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How it's built

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Parts and systems, one at a time: what the part is, where it sits, and what actually happens when it works or fails.

  1. Front-mount intercooler core being fitted in the nose of a Subaru WRX STI, with end tanks and open charge pipes in the bumper opening How it's built What an intercooler actually does The compressor heats the air it just squeezed. An intercooler pulls that heat out, into outside air or into a coolant loop, so the charge stays denser and less likely to knock, and the pipes give some of the pressure back to do it. Image: Freonr2 · CC BY 2.5
  2. Universal-joint cross with bearing cups, one cup off a trunnion so the needle rollers show How it's built What a universal joint actually does A Cardan joint passes torque from one yoke to the other through a cross and four needle-bearing cups. At an angle the output speed rises and falls twice a turn, so a driveshaft runs two joints with the yokes in phase. Image: Jjvcela · CC BY-SA 3.0
  3. Partial cutaway of an engine showing a piston, connecting rod, and crank throw in one cylinder How it's built What a connecting rod actually does The rod carries the piston's straight shove to an offset crank journal. The small end rides the piston pin, and the big end clamps bearing inserts around the crankpin. Image: Mj-bird · CC BY-SA 3.0
  4. Crankshaft displayed with journals, offset throws and counterweights visible How it's built What a crankshaft actually does The crank turns the piston's shove into rotation. Main journals ride the block, the rod journals are the offset, and the counterweights look after the spinning mass. Image: Arnoldius · CC BY-SA 4.0
  5. Engine with the valve cover removed, exposing two camshafts and their timing drive How it's built What a camshaft actually does A camshaft uses shaped lobes to control valve motion. Lift, duration and phase describe different parts of that motion; variable timing does not by itself mean variable lift. Image: Randaarde · CC BY-SA 4.0
  6. Passenger-car clutch friction disc with damper springs around the splined hub and a ring of friction material How it's built What a clutch actually does The clutch is three pieces between the engine and the gearbox. The pressure plate clamps a friction disc to the flywheel, and the release bearing is what lets that clamp go. Image: M.james · Public-domain dedication (source declaration)
  7. Engine-side clutch assembly with the pressure plate still installed and starter teeth visible around the outer rim How it's built What a flywheel actually does A manual flywheel adds rotating inertia and a clutch friction face. A dual-mass design also isolates torsional vibration; a torque-converter automatic uses a flexplate as its drive connection. Image: dave_7 from Lethbridge, Canada · CC BY 2.0
  8. Heater-core fin stack and coolant pipes visible during work on a vehicle How it's built What a heater core actually does A heater core transfers heat from coolant to cabin air. It needs heat supply, coolant circulation and airflow; the heat can come from an engine or an electrical source. Image: Stahlkocher · CC BY-SA 3.0
  9. Front crankshaft pulley and belt drive on a polished display engine How it's built What a harmonic balancer actually does A harmonic balancer reduces crankshaft torsional vibration. Elastomer and viscous designs do that differently; some dampers also carry a balance weight. Image: CZmarlin — Christopher Ziemnowicz, releases all rights but a photo credit would be appreciated if this image is used anywhere other than Wikipedia. · Public-domain dedication (source declaration)
  10. Cylinder block with the head removed and a head gasket held above the deck How it's built What a head gasket actually does It is the seal between the block and the head. Combustion stays in the cylinders. Coolant and oil cross the joint in their own passages. Image: 1-1111 · CC BY 4.0
  11. MAP sensor and vacuum hose behind the passenger kick panel of a 1986 Chrysler LeBaron, next to the logic module How it's built What a MAP sensor actually does A pressure sensor on the intake manifold tells the ECU the absolute pressure there so the computer can infer engine load. Image: dave_7 from Lethbridge, Canada · CC BY 2.0
  12. Volkswagen EGR valve 03G131501J, a black electric actuator on a cast body with an outlet pipe and a wiring connector How it's built What an EGR valve actually does External EGR meters a controlled exhaust stream back into the intake to reduce combustion temperature and nitrogen oxide formation. Image: Paruna12 · CC BY-SA 4.0
  13. Oil pump from a Toyota 1HZ engine, a cast housing with a mounting flange and a drive gear on the shaft How it's built What an oil pump actually does The pump circulates lubricating oil. Flow, viscosity and engine clearances affect pressure, while some pumps vary their delivery to match demand. Image: Ll1324 · CC0
  14. Cutaway of a ZF torque converter, the shell opened to show the bladed wheels inside How it's built What a torque converter actually does A torque converter transfers torque through fluid at different input and output speeds. A stator redirects flow; a lock-up clutch provides a mechanical path. Image: Aconcagua · CC BY-SA 3.0
  15. Chromed Jeep 2.5 display engine, close-up of the air-conditioning compressor from the front, grooved clutch pulley in the belt How it's built What an A/C compressor actually does The compressor raises refrigerant vapor pressure and temperature. The condenser rejects heat; the evaporator absorbs cabin heat. Image: CZmarlin — Christopher Ziemnowicz, releases all rights but a photo credit would be appreciated if this image is used anywhere other than Wikipedia. · Public-domain dedication (source declaration)
  16. Muffler and tailpipe under a 1997 Chrysler Sebring, the oval can ahead of the pipe that exits the rear bumper How it's built What a muffler actually does A muffler reduces exhaust noise through sound-wave reflection, tuning and absorption while allowing gas to flow. A catalytic converter has a separate chemical-treatment job. Image: KeysPhotography.com · CC BY 2.5
  17. Chromed Jeep 2.5 display engine with a belt-driven power steering pump, grooved pulley, and reservoir on the front of the block How it's built What a power steering pump actually does A hydraulic steering pump supplies fluid flow for assistance and can be driven by a belt or electric motor. Electric power steering adds motor force directly at the steering mechanism. Image: CZmarlin — Christopher Ziemnowicz, releases all rights but a photo credit would be appreciated if this image is used anywhere other than Wikipedia. · Public-domain dedication (source declaration)
  18. Cutaway automobile fuel tank with the pump, a swirl pot, a level-sensor arm, and an inlet screen How it's built What a fuel pump actually does The fuel pump supplies fuel flow at the required pressure. Filtering, level sensing and pressure control are separate jobs; gasoline direct injection adds a high-pressure pumping stage. Image: Cschirp · CC BY-SA 3.0
  19. Removed strut assembly with coil spring, damper, knuckle, hub and brake disc How it's built What a coil spring actually does A coil spring supports the car through elastic deflection. Its rate and loaded length affect ride height and movement; the damper controls how that movement settles. Image: Bukk · Public-domain dedication (source declaration)
  20. Cutaway diagram labeled Einrohrdämpfer and Zweirohrdämpfer: a monotube with a floating gas piston on the left, and a twin-tube with an inner working cylinder inside an outer reserve on the right How it's built What a shock absorber actually does The spring carries the load; the damper controls motion by moving oil through valves. A strut adds a structural suspension role. Image: Plexi83 · CC BY-SA 4.0
  21. Diagram of a tandem brake master cylinder: fluid reservoir on top, two plungers in one bore, and separate outlets for circuit 1 and circuit 2 How it's built What a brake master cylinder actually does A brake master cylinder turns a push from the pedal or the booster into hydraulic pressure for two brake circuits. It is not the booster, not ABS, and not a caliper. Image: Fred the Oyster iThe source code of this SVG is valid. This vector image was created with Adobe Illustrator by v. · CC BY-SA 4.0
  22. Cutaway of a vacuum brake booster: diaphragm, reaction disc, air valve, and the pushrod that leaves the can toward the master cylinder How it's built What a brake booster actually does A brake booster adds assistance to pedal force. A vacuum diaphragm, hydraulic supply or electric motor can provide that assistance; the master cylinder converts the resulting force into brake pressure. Image: Paul Day · CC0
  23. A whole ball joint beside a cutaway: stud, steel ball in a socket, rubber boot, and the housing that bolts to the control arm How it's built What a ball joint actually does A ball joint is the spherical pivot between the control arm and the steering knuckle. It is not the outer tie-rod end. A clunk can be another fault. Image: Silverxxx (talk) · Public-domain dedication (source declaration)
  24. Caterham chassis on stands: silver steering rack spanning the front tubes, inner rods and outer ball-joint ends left and right How it's built What a tie rod actually does Tie rods transmit steering force to the knuckle. Their articulated joints allow suspension movement, and their effective length affects toe. Image: vipdesilva · CC BY 2.0
  25. Double-wishbone corner with the upper and lower control arms and upright painted yellow, coil and damper in red and blue How it's built What a control arm actually does A control arm locates the hub on the body and sets geometry as the wheel moves. It is not the ball joint alone, not the sway bar, and not the strut. Image: RB30DE · CC BY-SA 3.0
  26. MacPherson-strut front corner, wheel off: labeled sway bar running to the body, radius rod below, strut tower above How it's built What a sway bar actually does A sway bar is a torsion spring coupling the two sides of an axle. It resists unequal suspension movement and adds roll stiffness. Image: RB30DE · Public-domain dedication (source declaration)
  27. Renault front corner, wheel off: MacPherson strut tower from the inner fender down to the hub, disc, and caliper How it's built What a MacPherson strut actually does A MacPherson strut controls suspension movement and forms a structural connection locating the wheel. The spring supports load; a mount bearing allows steering where required. Image: 4028mdk09 · CC BY-SA 3.0
  28. Ram 10.5-inch rear axle pumpkin and axle tubes, yellow shock, wheel at the right end How it's built What a differential actually does On a left turn the right wheel has farther to go. The case splits speed after the transmission, not instead of it. Image: Dana60Cummins · CC0
  29. Ferrari F430 Challenge drilled brake disc and grey caliper, wheel off, hat bolted to the hub How it's built What a brake rotor actually does The rotor turns with the wheel. The pads press against its two faces, slowing the wheel and heating the disc. Its shape has to manage that heat as well as the contact. Image: The359 · CC BY-SA 3.0
  30. Passenger-car rear wheel hub assembly on concrete, four studs, machined flange, and a sealed bearing in the casting How it's built What a wheel bearing actually does A wheel bearing supports the rotating hub under load. Sealed cartridges, integrated hubs and serviceable bearings require different procedures. Image: Cschirp · CC BY 3.0
  31. Front half-shaft on a floor, outer CV joint in a ribbed rubber boot, splined stub and axle nut How it's built What a CV joint actually does A CV joint transmits torque while the shaft angle changes. Fixed joints provide articulation; plunging joints also accommodate length changes. The boot protects the lubricated working parts. Image: BiH · Public-domain dedication (source declaration)
  32. Black spin-on oil filter threaded onto an engine in the bay, sensor plugged into the housing How it's built What an oil filter actually does Oil-filter media captures contaminants. A bypass preserves flow when restriction is excessive; an anti-drainback valve serves a different purpose. Image: Dvortygirl · CC BY-SA 3.0
  33. Toyota Camry DOHC head with a timing chain around both cam sprockets, cover off How it's built What a timing chain actually does The chain and sprockets maintain crank-to-cam timing. Guides and tensioners control its path; metal construction does not make it immune to wear. Image: Logansenf · CC BY-SA 4.0
  34. Sectioned Garrett turbocharger, yellow turbine and compressor wheels on one shaft, red-painted cut housings How it's built What a turbocharger actually does Exhaust drives one wheel. A shared shaft turns a second wheel that compresses fresh intake air. The two gas streams follow separate paths. Image: Tommi Nummelin · CC BY-SA 3.0
  35. Labeled spark-plug cutaway showing the terminal, insulator, shell and electrodes How it's built What a spark plug actually does The ignition coil supplies voltage; the plug provides the insulated path and electrode gap that starts combustion. Heat range describes heat transfer. Image: Motorhead at en.wikipedia · Public-domain dedication (source declaration)
  36. Deka VII port fuel injector with a green inlet O-ring, a blue nozzle O-ring, and a two-pin connector How it's built What a fuel injector actually does An injector controls fuel delivery and spray formation. The dose depends on time, pressure and injector behavior; port and direct injection describe where the fuel enters. Image: David DeGrace · CC BY-SA 3.0
  37. Looking down a throttle-body bore at a brass butterfly plate on a shaft, held by a Torx screw How it's built What a throttle body actually does The throttle plate controls an intake passage. Electronic control sets its position from a torque request and other operating needs. Image: Florian Lindner · CC BY 2.5
  38. Mass-airflow sensor housing with a mesh inlet and electrical connector How it's built What a mass airflow sensor actually does A mass airflow sensor uses a calibrated signal to report intake air mass. Thermal designs measure cooling of a heated element; an airflow code can also reflect another fault. Image: FLOEP · CC BY 4.0
  39. Black canister ignition coil with a high-voltage tower and two primary screw terminals How it's built What an ignition coil actually does Current builds a magnetic field in the coil. Interrupting it induces a high-voltage pulse in the secondary winding for the spark plug. Image: Nick Ares from Auburn, CA, United States · CC BY-SA 2.0
  40. Automobile starter motor with solenoid on top and pinion visible in the nose housing How it's built What a starter motor actually does A conventional starter engages a pinion with the engine ring gear, then uses battery current to crank the engine. A freewheel protects the drive. Image: Willdre 00:20, 8 February 2007 (UTC) · CC BY-SA 3.0
  41. Toyota Corolla alternator in the bay, serpentine belt on the pulley and stator visible through the vents How it's built What an alternator actually does A conventional alternator generates AC, rectifies it to DC and regulates output for the electrical system. Charging targets depend on the vehicle. Image: Kolossos · CC BY-SA 3.0
  42. Poly-v serpentine belt wrapping the crank, power-steering pump, and idlers on a VW T4 How it's built What a serpentine belt actually does A ribbed accessory belt transmits crankshaft power. Routing, tension and pulley condition determine which accessories it can drive. Image: Hans Haase · CC BY-SA 4.0
  43. Red Porsche four-piston brake caliper clamped on a cross-drilled disc, wheel off How it's built What a brake caliper actually does The caliper is the clamp. Fluid moves a piston. The pads are what grab the disc. Image: Bill Abbott · CC BY-SA 2.0
  44. Opened automotive water pump showing a five-blade impeller in a cast housing How it's built What a water pump actually does A rotating impeller circulates coolant. Pumps may be mechanically or electrically driven, and small relief-hole traces do not alone prove failure. Image: Raimond Spekking · CC BY-SA 4.0
  45. Aluminum automotive radiator with side tanks, a finned core, filler neck, and cap How it's built What a radiator actually does Coolant carries engine heat into the radiator. Tubes and fins pass that heat to air; the cap and reservoir manage pressure and expansion. Image: Bill Wrigley (BillWrigley) · Public-domain dedication (source declaration)
  46. Looking into a rusty catalytic converter, ceramic honeycomb brick filling the inlet How it's built What a catalytic converter actually does A catalytic converter gives exhaust gas a coated surface on which harmful constituents can react. Heat and controlled mixture matter as much as the shell or honeycomb. Image: The RedBurn · CC BY-SA 3.0
  47. Automotive thermostat on its side, brass wax cup, coil spring, and rubber seal How it's built What a thermostat actually does The thermostat regulates flow to the radiator while a bypass can keep coolant circulating through the engine during warm-up. Image: 1-1111 · CC BY-SA 4.0
  48. Oxygen sensor threaded into a stainless exhaust pipe, harness clipped to the underbody How it's built What an oxygen sensor actually does An exhaust oxygen sensor provides mixture feedback. Switching and wideband sensors encode that information differently; a dark tip is not a failure test. Image: Brian Snelson from Hockley, Essex, England · CC BY 2.0
  49. Engine bay illustrating a crankcase-ventilation hose arrangement near the valve cover How it's built What a PCV valve actually does A PCV valve regulates part of the crankcase-ventilation path. Removing blow-by, controlling crankcase pressure and separating oil are different jobs within the system. Image: Flippythedragonslayer · CC BY-SA 4.0
  50. Gold wastegate actuator can, black hose, and rod on a turbo compressor housing How it's built What a wastegate actually does A wastegate routes some exhaust around the turbine. Its actuator controls that bypass to help regulate boost. Image: Panoha · CC BY-SA 3.0
  51. Silver Ford Fusion sedan in an official NHTSA test photograph How it's built Why curb weight is not the same as GVWR Curb weight describes an unloaded vehicle under a defined convention. GVWR is a manufacturer rating for the loaded vehicle; payload needs the actual configuration. Image: U.S. National Highway Traffic Safety Administration · Public domain in the United States (source declaration)