Automotive Handbook

7th EDITION
List of Chapters:

Basic principles of physics Density and pressure

Quantities and units Buoyancy
Sl units Fluid mechanics
Legal units Symbols and units
Systems of units not to be used Basic principles
Quantities and units Continuity equation
Conversion of units Bernoulli equation
Basic equations used in mechanics Discharge from a pressure vessel
Symbols and units Resistance of bodies submerged in a
Rectilinear and rotary motion fluid flow
Laws of projectile motion Heat
Free fall Symbols and units
Moments of inertia Enthalpy (heat content)
Transmission of force Heat transfer
Friction Technical temperature measurement
Vibrations and oscillations Thermodynamics
Symbols and units Change of state for gases
Terms Electrical engineering
Vibration reduction Quantities and units
Modal analysis Electromagnetic fields
Optical technology Electric field
Photometric quantities and units Direct current (DC)
Electromagnetic radiation Direct-current circuits
Geometrical optics Alternating current (AC)
Components Alternating-current circuits
Light sources Three-phase current
Light and the physiology of vision Magnetic field
Laser technology Ferromagnetic materials
Optical fibers/waveguides The magnetic circuit
Display elements Magnetic field and electric current
Acoustics Electric effects in metallic conductors
Quantities and units Gas and plasma discharge
General terminology Electronics
Quantities for noise emission Basic principles of semiconductor
measurement technology
Motor-vehicle noise measurements and Discrete semiconductor components
limits Monolithic integrated circuits
Measured quantities for noise immissions Film and hybrid circuits, MCM
(noise protection) Circuit-board technology, SMT
Perceived sound levels Micromechanics
Engineering acoustics Analog/digital conversion
Hydrostatics Mechatronics
Symbols and units Mechatronic systems and components
Automotive Handbook
7th EDITION

Development methods Evaluation of series of measurements

Outlook Weibull distribution of lifetimes
Sensors Statistical evaluation of test results
Basic principles Measurement: basic terms
Position sensors Control engineering
Speed/rpm sensors Terms and definitions
Acceleration and vibration sensors Control modes
Pressure sensors
Flowmeters Materials science
Gas sensors, concentration sensors Chemical elements
Temperature sensors Designations
Force and torque sensors Periodic table of elements
Optoelectronic sensors Materials
Outlook Material terminology
Actuators Material parameters
Function Properties of solids
Electromechanical actuators Properties of liquids
Actuator performance data Properties of water vapor
Electrical machines Properties of gases
Operating concept Materials
Direct-current machines Material groups
Three-phase machines EN metallurgy standards
Single-phase alternating-current machines Properties of metallic materials
Duty-type ratings for electrical machines Casting and steel materials
Degrees of protection for electrical machines Vehicle-body sheet metals
Nonferrous metals, heavy metals
Mathematics and methods Nonferrous metals, light alloys
Mathematics Sintered metals
Mathematical signs and symbols Magnetic materials
Useful numbers Solders and filler materials
Number systems Electrical properties of materials
Preferred numbers Insulating materials
Trigonometric functions Properties of non-metallic materials
Equations for plane and spherical triangles Ceramic materials
Equations often used Laminates
Areas of plane surfaces Plastic molding compounds
Volume and surface area of solids Plastic codes with chemical names and
Finite-element method (FEM) trade names
What is FEM? Automotive paints
Areas of FEM application Corrosion and corrosion protection
Elements of FEM Corrosion processes
Modeling and evaluation of results Types of corrosion
FEM application examples Corrosion testing
Quality Corrosion protection
Quality management (QM) Coating systems
Measuring and inspection equipment Coatings
Reliability Diffusion coatings
Technical statistics Conversion coatings
Purpose of statistics Tribology
Types of characteristics Purpose and goals
Presentation of measured values Definitions
Automotive Handbook
7th EDITION

Tribological system Springs

Types of wear Symbols and units
Manifestations of wear Functions
Wear mechanisms Characteristic, work and damping
Wear quantities Spring combinations
Tribological damage analysis Metal springs
Tribological test procedures Friction bearings
Inhibiting wear Characteristics
Lubricants Hydrodynamic sliding bearings
Terms and definitions Sintered metal sliding bearings
Engine oils Sliding-contact bearings
Transmission lubricants Roller bearings
Lubricating oils Applications
Lubricating greases General principles
Fuels Selection of roller bearings
Characteristics Calculation of load capacity
Fuels for gasoline engine Gears and tooth systems
Fuel standards Quantities and units
Diesel fuels Definitions
Alternative fuels DIN gear qualities
Properties of liquid fuels and hydrocarbons Addendum-modification coefficient
Properties of gaseous fuels and Starter-tooth design
hydrocarbons American gear standards
Antifreeze and brake fluids Calculation of load capacity
Brake fluids Teeth calculations for bending and tooth
Coolants fracture
Nomenclature of chemicals Gear materials
Belt drives
Machine parts Friction belt drives
Frictional joints Positive belt drives
Basic principles Chain drives
Press fit (cylindrical Interference fit) Overview
Tapered connection (tapered interference fit) Chain designs
Taper-lock joints Sprockets
Clamp joints Chain-tensioning and chain-guide elements
Keyed joints
Positive or form-closed joints Manufacturing processes
Basic principles Heat treatment of metallic materials
Feather-key and woodruff-key couplings Hardening
Profiled shaft-hub connections Austempering
Bolt and pin connections Draw tempering
Threaded fasteners Quench and draw
Symbols and units Thermochemical treatment
Basic principles Annealing
Threads Hardness
Property classes Hardness testing
Tightening of threaded fasteners Test methods
Fastener forces and torques Tolerances
Design of threaded fasteners Correlations
Threaded fastener locking devices ISO system for limits and fits
Thread selection Tolerances of form and position
Automotive Handbook
7th EDITION

Geometrical deviations VALVETRONIC

Surface parameters Supercharging processes
Sheet-metal processing Evaluating gas-exchange components
Deep-drawing technology Cooling
Laser technology Lubrication
Joining and bonding techniques The gasoline engine
Welding Mixture formation
Soldering Ignition
Adhesive technologies Load control
Riveting Power output and economy
Punch riveting The diesel engine
Bonding and joining (pressurized clinching) Mixture formation
Snap-on connections on plastic Diesel combustion process
components Combustion process
Hybrid engines
Influences on motor vehicles Charge stratification
Motor-vehicle dynamics Multifuel engines
Dynamics of linear motion Empirical values and data for calculation
Adhesion to road surface Comparisons
Accelerating and braking Engine output, atmospheric conditions
Actions: Reaction, braking and stopping Definitions of power
Passing (overtaking) Calculation
Vehicle dynamics Reciprocating-piston engine with external
Cornering behavior combustion (Stirling engine)
Operating dynamics - test procedures Operating concept and efficiency
as per ISO Design and operating characteristics
Special operating dynamics for commercial Wankel rotary engine
vehicles Design and operating principle
Requirements for agricultural tractors Properties of the rotary engine
Environmental stresses on automotive Gas turbine
equipment Operating principle, comparative cycle and
Climatic factors efficiency
Laboratory simulation
Engine peripherals
Internal-combustion engines Engine cooling
Internal-combustion engines Air cooling
Operating principle and classifications Water cooling
Cycles Intercooling (charge-air cooling)
Reciprocating-piston engine with internal Oil and fuel cooling
combustion Cooling-module technology
Operating principle Cooling-system technology
Engine types Intelligent thermal management
Definitions Exhaust-gas cooling
Crankshaft-assembly operation and Engine lubrication
dynamic properties Force-feed lubrication system
Balancing of masses in the reciprocating- Components
piston engine Air filtration
Main components of reciprocating-piston Air pollution
engine Air filters (air cleaners)
Gas exchange Turbochargers and superchargers for internal-
Variable valve timing combustion engines
Automotive Handbook
7th EDITION

Superchargers (mechanically driven) Diagnostics

Pressure-wave superchargers Introduction
Exhaust-gas turbochargers Monitoring during vehicle operation (On-
Multistage supercharging board diagnosis)
Acceleration aids On-Board Diagnosis (OBD)
Emission reduction systems
Exhaust-gas recirculation system Gasoline-engine management
Secondary-air injection Description of the engine management system
Evaporative-emissions control system Cylinder charge
Crankcase ventilation Component parts
Exhaust-gas system Controlling the air charge
Design and purpose Air-system components
Manifold Fuel supply
Catalytic converters Fuel supply and delivery with intake-manifold
Particulate filters injection
Mufflers Fuel supply and delivery with gasoline direct
Connecting elements injection
Acoustic tuning devices High-pressure pumps for gasoline direct
injection
Emission-control and diagnosis legislation Fuel supply and delivery components
Exhaust emissions Mixture formation
Combustion products Basic principles
Properties of exhaust-gas components Mixture-formation systems
Emission-control legislation Carburetors
Overview Intake-manifold injection (external mixture
CARB legislation (passenger cars/light-duty formation)
trucks) Gasoline direct injection (internal mixture
EPA legislation (passenger cars/light-duty formation)
trucks) Mixture-formation components
EU legislation (passenger cars/light Ignition
commercial vehicles) Basic principles
Japanese legislation (passenger cars/light- Moment of ignition
duty trucks) Ignition systems
US legislation (heavy commercial vehicles) Ignition components
EU legislation (heavy commercial vehicles) Motronic engine-management system
Japanese legislation (heavy commercial Function
vehicles) System overview
US test cycles for passenger cars and light- Versions of Motronic
duty trucks Older fuel-injection systems
European test cycle for passenger cars and Overview
light-duty trucks Mono-Jetronic
Japanese test cycle for passenger cars and K-Jetronic
light-duty trucks KE-Jetronic
Test cycles for heavy commercial vehicles L-Jetronic
Exhaust-gas measuring techniques LH-Jetronic
Exhaust-gas test on chassis dynamometers Older coil-ignition systems
Exhaust-gas measuring devices Conventional coli ignition (CI)
Diesel smoke-emission test (opacity Transistorized ignition (TI)
measurement) Electronic ignition (EI and DLI)
Evaporative-emissions test Capacitor-discharge ignition (CDI)
Automotive Handbook
7th EDITION

Minimizing pollutants in the gasoline engine Drivetrain

Engine-design measures Drivetrain
Reducing engine external interference Quantities and units
Catalytic exhaust-gas treatment Function
Effect of vehicle design on fuel consumption Design
Drivetrain configurations
Alternative gasoline-engine operation Drivetrain elements
Engines fueled by LPG (liquefied petroleum Power take-up elements
gas) Multi-speed gearbox
Applications Manually shifted transmissions
LPG systems Automatic transmissions
Engines fueled by natural gas Electronic transmission control
Applications Continuously variable transmission (CVT)
Natural-gas systems Final-drive unit
Engines fueled by alcohol Differential
Applications All-wheel drive and transfer case
System
Engines fueled by hydrogen Chassis systems
Applications Suspension
Hydrogen system Types of oscillation
Controlled suspension systems
Diesel-engine management Active suspension
Fuel supply (low-pressure stage) Shock absorbers
Diesel fuel-injection system Vibration absorber
Diesel fuel-supply components Suspension design elements
Diesel fuel-injection systems Wheel suspension
Overview Kinematics
In-line fuel-injection pump Elastokinematics
In-line control-sleeve fuel-injection pump Basic suspension types and their
Distributor injection pump characteristics
Time-controlled single-cylinder pump Wheels
system Passenger-car wheels
Common-rail system (CRS) Commercial-vehicle wheels
Injection-system components Tires
Start-assist systems Tire categories
Preheating systems Tire design
Minimizing pollutants in the diesel engine Tire designation
Engine-design measures Tire applications
Exhaust-gas treatment Power transmission properties of tires
Tire-pressure monitoring system
Alternative drives Steering-system requirements
Hybrid drives Steering behavior
Drive concepts Types of steering box
Hybrid strategies Steering kinematics
Batteries Classification of steering systems
Fuel cells Hydraulic power-assisted steering
Design variations Electric power-assisted steering
Fuel conditioning Active steering system
Thermodynamics and kinetics Power-assisted steering for commercial
Fuel cells in motor vehicles vehicles
Automotive Handbook
7th EDITION

Vehicle safety systems Electronic commercial-vehicle brake

Braking systems management as the platform for driver-
Definitions, principles assistance systems
Legal requirements Basic electronic braking system
Design and components of a braking Subsystems
system
Braking-system design Vehicle bodies
Brake-circuit configurations Road-vehicle systematics
Braking systems for passenger cars and light Classification according to ECE
utility vehicles Classification according to USA
Overview Vehicle bodies, passenger cars
Brake booster Main dimensions
Brake master cylinder Body design
Braking-force limiters Aerodynamics
Disk brakes Aeroacoustics
Drum brakes Body structure
Vehicle stabilization systems for passenger Body materials
cars Body surface
Antilock braking systems (ABS) Body finishing components
Traction control system (TCS) Safety
Electronic stability program (ESP) for Vehicle bodies (commercial vehicles)
passenger cars Commercial vehicles
Supplementary functions (automatic brake- Light utility vans
system operations) Medium- and heavy-duty trucks and tractor
Electrohydraulic brakes (SBC) vehicles
Purpose and function Buses
Design Passive safety in commercial vehicles
Operating principle Lighting technology
Braking systems for commercial vehicles Functions
> 7.5 t permissible total weight Regulations and equipment
System and configuration Definitions and terms
Air supply and processing Main headlamps, European system
Transmission device Main headlamps, European regulations
Wheel brakes Headlamps, USA
Parking-brake system Headlamps, US regulations
Retarder braking systems (additional Headlamp leveling, Europe
retarding braking systems) Headlamp cleaning systems
Vehicle stabilization systems for commercial Fog lamps
vehicles Auxiliary driving lamps
Antilock braking system (ABS) Lights and lamps
Traction control system (TCS) Hazard-warning and turn-signal flashers
Electronic Stability Program Side-marker, clearance, and tail lamps
(ESP) for commercial vehicles Parking lamps
Electronically controlled braking system (ELB) License-plate lamps
Function Stop lamps
System design Rear fog warning lamps
ELB components Reversing lamps
Electropneumatic braking (operating Daytime running lamps
principle) Other lighting devices
Control and management functions Motor-vehicle bulbs
Monitoring and diagnostic functions
Automotive Handbook
7th EDITION

Automotive windshield and window glass Requirements

The material properties of glass Sources of interference
Automotive glazing Potentially susceptible devices
Functional design glazing Interference coupling
Windshield and rear-window cleaning Eiectrostatic discharge
systems Measuring techniques
Windshield wiper systems Regulations and standards
Rear-window wiper systems
Headlamp cleaning systems Vehicle security systems
Wiper motors Locking systems
Washing systems Function, structure, operating principle
Passenger-compartment heating, ventilation Mechanical locking system
and air conditioning (HVAC) Open-by-wire
Function Electrical locking system
Systems with engine-dependent heating Central locking system
Air conditioners Electronic vehicle immobilizer
Auxiliary heater systems Comfort Entry/Go system
Cabin filters for passenger cars Theft-deterrent systems
Regulations
Automotive electrical systems System design
Vehicle electrical systems Acoustic signaling devices
Electrical energy supply in the Applications
passenger car Horn
Electrical energy management Fanfare horn
Two-battery vehicle electrical system
Vehicle electrical systems for commercial Safety and convenience
vehicles Occupant-protection systems
Starter batteries Seat belts and seat-belt pretensioners
Alternators Front airbag
Starting systems Side airbag
Requirements Components
Design factors Rollover protection systems
Starter Further development
Starter design and operation Power-window drives
Triggering the starter Power-window motors
Circuit symbols used in vehicle electrical Power-window control
systems Power-sunroof drives
Circuit symbols, general Comfort and safety functions in the passenger
Circuit diagrams compartment
Schematic diagrams Electrical seat adjustment
Section designation and device Electrical steering-column adjustment
identification Multi purpose actuator
Wiring diagram: Detached representation Driver-assistance systems
Assembled-representation diagrams Adaptive Cruise Control (ACC)
Terminal designations Design and function
Wiring harnesses and plug-in connections Control algorithms
Wiring harnesses Applications
Plug-in connections Outlook
Electromagnetic compatibility (EMC) and Night Vision
interference suppression
Automotive Handbook
7th EDITION

Information and communication Development methods and processes

Data processing in motor vehicles Methods and tools
Requirements Function and requirements
Electronic control unit (ECU) Model-based development of vehicle
Architecture functions
CARTRONIC® Software architecture and standardized
Automotive networking software components
Cross-system functions Modeling and simulation of software
Requirements for bus systems functions
Classification of bus systems Rapid prototyping of software functions
Applications in the vehicle Design and implementation of software
Coupling of networks functions
Example Integration and testing of software and
Instrumentation ECUs
Information and communication areas Calibration of software functions
Driver information systems Sound design
Instrument clusters Definition
Display types Implementation
EU recording equipment Vehicle wind tunnels
Legal requirements Applications
Design variations Aerodynamic parameters
Parking systems Wind tunnel designs
Parking aid with ultrasonic sensors
Further development Workshop technology
Automotive sound systems Vehicle system test
Radio tuners Workshop equipment
Conventional tuners System test using KTS tester
Digital receivers (DigiCeivers) Engine-test technology
Reception quality Electrical tests
Reception improvement Testing and charging starter batteries
Auxiliary equipment Test technology for alternators
Vehicle antennas Test technology for starters
Navigation systems Headlamp adjustment
Position locating Headlamp adjustment, Europe
Destination entry Headlamp adjustment, USA
Route computation Testing diesel fuel-injection pumps
Route guidance Testing on test benches
Map display Testing in the vehicle
Road-map memory Brake testing
Traffic telematics Brake test stands
Transmission paths German emissions inspection
Standardization Regulations
Referencing Test procedure
Selection Test equipment
Decoding of traffic messages Appendices
Dynamic route guidance International registration plates
Offboard navigation Alphabets and numbers
Information recording Index of technical terms
Abbreviations