James E.

Duffy
Automotive Writer

Publisher
The Goodheart-Willcox Company, Inc.
Tinley Park, Illinois
www.g-w.com
 Copyright © 2009

by

The Goodheart-Willcox Company, Inc.

Previous editions copyright 2004, 2000. 1998, 1994, 1990, 1985

All rights reserved. No part of this work may be reproduced, stored, or

transmitted in any form or by any electronic or mechanical means,
including information storage and retrieval systems, without the prior
written permission of The Goodheart-Willcox Company, Inc.

Manufactured in the United States of America.

Library of Congress Catalog Card Number 2008007116

ISBN 978-1-59070-956-6

5 6 7 8 9 - 0 9 - 13 12 11

The Goodheart-Willcox Company, Inc. Brand Disclaimer: Brand names, company names, and illustrations for products and services included in
this text are provided for educational purposes only and do not represent or imply endorsement or recommendation by the author or the publisher.

The Goodheart-Willcox Company, Inc. Safety Notice: The reader is expressly advised to carefully read, understand, and apply all safety pre-
cautions and warnings described in this book or that might also be indicated in undertaking the activities and exercises described herein to min-
imize risk of personal injury or injury to others. Common sense and good judgment should also be exercised and applied to help avoid all potential
hazards. The reader should always refer to the appropriate manufacturer's technical information, directions, and recommendations; then proceed
with care to follow specific equipment operating instructions. The reader should understand these notices and cautions are not exhaustive.

The publisher makes no warranty or representation whatsoever, either expressed or implied, including but not limited to equipment, procedures,
and applications described or referred to herein, their quality, performance, merchantability, or fitness for a particular purpose. The publisher
assumes no responsibility for any changes, errors, or omissions in this book. The publisher specifically disclaims any liability whatsoever,
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Library of Congress Cataloging-in-Publication Data

Duffy, James E.
Modern automotive technology / James E. Duffy. — 7th ed.
p. cm.
Includes index.
ISBN 978-1-59070-956-6
1. Automobiles—Design and construction. 2. Automobiles—
Maintenance and repair. 3. Automobiles. I. Title.
TL146.D84 2009
629.2' 3—dc22 2008007116

Welcome to the exciting, challenging world of auto-
motive technology! You have selected a rewarding field
of study.
Modern Automotive Technology is an easy-to-
understand, up-to-date book summarizing the operation
and repair of all makes and models of vehicles. The text
uses a building-block approach that starts with the simple
and progresses gradually to the more complex. Short sen-
tences, concise definitions, and thousands of color illus-
trations will help you learn quickly and easily.
Modern Automotive Technology is a valuable refer-
ence for anyone interested in the operation, construction,
and repair of automobiles and light trucks. Vehicle
owners who need a general guide to automotive service
will find the book both interesting and informative. Those
who are preparing for a career in automotive technology
will find the text a "must." Experienced technicians can
use it when preparing for the ASE certification tests.
No longer can the untrained person hope to fix the
modern automobile. Multiple on-board computers are
now used to monitor and control the engine, transmission,
suspension, braking, emission control, and other systems.
Although computer systems are discussed in almost
every chapter, three chapters—Chapter 17, Computer
System Fundamentals; Chapter 18, On-Board Diag-
nostics and Scan Tools; and Chapter 19, Computer
System Service—explain the operation and service of
these important systems in detail.
Additionally, Chapter 46, Advanced Diagnostics,
emphasizes the use of the latest diagnostic equipment and
techniques to locate engine performance problems. A few
of the other topics discussed in the text include anti-lock
brakes, four-wheel steering, four-valve cylinders, active
suspension systems, passive restraint systems, security
systems, and navigation systems.
The 2009 edition of Modern Automotive
Technology is organized around the eight ASE automo-
bile test areas and is correlated to the NATEF Task List.
Introduction
Each automotive system is presented in two or more
chapters. The first chapter explains the construction and
operation of a specific system. The following chapter
expands on this by detailing the troubleshooting and
repair of the same system.
Type Styles Used in This Text
Various type styles are used throughout this text to
emphasize words, identify important terms, and highlight
figure references.
Italic type is used to emphasize words and terms. For
example, the word not is often printed in italic type when
it is imperative that an operation be avoided.
Important terms appear in bold-italic type. These
terms are defined when introduced and most are listed in
the Important Terms list at the end of the chapter, as well
as in the Glossary at the back of the text. Study the bold-
italic terms carefully.
Figure references in the body of the text and in the
captions always appear in bold type. This makes them
easy to identify.
Chapter Components
Each chapter opens with a list of learning objectives.
These objectives identify the topics covered and goals to
be achieved in the chapter. Review the objectives before
reading the chapter to determine what you can expect to
learn. After completing the chapter, read the objectives
once more and make sure you have met each objective.
A summary is found at the end of each chapter. The
summary highlights the material covered in the chapter.
Review the summary after completing a chapter.
A list of important terms is also included at the end
of each chapter. The terms in the list appear in the
order in which they are presented in the chapter. After
completing a chapter, review each term. If a term cannot
be defined, review the related section in the chapter.
 Conventional review questions, as well as a separate Warning!
section of ASE-type questions, are presented at the end of Always wear eye protection when cleaning
each chapter. After completing a chapter, answer all the parts with power tools. Metal bristles, bits of
questions on a separate sheet of paper. This is a great way carbon, or metal pieces from a broken tool or
of reviewing the material presented in the chapter. It will part can fly into your face.
also help prepare you for the types of questions encoun-
Other warning icons used in this text include:
tered on the ASE certification tests.
Each chapter closes with a number of activities. Face shield required.
These activities are automotive-related exercises that
emphasize math and communication skills, as well as
Respirator required.
improve performance on the job.

Special Notices Body protection required.

There are a variety of special notices used throughout
this text. These notices contain technical information, Shock or electrocution hazard.
cautions, warnings, and references to pertinent material
in other parts of the text. The notices are identified by
color and by an icon. Fire hazard.
A note may contain a reference to another section of
the text that relates to the subject at hand. It may also
highlight important technical information. For example: Explosion hazard.
Note!
For more information on on-board diagnostics,
Injury hazard (rotating parts, hot surfaces, etc.).
refer to Chapter 18, On-board Diagnostics and
Scan Tools.
A caution identifies a situation that may cause Tech tips provide supplemental technical information
damage to a vehicle, equipment, or tools if the proper and service hints related to the procedure or system being
procedures are not followed. For example: explained. For example:
Caution! Tech Tip!
Tighten an alternator belt only enough to pre- Oxygen sensors should be replaced at periodic
vent slippage. Overtightening is a common mis- intervals. After prolonged service, they become
take that can quickly ruin alternator bearings. coated with exhaust byproducts. As this hap-
pens, fuel economy and emissions will be
Cautions that warn against certain procedures or
adversely affected. If gas mileage is 10% to
activities are identified by a "do not" icon:
15% lower than normal, suspect the oxygen
Caution! sensor of slow response.
Do not disconnect the EFI harness terminal
when the ignition switch is in the on position.
Repair Procedures
This can damage the control module.
Procedures present common service and repair
A warning identifies repair operations that can result
operations in an easy-to-follow, step-by-step format. For
in personal injury if proper procedures or safety measures
example:
are not followed. For example:
To perform an injector balance test:
Warning!
1. Connect a pressure gauge to the test fitting
A steam cleaner operates at high pressures and on the fuel rail.
temperatures. Follow the manufacturer's safety
2. Close off the valve for measuring fuel
rules and operating instructions. volume if provided on the fuel gauge
When a warning refers to a particular danger or assembly.
warns reader to wear protective gear, specific icons are 3. Connect the balance tester wiring to the
used to help clearly identify the hazard. For example: injectors or injector in question.
 4. Turn the ignition key on to pressurize the
system. Then, turn the ignition key off.
5. Press the injector balance tester button
while watching the pressure gauge drop.
6. Record the pressure drop reading.
7. Repeat this on the other fuel injectors. This
will allow you to measure how much fuel
each injector is feeding into the engine
when energized.
Troubleshooting Charts
Troubleshooting charts have been added to the end of
each service chapter. These charts will help the reader
diagnose and repair common problems.
Duff's Garage
This feature is designed to help reinforce logical
troubleshooting techniques. Each Duff's Garage presents
a common automotive problem, details the procedure for
pinpointing the source trouble, and provides an overview
of the necessary repairs.
Accident Report, Customer Care, Highway
History, Industry Trends, Workplace Skills,
and Focus on Hybrids Features
The new edition of the text contains a variety of fea-
tures designed to generate interest in the field of automo-
tive technology and cultivate the skills needed to succeed
as an automotive technician. These features include:
Industry Trends—Highlights new and emerging
technologies in the automotive industry.
Workplace Skills—Helps cultivate the skills needed
to become a successful automotive technician.
Customer Care—Helps develop skills required to
effectively interact with customers.
Highway History—Chronicles important milestones
in the automobile industry.
Accident Reports—Emphasizes the importance of
working safely.
Focus on Hybrids—Highlights the technologies used
in hybrid gas-electric vehicles.
Color Use
Color is used extensively throughout this text to
enhance understanding and highlight important informa-
tion. In illustrations, dark yellow is used for primary
emphasis in illustrations and blue is used for secondary
emphasis. Other colors are used as needed to help clarify
the illustrations. For example, red arrows are often used
to show motion. Color is also used to represent different
pressures, states of matter, temperatures, etc.
Enhancing the Text
To aid in the learning process, a comprehensive work-
book and a shop manual have been created. These items
are designed to be used with this text.
The workbook contains a variety of questions that
correlate with the text and a number of jobs that are
related to specific service or repair procedures.
The shop manual complements the material presented
in this textbook. It contains 177 step-by-step jobs cov-
ering the most vital tasks listed in the NATEF Task List.
Both the workbook and shop manual can be purchased
directly from Goodheart-Willcox Company, Inc.
 Brief Contents

Section 1 Chapter 22. Gasoline Injection Fundamentals 340

Introduction to Automotive Technology Chapter 23. Gasoline Injection Diagnosis and
Repair 371
Chapter 1. The Automobile 1
Chapter 2. Automotive Careers and ASE Chapter 24. Carburetor Operation and Service 396
Certification 22 Chapter 25. Diesel Injection Fundamentals 410
Chapter 3. Basic Hand Tools 34 Chapter 26. Diesel Injection Diagnosis, Service, and
Chapter 4. Power Tools and Equipment 47 Repair 429
Chapter 5. The Auto Shop and Safety 60 Chapter 27. Exhaust Systems, Turbochargers, and
Chapter 6. Automotive Measurement and Math 70 Superchargers 449
Chapter 7. Service Information and Work Orders 85
Chapter 8. Basic Electricity and Electronics 97 Section 5
Chapter 9. Fasteners, Gaskets, Seals, and Electrical Systems
Sealants 111 Chapter 28. Automotive Batteries 473
Chapter 10. Vehicle Maintenance, Fluid Service, and Chapter 29. Battery Testing and Service 483
Recycling 127 Chapter 30. Starting System Fundamentals 499
Chapter 31. Starting System Testing and Repair 513
Section 2 Chapter 32. Charging System Fundamentals 532
Engines Chapter 33. Charging System Diagnosis, Testing, and
Chapter 11. Engine Fundamentals 145 Repair 548
Chapter 12. Engine Design Classifications 162 Chapter 34. Ignition System Fundamentals 567
Chapter 13. Engine Top End Construction 182 Chapter 35. Ignition System Problems, Testing, and
Chapter 14. Engine Bottom End Construction 199 Repair 595
Chapter 15. Engine Front End Construction 217 Chapter 36. Lights, Instrumentation, Wipers, and
Chapter 16. Engine Size and Performance Horns—Operation and Service 631
Measurements 225 Chapter 37. Sound Systems and Power Accessories 667
Chapter 38. Hybrid Drive System Operation and
Section 3 Service 694
Computer Systems
Chapter 17. Computer System Fundamentals 235 Section 6
Chapter 18. On-Board Diagnostics and Scan Tools 261 Cooling and Lubrication Systems
Chapter 19. Computer System Service 282 Chapter 39. Cooling System Fundamentals 725
Chapter 40. Cooling System Testing, Maintenance, and
Section 4
Repair 745
Fuel Systems Chapter 41. Lubrication System Fundamentals 768
Chapter 20. Automotive Fuels, Gasoline and Diesel Chapter 42. Lubrication System Testing, Service, and
Combustion 301 Repair 786
Chapter 21. Fuel Tanks, Pumps, Lines, and Filters 315
 Section 7 Chapter 68. Suspension System Diagnosis and
Emission Control Systems Repair 1302
Chapter 43. Emission Control Systems 803 Chapter 69. Steering System Fundamentals 1324
Chapter 44. Emission Control System Testing, Service, Chapter 70. Steering System Diagnosis and
and Repair 831 Repair 1347
Chapter 71. Brake System Fundamentals 1369
Section 8 Chapter 72. Brake System Diagnosis and Repair 1394
Chapter 73. Anti-Lock Brakes, Traction Control, and
Engine Performance
Stability Control 1422
Chapter 45. Engine Performance and Driveability 859
Chapter 74. Wheel Alignment 1445
Chapter 46. Advanced Diagnostics 871
Chapter 47. Engine Tune-Up 901
Section 12
Section 9 Heating and Air Conditioning
Chapter 75. Heating and Air Conditioning
Engine Service and Repair
Fundamentals 1469
Chapter 48. Engine Mechanical Problems 913
Chapter 76. Heating and Air Conditioning Service
Chapter 49. Engine Removal, Disassembly, and Parts
1493
Cleaning 931
Chapter 50. Engine Bottom End Service 948
Section 13
Chapter 51. Engine Top End Service 971
Chapter 52. Engine Front End Service and Engine Safety, Security, and Navigation Systems
Installation 1001 Chapter 77. Restraint Systems 1521
Chapter 78. Restraint System Service 1534
Section 10 Chapter 79. Security and Navigation Systems, New and
Future Technologies 1544
Drive Trains and Axles
Chapter 80. Career Success 1557
Chapter 53. Clutch Fundamentals 1017
Chapter 54. Clutch Diagnosis and Repair 1031
Reference Sections 1564
Chapter 55. Manual Transmission Fundamentals 1049
Glossary of Terms 1568
Chapter 56. Manual Transmission Diagnosis and
Internet Resources 1589
Repair 1070
Acknowledgments 1590
Chapter 57. Automatic Transmission
Index
Fundamentals 1083
Chapter 58. Automatic Transmission Service 1110
Chapter 59. Drive Shafts and Transfer Cases 1131
Chapter 60. Drive Shaft and Transfer Case Diagnosis,
Service, and Repair 1144
Chapter 61. Differential and Rear Drive Axle
Fundamentals 1157
Chapter 62. Differential and Rear Drive Axle Diagnosis
and Repair 1173
Chapter 63. Transaxle and Front Drive Axle
Fundamentals 1193
Chapter 64. Transaxle and Front Drive Axle Diagnosis
and Repair 1217

Section 11
Suspension, Steering, and Brakes
Chapter 65. Tire, Wheel, and Wheel Bearing
Fundamentals 1241
Chapter 66. Tire, Wheel, and Wheel Bearing
Service 1257
Chapter 67. Suspension System Fundamentals 1280
 Expanded Contents

Section 1 Chapter 4 47
Introduction to Automotive Technology Power Tools and Equipment
Compressed-Air System 47
Chapter 1 1 Air Tools 48
T h e Automobile Electric Tools 50
Parts, Assemblies, and Systems 1 Hydraulic Tools 52
Hybrid Vehicle 18 Shop Equipment 53
Workplace Skills 57
Chapter 2 22
Chapter 5 60
Automotive Careers and A S E Certification
The Automotive Technician 22 The Auto Shop and Safety
Preparing for a Career in Automotive Technology 27 Auto Shop Layout 60
ASE Certification 27 Shop Safety 62
Entrepreneurship 31 Types of Accidents 62
Workplace Skills 31 General Safety Rules 66
Customer Relations 67
Chapter 3 34
Chapter 6 70
Basic Hand Tools
Tool Rules 34 Automotive Measurement and Math
Tool Storage 34 Measuring Systems 70
Wrenches 35 Measuring Tools 72
Screwdrivers 38 Other Measurements and Measuring Tools 77
Pliers 39 Using Basic Mathematics 79
Hammers 40 Workplace Skills 82
Chisels and Punches 40
Files 42 Chapter 7 85
Saws 43 Service Information and Work Orders
Holding Tools 43 Service Manuals 85
Cleaning Tools 44 Using a Service Manual 90
Probe and Pickup Tools 44 Service Publications 92
Pry Bars 45 Technical Assistance Hotlines 92
Workplace Skills 45 Computer-Based Service Data 94
Work Orders 94
Workplace Skills 95
Chapter 8 97 Typical Automotive Engines 173
Basic Electricity and Electronics Workplace Skills 175
Electricity 97
Automotive Electronics 100 Chapter 13 182
Automotive Wiring 103 Engine Top End Construction
Basic Electrical Tests 105 Cylinder Head Construction 182
Oscilloscope 107 Valve Train Construction 185
Scan Tools 108 Intake Manifold Construction 195
Customer Relations 108 Exhaust Manifold Construction 196
Workplace Skills 196
Chapter 9 111
Fasteners, Gaskets, Seals, and Sealants Chapter 14 199
Fasteners 111 Engine Bottom End Construction
Washers 113 Cylinder Block Construction 200
Machine Screws 114 Piston Construction 201
Sheet Metal Screws 114 Piston Ring Construction 204
Nonthreaded Fasteners 114 Piston Pin Construction 206
Torquing Bolts and Nuts 115 Connecting Rod Construction 207
Thread Repairs 117 Crankshaft Construction 209
Removing Damaged Fasteners 119 Engine Bearing Construction 209
Gaskets and Seals 120 Rear Main Bearing Oil Seal Construction 212
Workplace Skills 124 Select-Fit Parts 213
Balancer Shafts 213
Chapter 10 127 Workplace Skills 214
Vehicle Maintenance, Fluid Service, and
Recycling Chapter 15 217
Lubrication Service 127 Engine Front End Construction
Vehicle Maintenance 127 Vibration Damper Construction 217
Fluid Service 127 Camshaft Drive Construction 218
Filter Service 135 Duff's Garage 222
Chassis Lubrication 135
Service Intervals 136 Chapter 16 225
General Inspection and Problem Location 137 Engine Size and Performance
Recycling and Disposal of Auto Shop Wastes 139
Measurements
Duff's Garage 140
Engine Size Measurement 225
Force, Work, and Power 226
Section 2
Compression Ratio 227
Engines Engine Torque 228
Horsepower 228
Chapter 11 145 Engine Efficiency 230
Engine Fundamentals Industry Trend 231
Engine Operation 145
Engine Bottom End 146
Section 3
Engine Top End 152
Engine Front End 156 Computer Systems
Workplace Skills 157
Chapter 17 235
Chapter 12 162 Computer System Fundamentals
Engine Design Classifications Cybernetics 235
Engine Classifications 162 Computer Advantages 236
Cylinder Arrangement 162 Digital Electronics 237
Alternative Engines 169 Integrated Circuits 239
Computer Signals 239 Chapter 22 340
Computer System Operation 243 Gasoline Injection Fundamentals
Sensors 244 Gasoline Injection Fundamentals 340
Computers 249 Gasoline Injection Classifications 342
Actuators 255 Throttle Body and Multiport Injection 342
Highway History 257 Gasoline Injection Controls 344
Electronic Fuel Injection 345
Chapter 18 267
Engine Sensors 348
On-Board Diagnostics and Scan Tools Injector Pulse Width 354
On-Board Diagnostic Systems 261 Throttle Body Injection 355
Scanning Computer Problems 265 Engine Idle Speed Control 357
Energizing OBD I Systems without a Scan Tool 274 Continuous Throttle Body Injection 358
Erasing Trouble Codes 277 Electronic Multiport Injection 358
Duff's Garage 278 Air-Fuel Emulsion Injector 358
Unitized Multiport Injection 358
Chapter 19 282 Injector Resistor Pack 362
Computer System Service Airflow-Sensing Multiport EFI 362
Preliminary Visual Inspection 282 Pressure-Sensing Multiport EFI 364
Computer System Circuit Problems 283 Hydraulic-Mechanical Continuous Injection
Sensor and Actuator Problems 284 System 364
Sensor Service 285 Fuel Accumulator 366
Actuator Service 288 Direct Gasoline Injection 366
Computer Industry Trend 367
Service 291
Duff's Garage Chapter 23 371
295 Gasoline Injection Diagnosis and Repair
Computer
Gasoline Injection Problem Diagnosis 371
System
Fuel Pressure Regulator Service 374
Sensor and
Injector Problems 376
Actuator
Throttle Body Injector Service 376
Diagnosis
Servicing EFI Multiport Injectors 378
298
Engine Sensor Service 384
Control Module Service 388
Section 4 Gasoline Injection Adjustments 389
Fuel Systems Testing Idle Control Motor 390
Multiport Throttle Body Service 391
Chapter 20 301 Duff's Garage 391
Automotive Fuels, Gasoline and Diesel Gasoline Injection System Diagnosis 392
Combustion
Chapter 24 396
Petroleum (Crude Oil) 301
Gasoline 301 Carburetor Operation and Service
Diesel Fuel 307 Basic Carburetor 396
Alternative Fuels 310 Carburetor Problem Diagnosis 403
Duff's Garage 312 Highway History 408

Chapter 21 315 Chapter 25 410

Fuel Tanks, Pumps, Lines, and Filters
Fuel Supply System 315
Fuel Supply System Service 324
Workplace Skills 335
Fuel Delivery System Diagnosis 339
Diesel Injection Fundamentals
Basic Diesel Injection System 410
Diesel Injection System Accessories 422
Piezo Diesel Injectors 424
Accident Report 425
Chapter 26
Diesel Injection Diagnosis, Service, and
Repair
Diesel Injection Maintenance 429
Diesel Injection Diagnosis 430
Diesel Injection Service 434
Duff's Garage 444
Diesel Engine Diagnosis 447
Chapter 27
Exhaust Systems, Turbochargers, and
Superchargers
Exhaust Systems 449
Exhaust System Service 452
Superchargers and Turbochargers
Accident Report 467
Section 5
Electrical Systems
Chapter 28
Automotive Batteries
Battery Principles 473
Battery Functions 474
Battery Construction 475
Wet- and Dry-Charged
Batteries 478
Maintenance-Free Battery 479
Gel Battery 479
Absorbed Glass Mat Battery 479
Battery Ratings 479
Battery Temperature and Efficiency
Focus on Hybrids 480
Chapter 29
Battery Testing and Service
Battery Maintenance 483
Jump Starting 491
Battery Load Test 492
Activating Dry-Charged Battery 494
Removing and Replacing a Battery 494
Duff's Garage 494
Battery Diagnosis 498
Chapter 30
Starting System Fundamentals
Starting System Principles 499
Starting Motor Construction 504
Focus on Hybrids 509
429 Chapter 31 513
Starting System Testing and Repair
Starting System Diagnosis 513
Battery Cable Service 517
Starter Solenoid Service 517
Ignition Switch Service 518
Starter Relay Service 518
Neutral Safety Switch Service 518
Starter Service 519
449 Duff's Garage 527
Starting System Diagnosis 531
Chapter 32 532
Charging System Fundamentals
Basic Charging System Parts 532
455
Charging System Functions 533
Types of Charging Systems 533
Alternator Operation 534
Alternator Construction 535
Charge Indicators 543
Focus on Hybrids 545
Chapter 33 548
473
Charging System Diagnosis, Testing,
and Repair
Charging System Diagnosis 548
Charging System Precautions 550
Charging System Tests 550
Alternator Service 556
Regulator Service 562
Duff's Garage 562
Charging System Diagnosis 565
Chapter 34 567
480
Ignition System Fundamentals
Functions of an Ignition System 567
Basic Ignition System 567
Ignition System Supply Voltage 568
483 Primary and Secondary Circuits 569
Ignition Coil 569
Ignition Distributors 572
Contact Point Ignition System 573
Electronic Ignition System 573
Distributor Cap and Rotor 576
Secondary Wires 578
Spark Plugs 579
Ignition Timing 581
Crankshaft-Triggered Ignition 584
499 Distributorless Ignition System 585
Direct Ignition System 587
Dual Spark Plug Ignition 590
Multiple Discharge Ignition 591
Engine Firing Order 591
Chapter 35 595 Reminder System 683
Cruise Control Systems 683
Ignition System Problems, Testing, and
Power Mirrors 687
Repair
Cellular Mobile Telephone 687
Ignition System Problem Diagnosis 595
Driver Information Center 688
Preliminary Checks of Ignition System 595
Vehicle Degaussing 688
Evaluating the Symptoms 599
Duff's Garage 688
Spark Plug Service 600
Sound System Diagnosis 693
Secondary Wire Service 602
Power Accessory Diagnosis 693
Distributor Service 603
Distributor Cap and Rotor Service 605
Chapter 38 694
Electronic Ignition Distributor Service 606
Pickup Coil Service 606 Hybrid Drive System Operation and Repair
Contact Point Distributor Service 608 Introduction 694
Dwell 610 Hybrid System Voltages 698
Ignition Timing Adjustment 611 Hybrid Drive Assemblies 699
Testing Centrifugal and Vacuum Distributor Advance Hybrid Service Safety 709
Systems 614 Hybrid Problem Diagnosis 711
Removing the Ignition Distributor 615 Hybrid Battery Pack Service 711
Rebuilding a Distributor 615 Checking HV Battery Relays and Contactors 715
Ignition Supply Voltage Test 618 Servicing Hybrid Power Cables 716
Ignition Coil (Coil Pack) Service 618 Servicing the Power Control Module 716
Ignition Switch Service 619 Servicing the Hybrid Cooling System 716
Ignition Control Module Service 620 Servicing the Motor-Generator 717
Distributorless Ignition System Service 621 Hybrid Wiring Problems 718
Direct Ignition System Service 622
Duff's Garage 622
Ignition System Diagnosis 627 Section 6
Cooling and Lubrication Systems
Chapter 36 631
Lights, Instrumentation, Wipers, and Chapter 39 725
Horns—Operation and Service Cooling System Fundamentals
Lighting Systems 632 Cooling System Functions 725
Light System Service 641 Cooling System Operation 726
Instrumentation 647 Cooling System Types 727
Windshield Wipers 654 Basic Cooling System 727
Horns 658 Closed and Open Cooling Systems 733
Theft-Deterrent Systems 659 Cooling System Instrumentation 738
Finding Common Electrical Problems 659 Antifreeze 739
Duff's Garage 661 Block Heater 740
Headlamp Diagnosis 665 Focus on Hybrids 740
Turn Signal Diagnosis 666
Chapter 40 745
Chapter 37 667 Cooling System Testing, Maintenance, and
Sound Systems and Power Accessories Repair
Sound Systems 667 Cooling System Problem Diagnosis 745
Power Seats 674 Cooling System Problems 746
Power Windows 675 Water Pump Service 750
Power Door Locks 678 Thermostat Service 751
Power Trunk Release 681 Cooling System Hose Service 754
Power Steering Wheel 681 Radiator and Pressure Cap Service 755
Rear Window Defogger 681 Fan Belt Service 756
Heated Windshield 683 Engine Fan Service 757
Freeze Plug Service 758
Coolant Service 759
Flushing a Cooling System 761
Temperature Gauge Service 762
Duff's Garage 763
Cooling System Diagnosis 766
Chapter 41
Lubrication System Fundamentals
Lubrication System Functions 768
Lubrication System Operation 768
Positive Crankcase Ventilation System 780
Oil Pressure Indicator 781
Industry Trend 783
Chapter 42
Lubrication System Testing, Service, and
Repair
Lubrication System Problem Diagnosis 786
Engine Oil and Filter Service 790
Oil Pan Service 791
Oil Pump Service 793
Pressure Relief Valve
Service 797
Oil Pressure Indicator and Gauge
Service 798
PCV Valve Service 799
Duff's Garage 799
Lubrication System
Diagnosis 801
Section 7
Emission Control Systems
Chapter 43
Emission Control Systems
Air Pollution 803
Motor Vehicle Emissions 803
Engine Modifications Related to Emission
Control 805
Vehicle Emission Control Systems 806
Positive Crankcase Ventilation (PCV) 806
Evaporative Emissions Control Systems 808
Exhaust Gas Recirculation (EGR) 811
Air Injection System 815
Pulse Air System 817
Thermostatic Air Cleaner System 818
Catalytic Converter 818
Computerized Emission Control Systems 821
OBD II Emission System Monitoring 826
Highway History 828
Chapter 44 831
Emission Control System Testing, Service,
and Repair
Computer-Controlled Emission System Service 831
Emission Maintenance Reminder 832
Inspecting Emission Control Systems 832
Exhaust Gas Analyzer 833
768
State Emissions Testing Programs 837
Vacuum Solenoid Service 840
PCV System Service 842
Evaporative Emissions Control System Service 843
Thermostatic Air Cleaner System Service 844
EGR System Service 845
Air Injection System Service 846
Pulse Air System Service 847
786 Catalytic Converter Service 847
Oxygen Sensor Service 849
Emission Control Information
Sticker 852
OBD II Drive Cycle 852
Duff's Garage 853
Emission Control System
Diagnosis 856
Section 8
Engine Performance
Chapter 45 859
Engine Performance and Driveability
Locating Engine Performance Problems 859
Typical Performance Problems 863
Other Performance Problems 866
Workplace Skills 866
803 Engine Performance Diagnosis 870
Chapter 46 871
Advanced Diagnostics
Advanced Diagnostics 871
Duff's Garage 896
Chapter 47 901
Engine Tune-Up
Engine Tune-Up 901
General Tune-Up Rules 903
Tune-Up Safety Rules 903
Typical Tune-Up
Procedures 904
Diesel Engine Tune-Up (Maintenance) 908
Engine Tune-Up (Maintenance) Intervals 909
Duff's Garage 909
 Section 9
Engine Service and Repair
Chapter 48
Engine Mechanical Problems
Why Is Diagnosis Important? 913
Symptoms of Engine Mechanical Problems 913
Decide What Type of Engine Repair Is Needed 920
Evaluating Engine Mechanical Problems 920
Service Manual Troubleshooting Charts 926
Duff's Garage 926
Compression Test Results 930
Cylinder Leakage Test Results 930
Chapter 49
Engine Removal, Disassembly, and Parts
Cleaning
Engine Removal 931
Engine Disassembly 937
Cleaning Engine Parts 942
Industry Trend 945
Chapter 50
Engine Bottom End Service
Do You Need Review? 948
Cylinder Block Service 948
Balancer Shaft Service 954
Piston Service 954
Piston Pin Service 956
Connecting Rod Service 958
Piston Ring Service 958
Crankshaft Service 960
Installing a Piston and Rod Assembly
Torque-to-Yield Bolts 966
Engine Balancing 966
Final Assembly of Engine 967
Workplace Skills 967
Chapter 51
Engine Top End Service
Cylinder Head Service 971
Diesel Precombustion Chamber Service
Valve Guide Service 974
Valve Grinding 976
Valve Seat Reconditioning 979
Testing Valve Springs 983
Assembling Cylinder Head 984
Camshaft Service 987
Lifter Service 988
Push Rod Service 989
Rocker Arm Assembly Service 989
Engine Top End Reassembly 989
Valve Adjustment 993
Installing Valve Covers 996
Duff's Garage 997
913
Chapter 52 1001
Engine Front End Service and Engine
Installation
Timing Chain Service 1001
Timing Gear Service 1003
Crankshaft Front Seal Service 1004
Engine Front Cover Service 1006
Timing Belt Service 1007
Complete Engine Assembly 1011
Installing the Engine 1011
937 Engine Break-In 1012
Duff's Garage 1012
Section 10
Drive Trains and Axles
Chapter 53 1017
Clutch Fundamentals
948 Clutch Principles 1017
Clutch Construction 1019
Workplace Skills 1028
Chapter 54 1031
Clutch Diagnosis and Repair
Diagnosing Clutch Problems 1031
Servicing a Clutch 1037
Duff's Garage 1043
Clutch Diagnosis 1047
964
Chapter 55 1049
Manual Transmission Fundamentals
Basic Transmission Parts 1049
Purpose of a Manual Transmission 1049
Gear Fundamentals 1050
971 Manual Transmission Construction 1052
Transmission Types 1060
Transmission Power
974 Flow 1060
Speedometer Drive 1066
Manual Transmission
Switches 1066
Workplace Skills 1066
Chapter 56 1070
Manual Transmission Diagnosis and Repair
Manual Transmission Problem Diagnosis 1070
Manual Transmission Problems 1070
Transmission Identification 1072
Manual Transmission Service 1072 Front Drive Axle—Four-Wheel-Drive Vehicles 1168
Adjusting Transmission Linkage 1078 Workplace Skills 1168
Duff's Garage 1078
Chapter 62 1173
Manual Transmission/Transaxle Diagnosis 1081
Differential and Rear Drive Axle Diagnosis
Chapter 57 1083 and Repair
Automatic Transmission F u n d a m e n t a l s Differential and Rear Axle Problem Diagnosis 1173
Basic Automatic Transmission 1083 Differential Maintenance 1175
Hydraulic System 1095 Rear Axle Service 1176
Parking Pawl 1100 Differential Service 1179
Automatic Transmission Power Flow 1100 Duff's Garage 1187
Electronic Transmission Control 1100 Rear Axle Diagnosis 1191
Continuously Variable Transmission 1103
Chapter 63 1193
Complete Transmission Assemblies 1105
Highway History 1105 Transaxle and Front Drive Axle
Fundamentals
Chapter 58 1110 Transaxle 1193
Automatic Transmission Service Manual Transaxle 1195
Automatic Transmission Identification 1110 Automatic Transaxle 1201
Automatic Transmission Diagnosis 1110 Front Drive Axle Assembly 1210
Automatic Transmission Maintenance 1116 Focus on Hybrids 1213
Major Transmission Service 1123 Chapter 64 1217
Duff's Garage 1124
Automatic Transmission and Transaxle Diagnosis 1130 Transaxle and Front Drive Axle Diagnosis
a n d Repair
Chapter 59 1131 Transaxle Problem Diagnosis 1217
Drive Shafts and Transfer C a s e s Front Drive Axle Problems 1219
Drive Shaft Assembly 1131 Transaxle Maintenance 1219
Drivelines 1137 Front Drive Axle Service 1222
Transfer Cases 1137 Transaxle Removal 1228
Industry Trend 1141 Transaxle Service 1228
Transaxle Installation 1229
Chapter 60 1144 Duff's Garage 1229
Drive Shaft and Transfer C a s e Diagnosis, Automatic Transmission and Transaxle Diagnosis 1236
Service, a n d Repair
Drive Shaft Problems 1144 Section 11
Drive Shaft Inspection 1145 Suspension, Steering, and Brakes
Drive Shaft Maintenance 1147
Drive Shaft Service 1147 Chapter 65 1241
Transfer Case Service 1150 Tire, W h e e l , and W h e e l Bearing
Duff's Garage 1151 Fundamentals
Drive Line Problem Diagnosis 1155 Tires 1241
Transfer Case Diagnosis Part-Time Drive 1155 Wheels 1248
Transfer Case Diagnosis Full-Time Drive 1156 Valve Stems and Cores 1249
Lug Nuts, Studs, and Bolts 1250
Chapter 61 1157
Wheel Weights 1250
Differential and Rear Drive Axle Hub and Wheel Bearing Assemblies 1250
Fundamentals Highway History 1253
Basic Rear Drive Axle Assembly 1157
Chapter 66 1257
Differential Construction 1158
Differential Action 1162 Tire, W h e e l , and W h e e l Bearing Service
Limited-Slip Differentials 1162 Tire, Wheel, and Wheel Bearing Diagnosis 1257
Rear Drive Axles 1166 Wheel Cover Removal and Installation 1260
Tire Maintenance 1260
Measuring Tire and Wheel Runout 1261
Wheel Balance 1262
Mounting and Dismounting Tires 1265
Tire Puncture Repair 1266
Wheel Bearing Service 1268
Duff's Garage 1273
Tire, Wheel, and Bearing Diagnosis 1277
Chapter 67
Suspension System Fundamentals
Functions of a Suspension System 1280
Basic Suspension System 1280
Independent and Nonindependent Suspension
Systems 1281
Understeer and Oversteer 1281
Suspension System Springs 1282
Suspension System Construction 1284
Long-Short Arm Suspension 1289
Torsion Bar Suspension 1289
MacPherson Strut Suspension 1289
Pickup Truck Suspension Systems 1289
Rear Suspension Systems 1289
Suspension Leveling Systems 1291
Electronic Suspension System 1295
Active Suspension System 1297
Highway History 1298
Chapter 68
Suspension System Diagnosis and Repair
Suspension System Diagnosis 1302
Shock Absorber Service 1302
Suspension Spring Service 1304
Ball Joint Service 1308
Suspension Bushing Service 1310
MacPherson Strut Service 1312
Wheel Alignment is Needed 1315
Computerized Suspension Diagnosis 1316
Duff's Garage 1319
Suspension System Diagnosis 1323
Chapter 69
Steering System Fundamentals
Functions of a Steering System 1324
Basic Steering Systems 1324
Steering Column Assembly 1325
Steering Gear Principles 1327
Steering Linkage (Worm-type Gearbox) 1329
Manual Rack-and-Pinion Steering 1330
Integral-Piston Power Steering System
(Linkage Type) 1336
External Cylinder Power Steering (Linkage Type)
Power Rack-and-Pinion Steering 1338
Electronic Steering Assist 1341
Four-Wheel Steering Systems 1342
Industry Trend 1344
Chapter 70 1347
Steering System Diagnosis and Repair
Steering System Problem Diagnosis 1347
Steering System Maintenance 1349
Steering Column Service 1350
1280 Manual Steering Gearbox Service (Recirculating-Ball
Type) 1351
Steering Linkage Service 1353
Manual Rack-and-Pinion Service 1355
Power Steering System Service 1356
Duff's Garage 1360
Manual and Power Steering Systems Diagnosis 1366
Chapter 71 1369
Brake System Fundamentals
Basic Brake System 1369
Braking Ratio 1371
Brake System Hydraulics 1371
Brake System Components 1372
Parking Brakes 1388
Focus on Hybrids 1389
Chapter 72 1394
Brake System Diagnosis and Repair
1302 Brake System Problem Diagnosis 1394
Brake System Inspection 1396
Vacuum Booster Service 1398
Hydraulic Booster Service 1399
Master Cylinder Service 1399
Brake System Bleeding 1401
Brake Line and Hose Service 1403
Disc Brake Service 1403
Brake Disc (Rotor) Service 1405
Drum Brake Service 1410
Parking Brake Adjustment 1416
Duff's Garage 1417
Brake System Diagnosis 1421
1324
Chapter 73 1422
Anti-Lock Brakes, Traction Control, and
Stability Control
Anti-Lock Brake Systems (ABS) 1422
Traction and Stability Control Systems 1430
ABS Service 1433
Traction and Stability Control System Service 1439
Final System Check 1441
Duff's Garage 1441
1337 Anti-Lock Brake and Traction Control System
Diagnosis 1444
Chapter 74 1445 Duff's Garage 1512
Wheel Alignment Climate Control System Diagnosis 1517
Wheel Alignment Principles 1445
Caster 1445 Section 13
Camber 1447 Safety, Security, and Navigation Systems
Toe 1447
Steering Axis Inclination 1448 Chapter 77 1521
Setback 1448 Restraint Systems
Toe-Out on Turns (Turning Radius) 1449 Vehicle Collisions 1521
Tracking 1449 Active and Passive Restraints 1523
Prealignment Inspection 1449 Seat Belt Systems 1523
Adjusting Wheel Alignment 1452 Knee Diverter 1523
Wheel Alignment Tools and Equipment 1455 Air Bag Systems 1525
Alignment Machines 1457 Air Bag Sensors 1529
Road Test after Alignment 1460 Air Bag Controller 1530
Duff's Garage 1460 Industry Trend 1531
Wheel Alignment Diagnosis 1465
Chapter 78
Section 12 1534
Heating and Air Conditioning Restraint System
Service
Chapter 75 1469 Seat Belt Service 1534
Heating and Air Conditioning Air Bag System Service 1535
Fundamentals Air Bag Module Service 1536
Principles of Refrigeration 1469 Air Bag Sensor Service 1538
Basic Refrigeration Cycle 1471 Air Bag Controller Service 1540
Automotive Air Conditioning System 1473 Duff's Garage 1540
Air Conditioning System Controls 1480 Restraint System Diagnosis 1543
Service Valves 1483
Chapter 79 1544
Heating System 1483
Heating and Air Conditioning Controls 1483 Security and Navigation Systems,
Ducts and Vents 1486 New and Future Technologies
Passenger Compartment Filters 1486 Security Systems 1544
Solar Ventilation 1486 Navigation Systems 1547
Focus on Hybrids 1488 Future Systems 1548
Alternate Power Sources 1551
Chapter 76 1493 Industry Trend 1554
Security System Diagnosis 1556
Heating and Air Conditioning Service
Inspecting an Air Conditioning System 1493 Chapter 80 1557
Refrigerant Safety Precautions 1495
Career Success
R-134a Service Differences 1495
Traits of Desirable Employees 1557
Testing an Air Conditioning System 1497
Earnings 1559
Recovering Refrigerant 1502
Types of Shops 1559
Common A/C Component Problems 1503
Getting a Job as an Automobile Technician 1560
Evacuating an Air Conditioning System 1507
Charging an Air Conditioning
System 1507 Reference Section 1564
Adding Refrigerant Oil 1509 Glossary of Terms 1568
A/C System Service Rules 1509 Internet Resources 1589
Heater Service 1510 Acknowledgments 1590
Electronic Climate Control Index 1591
Service 1511
 Section 1

Introduction to Automotive
Technology

1. The Automobile
2. Automotive Careers and ASE Certification
3. Basic Hand Tools
4. Power Tools and Equipment
5. The Auto Shop and Safety
6. Automotive Measurement and Math
7. Service Information and Work Orders
8. Basic Electricity and Electronics
9. Fasteners, Gaskets, Seals, and Sealants
10. Vehicle Maintenance, Fluid Service, and Recycling

We are truly living in a "world of wheels." Every day, millions of people

depend on their cars, trucks, vans, and sport-utility vehicles as their primary
means of transportation. As a result, economic experts predict a strong
demand for skilled automobile technicians and related professionals for the
foreseeable future. You have chosen to study an area of employment that
pays well and will require thousands of new graduates yearly.

Section 1 will introduce you to the "basics" of automotive technology. It

contains information on automobile construction and operation, ASE
certification, safety, tools, service information, electricity, and vehicle
maintenance.

This section will give you the knowledge needed to secure an entry-level
job. It will also lay the groundwork for later chapters, which provide in-
depth coverage of automotive technology.
 The Automobile

After studying this chapter, you will be able to:

Parts, Assemblies, and Systems
Identify and locate the most important parts of a
vehicle. A part is the smallest removable item on a car. A part
is not normally disassembled. The word component is
Describe the purpose of the fundamental auto-
frequently used when referring to an electrical or elec-
motive systems.
tronic part. For example, a spark plug is an ignition
Explain the interaction of automotive systems. system component that ignites the fuel in the engine.
Describe major automobile design variations. An assembly is a set of fitted parts designed to com-
Comprehend later text chapters with a minimum plete a function. For example, the engine is an assembly
amount of difficulty. that converts fuel into useable power to move the vehicle.
Correctly answer ASE certification test questions Technicians must sometimes take assemblies apart and
that require a knowledge of the major parts and put them back together during maintenance, service, and
systems of a vehicle. repair operations. See Figure 1-1.
An automotive system is a group of related parts and
The term automobile is derived from the Greek word assemblies that performs a specific function (job or task).
autos, which means self, and the French word mobile,
which means moving. Today's "self-moving" vehicles
are engineering marvels of safety and dependability.
Over the last century, engineers and skilled workers the
world over have used all facets of technology (the appli-
cation of math, science, physics, and other subjects) to
steadily give us a better means of transportation.
You are about to begin your study of the design, con-
struction, service, maintenance, and repair of the modern
automobile. This chapter provides a "quick look" at the
major automotive systems. By knowing a little about
each of these systems, you will be better prepared to learn
the more detailed information presented later in this text.
Today, failure of one system can affect the operation
of a seemingly unrelated system. This makes a thorough
understanding of how the whole automobile works espe-
cially important.
Tech Tip!
Try to learn something new about automotive Assembly
technology every day. In addition to studying
this book and doing the hands-on activities, read Figure 1-1. An assembly is a group of parts that work together
to perform a function. For example, an engine is an assembly
automotive magazines, "surf' the Internet, and that contains pistons, which convert the fuel's heat energy into
watch "motor-sport" television programs. This useable kinetic energy (motion). As you will learn, an engine
will help you become a better technician by has many other parts. (Saturn)
increasing your knowledge daily.
For example, your vehicle's steering system contains the
steering wheel, steering shaft, steering gears, linkage
rods, and other parts. These parts allow you to control the
direction of the wheels and tires for maneuvering
(turning) your vehicle. Another example of a familiar
system is the brake system. This system is a group of
parts that performs a very important task—slowing and
stopping your vehicle quickly and safely.
Figure 1-2 shows the major systems of a vehicle.
Memorize the name and general location of each system.
Automotive parts and systems can be organized into ten
major categories:
• Body and frame—support and enclose the vehicle.
• Engine—provides dependable, efficient power for
the vehicle.
• Computer systems—monitor and control various
vehicle systems.
• Fuel system—provides a combustible air-fuel
mixture to power the engine.
• Electrical system—generates and/or distributes the
power needed to operate the vehicle's electrical
and electronic components.
• Cooling and lubrication systems—prevent engine
damage and wear by regulating engine operating
temperature and reducing friction between
internal engine parts.
• Exhaust and emission control systems—quiet
engine noise and reduce toxic substances emitted
by the vehicle.
• Drive train systems—transfer power from the
engine to the drive wheels.
• Suspension, steering, and brake systems—support
and control the vehicle.
• Accessory and safety systems—increase occupant
comfort, safety, security, and convenience.
Frame, Body, and Chassis
The body and frame are the two largest sections of a
motor vehicle. The frame is the strong metal structure
that provides a mounting place for the other parts of the
vehicle. The frame holds the engine, transmission, sus-
pension, and other assemblies in position.
The body is a steel, aluminum, fiberglass, plastic, or
composite skin forming the outside of the vehicle. The
body is painted to give the vehicle an attractive appearance.
The term chassis is often used when referring to a
vehicle's frame and everything mounted to it except the
body—tires, wheels, engine, transmission, drive axle
assembly, and frame. You can see the complex network of
automotive parts and systems on the chassis shown in
Figure 1-3A. When each part or system is "disassembled
and studied" separately, you will find the inner workings
of a motor vehicle easy to understand.

Intake manifold
Throttle body
Fuel in Fuel filter Fuel injector

Air in

Fuel tank Fuel system

Fuel
pump Ignition system

Transmission Engine
Clutch
Drive axle assembly
Drive train
system

Drive shaft Starting system

Power out Exhaust Cooling
manifold system
Muffler
Oil pan Charging
Catalytic converter system
Exhaust out
Exhaust and emission Lubrication system
control systems

Figure 1-2. Note the general location of the major vehicle systems. Study the flow of fuel, air, exhaust, and power.
 Engine

Transmission

Drive shaft

Muffler

Frame

Gas tank

Tire
Wheel

Sheet metal
panels

C-pillar

B-pillar

A-pillar

Door
beams

Figure 1-3. Compare body-over-frame and unibody construction. A—In body-over-frame construction, the chassis parts bolt to a
strong perimeter frame. The body bolts to this thick steel frame. B—Unibody vehicles do not have a separate perimeter frame.
Chassis components bolt directly to the unibody assembly. (DaimlerChrysler, Saab)
 In body-over-frame construction, the frame consists
of thick steel members. The chassis parts and the body
bolt to this frame. Also called full frame construction or
perimeter frame construction, this design is heavy but
strong. Body-over-frame construction is used on full-size
cars, vans, pickup trucks, and sport-utility vehicles
(SUVs). See Figure 1-3A.
With unibody construction, sheet metal body panels
are welded together to form the body and frame. Also
called space frame construction or unitized construction,
this is the most common type of configuration used to
build small and medium passenger cars. Unibody con-
struction reduces weight, improves fuel economy, and
has a high strength-to-weight ratio. However, unibody
Figure 1-4. Note the various vehicle body styles. A—Sedan. B—Convertible. C—Hatchback. D—Station wagon. E—Minivan.
F—Sport-utility vehicle. (Toyota, Ford, Honda, Mazda)
vehicles are not as strong as those with body-over-frame
construction. See Figure 1-3B.
Body Types
Automobiles are available in several body types,
including the sedan, hardtop, convertible, hatchback, and
station wagon. In addition, the minivan, the sport-utility
vehicle, and the pickup truck have become increasingly
popular.
A sedan is a car that has front and back seats
and will carry four to six people. It has center body pil-
lars, or "B" pillars, between the front and rear doors,
Figure 1-4A. Both two-door and four-door sedans are
available.
 A hardtop is similar to the sedan, but it has no "B" Engine
pillars. Hardtop vehicles are also available in both two-
The engine provides the energy to propel (move) the
and four-door models.
vehicle and operate the other systems. Most engines con-
A convertible has a vinyl or cloth top that can be
sume gasoline or diesel fuel. The fuel burns in the engine
raised and lowered. A convertible has no door pillars,
to produce heat. This heat causes gas expansion, creating
and its strength is designed into the frame or floor pan.
pressure inside the engine. The pressure moves internal
Although most convertibles are two-door models,
engine parts to produce power. See Figure 1-6.
Figure 1-4B, a few four-door convertibles have been
The engine is usually located in the front portion of
produced.
the body. Placing the heavy engine in this position makes
A hatchback, or liftback, has a large rear door for
the vehicle safer in the event of a head-on collision. In a
easy access when hauling items. This style car is avail-
few vehicles, the engine is mounted in the rear to improve
able in three- and five-door models, Figure 1-4C.
handling. Refer to Figure 1-7.
A station wagon has a long, straight roof that extends
to the rear of the vehicle. Station wagons have large rear
Basic Engine Parts
interior compartments and come in two- and four-door
The basic parts of a simplified one-cylinder engine
models. Some station wagons have space for up to nine
are shown in Figure 1-8. Refer to this illustration as each
passengers, see Figure 1-4D.
part is introduced.
The minivan is similar to the station wagon, but it
has a higher roofline for more headroom and cargo space. • The block is metal casting that holds all the other
Most minivans are designed to carry seven passengers. engine parts in place.
See Figure 1-4E. • The cylinder is a round hole bored (machined) in
Sport-utility vehicles are often equipped with four- the block. It guides piston movement.
wheel-drive systems and have a tall body design. They • The piston is a cylindrical component that trans-
provide the comfort of a passenger car, the interior fers the energy of combustion (burning of air-fuel
space of a station wagon, and the durability of a truck, mixture) to the connecting rod.
Figure 1-4F.
• The rings seal the small gap around the sides of
Common names for various automobile body parts
the piston. They keep combustion pressure and oil
are shown in Figure 1-5. Note that a vehicle's right and
from leaking between the piston and the cylinder
left sides are denoted as if you were sitting in the car
wall (cylinder surface).
looking forward.
• The connecting rod links the piston to the
crankshaft.
• The crankshaft changes the reciprocating (up-
Front bumper and-down) motion of the piston and rod into
useful rotary (spinning) motion.
Left front Right front
fender fender
Hood

Carbon Dioxide Gasoline

(Carbon) (Carbon)
Left front Right front (Oxygen) (Hydrogen)
door door
Nitrogen Air
(Oxygen)
Water (Nitrogen)
(Argon)
Left rear Right rear (Hydrogen) Combustion (Carbon Dioxide)
door door (Oxygen)
(etc.)
Left rear Right rear Pollutants
quarter quarter (Hydrocarbons)
(Carbon Monoxide)
Trunk lid Rear bumper (Oxides of Nitrogen)

Figure 1-5. The right and left sides of a vehicle are denoted as Figure 1-6. An automotive engine commonly burns gasoline or
if you were sitting forward inside passenger compartment. diesel fuel to produce power. (Ford)
 • The cylinder head covers and seals the top of the
cylinder. It also holds the valves, rocker arms, and
often, the camshaft.
• The combustion chamber is a small cavity (hollow
area) between the top of the piston and the bottom
of the cylinder head. The burning of the air-fuel
mixture occurs in the combustion chamber.
• The valves open and close to control the flow of
the air-fuel mixture into the combustion chamber
and the exhaust gases out of the combustion
chamber.
• The camshaft controls the opening of the valves.
• The valve springs keep the valves closed when
they do not need to be open.
• The rocker arms transfer camshaft action to the
valves.
• The lifters, or followers, ride on the camshaft and
transfer motion to the other parts of the valve
train.
• The flywheel helps keep the crankshaft turning
smoothly. It also provides a large gear for the
starting motor.
Four-Stroke Cycle
Automobile engines normally use a four-stroke
cycle. Four separate piston strokes (up or down move-
ments) are needed to produce one cycle (complete series
of events). The piston must slide down, up, down, and up
again to complete one cycle.
As the four strokes are described below, study the
simple drawings in Figure 1-9.
1. The intake stroke draws the air-fuel mixture
into the engine's combustion chamber. The
piston slides down while the intake valve is
open and the exhaust valve is closed. This pro-
duces a vacuum (low-pressure area) in the
cylinder. Atmospheric pressure (outside air
pressure) can then force air and fuel into the
combustion chamber.
2. The compression stroke prepares the air-fuel
mixture for combustion. With both valves
closed, the piston slides upward and compresses
(squeezes) the trapped air-fuel mixture.
Lifters Rocker arms

Camshaft

Valve spring
Valves

Cylinder
head
Combustion
Front engine, front-wheel drive Transverse chamber
engine mounting
Block
Piston

Piston
Cylinder
rings

Connecting
rod
Front engine, rear-wheel drive Longitudinal
engine mounting

Crankshaft

Flywheel
Rear engine, rear-wheel drive

Figure 1-7. The engine can be located in the front or rear of the Figure 1-8. Memorize the basic parts of this one-cylinder
vehicle. (Dana Corp.) engine.
 Both
Intake Exhaust
valves
valve valve
closed
open closed

Air-fuel Air-fuel
mixture mixture
pulled into compressed
cylinder

Piston and rod

Piston and rod moving up
moving down

1—Intake stroke. Intake valve open. Exhaust valve closed. 2—Compression stroke. Both valves are closed. Piston slides
Piston slides down, forming vacuum in cylinder. Atmospheric up and pressurizes air-fuel mixture. This readies mixture for
pressure pushes air and fuel into combustion chamber. combustion.

Both
valves Intake Exhaust
closed valve valve
closed open

Spark plug
fires, mixture
burns and
expands
Piston forces
rod down
and turns Piston slides up
crankshaft and pushes
burned gases out

3—Power stroke. Spark plug sparks. Air-fuel mixture burns. 4—Exhaust stroke. Exhaust valve opens. Intake valve remains
High pressure forces piston down with tremendous force. closed. Piston slides up, pushing burned gases out of cylinder.
Crankshaft rotates under power. This prepares combustion chamber for another intake stroke.

Figure 1-9. A gasoline engine normally operates on a four-stroke cycle. Study the series of events.

3. The power stroke produces the energy to operate
the engine. With both valves still closed, the
spark plug arcs (sparks) and ignites the com-
pressed air-fuel mixture. The burning fuel
expands and develops pressure in the combustion
chamber and on the top of the piston. This pushes
the piston down with enough force to keep the
crankshaft spinning until the next power stroke.
4. The exhaust stroke removes the burned gases
from the combustion chamber. During this
stroke, the piston slides up while the exhaust
valve is open and the intake valve is closed. The
burned fuel mixture is pushed out of the engine
and into the exhaust system.
During engine operation, these four strokes are
repeated over and over. With the help of the heavy fly-
wheel, this action produces smooth, rotating power
output at the engine crankshaft.
Obviously, other devices are needed to lubricate the
engine parts, operate the spark plug, cool the engine, and
provide the correct fuel mixture. These devices will be
discussed shortly.
Automotive Engines
Unlike the basic one-cylinder engine just discussed,
automotive engines are multi-cylinder engines, which
means they have more than one piston and cylinder.
Vehicles commonly have 4-, 6-, 8-, or 10-cylinder
engines. The additional cylinders smooth engine operation
because there is less time (degrees of crankshaft rotation)
between power strokes. Additional cylinders also
increase power output.
An actual automotive engine is pictured in
Figure 1-10. Study the shape, location, and relationship
of the major parts.

Throttle valve Intake manifold

Intake
valve

Exhaust
valve
Cylinder

Exhaust
manifold

Piston

Connecting
rod

Oil Cylinder
filter block

Crankshaft

Oil pan

Figure 1-10. Automotive engines are multi-cylinder engines. Locate the major parts and visualize their operation. (Ford)
Computer System
The computer system uses electronic and electrical
devices to monitor and control various systems in the
vehicle, including the fuel, ignition, drive train, safety,
and security systems. See Figure 1-11. The use of com-
puter systems has improved vehicle efficiency and
dependability. Additionally, most of these systems have
self-diagnostic capabilities. There are three major parts of
an automotive computer system:
• Sensors—input devices that can produce or
modify electrical signals with a change in a
condition, such as motion, temperature, pressure,
etc. The sensors are the "eyes, ears, and nose" of
the computer system.
• Control module—computer (electronic circuit)
that uses signals from input devices (sensors) to
control various output devices. The control
module is the "brain" of the computer system.
• Actuators—output devices, such as small electric
motors, that can move parts when energized by
the control module. The actuators serve as the
"hands and arms" of the computer system.
A modern car can have several control modules and
dozens of sensors and actuators. These components will
be detailed throughout this book.
Sensing Control Output
Door lock
solenoid
Control module (actuator)
(computer)
Gear shift
sensor
Vehicle
speed
sensor
Figure 1-11. This computer-controlled lock system automati-
cally locks the doors as soon as the vehicle starts moving.
When the gear shift sensor and the vehicle speed sensor send
the correct signals to the control module, the module energizes
the solenoid (actuator). The solenoid then converts the elec-
trical signal from the control module to a linear motion, locking
the doors.
Tech Tip!
Learn all you can about electricity and elec-
tronics. Nearly every automotive system is now
monitored or controlled by a computer. It is
almost impossible to service any system of a car
without handling some type of electric or elec-
tronic component. This book covers electronics
in almost every chapter.
Fuel System
The fuel system must provide the correct mixture of
air and fuel for efficient combustion (burning). This
system must add the right amount of fuel to the air
entering the cylinders. This ensures that a very volatile
(burnable) mixture enters the combustion chambers.
The fuel system must also alter the air-fuel ratio
(percentage of air and fuel) with changes in operating
conditions (engine temperature, speed, load, and other
variables).
There are three basic types of automotive fuel systems:
gasoline injection systems, diesel injection systems, and
carburetor systems. Look at the three illustrations in
Figure 1-12.
Gasoline Injection System
Modern gasoline injection systems use a control
module, sensors, and electrically operated fuel injectors
(fuel valves) to meter fuel into the engine. This is the
most common type of fuel system on gasoline, or spark
ignition, engines. See Figure 1-12A.
An electric fuel pump forces fuel from the fuel tank
to the engine. The control module, reacting to electrical
data it receives from the sensors, opens the injectors for
the correct amount of time. Fuel sprays from the open
injectors, mixing with the air entering the combustion
chambers.
A throttle valve controls airflow, engine speed, and
engine power. When the throttle valve is open for more
engine power output, the computer holds the injectors
open longer, allowing more fuel to spray out. When the
throttle valve is closed, the computer opens the injectors
for only a short period of time, reducing power output.
The throttle valve (air valve) is connected to the
accelerator pedal. When the pedal is pressed, the throttle
valve opens to increase engine power output.
Diesel Injection System
A diesel fuel system is primarily a mechanical
system that forces diesel fuel (not gasoline) directly into
the combustion chambers. Unlike the gasoline engine,
the diesel engine does not use spark plugs to ignite the
air-fuel mixture. Instead, it uses the extremely high
 When open, fuel injector
(fuel valve) sprays fuel
toward intake valve Spark plug
ignites mixture

Throttle
valve

Electric
fuel pump

Gasoline
from tank

Wires to
engine
sensors
Computer

A—Gasoline injection system. Engine sensors feed information (electrical signals) to computer about engine conditions.
Computer can then open injector for right amount of time. This maintains correct air-fuel ratio. Spark plug ignites fuel.

Mechanical injection nozzle sprays fuel Injection line

into combustion chamber

Air enters Fuel ignites as it

touches hot air

High-pressure
mechanical pump

No throttle used

Only air flows past intake valve

and into combustion chamber Diesel fuel
from tank
Air compressed so tight
it becomes red hot
B—Diesel injection system. High-pressure mechanical pump sprays fuel directly into combustion chamber. Piston squeezes and
heats air enough to ignite diesel fuel. Fuel begins to burn as soon as it touches heated air. Note that no throttle valve or spark plug
is used. Amount of fuel injected into chamber controls diesel engine power and speed.

Air enters filter

Fuel line
Carburetor

Fuel pulled into airstream

by vacuum
Low-pressure
mechanical fuel
Throttle controls airflow pump
and engine speed
Gasoline
Air-fuel mixture flows from tank
to cylinder
Mixture ignited
by spark plug

C—Carburetor fuel system. Fuel pump fills carburetor with fuel. When air flows through carburetor, fuel is pulled into engine in
correct proportions. Throttle valve controls airflow and engine power output.

Figure 1-12. Note the three basic types of fuel systems. Compare differences.
pressure produced during the compression stroke to
heat the air in the combustion chamber. The air is
squeezed until it is hot enough to ignite the fuel. Refer
to Figure 1-12B.
When the mechanical pump sprays the diesel fuel into
a combustion chamber, the hot air in the chamber causes
the fuel to begin to burn. The burning fuel expands and
forces the piston down on the power stroke. Electronic
devices are commonly used to monitor and help control
the operation of today's diesel injection systems.
Carburetor Fuel System
The carburetor fuel system uses engine vacuum
(suction) to draw fuel into the engine. The amount of air-
flow through the carburetor determines the amount of
fuel used. This automatically maintains the correct air-
fuel ratio. Refer to Figure 1-12C.
Either a mechanical or an electric fuel pump draws
fuel out of the tank and delivers it to the carburetor. The
engine's intake strokes form a vacuum inside the intake
manifold and carburetor. This causes gasoline to be drawn
from the carburetor and into the air entering the engine.
Electrical System
The vehicle's electrical system consists of several
subsystems (smaller circuits): ignition system, starting
system, charging system, and lighting system. Each sub-
system is designed to perform a specific function, such as
"fire" the spark plugs to ignite the engine's fuel mixture,
rotate the crankshaft to start the engine, illuminate the
highway for safe night driving, etc.
Ignition System
An ignition system is needed on gasoline engines to
ignite the air-fuel mixture. It produces an extremely high
voltage surge, which operates the spark plugs. A very hot
electric arc jumps across the tip of each spark plug at the
correct time. This causes the air-fuel mixture to burn,
expand, and produce power. Study Figure 1-13.
With the ignition switch on and the engine running,
the system uses sensors to monitor engine speed and other
operating variables. Sensor signals are fed to the control
module. The control module then modifies and amplifies
(increases) these signals into on-off current pulses that

Control module

Ignition coil

Secondary
Ignition wire
switch

Spark plug

Trigger
Resistor wheel

Electric arc
Battery
Crankshaft
position sensor

Figure 1-13. The ignition system is used on gasoline engines to start combustion. The spark plug must fire at the correct time during
the compression stroke. A crankshaft position sensor or a distributor operates the ignition module. The module operates the ignition
coil. The coil produces high voltage for the spark plugs.
trigger the ignition coil. When triggered, the ignition coil
produces a high voltage output to "fire" the spark plugs.
When the ignition key is turned off, the coil stops func-
tioning and the spark-ignition engine stops running.
Starting System
The starting system has a powerful electric starting
motor that rotates the engine crankshaft until the engine
"fires" and runs on its own power. The major parts of the
starting system are shown in Figure 1-14A.
A battery provides the electricity for the starting
system. When the key is turned to the start position, cur-
rent flows through the starting system circuit. The starting
motor is energized, and the starting motor pinion gear
engages a gear on the engine flywheel. This spins the
crankshaft. As soon as the engine starts, the driver must
shut off the starting system by releasing the ignition key.
Charging System
The charging system is needed to replace electrical
energy drawn from the battery during starting system
operation. To re-energize the battery, the charging system
forces electric current back into the battery. The fun-
damental parts of the charging system are shown in
Figure 1-14B. Study them!
When the engine is running, a drive belt spins the
alternator pulley. The alternator (generator) can then
Starting system
Small current
activates starter
Ignition
switch
Alternator
Flywheel
gear
Starting
motor
High current
flow to starter
Battery
Figure 1-14. Note the basic actions and components of the starting and charging systems.
produce electricity to recharge the battery and operate
other electrical needs of the vehicle. A voltage regulator,
usually built into the alternator, controls the voltage and
current output of the alternator.
Lighting System
The lighting system consists of the components that
operate a vehicle's interior and exterior lights (fuses,
wires, switches, relays, etc.). The exact circuit and part
configurations will vary from one model to another.
The exterior lights typically include the headlights,
turn signals, brake lights, parking lights, backup lights,
and side marker lights. The interior lights include the
dome light, trunk light, instrument panel lights, and other
courtesy lights.
Cooling and Lubrication Systems
The cooling and lubrication systems are designed to
prevent engine damage and wear. They are important sys-
tems that prevent the engine from self-destructing.
The cooling system maintains a constant engine
operating temperature. It removes excess combustion
heat to prevent engine damage and also speeds engine
warm-up. Look at Figure 1-15.
The water pump forces coolant (water and antifreeze
solution) through the inside of the engine, hoses, and
Charging system
Voltage to
activate regulator
Voltage
regulator
Ignition
switch
Drive
belt
Current flows through
and recharges battery
Battery
radiator. The coolant collects heat from the hot engine
parts and carries it back to the radiator.
The radiator allows the coolant heat to transfer into
the outside air. An engine fan draws cool air through the
radiator. The thermostat controls coolant flow and engine
temperature. It is usually located where the top radiator
hose connects to the engine.
The lubrication system reduces friction and wear
between internal engine parts by circulating filtered
engine oil to high-friction points in the engine. The lubri-
cation system also helps cool the engine by carrying heat
away from internal engine parts.
Study the parts and operation of the lubrication
system shown in Figure 1-16. Note how the oil pump
pulls oil out of the pan and pushes it to various moving
parts of the engine.
Exhaust and Emission Control Systems
The exhaust system quiets the noise produced during
engine operation and routes engine exhaust gases to the
rear of the vehicle body. Figure 1-17 illustrates the basic
parts of an exhaust system. Trace the flow of exhaust
Hot coolant
Radiator
Fan
Water
pump
Airflow to
remove heat
from coolant
Engine
water
jacket
Cooled coolant
Fan belt
Crankshaft
Figure 1-15. The cooling system must protect the engine from
the heat of combustion. Combustion heat could melt and ruin
engine parts. The system must also speed warm-up and main-
tain a constant operating temperature. Study the part names.
gases from the engine exhaust manifold to the tailpipe.
Learn the names of the parts.
Various emission control systems are used to reduce
the amount of toxic (poisonous) substances produced by
an engine. Some systems prevent fuel vapors from
entering the atmosphere (air surrounding the earth).
Other emission control systems remove unburned and
partially burned fuel from the engine exhaust. Later chap-
ters cover these systems in detail.
Drive Train Systems
The drive train transfers turning force from the engine
crankshaft to the drive wheels. Drive train configurations
vary, depending on vehicle design. See Figure 1-18.
The drive train parts commonly found on a front-
engine, rear-wheel-drive vehicle include the clutch, trans-
mission, drive shaft, and rear axle assembly. The drive
train parts used on most front-engine, front-wheel-drive
vehicles include the clutch, transaxle, and drive axles.
Refer to Figure 1-18 as these components and assem-
blies are discussed.
Clutch
The clutch allows the driver to engage or disengage
the engine and manual transmission or transaxle. When
the clutch pedal is in the released position, the clutch
locks the engine flywheel and the transmission input
shaft together. This causes engine power to rotate the
transmission gears and other parts of the drive train to
propel the vehicle. When the driver presses the clutch
pedal, the clutch disengages power flow and the engine
no longer turns the transmission input shaft and gears.
Transmission
The transmission uses various gear combinations, or
ratios, to multiply engine speed and torque to accommo-
date driving conditions. Low gear ratios allow the vehicle
to accelerate quickly. High gear ratios permit lower
engine speed, providing good gas mileage.
A manual transmission lets the driver change
gear ratios to better accommodate driving conditions,
Figure 1-19. An automatic transmission, on the other
hand, does not have to be shifted by the driver. It uses an
internal hydraulic system and, in most cases, electronic
controls to shift gears. The input shaft of an automatic
transmission is connected to the engine crankshaft
through a torque converter (fluid coupling) instead of a
clutch. The elementary parts of an automatic transmis-
sion are pictured in Figure 1-20.
Drive Shaft
The drive shaft, or propeller shaft, transfers power
from the transmission to the rear axle assembly. Look at
 To turbocharger
Camshaft (for exhaust valves)

Lash
adjusters

Valve
Camshaft (for intake valves)

Oil filter Oil Piston

pressure
switch

Relief
valve

Oil pump
Crankshaft

Oil screen

Figure 1-16. The lubrication system uses oil to reduce friction and wear. The pump forces oil to high-friction points.

Intermediate pipes Exhaust

manifolds

Tailpipes
Mufflers Catalytic converters Header pipes

Figure 1-17. The exhaust system carries burned gases to the rear of the vehicle. It also reduces engine noise. (Nissan)
 Transmission Clutch Engine

Engine Front
Differential
drive
Clutch Manual transaxle axle

Manual
transmission

Drive shaft

Differential

Rear Dead axle

drive axle

Figure 1-18. The drive train transfers engine power to the drive wheels. Study the differences between the two common types of
drive trains. A—Front-engine, rear-wheel-drive vehicle. B— Front-engine, front-wheel-drive vehicle.

Gear shift lever

Shift
mechanism
Sychronizer for
shifting gears

Input shaft Output shaft

from clutch to drive shaft

Gears
Transmission case

Figure 1-19. A manual transmission uses gears and shafts to achieve various gear ratios. The speed of the output shaft compared
to the speed of the input shaft varies in each gear position. This allows the driver to change the amount of torque going to the drive
wheels. In lower gears, the car accelerates quickly. When in high gear, engine speed drops while vehicle speed stays high for good
fuel economy. (Ford)
 Torque converter
Transaxle
(fluid clutch) The transaxle consists of a transmission and a dif-
ferential in a single housing. Although a few rear-wheel-
Bands Gearsets drive vehicles are equipped with transaxles, they are
most commonly used with front-wheel-drive vehicles,
Output
shaft Figure 1-22. Both manual and automatic transaxles are
available. The internal parts of a modern transaxle
assembly are illustrated in Figure 1-23.

Front Drive Axles

Oil
pump Transmission The front drive axles connect the transaxle differen-
case tial to the hubs and wheels of the vehicle. These axles are
Clutches Valve
equipped with constant-velocity joints, which allow the
body Shift lever
front wheels to be turned to the left or right and to move
up and down.
Figure 1-20. An automatic transmission serves the same
function as a manual transmission. However, it uses a hydraulic
pressure system to shift gears. (Ford)

Transverse
(sideways)
mounted
Figure 1-21. It is a hollow metal tube with two or more engine
universal (swivel) joints. The universal joints allow the
rear suspension to move up and down without damaging
the drive shaft.

Rear Axle Assembly

Front drive
The rear axle assembly contains a differential and axles Transaxle
two axles. The differential is a set of gears and shafts that
transmits power from the drive shaft to the axles. The Figure 1-22. Front-wheel-drive vehicles do not have a drive
axles are steel shafts that connect the differential and shaft or a rear drive axle assembly. The complete drive train is
drive wheels, Figure 1-21. in the front of the vehicle. (Ford)

Rear axle
assembly
Transmission

Engine

Drive Drive
Universal-joint shaft Differential wheel

Figure 1-21. The drive shaft sends power to the rear axle assembly. The rear axle assembly contains the differential and two axles
that turn the rear drive wheels. (Lexus)
Differential Suspension, Steering, and Brake Systems
assembly
The suspension, steering, and brake systems are the
movable parts of the chassis. They bolt or anchor to the
frame and provide important functions that will be
explained in the following sections.

Suspension System
The suspension system allows the vehicle's wheels
and tires to move up and down with little effect on body
movement. This makes the vehicle's ride smooth and
safe. The suspension system also prevents excessive body
Transmission lean when turning corners quickly.
Power assembly
As you can see in Figure 1-24, various springs, bars,
output to
drive axle swivel joints, and arms make up the suspension system.

Shift rod Housing or

Steering System
assembly case The steering system allows the driver to control
vehicle direction by turning the wheels right or left. It
Figure 1-23. A transaxle contains a transmission and a differ- uses a series of gears, swivel joints, and rods to do this.
ential in one housing. (Ford) Study the names of the parts in Figure 1-24.

Engine

Suspension
system
spring
Power
steering
pump
Tire
Shock
absorber

Transaxle
Steering
Steering system
Wheel gear
Front drive Suspension tie rod
axle system control arm

Figure 1-24. The suspension and steering systems mount on the frame. Study the part names. (Saab-Scania)
Brake System
The brake system produces friction to slow or stop the
vehicle. When the driver presses the brake pedal, fluid pres-
sure actuates a brake mechanism at each wheel. These
mechanisms force friction material (brake pads or shoes)
against metal discs or drums to slow wheel rotation.
Figure 1-25 shows the fundamental parts of a brake
system.
Accessory and Safety Systems
Common accessory systems include the air condi-
tioner, sound system, power seats, power windows, and
rear window defogger. Common safety systems include
seat belts, air bags, and security systems. See Figure 1-26.
Hybrid Vehicle
Most auto manufacturers now build and sell hybrid
vehicles. A hybrid vehicle uses two methods of propul-
sion—an internal combustion engine and a large electric
motor-generator—to help improve vehicle performance
(acceleration), increase fuel economy (gas mileage), and
reduce emissions (air pollution). See Figure 1-27.
The fundamental parts of a hybrid vehicle include:
• Motor-generator—device that can propel the
vehicle like a motor or produce electrical energy
like an alternator.
Emergency brake
Brake booster
Master
cylinder
Brake
pedal
Rotor
Hydraulic or disc
Caliper
unit
Figure 1-25. When the brake pedal is pressed, pressure is placed on a confined fluid. The fluid pressure transfers through the
system to operate the brakes. An emergency brake is a mechanical system that applies the rear wheel brakes. A—Complete system.
B—Close-up. (Cadillac, Nissan)
• High voltage cables—large diameter, insulated
conductors that carry voltage between the motor-
generator, hybrid control module, and battery
pack.
• Hybrid control module—high power electrical-
electronic circuits that manage the flow of electrical
energy through a vehicle's electrical-mechanical
drive train.
• Hybrid battery pack—large set of battery cells
that can store huge amounts of electrical energy
and output high current and voltage to help propel
the vehicle.
• Internal combustion engine—gasoline or diesel
engine that propels the vehicle at cruising speeds
and drives the motor-generator.
During acceleration, hybrid vehicles rely on the
motor-generator for propulsion. Then, when the vehicle
reaches a specific speed (or the battery pack becomes dis-
charged), the internal combustion engine takes over. In
addition to propelling the vehicle, the engine also spins
the motor-generator's armature. This causes the motor-
generator to produce electricity to recharge the battery
pack for the next vehicle acceleration cycle.
During braking, the rotational force of the vehicle's
drive axles spins the motor-generator's armature, causing
the motor-generator to produce electrical energy to
recharge the battery. This is known as regenerative
Brake rotor
or disc
Wheel
Wheel
hub
Brake
lines
Tire
Brake
caliper
 braking. Since it takes considerable torque to rotate the
armature, the motor-generator resists drive axle rotation
to help slow and stop the vehicle.

Highway History
Early automobile manufacturers originated in var-
ious ways. In many instances, they evolved from
bicycle makers, carriage and wagon makers, and
other types of industry. Early motorcars were similar to
Front horse-drawn buggies, but they were equipped with
air bags noisy gasoline-powered engines, steam engines, or
electric motors and batteries. A single lever called a
tiller was used to steer the vehicle and another lever
was used to apply the brakes.

Summary
• The body and frame support, stop, and enclose
the vehicle.
• The engine provides dependable, efficient power
Side-impact
air bags for the vehicle.
• The intake stroke draws the air-fuel mixture into
the engine combustion chamber.
• The compression stroke prepares the fuel mixture
for combustion.
• The power stroke produces the energy to operate
Figure 1-26. Various safety systems are used on modern vehi-
cles to protect both the driver and the passengers. This vehicle the engine.
is equipped with both front and side-impact air bags. (Audi) • The exhaust stroke must remove the burned gases
from the engine cylinders.
• The computer system uses electronic and elec-
Internal combustion
trical devices to monitor and control various sys-
engine
tems in the vehicle.
• The fuel system provides the correct mixture of
air and fuel for efficient combustion.
• Electrical systems operate the electrical-electronic
devices.
• The cooling system maintains a constant engine
operating temperature.
• The lubrication system reduces friction between
internal engine parts.
• Emission control systems reduce air pollution
produced by the vehicle.
• Drive train systems transfer turning force from
Motor-generator
Continuously the engine crankshaft to the drive wheels.
variable transmission • Suspension, steering, and brake systems support
and control the vehicle.
Figure 1-27. This hybrid power train contains an internal com-
bustion engine, a motor-generator, and a continuously variable • Accessory and safety systems increase passenger
transaxle. (Honda) comfort, safety, security and convenience.
 4. Explain the engine's four-stroke cycle.
Important Terms
5. Most car engines are multi-cylinder engines.
Automobile Gasoline injection
True or False?
Technology systems
Part Diesel fuel system 6. List and describe the three common types of
Component Carburetor fuel system fuel systems.
Assembly Ignition system 7. A diesel engine does not use spark plugs. True
System Starting system or False?
Frame Charging system 8. The car's electrical system consists of the:
Body Lighting system (A) ignition, starting, lubrication, and lighting
Chassis Cooling system systems.
Body-over-frame Lubrication system (B) ignition, charging, lighting, and hydraulic
construction Exhaust system systems.
Unibody construction Emission control (C) lighting, charging, starting, and ignition
Engine systems systems.
Four-stroke cycle Drive train (D) None of the above.
Intake stroke Suspension system
9. The system reduces the amount of
Compression stroke Steering system
toxic substances released by the vehicle.
Power stroke Brake system
Exhaust stroke Accessory systems 10. What is the difference between a manual trans-
Multi-cylinder engines Safety systems mission and an automatic transmission?
Computer system Hybrid vehicle 11. A one-piece drive shaft rotates the drive wheels
Fuel system Regenerative braking on most front-wheel drive cars. True or False?
Air-fuel ratio 12. A rear axle assembly contains two and
a(n) .
Review Questions—Chapter 1 13. Explain the term "transaxle."

Please do not write in this text. Place your answers 14. The suspension system mounts the car's wheels
solidly on the frame. True or False?
on a separate sheet of paper.
1. What is an automotive system? 15. List four accessory systems.
2. Automotive parts and systems can be grouped 16-25. Identify the parts and systems illustrated
into ten categories. Name them. below. Write the numbers 16-25 on your paper.
3. Which of the following is not part of an engine? Then write the correct letter and words next to
(A) Block. each number.
(B) Piston.
(C) Muffler.
(D) Crankshaft.

Can you identify the following parts and systems? (A) Starting system. (B) Charging system. (C) Drive train. (D) Fuel system.
(E) Cooling system. (F) Engine. (G) Ignition system. (H) Lubrication system. (I) Exhaust system. (J) Intake manifold.
 7. Tests show that an engine is not getting spark
ASE-Type Questions at the spark plugs. Technician A says it could
be due to the diesel injection system.
Technician B says to test the ignition coil. Who
1. A vehicle is brought into the shop with a slip-
is right?
ping clutch. Technician A says that the clutch
(A) A only.
is part of the drive train system. Technician B
(B) Bonly.
says that the clutch is part of the suspension
(C) Both A and B.
system. Who is correct?
(D) Neither A nor B.
(A) A only.
(B) Bonly. 8. A car with a dead battery is brought into
(C) Both A and B. the shop. Technician A says to check the
(D) Neither A nor B. output of the alternator. Technician B says to
2. When the internal body structure of a vehicle check the condition of the spark plugs. Who
is used as its frame, it is called: is right?
(A) unibody construction. (A) A only.
(B) body-frame construction. (B) Bonly.
(C) integral construction. (C) Both A and B.
(D) body-over-frame construction. (D) Neither A nor B.
3. The controls the opening of engine's 9. Since an automatic transmission does not have
valves. to be shifted by hand, Technician A believes it
(A) camshaft uses a hydraulic system to shift gears.
Technician B believes it uses oil pressure to
(B) crankshaft
shift gears. Who is right?
(C) valve springs
(D) combustion chamber (A) A only.
(B) Bonly.
4. Which piston stroke of the four-stroke cycle (C) Both A and B.
prepares the fuel mixture for combustion?
(D) Neither A nor B.
(A) Power.
(B) Intake. 10. A transaxle case contains both the:
(C) Exhaust. (A) carburetor and drive shaft.
(D) Compression. (B) transmission and differential.
(C) multi-cylinder engine and clutch.
5. All of the following are major components in (D) suspension components and brakes.
the computer system except:
(A) regulators.
(B) sensors. Activities—Chapter 1
(C) actuators.
(D) computer. 1. Draw an automotive engine and drive train and
label the parts. Then describe how the power is
6. Each of the following is a basic type of auto- transferred from the engine to the drive wheels.
motive fuel system except:
2. Using illustrations from the text, produce over-
(A) carburetor.
head transparencies of the four-stroke cycle and
(B) auto injection.
demonstrate the cycle to your class.
(C) diesel injection.
(D) gasoline injection. 3. Arrange a field trip to tour an automobile
assembly plant or to an auto shop.