CHAPTER 1

ENGINE SYSTEM

OBJECTIVES
 Explain the principles of internal combustion engine operation  Identify internal combustion engine parts  Describe the function of engine parts

Engine characteristics

ENGINE DESIGN AND OPERATION

Four Stroke Cycle  Intake  Compression  Power  Exhaust

TWO-STROKE CYCLE
 Common in some small engine such as lawn mover engines, and some diesel engine  Valve train is eliminated  Each upward piston stroke is a compression stroke, and each downward piston stroke is a power stroke in a twostroke cycle engine.

OTTO CYCLE

DIESEL CYCLE

VALVE MECHANISM AND CAM SHAFT DRIVES

 Valve mechanisms vary depending on the camshaft location

CAMSHAFT AND VALVE OPERATION

 Intake stroke: The crankshaft completed onehalf a revolution, while the camshaft rotated onequarter revolution.  Compression stroke: valves remain closed. the crankshaft rotates for one half revolution while the camshaft turns one-quarter revolution.

..
 Power stroke: Both valves remain closed the crankshaft turns half revolution, and the camshaft rotates one quarter revolution.  Exhaust stroke: The crankshaft completes another half turn, and the camshaft rotates onequarter revolution.

CAMSHAFT LOCATION
 Flathead or Side Valve  Overhead Valve (OHV)  Overhead Cam (OHC

ENGINE BLOCK TYPES

 In-Line Blocks  V-Type Blocks  Opposed type Blocks:

ENGINE SYSTEMS
 Ignition System.  Fuel System  Emission Control Systems  Exhaust System.  Lubrication system:  Cooling system

REVIEW OF ENGINE MEASUREMENTS

Bore and Stroke  The bore is the diameter of the cylinder and is measured across the cylinder. Piston stroke:  It is the distance that the piston moves from TDC to BDC

Continue.
 Displacement: The volume of the cylinder between TDC and BDC is referred to as displacement  valve overlap. The crankshaft rotation near TDC on the exhaust stroke when both the intake and exhaust valves are open is called valve overlap.  Compression ratio The compression ratio is the ratio of the cylinder volume with the piston at BDC to the cylinder volume with the piston at TDC

COMPRESSION CALCULATION:

RATIO

 If the cylinder volume with the piston at BDC is 480 cubic centimeters [cc], and the cylinder volume with the piston at TDC is 60 cc, the compression ratio is 8:1.

EFFECTS OF COMPRESSION RATIO

 Higher compression ratio produce more power than engines with a lower compression ratio.  The cylinder heat on the compression stroke increases proportionally.  The fuel may explode rather than burn smoothly in the combustion chamber.  This exploding action causes detonation  Higher octane fuel reduces this detonation problem to some extent.  The type of fuel recommended by the vehicle manufacturer is determined largely by the compression ratio.

Continue
Compression Ratio for BMW Engine Series  M 43  M54B22  M54B25  M54B30 9.7:1 10.8:1 10.5:1 10.2:1

FIRING ORDER
The order in which various cylinders of Multi cylinder engine fire is called the firing order 4 Cylinder Engine 1 2 4 3 or 1 3 4 2 6 Cylinder Engine1 5 3 6 2 4 or 1 4 2 6 3 5

ENERGY EFFICIENCY
 Thermal Efficiency

Thermal energy is the relationship between the engine power output and the heat energy available in the fuel. A percentage is used to express this relationship.


 Mechanical Efficiency Mechanical efficiency is the relationship between the engine power delivered and the power that would be delivered if the engine operated without any power loss. The mechanical efficiency of an engine is expressed as a percentage.


 Volumetric Efficiency. Volumetric efficiency is the relationship between the amounts of air actually taken into the cylinder on the intake stroke compared to the amount of air required to fill the cylinder at atmospheric pressure. Volumetric pressure is also expressed as a percentage.

.
 Torque and Horsepower Torque is transferred from the engine crankshaft through the drive train to the drive wheels. Torque = force x distance. torque is measured in Newton-meters (Nm).

BASIC ENGINE SYSTEM

Crank case

MECHANICAL

The crankcase is made of Aluminum alloy with drawn cast iron bushes ( M54) Cast iron crankcase used in M 43 engine

BLOCK ASSEMBLIES
 Cast iron alloy  Aluminum block are becoming more common.  Aluminum block has steel cylinder liners  The aluminum in other block is mixed with silicon so the silicon accumulates on the cylinder walls to provide a hard surface that does not require a sleeve.

CYLINDER SLEEVES
 The cylinder is cast integrally with the block in most engines.  Heavy-duty engines have removable dry-type or wet-type replaceable cylinder sleeves.  A wet-type cylinder sleeve is in contact with the coolant. This type of sleeve must be sealed in the block at the top and bottom

MAIN BEARING BORES.

 The main bearing bores support the crankshaft in the block.  The main bearing bores must be strong enough to withstand combustion forces without distorting or stretching.

CAMSHAFT BEARING

 Camshaft bearing and bearing bores must support the load of the camshaft and valve train.

VALVE LIFTER BORES

 The valve lifter bores are machined in the block directly above the camshaft lobes.  Oil is supplied from the main oil gallery in the block to each valve lifter bore.

COOLANT JACKETS.
Coolant jackets surround the outside of each cylinder wall in the block. Coolant is circulated through each of these coolant jackets to cool the cylinder walls. A threaded coolant drain plug is positioned near the bottom of the coolant jackets in the block

CRANKSHAFTS

4 6

INDEX EXPLANATION
1 Crankshaft 2 Upper bearing shells 3 Lower bearing shells 4 Upper thrust bearing shell 5 Lower bearing shell 6 Incremental gearwheel 7 Ball bearing for gear shaft

.
 The crankshaft changes the vertical piston movement to rotary motion  Crankshafts may contain cast iron alloy or forged steel.  All the main bearing and connecting rod bearing journals are machined to a highly polished finish.

.
 Bearing inserts are located between the main bearing bores and the main bearing journals on the crankshaft  Connecting rod bearing inserts are mounted between the connecting rod bores and the crankshaft journals.  Oil passages are drilled from each main bearing journal to the connecting rod journals to assure adequate oil supply at the connecting rod bearings.


 A flex plate, or flywheel, is bolted to the transmission end of the crankshaft and a vibration damper and pulley is pressed onto the front of the crankshaft

CONNECTING RODS, PISTONS, PISTON PINS, AND PISTON RINGS.

Connecting Rod

Connecting Rod.
Steel-forged, tapered I beam design. The connecting rod bore fits over the crankshaft journal, and the eye in the upper end of the connecting rod fits over the piston pin The connecting rod cap is bolted to the upper part of the rod.

Piston
PISTON

Piston.

Piston..

Piston..
Aluminum alloy pistons The top of the piston is called the head, or dome Piston ring grooves are cut into the sides of the piston just below the piston head The ridges between the ring grooves are referred to as lands

Piston
 Piston must be assembled on the connecting rods correctly, and the complete piston and rod assembly must be installed properly in the cylinder to maintain the pin offset in the correct position  The piston must have sufficient clearance to allow a film of oil between the piston and the cylinder wall.

PISTON PIN.
 Piston pins are manufactured from hard steel  Polished exterior surface  One of the most common methods of a mounting the pin the piston and connecting rod is to press the pin into the rod and allow it to rotate in the piston with a precision clearance  There must be enough clearance between the pin and the piston pin bore or rod bushing to allow a film of oil between these components.

PISTON RINGS
 The piston rings fit into the piston ring grooves and provide sealing between the piston and the cylinder walls  Control the amount of oil on the cylinder walls to prevent excessive amounts of oil from moving past the rings into the combustion chamber.  Made from cast iron or nodular iron.  Piston rings may be classified as compression rings or oil rings. Many pistons have two compression rings in the upper ring grooves and an oil ring in the lower groove.

CAMSHAFT
 camshafts are made from a hardened cast iron alloy  A lobe is positioned on the camshaft for each valve in the engine.  The camshaft changes the rotary motion of this shaft to reciprocating motion of the valves  Marks on the camshaft and crankshaft sprockets must be properly aligned before the timing chain is installed to time the camshaft in relation to the crankshaft.

PARTS OF A CAM LOBE AND A VALVE TIMING CHART

Parts of a cam lobe

A Valve timing chart

VALVE LIFTERS,PUSH ROD,ROCKER ARMS AND VALVES

CYLINDER HEAD
 Cylinder heads were made from cast iron  modern engines are usually equipped with aluminum cylinder heads.  The lower side of the cylinder head contains the combustion chamber recesses  Threaded openings in the combustion chamber accept the spark plugs  Coolant passages surround the combustion chamber and spark plug to provide adequate cooling.

CYLINDER HEADS AND INTAKE MANIFOLD

 Warning: The torque on engine bolts is extremely important, especially on aluminum components. Improper torque results in warped components. When servicing an engine, always follow the torque instructions in the vehicle manufacturers service manual.