CHAPTER 1 ENGINE

COMPONENTS & CLASSIFICATION

SUMMARY

The topic covers basic theoretical knowledge and understanding of engine

components, classifications and terminologies. Areas involving engine
construction, operating principles and valve train
SYLLABUS
Understand engine construction
Explain various types of internal combustion engines construction and operation:
twostroke petrol and diesel
fourstroke petrol and diesel
rotary!"ankel
Understand basic engine terminologies
Explain basic engine terminologies such as T#$, %#$, stroke, bore,
displacement, compression ratio etc.
Understand cylinder head and valve train construction
&tate the purpose of cylinder head
#escribe various type of valve train:
'()
'($
*ultivalve
Explain typical valve timing diagram
Explain basic operating principles of:
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INTRODUCTION TO ENGINES
Engine provides the power to drive the vehicle-s wheel.
%iggest part of the engine is the cylinder block. The cylinder block is a large
casting of metal that is drilled with holes to allow for the passage of
lubricants and coolant through the block and provide spaces for movement of
mechanical parts.
The block contains the cylinders, which are round passageways fitted with
pistons.
The block houses or holds the ma.or mechanical parts of the engine.
The cylinder head fits on top of the cylinder block to close off and seal the
top of the cylinder.
The combustion chamber is an area into which the airfuel mixture is
compressed and burned.
The cylinder head contains all or most of the combustion chamber.
The cylinder head also contains ports through which the airfuel mixture
enters and burned gases exit the cylinder and the bore for the sparkplug.

The valve train is a series of parts used to open and close the intake and
exhaust ports.

A valve is a movable part that opens and closes the ports.

A camshaft controls the movement of the valves.

&prings are used to help close the valves.

The upanddown motion of the pistons must be converted to rotary motion
before it can drive the wheels of a vehicle.
This conversion is achieved by linking the piston to a crankshaft with a
connecting rod.
The upper end of the connecting rod moves with the piston.
The lower end of the connecting rod is attached to the crankshaft and moves
in a circle.
The end of the crankshaft is connected to the flywheel.
ENGINE CLASSIFICATIONS

'perational cycles. /0 stroke or 1 stroke2

3umber of cylinders. /4,0,5,6,7,89,81 cylinders2

$ylinder arrangement. /:lat, inline, )type2

)alve train type. /'($,'(), #'($2

+gnition type /&park, $ompression2

:uel type /gasoline, natural gas, methanol, diesel, propane, fuel cell, electric,
hybrid2
ENGINE CONSTRUCTION

Types of internal combustion engines construction:

0 &troke petrol and diesel

1 &troke petrol and diesel

;otary!wankel
4 STROKE PETROL
+ntake
&troke
$ompression
&troke
,ower &troke
Exhaust
&troke
INTAKE STROKE
The first stroke of the cycle is the intake stroke.
As the piston moves away from top dead e!te" #TDC$, the intake valve
opens.
The downward movement of the piston increases the volume of the cylinder
above it, reducing the pressure in the cylinder. <ow pressure /engine vacuum2
causes the atmospheric pressure to push a mixture of air and fuel through the
open intake valve.
As the piston reaches the bottom of its stroke, the reduction in pressure
stops, causing the intake of airfuel mixture to slow down. +t does not stop
because of the weight and movement of the airfuel mixture.
+t continues to enter the cylinder until the intake valve closes. The intake
valve closes after the piston has reached %otto& dead e!te" #BDC$.
This delayed closing of the valve increases the volumetric efficiency of the
cylinder by packing as much air and fuel into it as possible.
COMPRESSION STROKE
The compression stroke begins as the piston starts to move from %#$.
The intake valve closes, trapping the airfuel mixture in the cylinder.
The upward movement of the piston compresses the airfuel mixture, thus
heating it up.
At T#$, the piston and cylinder walls form a combustion chamber in which the
fuel will be burned.
The volume of the cylinder with the piston at %#$ compared to the volume of
the cylinder with the piston at T#$ determines the compression ratio of the
engine.
PO'ER STROKE
The power stroke begins as the compressed fuel mixture is ignited.
"ith the valves still closed, an electrical spark across the electrodes of a
spark plug ignites the airfuel mixture.
The burning fuel rapidly expands, creating a very high pressure against the top
of the piston.
This drives the piston down toward %#$. The downward movement of the
piston is transmitted through the connecting rod to the crankshaft.
E(HAUST STROKE
The exhaust valve opens .ust before the piston reaches %#$ on the power
stroke.
,ressure within the cylinder causes the exhaust gas to rush past the open
valve and into the exhaust system.
*ovement of the piston from %#$ pushes most of the remaining exhaust gas
from the cylinder.
As the piston nears T#$, the exhaust valve begins to close as the intake valve
starts to open.
The exhaust stroke completes the fourstroke cycle.
The opening of the intake valve begins the cycle again.
This cycle occurs in each cylinder and is repeated over and over, as long as the
engine is running.

+t takes two full revolutions of the crankshaft to complete the fourstroke

cycle.

'ne full revolution of the crankshaft is e=ual to 469 degrees of rotation>

therefore, it takes ?19 degrees to complete the fourstroke cycle.

#uring one piston stroke, the crankshaft rotates 879 degrees.

4 STROKE DIESEL
The operation of a d)e*e+ e!,)!e is comparable to a gasoline engine.
They also have a number of components in common, /crankshaft, pistons,
valves, camshaft, and water and oil pumps.
(owever, diesel engines have o&p"e**)o! ignition systems. ;ather than
relying on a spark for ignition, a diesel engine uses the heat produced by
compressing air in the combustion chamber to ignite the fuel.
The compression ratio of diesel engines is typically three times /as high as
15:82 that of a gasoline engine.
As intake air is compressed, its temperature rises to ?99@$ to A99@$. Bust
before the air is fully compressed, a fuel in.ector sprays a small amount of
diesel fuel into the cylinder. The high temperature of the compressed air
instantly ignites the fuel.
The combustion causes increased heat in the cylinder and the resulting high
pressure moves the piston down on its power stroke.
4 STROKE DIESEL ENGINE
- STROKE ENGINE
This engine re=uires only two strokes of the piston to complete all four
operations: intake, compression, power, and exhaust.
This is accomplished as follows:
*ovement of the piston from %#$ to T#$ completes both intake and compression.
"hen the piston nears T#$, the compressed air!fuel mixture is ignited, causing an
expansion of the gases. #uring this time, the intake and exhaust ports are closed.
Expanding gases in the cylinder force the piston down, rotating the crankshaft.
"ith the piston at %#$, the intake and exhaust ports are both open, allowing exhaust
gases to leave the cylinder and airfuel mixture to enter.
- STROKE ENGINE
- STROKE ENGINE
Although the twostrokecycle engine is simple in design and lightweight
because it lacks a valve train, it has not been widely used in automobiles.
+t tends to be +e** ./e+ e..))e!t and releases &o"e po++/ta!t* into the
atmosphere than fourstroke engines.
ROTARY0'ANKEL ENGINE
The "ota"1 engine, or 'a!2e+ engine, is similar to the standard piston engine
in that it is a spark ignition, internal combustion engine.
+ts design, however, is =uite different. :or one thing, the rotary engine uses a
rotating motion rather than a reciprocating motion.
+n addition, it uses ports rather than valves for controlling the intake of the
airfuel mixture and the exhaust of the combusted charge.
ROTARY0'ANKEL ENGINE
CHARACTERISTICS OF ROTARY ENGINE

The rotating combustion chamber engine is small and light for the amount of
power it produces, which makes it attractive for use in automobiles.

(owever, the rotary engine at present cannot compete with a piston gasoline
engine in terms of durability, exhaust emissions, and economy.
BASIC ENGINE TERMINOLOGIES
%ore C cylinder diameter measured in inches/in2 or milimeters /mm2.
&troke C length of the piston travel between T#$ D %#$.
T#$ C Top dead center
%#$ C %ottom dead center
+f bore E stroke, the engine is called a *3/a"e e!,)!e.
+f bore F stroke, the engine is called a o4e"*3/a"e e!,)!e.
+f bore G stroke, the engine is called a /!de"*3/a"e e!,)!e.
$ylinder #isplacement C volume of the cylinder when the piston is at %#$.
Engine displacement C sum!total of the displacement of each of the engine
cylidners.
Typically, an engine with a larger displacement produces more tor=ue than a
smaller displacement engine.
$ompression ratio C comparison of a cylinder-s volume when the piston is at
%#$ to the cylinder-s volume when the piston is at T#$.
The higher the compression ratio, the more power an engine theoretically can
produce.
ENGINE EFFICIENCY

)olumetric efficiency describes the engine-s ability to have its cylinders filled
with airfuel mixture.

+f the engine-s cylinders are able to be filled with airfuel mixture during its
intake stroke, the engine has a volumetric efficiency of 899H.

Typically, engines have a volumetric efficiency of 79H to 899H.

CYLINDER HEAD & 5AL5E TRAIN

,urpose of cylinder head

The cylinder head fits on top of the cylinder block to close off and seal the top of the
cylinder.

The cylinder head also contains ports through which the airfuel mixture enters and
burned gases exit the cylinder and the bore for the sparkplug.
TYPE OF 5AL5E TRAIN

'verhead )alve /'()2

'verhead $am /'($2

*ultivalve
O5ERHEAD 5AL5E #OH5$
The intake and exhaust valves in an '() engine are mounted in the cylinder
head and are operated by a camshaft located in the cylinder block.
This arrangement re=uires the use of valve lifters, pushrods, and rocker arms
to transfer camshaft rotation to valve movement.
O5ERHEAD CAM #OHC$
An '($ engine also has the intake and exhaust valves located in the cylinder head.
%ut the cam is located in the cylinder head.
+n an '($ engine, the valves are operated directly by the camshaft or through cam
followers or tappets.
Engines with one camshaft above a cylinder are often referred to as single overhead
camshaft /&'($2 engines.
MULTI5AL5E
A multivalve design typically has three, four, or five valves per cylinder to
achieve improved performance.
Any fourstroke internal combustion engine needs at least two valves per
cylinder: one for intake of air and fuel, and another for exhaust of combustion
gases.
*ultivalve engines tend to have smaller valves
have lower reciprocating mass,
can reduce wear on each cam lobe,
more power from higher ;,* without the danger of valve bounce.
MULTI5AL5E
Threevalve cylinder head
This has a single large exhaust valve and two smaller intake valves
:ourvalve cylinder head
This is the most common type of multivalve head, with two exhaust valves and two
similar /or slightly larger2 inlet valves.
:ivevalve cylinder head
<ess common is the fivevalve head, with two exhaust valves and three inlet valves.
All five valves are similar in siIe.
5AL5E TIMING
)alve timing is the precise timing of the opening and closing of the valves.
'ne way to look at this diagram is to think of these events in terms of the
position of the crankshaft and 469 degrees rotation.
5AL5E TIMING

"ith traditional fixed valve timing, an engine will have a period of valve overlap at the end of the exhaust
stroke, when both the intake and exhaust valves are open.

The intake valve is opened %T#$ because to give enough time for airfuel mixture to get into the cylinder.

The intake valve is allowed open A%#$ because to get advantages of inertia created by velocity assists in drawing
in the fresh charge.

The exhaust valve is opened %%#$ because the gases inside the cylinder posses a higher pressure even after the
expansion stroke. This higher pressure enables it to reduce the work that needs to be done by the engine piston
in pushing out these gases.

The exhaust valve close AT#$ because to give sufficient time for exhaust gas exit through the exhaust valve. +f
the exhaust valve is closed like in actual timing diagram, a certain amount of exhaust gases will get compressed
and remain inside the cylinder and will be carried to the next cycle also.
5ARIABLES 5AL5E TIMING
At low speed, a little valve lift already sufficient for air!fuel to enter the
cylinder.
The fuel consumption is better and enough for cruising and low speed.
%ut at high speed, the valve need to open and close very fast and need more
longer time for air!fuel to enter the cylinder.
Therefore, the valve lift must be higher and the timing is longer.
+f the engine has fixed valve lift and valve timing, the performance will be
bad.
To increase the performance of the engine and better fuel consumption,
variable valve timing is introduced.
5ARIABLES 5AL5E TIMING
(ow it worksJ
As the camshaft spins, the lobes open and close the intake and exhaust valves in time
with the motion of the piston.
))T is the process of altering the timing of a valve lift event, and is often used to
improve performance, fuel economy or emissions.
&ome cars use a device that can ad4a!e t6e 4a+4e t)&)!,. This does not keep the
valves open longer> instead, it opens them later and closes them later.
)+#E'
5ARIABLES 5AL5E TIMING

Type of variables valve timing

)TE$ /(onda2

*+)E$ /*itsubishi2

))T+ /Toyota2

$,& /,roton2

#))T /,erodua2
5IDEO

(ow an Engine "orks $omprehensive Tutorial Animation featuring Toyota Eng

ine Technologies
E(ERCISE
8. Explain how 0stroke engine worksJ
1. $ompare 1stroke and 0stroke engines.
4. $ompare petrol and diesel engine.
0. &ketch and explain 0 process in the rotary engine.
5. An engine has 0 cylinders. Each cylinder has a bore of 5.85cm and its stroke
is 6cm. $alculate the engine displacements.
6. #raw and explain a typical valve timing diagram for 0stroke petrol engine.
?. "hat is Kvalve overlap-J
7UI8 1
$hapter 8
A Buly 1984 /Tuesday2
THANK YOU