Professional Documents
Culture Documents
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Part 5 Maintenance
32 33 34 Fuels, uids and lubricants Service and maintenance Basic mechanics and diagnosis
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Workshop practices
Automotive service procedures Workshop operations Production processes Fasteners Locking devices Screw threads V-threads Sources of information Vehicle identication Technical terms Review questions
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Workshop safety
Personal safety Other personal safety issues Machine and equipment safety Motor vehicle safety Safety with vehicle components Engine safety Battery safety Hazardous materials Emergency procedures Fire safety Fires Fire extinguishers First aid Technical terms Review questions
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98 99 99 101 101 102
Tools for turning 34 Tools for holding and gripping 38 Tools for hammering and driving 39 Tools for cutting and forming 41 Tools for drilling and reaming 44 Tools for threading 46 Tools and materials for grinding and abrading 48 Tools for pulling and pushing 51 Portable power tools Special service tools 52 Technical terms 52 Review questions 52
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Vernier calipers Dial gauge and its use Hole gauges Depth gauges Marking and checking Tools for marking and checking Other gauges and instruments Electrical test instruments Technical terms Review questions
59 60 61 61 62 65 66 67 67
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86 86 88 91 92 93 93 93 95 95 96 96
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70 70 71 71 73 74 76 77 78 79 80 81 83 83
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110 110 112 112 116 118 119 119 121 122 121 122 123
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144 145 146 146 148 152 153 154 155 158 160 161 162 162 162
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196 198 199 199 201 201 203 204
Engine-lubricating systems
Engine lubrication Oil circulation Oil pumps Oil pump service Oil lters Oil coolers Lubrication of engine bearings Crankcase ventilation Lubricating-system maintenance Lubricating-system problems Technical terms Review questions
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164 165 167 169 170 171 173 174 175 177 178 178
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214 214 215 216 217 219 220 220 223 224 224 225 227 228 229 230 230
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180 180 181 181 181 184 189 190 191 193 193 193
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Intake-system problems Exhaust systems Exhaust-system service Exhaust-system problems Technical terms Review questions
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250 250 250 251 252 255 258 259 260 260 261 262
Sliding and synchromesh gears Basic synchromesh transmission Five-speed synchromesh transmission Power ow through a ve-speed transmission Six-speed transmission Transaxles Transaxle construction Transaxle operation Synchromesh operation Types of synchromesh Gearshift mechanisms Technical terms Review questions
281 283 285 286 286 286 290 293 295 295 300 300
Clutch service
General checks and adjustments Adjusting mechanical controls Servicing mechanical controls Adjusting hydraulic controls Servicing hydraulic controls Bleeding the clutch system Major clutch service Repairs to pressure-plate assemblies Clutch housing alignment Analysing clutch problems Diagnosing clutch noise General clutch problems Technical terms Review questions
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264 264 265 265 266 269 269 273 273 273 274 275 276 276
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Purpose of a transmission Types of gears Gear ratio Basic transmission Basic transmission power ow
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Rear axles for independent rear suspension Transaxle nal drive Four-wheel drive Technical terms Review questions
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344 344 346 349 349 350 352
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Master cylinders Compensating-type master cylinder Centre-valve master cylinder Valves in the hydraulic system Wheel cylinders Hydraulic brake uid Brake booster Drum-brake assemblies Brake-shoe assemblies Disc-brake assemblies Parking brakes Technical terms Review questions
410 413 414 416 418 420 420 423 424 426 430 432 432
Brake service
Maintenance and inspection Brake booster Hydraulic system service points Bleeding brakes Master-cylinder service Drum-brake service Drum-brake adjustments Self-adjusting drum brakes
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Brakes
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Disc-brake service Parking brakes Brake tools Fault diagnosis Technical terms Review questions
Suspension systems
General suspension designs Leaf springs Rear suspension with leaf springs Front suspension with leaf springs Types of coil springs Front suspension with coil springs Strut or McPherson suspension Rear suspension with coil springs Independent rear suspensions with struts Rear suspension with swing axles Torsion rear axle Torsion bar suspension Shock absorbers Height-control suspension Technical terms Review questions
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470 471 471 473 474 474 476 477 479 480 480 483 483 486 486 487
Steering boxes Rack-and-pinion steering boxes Rack-and-pinion power steering Rack-and-pinion power steering components Speed-sensitive rack-and-pinion power steering Electro-hydraulic power steering Electric power steering Steering boxes with worm gearing Power steering for worm-type boxes Four-wheel steering Four-wheel-steering systems Four-wheel steering with rear power cylinder Other steering features Technical terms Review questions
516 517 518 519 521 522 523 524 525 528 529 530 533 534 534
Steering-system service
Servicing steering linkage Steering-column service Power-steering maintenance Rack-and-pinion steering service Rack-and-pinion power-steering service Analysing power-steering problems Servicing a recirculating-ball steering box Worm-type steering box adjustments Recirculating-ball box with power steering Steering faults Technical terms Review questions
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536 538 540 542 545 547 547 550 551 551 552 552
Suspension service
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Maintenance 490 Dismantling and reassembling procedures 490 Ball joint front suspension 491 Strut (McPherson) suspensions 492 Rigid rear axle with coil springs 494 Independent rear suspension (RWD vehicles) 495 Rigid rear axle with leaf springs 496 Dismantling and reassembling struts 498 Servicing components 499 Servicing hubs and bearings 502 Hubs with tapered roller bearings 502 Hubs with unitised bearings 504 Other bearing arrangements 506 Checking suspension parts 507 Servicing shock absorbers 509 Technical terms 510 Review questions 510
Wheel alignment
Steering and suspension angles Front-suspension and steering adjustments Caster and camber adjustments Toe adjustments Adjustments for toe-out-on-turns Rear-suspension adjustments Wheel-alignment equipment Types of wheel aligners Using wheel aligners Front-wheel alignment Rear-wheel alignment Function and effects of the various angles More about suspension angles Technical terms Review questions
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554 556 556 558 560 560 561 562 565 568 569 569 571 573 573
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Steering systems Rack-and-pinion steering systems Steering systems with worm gearing Steering and suspension angles
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Steering systems
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PART 5 MAINTENANCE
Fuels, uids and lubricants
Crude oil and its products Petrol Ethanol Gas fuels Automotive diesel fuels Alternative fuels Lubricating oil Grease Transmission oils Hydraulic brake uids Technical terms Review questions
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578 578 580 581 582 585 586 587 588 588
Special services General service and repairs Lifting and jacking Towing and recovering Technical terms Review questions
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604 604 607 607 608 609 610 611 613 613 614 614 614
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590 590 590 592 597
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620 621 622 623 623 624 625 627 627 630 630 632 633 633
Theory of magnetism Electromagnetism Solenoids and electromagnets Electromagnetic switches (relays) Electrical measuring instruments Electromagnetic induction Electric motors Direct and alternating current Technical terms Review questions
638 640 641 643 644 645 648 649 649 649
Basic electronics
Electronics Electronic semiconductors Electronic components diodes and transistors Other electronic components Use of electronic components Electronic systems Micro-computer Body electronic module Technical terms Review questions
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Description Apply safe working practice Communicate effectively in the workplace Remove and replace electrical/electronic units/assemblies Test, service and repair batteries Install, test and repair low-voltage wiring/lighting systems
Volume 1 1 2 1 1 2
Chapter 2 2,3
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Install ancillary electrical components Carry out soldering of electrical wiring/circuits Repair instruments and warning systems Service and repair electronically controlled steering systems Service and repair electronically controlled suspension systems Repair electronic systems Service and repair electronic drive management systems Service and repair electronic body management systems Service and repair electronically controlled antilock braking systems
2 2 2 1 1 1 2 2 1 2
Service and repair electronically operated traction control system Service and repair electronically operated stability control Service and repair electronic spare ignition engine management systems. Test, service and charge batteries Carry out repairs to single electrical circuits
2 2 2 1 1 2
AURE320666A AURE319266A AURE319166A AURE318866A AURT200108A AURT205166A AURT201170A AURT202170A AURT203170A AURT206670A AURT207170A AURT210170A
Repair ignition systems Repair starting systems Repair charging systems Repair electrical systems Carry out servicing operations Repair exhaust system components Inspect and service engines Inspect and service cooling systems Service petrol fuel systems Inspect and service transmissions (manual) Inspect and service transmissions (automatic) Inspect and service braking systems
2 2 2 2 1 1 1 1 2 1 2 1
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Aur AURT212670A AURT213170A AURT215170A AURT216170A AURT217606A AURT270278A AURT200368A AURT201164A AURT202166A AURT203670A AURT204670A AURT205166A AURT213165A AURT217108A AURT217665A AURT217668A AURT217766A AURT217865A AURT225667A AURT216170A AURT209170A AURT301383A AURT301483A AURT303666A AURT304270A AURT305671A AURT307166A AURT318054A AURT401145A AURT403145A AURT406145A AURT406645A AURT407145A AURT410145A
Description Service nal drive assemblies Service nal drive (drive line) Inspect and service steering systems Inspect an service suspension systems Balance wheels and tyres Use and maintain workplace tools and equipment Select and use bearings, seals, gaskets, sealants and adhesives Remove and install engine assemblies Repair cooling systems Service diesel fuel injection systems Inspect and service emission control systems Repair exhaust system components Remove and ret drive-line components Carry out wheel alignment operations Remove, t and inspect wheel assemblies Select tyres and rims for specic applications (light) Remove, inspect, repair and t tyres and tubes (light) Remove and ret wheel hubs and associated brake components Use and maintain measuring equipment Inspect and service suspension systems Service hydraulic systems Dismantle, assemble and repair engine block and sub-assemblies Recondition cylinder heads Repair diesel fuel systems Service LPG Fuel systems Inspect and repair engine forced induction systems Repair transmissions (automatic) Provide advice on the effects of wheel and tyre combinations Overhaul engines and associated engine components Overhaul petrol fuel system components Overhaul clutch assemblies Overhaul transmissions (manual) Overhaul transmissions (automatic) Overhaul braking system components (light)
Volume 1 1 1 1 1 1 1 2 1 2 2 1 1 1 1 1 1 1 1 1 2 2 2 2 1 2 2 1 2 1 1 1 2 1
Chapter 22, 23 21 29, 30 27, 28 24 25 6, 7 1 11 15, 16, 17 12 16 21, 22, 23 31 24 24 24 25 5, 8 27, 28 21 4, 5, 6, 7 2, 3 15, 16, 17 15, 32 13
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Aur AURT412645A AURT415145A AURT466208A AURT202166A AURT271781A AURT301166A AURT303166A AURT304666A AURT306170A AURT306666A AURT310166A AURT312666A AURT313166A AURT315166A AURT316166A AURT366108A AURV327164A
Description Overhaul nal-drive assemblies Overhaul steering system components Carry out diagnosis of complex system faults Repair cooling systems Implement and monitor environmental regulations in the automotive mechanical industry Repair engines and associated engine components Repair petrol fuel systems Repair and replace emission control systems Inspect, service and/or repair clutch assemblies and associated operating system components Repair transmissions (manual) Repair hydraulic braking systems Repair nal-drive assemblies Repair nal drive (drive line) Repair steering systems Repair suspension systems Carry out diagnostic procedures Remove and replace supplementary restraint systems (SRS)
Volume 1 1 1 1 1 2 1 2 1 1 1 1 1 1 1 1 2
Chapter 21, 22, 23 2930 34 11 8 18 10, 14 12 1718 1920 25, 26 22, 23 21 2930 2728 34 33
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ngements Mechanical arra ehicle Sections of a motor v icles Hybrid-drive veh mbly The engine asse tion Vehicle construc The drive train Transmissions Running gear Electrical system ted parts Body and associa and parts Names of components Technical terms s Review question
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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 tted together to form larger components. 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.
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.
Mechanical arrangements
There are two basic arrangements of the major mechanical components of passenger and light commercial vehicles: front-wheel drive and rearwheel drive. These are shown in simplied form in Figures 1.1 and 1.2 with their parts identied. While the main difference is whether the front wheels or the rear wheels drive the vehicle, this can affect a
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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 nal drive, 17 exhaust system, 18 catalytic converter, 19 wheel hub, 20 battery
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Figure 1.2 Skeletal arrangement of a front-wheel-drive vehicle 1 manual transaxle, 2 nal 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
The electrical system, which includes the battery, wiring, lights, starter, alternator and other electrical components. 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 servicing requirements is also important, together with accepted methods of carrying out repairs.
The basic hybrid arrangement is shown in Figure 1.3 on the following page with its main parts identied. 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.
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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 efcient. The electric motor produces no emissions.
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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
exhaust valve
intake valve
flywheel
timing pulley
oil pan
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four-cylinder petrol engine of the type tted to passenger 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 transmission, the front and rear suspensions and other mechanical parts are built into the reinforced underbody 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
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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 ller cap, 7 valve rocker gear, 8 cylinder head, 9 piston in section, 10 cylinder block, 11 cylinder, 12 connecting rod, 13 ywheel, 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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Figure 1.6 Body structure with different metals used. These provide light weight and strength
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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 drivers 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 tted. 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.
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 engines ywheel 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 simplied clutch arrangement is shown in Figure 1.7. The clutch disc is normally held against the face of the ywheel 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.
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Technical terms
Motor vehicle, front-wheel drive, rear-wheel drive, fourwheel 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 tted 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 frontwheel-drive and a rear-wheel-drive vehicle? 18. Name the main body parts of a passenger car. Refer to the appropriate illustration.
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 tted 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 identied.
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Handy hint: The terms components, parts, units and items are all used in relation to motor vehicle parts.
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