The modern car comprises around 30,000 parts, fashioned together to form a functional vehicle and in this short article, we take a closer look at the major components to help you gain a deeper understanding of how a car works.
- Chassis – Typically made from aluminium, the chassis of the frame that everything else is connected to. The engine sits in the bay at the front, while axles and suspension are added. Small swing frames give excellent shock absorption, while the gearbox and running gear are bolted and welded on from below.
- Electrics – Today’s excellent wire harness design is simply fitted and comes with all the power connectors for easy connection. Seamless electrics are a major feature on 2025 models, thanks to the ingenious harness design. There are specialist companies in Australia that design wiring harnesses specifically for a model, they work with the manufacturer to come up with a winning design.
- Power unit – Traditionally, this would be an internal combustion engine, running on either gasoline or diesel. The EV market is growing and experts predict EVs will eventually replace internal combustion engines. There is no pollution with EVs, although there are obstacles like a shortage of charging stations in remote regions. The gearbox is typically fitted before the engine is installed.
- Onboard computer – The wiring harness is connected to an onboard computer that monitors vehicle performance; when there is an issue, the mechanic plugs his laptop into the harness and the fault is easily found. This makes servicing that much easier as the diagnostics are done by the computer. Those looking for a used car would do well to attend local car auctions, where they would likely find a bargain.
- Interior – A plastic shell is inserted into the chassis and the front and back seats are bolted/welded into place; the dashboard comes as a complete unit and is dropped into place by a hydraulic crane, then the doors and panels are fitted and everything is connected to the harness. Fixtures are attached and finally, the windows are fitted. Then everything is covered in protective coatings of various types.
- Wheels and brakes – These are typically fitted from the underside of a raised vehicle, with the use of small hydraulic robots that take the weight. As each wheel is fitted, the brake pads are inserted, pipes tightened and brake fluid installed in the reservoir. The tyres are also fitted at this station, then the vehicle is ready for testing and inspection.
- Final inspection – Fuel is added and the engine started and revved to mid-level, while all electrical systems are tested; lights, brakes, steering, indicators, warning lights and finally the car is taken onto a special track where the driver puts it through a series of tests to determine performance and safety.
If you are planning on investing in a new vehicle, we hope this short blog helps you to better understand how a car is put together. There are many safety standards to meet and the government often carries out spot checks at auto factories.
