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Table of Contents
Prefix I: Introduction ................................................ 7
Prefix II: Who is this book for? ................................. 7
Chapter 1: History of Diesel Engines ........................ 9
Chapter 2: What is an Internal Combustion Engine?
............................................................................... 11
Chapter 3: Differences between a Diesel and Gas
Engine..................................................................... 15
Chapter 4: How do Diesel Engines Work in Vehicles?
............................................................................... 19
Chapter 5: Diesel Engines are better for the
Environment? ......................................................... 21
Chapter 6: Upgrading Your Diesel Truck ................ 23
Chapter 7: Pros and Cons of Diesel Engines .......... 27
Chapter 8: Uses and the future of Diesel Engines . 29
Prefix I: Introduction
Most people in the 21st century dont understand how diesel engines impact todays society. To
fully appreciate diesel engines, one must know how they were created, as well as how they work
and are used. One also must understand how diesel engines are better for the environment,
compared to other types of popular engines. In addition, one will learn different ways diesel
engines can be made even better for the environment, and how to go about doing so. To finish
off, we will talk about how diesel engines will impact our future?
Adolphus Busch bought a license from Rudolf Diesel in 1898 for his company Busch-Zulzer
Brothers Diesel Engine Company. With this license, Adolphus could commercially manufacture
and sell diesel engines in the United States. These engines were used in many places: from
submarines in World War I to trucks nicknamed smokers because of the dark unburnt fuel that
would come out of the exhaust.
In the 1960s, the government realized how much engines polluted the environment; this is when
they started adding regulation controls on engines to help reduce pollutants released into the air,
and save the environment. Things they did to help included the addition of the Exhaust Gas
Recirculation system, Diesel Particulate Filter, modified injection timing and pressures, along
with higher quality fuel. Over the years, the combination of these devices has decreased
emissions incredibly.
Note: The information above was taken from (Inventor of the Diesel Engine), (Early History of the Diesel
Engine) and (History of Diesel Fuel & Engines)
Basics
The four steps, or strokes that allow
internal combustion engines to work
include: the intake, compression,
power, and exhaust strokes. It all starts
with the intake stroke, when oxygen
gets sucked into the engine when the
piston goes downward or on its intake
stroke. The oxygen enters the cylinder
through a valve called the intake
valve.
Figure 3: Strokes of internal compression engines
After the proper amount of oxygen
(Fuel Injected ECU)
gets sucked into the cylinder, the
piston goes up on its compression stroke, compressing the oxygen. During the compression
stroke, fuel gets injected into the cylinder, and once the piston reaches top dead center, or when
the piston reaches the top of the cylinder, the spark plug sparks, igniting the fuel which then
causes the piston to go back down; this is called the power stroke.
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After the power stroke pushes the piston down, the hot exhaust gases have to exit the cylinder to
repeat the cycle, so another valve called the exhaust valve opens, allowing the piston to go up
with ease and push out the hot exhaust gases; this is called the exhaust stroke.
Fuel system
For the engine to run, fuel must get transferred from the holding tank to the engine; the engine
does this with the lift pump. After the fuel gets lifted to the engine, the fuel gets pressurized; the
system does this with the use of the high pressure fuel pump. The high pressure fuel pump
pressurizes the fuel, so the engine has a constant supply of fuel. The fuel then travels from the
high pressure fuel pump to the fuel rail. The fuel rail then distributes the fuel to each injector.
The injectors then inject the fuel into the cylinder when the Fuel Injection Control Module
(FICM or part of the computer) tells them to.
Electrical
Without the alternator, the battery would drain quickly, and therefore engines would constantly
need new batteries. The alternator connects to the engines crankshaft with the use of a belt, and
this belt turns the alternator and generates power using magnets spun next to coils of wires,
which in turn generated power and charges the battery. The battery must always have power
because it powers the spark plugs, which keep the engine running. The battery also keeps the
computer of the engine alive; the computer tells the engine when the injectors should inject fuel,
when the spark plugs should spark to ignite the fuel, and in the case of in vehicles, tells the
transmission when to shift gears to achieve higher speeds.
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Starting
The engine starts with the use of the starter. The starter, an electric motor, simply turns the
engine, which starts the engine stroke cycle without the use of explosions, and the engines goes
through each cycle, and once the injected fuel ignites, the engine takes over, and the starter gets
disengaged.
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15
Turbo Chargers
Diesel engines must use a turbo charger
(Figure 4) to run properly. A turbo
charger basically use a fan to push air
into the engine, giving the engine more
oxygen, which allows for more frequent
explosions in the cylinder. Without a
turbo charger, diesel engines would run
very slow, and wouldnt have very much
power. Gas engines do not need turbo
Figure 5: Turbo Chargers
chargers, or the almost equivalent belt
driven super chargers (Belt driven fans), but they can use them to increase the power made.
The Brains
All engines have a computer; or the brains of the engine. All engines require a computer to
properly function; both gas and diesel engines use computers. When engine manufacturers
program the computers, they dont know what the vehicle will do exactly. Most diesel trucks
haul heavy loads, but may also transport people from one location to another, like most gas cars
do. Manufacturers must take this into account and program diesel engines so they can do both as
efficiently as possible. Most gas engines only have one function, to bring people from one
location to another, so the gasoline engine manufacturers dont need to balance both power and
efficiency, so they can simply aim the programming towards fuel economy. Because
manufactures do this, companies sell programs so people can program their vehicle to their
needs, from a simple economy tune with less power but more fuel economy, to a tune that makes
the most power, which makes heavy loads much easier to haul. Companies do sell new programs
for gas engines, but they wont change performance of the engine like diesel engine programs
do.
Power vs RPM
Diesel engines produce maximum power at low engine speeds (revolutions per minute, rpm), but
gas engines produce their maximum power at high rpms. Since diesel engines run at slower
rpms to reach their maximum power, they burn less fuel. When an engine runs at high rpms, it
uses much more fuel because the pistons move much faster, so more fuel gets injected more
times a second to keep the engine at that speed. Running at lower rpms also causes alot less
stress on the engine, so diesel engines tend to last much longer. When engines run at higher
rpms, more heat gets generated, which effects the engine components. When metal gets hot, it
tends to bend much easier; so when metal engine components start to bend, they must get
replaced, and if they break, the engine can completely fail.
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Fuel Economy
Many people may think diesels get very bad fuel economy, but when you take into consideration
that diesel trucks weight around 6 tons, you will easily see why. Surprisingly diesel cars, which
weight significantly less, do exist in the United States, but most cost alot due to their rarity. To
compare the fuel efficiency (mpg) between gasolines vs. diesel cars, I have chosen the two best
from each class, excluding hybrids because of unfair advantages from electric motors. The 2015
Mitsubishi Mirage (Gas Engine) got an astounding combined mpg of 40, and the BMW 328d
Sedan (Diesel) got 39 mpg. Many may say the gas car still gets better mpg, but you must also
take into consideration the size of the engine as well as the weight of the vehicle. The Mitsubishi
Mirage weights about 2000lb which makes its weight to mpg ratio 50lbs for every 1 mpg. The
BMW 328d Sedan weights almost double at 3510lbs, so its weight to mpg ratio, 90 lbs. for every
1 mpg. So with the weight taken into consideration, the BMW is much more efficient because it
carries 90 lbs. for every mpg, while the Mitsubishi only carries 50lbs. In addition, the BMW has
an almost twice as large displacement, or engine size, as the Mitsubishi. When an engines
displacement gets larger, the fuel economy drops because more fuel is need to move the larger
engine components. Because the BMW has a larger displacement, it should have much less mpg,
showing how much more efficient the BMW is.
Note: The vehicle specifications were taken from (2015 Mitsubishi Mirage) and (Features & Specs)
Vehicle
MPG
Mitsubishi Mirage
40 MPG
(Gas Engine)
BMW 328d
Sedan
39 MPG
(Diesel Engine)
Figure 6: MPG to weight ratio
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Weight
MPG to Weight
Ratio
Engine Size
2000lbs
50/1
1.2 liter
3510lbs
90/1
2 liter
Basics
Diesel engines use the same concept as a regular internal combustion engine. It all starts with the
intake stroke when the piston goes down, sucking cold air and fuel into the cylinder. The piston
goes to the top of the cylinder, compressing the fuel air mixture. This compression heats up the
fuel/air mixture to the point of combustion. Diesel engines use this compression to ignite the
fuel, instead of spark plugs. This combustion expands the gas, and sends the piston down in the
power stroke. This power then gets converted into mechanical energy with the use of the
crankshaft. Gasoline engines cant do this because they dont compress the fuel air mixture as
much as diesel engines, so when gasoline engines compress their fuel air mixture, they generate
heat, but not enough to ignite gasoline.
Turbo Chargers
These hot exhaust gases power what we
mentioned in Chapter 2 as the turbo charger
(Figure 6). As the hot gases get pushed out of
the cylinder, they spin a fan in the turbo
charger, which connects to another fan in the
turbo charger which then sucks the oxygen into
the engine; therefore, the system uses the
already fast moving hot exhaust gases to force
the necessary oxygen into the engine. This
creates pressure, which gives the engine more
oxygen than it would if it didnt have a turbo
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charger. If diesel engines didnt have a turbo charger, they would lack responsiveness, and would
produce much less power.
Cooling
Engines use coolant to keep the engine cool. This coolant runs through small passages in the
engine, and simply takes the heat from the engine. The coolant then flows through the radiator,
which then cools the coolant using the air from outside. Without coolant, engines would easily
overheat and people would have to stop on the side of the road to give their engines time to cool
down.
Because the hot exhaust gas runs through the turbo, the turbo gets very hot. When the cool
oxygen gets sucked through the intake side of the turbo, the oxygen tends to increase in
temperature because it runs through the now hot turbo. Before this oxygen enters the engine, it
must get as cool as it can to produce the most power. To cool the oxygen, the system pushes it
through the intercooler, which acts just like a radiator, and cools the oxygen. The cold air not
only helps produce more power but also cools the engine down. Furthermore, when cold air and
fuel gets ignited, it actually expands more, resulting in a more violent explosion creating more
power.
Note: See Chapter 3: Igniting the fuel, to get a better understanding of how colder air makes
more violent explosions.
Emissions
Diesel engines have alot of emissions controls, but for good reason. Like gas engines, diesel
engines use a Catalytic Converter, Exhaust Gas Re-circulator, and a Diesel Particulate Filter to
help lower the amount of bad chemicals coming out of the engine. These emission controls
decrease the emissions that diesel engines put out significantly, which allows for a cleaner
atmosphere and a better world to live in.
Note: Refer to Chapter 5 to understand how emission controls work.
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The DPF
The Diesel Particulate Filter aka the DPF, filters the black smoke, or soot, out of the exhaust.
Unfortunately the DPF requires a separate tank of diesel, around 2-5 gallons, because when the
DPF gets clogged, the system injects fuel into the exhaust, and ignites it to unclog the filter. The
DPF, a necessary emission control, constantly requires fuel to unclog the filter, which adds to the
existing fuel costs.
The CAT
Catalytic converters (CAT) use a chemical process to clean the exhaust by changing the chemical
composition of carbon monoxide, and nitrogen oxide. It does this by breaking the bonds between
each element, leaving the carbon, nitrogen, and oxygen elements all separate. CATs must do
this because carbon monoxide poisons humans, and nitrogen oxide destroys the ozone, which
ultimately allows more radiation rays to reach humans.
Unfortunately the CAT slows the flow of the exhaust out of the exhaust pipe. Slowing the
exhaust causes the exhaust pipe to heat up which ultimately increases the temperature of the
engine. The faster the exhaust can flow out of the engine through the exhaust pipe, the cooler the
system will stay.
The EGR
The Exhaust gas re-circulator (EGR) says what it does in the name. After the diesel has ignited in
the cylinder and has escaped as hot exhaust gas, it still has unburnt fuel in it, so the EGR sends
about of the exhaust gas back into the engine. Sending the hot exhaust gas back into the engine
heats the engine up. Though the hot exhaust that goes back into the engine gets cooled with the
use of the EGR cooler, the engine still gets effected because the coolant cools the hot exhaust
gases, or the same coolant that cools the engine.
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The Intake
Upgrading the intake easily benefits diesels. Adding
one wont add major amounts of horse power, but
will allow the truck to breathe clean cool air at a
higher rate. The three options of intakes include:
Stages 1, 2 and 3. Stage one consists of a higher
flowing filter, with tubing going to the engine. In
addition to Stage one, Stage two also has a partially
enclosed box and tubing. And stage three, the best
stag, contains a higher flowing filter, enclosed box
with tubing to gather cleaner air, and larger tubing
for faster flow into the engine. One may also upgrade Figure 9: Stage 3 Cold Air Intake
(Xtreme Diesel Performance)
their intake horn, or the metal tubing that goes
directly into the engine. The intake horn must connect to the engine first because the engine gets
really hot, and the plastic hose would easily melt; so the horn acts as a more heat resistant
connection. Installation of a cold air intake takes no time at all because the intake sits on the side
of the engine, allowing for easy access.
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Tuning
Adding a tuner will add quick and easy horsepower for
prices ranging from $350-$1000. One can install a tuner
simply by plugging it into their truck and selecting which
tune they want. Tuning usually takes around 15 minutes
and will add 50 to 200 horse power depending on which
tuner they get. Unfortunately, some tunes nick named hot
tunes actually damage the engine so one must read up on
which tuner to get. These hot tunes usually add 150+ horse
power.
Fuel
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Upgrading fuel components will increase horsepower from 50 to 250 horsepower. Some
upgradable fuel components include: the lift pump, high pressure fuel pump (cp3), and the
injectors. The lift pump carries fuel from the gas
tank to the second pump which then pressurizes
the fuel. Some lift pumps also filter the diesel
fuel, taking out any air, which makes fuel pure,
and allows for exact measurements of the
computer. The computer calculates how much
fuel to inject with sensors that identify how much
fuel passes through the system, but when oxygen
gets mixed with the fuel, the calculation becomes
off, so the purer the fuel the more accurate the
reading. Another fuel component that can get
Figure 12: An Injector (Xtreme
upgraded, the cp3, pressurizes the fuel so the
Diesel Performance)
injectors always have a constant supply fuel to
inject into the cylinder. A new cp3 will range
from $400-$600, injectors start at $1500 and go as
far as $5000.
Installing a lift pump takes about 3 to 5 hours because one must drop down the gas tank and drill
a hole into it. To install a cp3, one will need about 30 minutes to an hour; doing this only
required a quick unbolting. To install injectors one will have to remove the valve cover, and
unbolt the injectors, which will take about 3-8 hours depending on the truck.
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Pros:
Diesel Engines are much more dependable than gas engines because of their more
durable design, not requiring spark plugs and the fact that they operate at lower
temperatures than gas
Diesel Engines are more efficient than Gasoline Engines. Gasoline engines convert
approximately 30 percent of the energy in the fuel into power but a diesel engine often
converts 45 to 50 percent (Diesel Mechanic Guide)
Diesel Engines can use Biodiesel and even cooking oil
Diesel Fuel is much safer than Gasoline. Diesel fuel is almost impossible to ignite with
even an open flame. Gasoline easily bursts into flame when even a spark in the area
Diesel Engines pollute the environment much less than Gasoline Engines
Modifying diesel engines is easier than gasoline engines
Diesel Engines are cheaper to modify than Gasoline Engines
Cons:
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Generators
Industrial generators use the power of diesel fuel to generate electricity. Many smaller generators
used residentially use gasoline engines but only because smaller generators need less power to
produce less electricity. Diesel engines run these big industrial generators not only because they
have higher torque than gas but also because of their reliability, and efficiency.
Pumps
Large pumps use diesel engines when they pump thick oil out of the ground. To pump this oil,
companies need powerful pumps to get it out of the ground. High torque engines like diesel
engines make this possible, to efficiently suck up oil thousands of feet out of the ground and into
trucks. Using gasoline engines would take much longer to do the same amount of work, and
would also use more fuel.
Trains
Trains haul 3000-4000 tons at a time, so they need diesel engines to pull them. If trains used
gasoline engines, they might pull the weight but like said with pumps, it would use much more
fuel, and would take much longer to get going, therefore using gas engines would lead to less
fuel efficiency.
The Future
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The future will consist of many diesel engines as they continue to increase efficiency. Diesel
engine manufacturers have improved the design since Rudolf Diesel created them, and will
continue to be improved. In addition, the emission controls will continue to improve, and these
manufacturers may discover other ways to save the environment that will do much less harm to
the engine.
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Index
Adolphus Busch, 5, 29
camshaft, 8, 21
carbon dioxide, 17
carbon monoxide, 17, 18
computer, 8, 12, 21
connecting rod, 8
coolant, 16, 18
cp3, 21
crankshaft, 8
diesel, 3, 5, 11, 12, 13, 15, 16, 17, 18, 19, 21, 23,
25, 26
Diesel Particulate Filter, 5, 16, 17, 18
emission, 16, 17, 18, 26
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