manual transmission,
housing, automatic transmission, torque converter, disc
brake, drum brake, rack, pinion, worm, starter, alternator,
electronic, electronic control unit, component, safety
glass, body panels, body hardware, laminated, trim,
mouldings, anticorrosive.
Review questions
1. Name the main sections of a motor vehicle.
2. Why is the engine referred to as an
internal-combustion engine?
3. What types of fuel are used in automotive engines?
4. What is the purpose of the shock absorbers?
5. Why are tyres necessary?
6. What are the parts of the power train?
7. Why is a clutch necessary?
8. Why is a transmission fitted to a vehicle?
9. What is a transaxle?
10. What is the function of the universal joints?
11. What does the differential do?
12. What are the two designs of brakes?
13. What is the purpose of the suspension?
14. Name some of the parts in a rear-axle assembly.
15. Name some of the electrical parts of a vehicle.
16. How is the alternator driven?
17. What are the main differences between a front-
wheel-drive and a rear-wheel-drive vehicle?
18. Name the main body parts of a passenger car. Refer
to the appropriate illustration.
19/5/09 2:56:34 PM