Learning Module in BTVTE-Automotive

School Year: 2020-2021

INTRODUCTION

Welcome to the course Automotive!

This course is an introduction to Internal Combustion Engine Servicing, Repair and

Maintenance program development as well as its management and awareness. It provides the
materials needed for basic understanding of the operation of internal engine combustion.

The main objective of this program is to prepare the students in handling, maintaining and
repairing the automobile combustion engines through safe and healthful conditions for the prevention
of loss or damage to lives and properties as their future careers.

The content of this module was taken from different and liable resources based on guidelines
of the course requirement. Assuredly, this module will help students in learning the basic operations
of this course. Through the content of this, learners’ skills will be developed and enhanced because
this module was written to be used as an applied thermo science in college or undergraduate courses
on internal combustion engines within a semester.

And it also helps for the complete development and enhancement of every learner as they
prepare their selves as automotive technicians.

Grading System ( BTVTE- Automotive )

Module/Portfolio/Activities 50%

Laboratory 30%

Exam 20%

Enjoy learning!

If you have questions, ask your teacher for assistance.

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 Learning Module in BTVTE-Automotive
School Year: 2020-2021

Lesson 1

Learning Objectives:
a. Define the meaning of Internal Combustion Engine.
b. Describe the internal combustion engine.
c. Summarizes the history of internal combustion engine.

Introduction and Brief History of Internal Combustion Engine Servicing, Repair, and
Maintenance

Introduction to Internal Combustion Engine

The engine is the power plant of a vehicle. Automotive engines have gone through
tremendous changes since the automobile was first introduced in the 1880s, but all combustion
engines still have three requirements that must be met to do their job of providing power – air, fuel,
and ignition.
The mixture of air and fuel must be compressed inside the engine in order to make it highly
combustible and get the most out of the energy contained in the fuel mixture.
Since the mixture is ignited within the engine, automobile power plants are called internal
combustion engines. Most can be further classified as reciprocating piston engines, since pistons
move up and down within cylinders to provide power. This up-and-down motion is converted into
turning motion by the crankshaft.
 Internal Combustion Engine (Ie) – is an engine that converts chemical energy heat in a fuel
into mechanical energy, usually made available on a rotating output shaft.
 An engine or motor is a machine designed to convert one form of energy into mechanical
energy. Heat engines, like the internal combustion engine, burn a fuel to create heat which is
then used to do work.
Chemical energy of the fuel is first converted to thermal energy by means of combustion or
oxidation with air inside the engine. This thermal energy raises the temperature and pressure of the
gases within the engine and the high pressure gas then expands against the mechanical mechanisms of
the engine.
Most internal engines are reciprocating engines having that reciprocate back and forth in
cylinders internally within the engine.

Brief History of Internal Combustion Engine

17th and 18th Centuries
Most of the very earliest internal combustion of the 17 th and 18th centuries can be classified
as atmospheric engines.
 In 1872, American George Brayton invented the first commercial liquid-fueled internal
combustion engine. In 1876, Nicolaus Otto, working with Gottlieb Daimler and Wilhelm
Maybach, patented the compressed charge, four-stroke cycle engine. In 1879, Karl Benz
patented a reliable two-stroke gas engine.
 The first commercially successful internal combustion engine was created by Étienne Lenoir
around 1860 and the first modern internal combustion engine was created in 1876 by
Nicolaus Otto (see Otto engine).

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 Learning Module in BTVTE-Automotive
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 These were large engines with a single piston and cylinder, the cylinder being open on the
end.
 Combustion was initiated in the open cylinder using any of the various fuels which were
available.
 Gunpowder was often used as the fuel.
 Immediately after combustion, the cylinder would be full of hot exhaust gas at atmospheric
pressure. At this time, the cylinder end was closed and the trapped gas was allowed to cool.
 Some early steam engines also were atmospheric engines. Instead of combustion, the open
cylinder was filled with hot steam. The end was then closed and the steam was allowed to
cool and condense. This created the necessary vacuum.

The Middle and latter half of the 1800’s

In addition to great amount of

experimentation and development in Europe
and United States, two other technological
occurrences during this time stimulated the
emergence of the internal combustion engine.
In 1859, the discovery of crude oil in
Pennsylvania finally made available which
could be used in newly developed engine.

 Fuels like whale oil, coal gas, mineral

oils, coal, and gun powder which were
available before this time were less
than ideal for engine use and
development.
 Many years before products of petroleum industry evolved from crude oil to gasoline, the
automobile fuel of the 20th century.
 However, improved hydrocarbon products began to appear as early as the 1860’s and
gasoline, lubricating oils, and the internal combustion engine evolved together.

The second technological invention that stimulated the development of the internal combustion
engine was the pneumatic rubber tire, which was first marketed by John B. Dunlop in 1888.

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 Learning Module in BTVTE-Automotive
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Activity 1.2

Name:________________________________ Date: ______________________________

Strand:_________________________________ Score: ______________________________

Direction: answer the following questions. Write your answer on the space provided.

1. What are the characteristics of the internal combustion engine?

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2. Why internal combustion engine is important?

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3. How will you manage the internal combustion engine of your vehicle?

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4. Who were the people 1st invented the internal combustion engine?

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5. Who is Étienne Lenoir and Nicolaus Otto?

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 Learning Module in BTVTE-Automotive
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Activity 1.3

Name:________________________________ Date: ______________________________

Strand:_________________________________ Score: ______________________________

Direction: Make a timeline showing the history of internal combustion engine. Use the flow chart
below.

History of Internal Combustion

Engine

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 Learning Module in BTVTE-Automotive
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Activity 1.4

Name:________________________________ Date: ______________________________

Strand:_________________________________ Score: ______________________________

Direction: Research for the latest internal combustion engine used in an automobile. Draw it on the
box below.

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 Learning Module in BTVTE-Automotive
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Lesson 2

Learning Objectives:
a. Discuss about the different terminologies and abbreviations used.
b. Shows awareness about terminologies.
c. Summarize the internal combustion engine terminologies.

Terminologies and Abbreviations Used in Internal Combustion Engine

The following terms and abbreviations are commonly used in engine technology literature and
will be used through-out this module.

Abbreviation Terminology Definition

Ie Internal Combustion The mixture is ignited within the engine,
automobile power plants.
SI Spark Ignition An engine in which the combustion process in
each cycle is started by use of a spark plug.
This is often called Diesel Engines.
CI Compression Ignition An engine in which the combustion process
starts when the air-fuel mixture self-ignites due
to higher temperature in the combustion chamber
caused by high compression.

TDC Top-Dead-Center Position of the piston when it stops at the furthest

point away from the crankshaft.
BDC Bottom-Dead-Center Position of the piston when it stops at the point
closest to the crankshaft.
DI Direct Injection Fuel injection into the main combustion chamber
of an engine.
IDI Indirect Injection Fuel injection into the secondary chamber of an
engine with a divided combustion chamber.
EMS Engine Management Computer and electronics used to control smart
Engine engines.
WOT Wide-Open Throttle Engine operated with throttle valve fully open
when maximum power and/or speed is desired.
ID Ignition Delay Time ignition interval between ignition initiation
and the actual start of combustion.
AF Air Fuel Ratio Ratio of mass of air to mass of fuel input into
engine.
FA Fuel-Air Ratio Ratio of mass fuel to mass of air input into
engine.
BMT Brake Maximum Torque Speed at which maximum torque occurs.
ORV Overhead Valve Valves mounted in engine head.
aRC Overhead Cam Camshaft mounted in engine head, giving more
direct control of valves which are also mounted
in engine head.

FI Fuel Injected The fuel injected to engine.

Activity 2.1
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 Learning Module in BTVTE-Automotive
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Name: ________________________________ Date: __________________________

Course:________________________________ Score: __________________________

Direction: Answer the question below and write it on the space provided.

1. Is it important to use abbreviations in different terminologies? Yes or No? Justify your

answer.

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2. How do the terminologies and abbreviations help you in understanding the concept of a
lesson?

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3. In general, make a summary of different abbreviations used.

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4. What do you mean by fuel ratio?

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5. Differentiate fuel and air ratio.

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Activity 2.2

Name: ________________________________ Date: __________________________

Strand:________________________________ Score: __________________________

Direction: Answer the following self-reflection.

MINUTE PAPER
Today, I have learned that:
1.______________________________________________________________
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2.______________________________________________________________
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3.______________________________________________________________
________________________________________________________________
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But, I’m a little bit confused with:
1_______________________________________________________________
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2_______________________________________________________________
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3.______________________________________________________________
________________________________________________________________
________________________________________________________________
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I still want to learn more on:
1._________________________________________________________
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2.______________________________________________________________
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3.______________________________________________________________
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Lesson 3
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 Learning Module in BTVTE-Automotive
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Learning Objectives:
a. Identify the engine parts and its components.
b. Summarize the components of combustion engine.
c. Illustrate and label the engine parts.

Engine Parts and Components

Engine is the main automotive component for any automobile. It works as a heart of automobile. 

An engine or motor is a machine designed to convert one form of energy into mechanical energy.
Heat engines, like the internal combustion engine, burn a fuel to create heat which is then used to do
work.
1. Exhaust Manifold – piping system which carries
exhaust gases away from the engine cylinders,
usually made of cast iron.
2. Exhaust System – flow system for removing exhaust
gases from the cylinders, treating them, and
exhausting them to the surroundings.
3. Fan – most engines have an engine-driven fan to
increase air flow through the radiator and through the
engine compartment, which increases waste heat
removal from the engine. Fans can be driven
mechanically or electrically, and can run continuously or be used only when needed.
4. Flywheel – rotating mass with large moment of inertia connected to the crankshaft of the
engine. The purpose of flywheel is to store energy and furnish a large angular momentum that
keeps the engine rotating between power strokes and smooth out engine operation.
5. Fuel Injector – a pressurized nozzle that sprays fuel into the coming air on SI engines or into
the cylinders on CI engines.
6. Carburetor Venturi flow device which meters the proper amount of fuel into the air flow by
means of a pressure differential.
7. Catalytic converter Chamber mounted in exhaust flow containing catalytic material that
promotes reduction of emissions by chemical reaction
8. Combustion chamber the end of the cylinder between the head and the piston face where
combustion occurs.
9. Connecting rod connecting the piston with the rotating crankshaft, usually made of steel or
alloy forging inmost engines but may be aluminum in some small engines.
10. Connecting rod bearing - bearing where connecting rod fastens to crankshaft.
11. Cooling fins- metal fins on the outside surfaces of cylinders and head of an air-cooled
engine. These extended surfaces cool the cylinders by conduction and convection.
12. Crankcase Part of the engine block surrounding the rotating crankshaft. In many engines, the
oil pan makes up part of the crankcase housing.

13. Crankshaft Rotating shaft through which engine work output is supplied to external systems.

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 Learning Module in BTVTE-Automotive
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14. Cylinders The circular cylinders in the engine block in which the pistons reciprocate back and
forth.
15. Camshaft - is a rotating object usually made of metal that contains pointed cams, which
converts rotational motion to reciprocal motion.

HISTORIC-FUEL PUMPS
Lacking a fuel pump, it was necessary to back Model T Fords (1909-1927) up high-
slope hills because of the location of the fuel tank relative to the engine.

1. Glow plug - small electrical resistance heater mounted inside the combustion chamber of
many CI engines, used to preheat the chamber enough so that combustion will occur when
first starting a cold engine.
2. Head - the piece which closes the end of the cylinders, usually containing part of the
clearance volume of the c Head gasket - gasket which serves as a sealant between the engine
block and head where they bolt together combustion chamber.
3. Intake manifold- piping system which delivers incoming air to the cylinders, usually made of
cast metal, plastic, or composite material.
4. Main bearing- the bearings connected to the engine block in which the crankshaft rotates.
5. Oil pump- used to distribute oil from the oil sump to required lubrication points.
6. Oil sump Reservoir for the oil system of the engine, commonly part of the crankcase.
7. Piston- the cylindrical-shaped mass that reciprocates back and forth in the cylinder,
transmitting the pressure forces in the combustion chamber to the rotating crankshaft.
8. Piston rings- metal rings that fit into circumferential grooves around the piston and form a
sliding surface against the cylinder walls.
9. Push rods- mechanical linkage between the camshaft and valves on overhead valve engines
with the camshaft in the crankcase.
10. Radiator Liquid-to-air heat exchanger of honeycomb construction used to remove heat from
the engine coolant after the engine has been cooled.
11. Spark plug- electrical device used to initiate combustion in an SI engine by creating a high-
voltage discharge across an electrode gap.

Early automobile engines were started with hand cranks that connected with the crankshaft of the
engine. This was a difficult and dangerous process, sometimes resulting in broken fingers and arms
when the engine would fire and snap back the hand crank. The first electric starters appeared on the
1912Cadillac automobiles, invented by C. Kettering, who was motivated when his friend was killed
in the process of hand starting an automobile.

Activity 3.1

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 Learning Module in BTVTE-Automotive
School Year: 2020-2021

Name: ________________________________ Date: __________________________

Course:________________________________ Score: __________________________

Direction: Draw at least 15 engine parts and give its function.

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 Learning Module in BTVTE-Automotive
School Year: 2020-2021

Activity 3.2

Name: ________________________________ Date: __________________________

Strand:________________________________ Score: __________________________

A. True or False
Direction: Write A if the statement is correct and B if it is not.

______1. Connecting rod is usually made of steel or alloy.

______2. The function of exhaust system is to add exhaust gases from the cylinders.
______3. The flywheel furnishes a large angular momentum that keeps the engine rotating and
stores energy.
______4. Catalytic converter chamber contains a catalytic material that promotes reduction of
emissions by chemical reaction.
______5. Camshaft is made up of plastics that contains pointed cams, which converts rotational
motion to reciprocal motion.
______6. Oil pump was used to distribute oil from the oil sump to required lubrication points.
______7. Intake manifold is a piping system which removes the incoming air to the cylinders.
______8. Connecting rod bearing fastens the crankshaft.
______9. Cooling pins are extended surfaces that cool the cylinder by conduction and conservation.
______10. Fans can be driven mechanically or electrically, and can run continuously or be used only
when needed.

B. Identification
Direction: Write your answer on the space provided.

__________________1. A bearing that is connected to the engine block in which the crankshaft
rotates.
__________________2. It is used to distribute oil from the oil sump to required lubrication
points.
__________________3. It is usually made of cast metal, plastic, or composite material which
delivers incoming air to the cylinders.
__________________4. Refers to a rotating object usually made of metal that contains pointed
cams.
__________________5. A cylindrical-shaped mass that reciprocates back and forth in the
cylinder.
__________________6. It refers to a heat exchanger of honeycomb construction used to remove
heat from the engine coolant.
__________________7. A piece which is close to the end of the cylinders.
__________________8. It is used to preheat the chamber of an engine.
__________________9. A rotating object usually made of metal that contains pointed cams,
which converts rotational motion to reciprocal motion.
__________________10. It is made up of steel or alloy forging inmost engines but may be
aluminum in some small engines.

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 Learning Module in BTVTE-Automotive
School Year: 2020-2021
Lesson 4

Learning Objectives:
a. Identify the engine classification.
b. Determine the different types of engine.
c. Label the parts oppose cylinder engine,
d. Draw the different classification of engine.

Engine Classifications

Automotive Engines are generally classified according to following different categories: Internal

combustion (IC) and External Combustion (EC) Type of fuel: Petrol, Diesel, Gas, Bio / Alternative
Fuels. Number of strokes – Two stroke Petrol, Two-Stroke Diesel, Four Stroke Petrol / Four Stroke
Diesel, method of ignition, firing order, No. of cylinder, arrangements of cylinder, type of cooling,
arrangements of valves and valve trains.

Basic Engine Design

• Reciprocating W-type In-line
V- type
Single Cylinder Radial Opposed
Cylinder Opposed Piston
Rotary:
Single Rotor
Multi-rotor

Working Cycle (Strokes)

1. Four stroke cycle engine - When the cycle is completed in two revolutions of the crankshaft, it is
called four stroke cycle engine.
2. Two stroke cycle engine. - When the cycle is completed in one revolution of the crankshaft, it is
called two stroke cycle engine

Gear Timing- chains and belts keep your camshaft correctly timed! To ensure
that engine valves move in synch with pistons, timing gears, belts or chains
coordinate movement between the crankshaft and camshaft.
Types of Gear Timing

 Timing Belt Drive

 Timing Gear Drive
 Timing Chain Drive

 Single-cylinder engine - is a piston engine with

one cylinder. They are often used for motorcycles,
motor scooters, go-karts, all-terrain vehicles, radio-
controlled vehicles, portable tools and garden
machinery.

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 Learning Module in BTVTE-Automotive
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 An inline three-cylinder engine with 180° crankshaft can

be found in early examples of the Laverda Jota
motorcycle made by Italian.

 V engine, or Vee engine is a common configuration for an

internal combustion engine. The cylinders and pistons are
aligned, in two separate planes or 'banks', so that they appear to
be in a "V" when viewed along the axis of the crankshaft.

 Opposed cylinder engine is a piston

engine in which each cylinder has a
piston at both ends, and no cylinder
head. 

 W engine is a type of piston engine where three or four

cylinder banks use the same crankshaft, resembling the
letter W when viewed from the front.

 Opposed piston engine- two piston in each cylinder

with the combustion chamber located centrally
between the pistons.

 Radial engine- radial engine is a reciprocating type internal

combustion engine configuration in which the cylinders
"radiate" outward from a central crankcase like the spokes
of a wheel.

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 Learning Module in BTVTE-Automotive
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 Engine valves are located in the cylinder head.

The main function of the engine valves is to let
air in and out of the cylinders. That air is used to
help ignite the fuel which will drive the pistons
up and down. 

 Valve train or valve train is a mechanical system

that controls operation of the intake and exhaust
valves in an internal combustion engine. 

Types of Valve Trains

 Overhead camshaft (OHC) engine is a piston engine
where the camshaft is located in the cylinder head
above the combustion chamber.

 Some overhead camshaft with rocker arm - engines employ

short rocker arms in which the cam lobe pushes down (rather
than up) on the rocker arm to open the valve.

 Camshaft Valve in block with pushrod- situated between

the camshaft and each engine's valve, is a hollow steel
cylinder encasing an internal piston through a pushrod.

Types of Cooling System

 Air Cooled - rely on the circulation of air directly over heat

dissipation fins or hot areas of the engine to cool them in
order to keep the engine within operating temperatures.

 Liquid Cooled - An internal combustion engine with a

jacket cooling system in which liquid, usually water, is
circulated to maintain acceptable operating temperatures of machine parts.

Activity4.1
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 Learning Module in BTVTE-Automotive
School Year: 2020-2021

Name: ________________________________ Date: __________________________

Strand:________________________________ Score: __________________________

Direction: Label the parts of the following.

Oppose Cylinder Engine

1. _______________________________ 10. _______________________________

2. _______________________________ 11. _______________________________
3. _______________________________ 12. _______________________________
4. _______________________________ 13. _______________________________
5. _______________________________ 14. _______________________________
6. _______________________________ 15. _______________________________
7. _______________________________ 16. _______________________________
8. _______________________________ 17. _______________________________
9. _______________________________

Direction: Answer the question below and write your answer on the space provided.

1. Among the engine classifications, which is the most important? Justify your answer.
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2. Differentiate the working cycles (four-stroke cycle and two stroke cycle).
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3. Give the importance of the two types of cooling system.
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Activity 4.2 17
 Learning Module in BTVTE-Automotive
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Name:________________________________ Date: ______________________________

Strand:_________________________________ Score: ______________________________

Direction: Draw and label the different classification of engine of engine.

Lesson 5

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 Learning Module in BTVTE-Automotive
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Learning Objectives:
a. Identify what is engine cycle.
b. Familiarize the 4 stroke cycle.
c. Draw the 2 and 4 stroke engine cycle.
d. Explain the concept of each cycle.

Engine Cycles

A sequence of processes that regularly recur in an internal or external combustion engine and form

the basis of the engine's operation.
 Most internal combustion engines, both spark ignition and compression ignition, operate on
either a four-stroke cycle or a two-stroke cycle.

Air-Standard Engine Cycle

 The Otto cycle is an air-standard cycle which approximates the processes in petrol or diesel
engines.

4 Stroke Cycle
 A four-stroke cycle engine is an internal combustion engine that utilizes four distinct piston
strokes (intake, compression, power, and exhaust) to complete one operating cycle. 
1. First Stroke: Intake Stroke or
Induction- the piston travels from
TDC to BDC with the intake
valve open and exhaust valve
closed. This creates an increasing
volume in combustion chamber,
which turn creates a vacuum.
2. Second Stroke: Compression
stroke- when the piston reaches
BDC, the intake valve closes and
the piston travels back to TDC
with all valves closed.
3. Third Stroke: with all valves
closed, the high pressure created by the combustion engine process pushes the piston away
4. Fourth Stroke: Exhaust stroke- by the time the piston reaches BDC, exhaust blow down is
complete with the exhaust valve remaining open, the piston now travels from BDC to TDC in
the exhaust stroke.

 The four-stroke cycle is presented in chart form below. Note the following:
• The piston direction has a distinct pattern.
• The intake valve is only open during the intake stroke.
• The exhaust valve is only open during the exhaust stroke.

Intake Compression Power Exhaust

Piston Down Up Down Up

Direction

Intake Valve Open Closed Closed Closed

Exhaust Valve Closed Closed Closed Open

Mixture Action Sucked In Being Squished Ignited Pushed Out

Remember ICPE: intake, compression, power, exhaust.

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 Learning Module in BTVTE-Automotive
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The cycle repeats itself. This order cannot change!

 The major products of the complete combustion of petroleum-based fuels in an internal

combustion engine are carbon dioxide (13%) and water (13%), with nitrogen from air
comprising most (73%) of the remaining exhaust. Some excess oxygen may be emitted,
depending on the operating conditions of the engine.

 Two-stroke (or two-cycle) engine is a type of internal combustion engine that completes a

power cycle with two strokes (up and down movements) of the piston during only one
crankshaft revolution. Compared to four-stroke engines, two-stroke engines have a greatly
reduced number of moving parts.

 The Diesel cycle is a combustion process of a reciprocating internal combustion engine. In

it, fuel is ignited by heat generated during the compression of air in the combustion chamber,
into which fuel is then injected. 

Activity 5.1

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 Learning Module in BTVTE-Automotive
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Name:________________________________ Date: ______________________________

Strand:_________________________________ Score: ______________________________
Direction: Draw and label the 2 and 4 stroke engine cycle.

4 Stroke Engine

2 Stroke Engine

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 Learning Module in BTVTE-Automotive
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Activity 5.2

Name:________________________________ Date: ______________________________

Strand:_________________________________ Score: ______________________________

Direction: Explain the following.

1. Explain the concept of 4 stroke engine cycle.

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2. Differentiate 2 stroke and 4 stroke engine cycle.

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3. What is TDC and BDC?

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4. Differentiate Diesel engine cycle and Gas engine cycle.

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5. Explain what is engine cycle.

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Lesson 6

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 Learning Module in BTVTE-Automotive
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Learning Objectives:
a. Identify what is gasoline and diesel engine.
b. Differentiate gasoline and diesel engine.
c. Explain the operation of gasoline and diesel engine.
d. Draw the engine cycle of gasoline and diesel engine.

Gasoline and Diesel Engine

History of the Gasoline Engine

Nikolaus Otto invented the gasoline engine and this four-stroke process. He was a German engineer
who patented this invention and named it the Otto Cycle.

In the early days of gasoline engines, there was a

component called a “carburetor” which was
responsible for mixing air with gasoline.
However, this older carburetor technology was
eventually replaced by a fuel-injection system
which is electronically linked to the engine
control unit of the vehicle.

In theory, diesel engines and gasoline engines are quite similar. They are both internal combustion
engines designed to convert the chemical energy available in fuel into mechanical energy. 

The diesel engine was invented by Rudolf Diesel while attending engineering school in Germany.
Rudolf was surprised how inefficient gasoline and steam engines were. The design of the diesel
engine was patented in 1892.
In a gasoline engine, the explosion
process is:
1. Intake stroke – fuel is mixed with
air
2. Compression stroke – piston
goes up, mixture of fuel and air is
compressed
3. Ignition stroke – fuel/air is
ignited through the use of a
spark plug
4. Exhaust stroke – piston goes up,
pushes exhaust through the
exhaust valve

In a diesel engine, the explosion process is:

1. Intake stroke – intake valve opens, air in, piston goes down
2. Compression stroke – piston goes up, air compressed (heated in excess of 540°C)
3. Combustion stroke – fuel is injected (right time), ignition, piston goes down
4. Exhaust – piston goes up, pushes exhaust through the exhaust valve

Remember that the diesel engine has no spark plug, that it intakes air and compresses it, and that it
then injects the fuel directly into the combustion chamber (direct injection). It is the heat of the
compressed air that lights the fuel in a diesel engine. 

Key Difference

Fuel Gasoline: Diesel:

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Faster ignition Higher energy density per gallon
Fuel is more readily available Less carbon monoxide produced
Higher levels of carbon dioxide Higher levels of soot and nitrogen
Lower of soot and nitrogen compounds
compounds
Ignition Gasoline: Diesel:
Utilizes spark plug igniters to Relies on compression to ignite
create combustion fuel rather than spark plugs.

Power Gasoline: Diesel:

More horsepower and torque More horsepower and torque
Generated at higher RMP’s generated at lower Rpm’s which
which translate to better translates to more pulling power
from a complete

Fuel Efficiency Advantage: Diesel

Department of Energy, diesel engines offer 30- to 35-percent greater fuel economy than comparable
gasoline engines. By design, diesel engines operate with a combustion process that's leaner, burning
less fuel than a conventional spark ignition (gasoline) engine. Diesel fuel also has higher energy
density than gasoline, which means less fuel is required to generate the same power as gas, improving
overall fuel economy.

Maintenance Cost Advantage: Gasoline

Over time, regular maintenance on a diesel generally will cost more than a gasoline engine. The
diesel engine has components that are either not found on a gasoline engine or require servicing more
often. Oil changes for a diesel engine cost more and are required more frequently. Filters are required
to be changed more often. Also, getting access to the engine and components can take longer,
resulting in higher labor costs.

Engine Lifespan Advantage: Diesel

Why are diesel engines expected to last substantially longer than comparable gasoline engines?
Diesel engines have high-compression ratios and high cylinder pressure and, as a result, require
sturdier engine parts - for example, block and cylinder heads, valves, crankshaft, and pistons.

This is necessary to dissipate the higher engine temperatures and the higher compression ratios
attained in a diesel engine. Also, a diesel engine's exhaust system will outlast a gas engine exhaust
system because diesel fuel exhaust is not as corrosive as gasoline engine exhaust. The diesel engine's
operating efficiency as another key to its longevity.

Activity 6.1

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Name:________________________________ Date: ______________________________

Strand:_________________________________ Score: ______________________________

Direction: Explain the following.

1. Explain the operation of gasoline and diesel engine.

___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________

2. Differentiate the gasoline and diesel engine. Use the table below.

Diesel Gasoline

Activity 6.3

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Name:________________________________ Date: ______________________________

Strand:_________________________________ Score: ______________________________

Direction: Draw the engine cycle of Gasoline and Diesel Engine and label its parts.

Lesson 7

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Learning Objectives:
a. Identify what is air and fuel induction system
. b. Determine the functions of intake manifold and intake valves.
c. Compare and contrast what are intake manifold and exhaust valves.
d. Generalize the air and fuel induction by explaining the intake manifold and intake valves.

Air and Fuel Induction System

This chapter describes intake systems of engines-how air and fuel are delivered into the cylinders.
The object of the intake system is to deliver the proper amount of air and fuel accurately and equally
to all cylinders at the proper time in the engine cycle. Flow into an engine is pulsed as the intake
valves open and close, but can generally be modeled as quasi-steady state flow.

Fuel systems
• Must deliver proper mixture of air and fuel to be burned efficiently
• Must store enough fuel so the car can complete a trip of a few hundred miles

Components of Air and Fuel Induction system

The primary function of the intake manifold is to evenly

distribute the combustion mixture (or just air in a direct injection
engine) to each intake port in the cylinder head(s). Even
distribution is important to optimize the efficiency and
performance of the engine.

Carburetor- is a device that mixes air and fuel for internal

combustion engines in the proper air–fuel ratio for combustion.

Fuel pump- pumps gasoline from

the vehicle's fuel tank to the engine and also distribute fuel under low
pressure to the carburetor or to the fuel injection system under higher
pressure.

Fuel tank- is a container or reservoir to carry fuel used by the vehicle.

Fuel Lines – are steel lines made of seamless tubing

• Run the length of the frame
• Transport fuel from tank to
engine
Fuel Hoses - used for flexible connection

Intake valve- is a valve that controls the amount of working fluid entering

the cylinder of an engine. When the intake valve for a particular cylinder is
open, the air flows through the throttle body, which is mounted on
the intake manifold.

Fuel induction service -is a maintenance procedure for your vehicle's engine. This process includes
cleaning the air intake valves, the throttle body, and fuel injectors. A mechanic will use special
cleaning substances to manually clean the valves. The proportion is dependent on the vehicle and the
computer's input.

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Air induction system is specifically used to maintain balance between air and fuel when it enters a
combustion chamber. This system is crucial in determining the performance of an engine.

Air Induction Service

What is Air Induction Service?

 Air induction service is a cleaning procedure to remove carbon buildup from your engine’s
throttle body and intake valves. The service can solve some performance related issues if
they’re caused by carbon buildup. 

How does an Air Induction Cleaning help my vehicle?

At Precision Tune Auto Care, we introduce a liquid cleaning agent into the air induction system. This
removes the carbon deposits and restores proper air flow into the combustion chamber, which will:
 Increase fuel efficiency.
 Increase performance.
 Reduce harmful emissions.
 Extend engine life.
 Increase catalytic converter efficiency.
 Intake valve cleaning for DI engines

Those same hot vapors can also cause carbon buildup on the back of intake valves. Over time, that
buildup can cause performance problems in the engine. Carbon buildup on the intake valves is far
more common on engines with DI because that type of fuel injection system injects fuel directly into
the combustion cylinder, as opposed to spraying fuel through the valve opening in a port injected
engine.
How intake valve cleaning is done
 The technician removes a vacuum line from your engine and attaches a dispensing device that
meters the flow of a special cleaner into the engine intake. The technician starts the engine
and opens the flow of the cleaner while increasing idle speed. 

Symptoms of carbon buildup

• Rough idle or hard starting caused by carbon buildup in the electronic throttle body. Make sure the
shop confirms that the carbon buildup is the cause of the rough idle before agreeing to the induction
cleaning service.
• Hesitation on acceleration caused by debris accumulation on the MAF sensor elements.
• Rough idle and lack of power caused by carbon buildup on the back of valves in DI engines.

Fuel induction services 

 Are recommended for most vehicles around 60k miles or so. Routine maintenance of
your fuel system can prevent many long term problems, engine damage, and cold starts. If
your car is showing these symptoms, it could mean you need a fuel induction service.
 Fuel induction service clears out the carbon deposits and other buildup that forms inside your
engine's parts. This makes sure they reduce the carbon on the intake valves, allowing for
better fuel flow into the combustion chamber, which will get better fuel mileage.

The stoichiometric mixture for a gasoline engine is the ideal ratio of air to fuel that burns all fuel with
no excess air. For gasoline fuel, the stoichiometric air–fuel mixture is about 14.7:1 i.e. for every one
gram of fuel, 14.7 grams of air are required.

Activity 7.1

Name:________________________________ Date: ______________________________

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Strand:_________________________________ Score: ______________________________

Direction: Differentiate the air and fuel induction system. Use the table below.

Air induction System Fuel Induction System

Activity 7.2

Direction: Explain the following.

1. What is Air and fuel induction system?
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
2. When do we need to perform air induction system?
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
3. What will happen if the carbon build ups on our intake valves?
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
4. What is the typical fuel ratio use in gasoline engine?
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
5. How do we know when the intake valves are already full of carbon?
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________

Lesson 8

Learning Objectives:

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a. Identify what is fuel injector,
b. Explain the operation of fuel injector.
c. Draw and label the parts of fuel injector.

Fuel Injector

A fuel injector is nothing but an electronically controlled valve. It is

supplied with pressurized fuel by the fuel pump in your car, and it is capable
of opening and closing many times per second. Inside a fuel injector.
A fuel injector is used to inject the fuel in the cylinder in atomized form and
in proper quantity.

Classification of Fuel injector

 Mechanical fuel injector- purely mechanical fuel injector for internal combustion engine
utilizes a single plunger within plunger barrel for fuel pumping , fuel/air mixing, and fuel
injection function.
Components
 Needle valve
 Compression spring
 Nozzle
 Injector body
Electronic fuel injector- electronic fuel injector through ECU signal to apply for the current or voltage
act on electromagnetic coil of fuel injector, then produce electromagnetic force, and enhance the
valve then opened and spraying fuel.
Components
 Electrical connection
 Electronic coil
 Magnet
 Nozzle- is that part of injector through which the liquid fuel is spread is spread into the
combustion chamber.

Types of nozzle
 Pintle
 Bosch disc injector
 Lucas disc injector
 Ball

Fuel Injection System

 Today’s modern engines are all fuel injected. Fuel
injection cleaning is a necessary maintenance service
required on today’s cars, trucks and SUVs.

Why do I need to clean my fuel injectors?

 Carbon deposits form on the fuel injectors during normal driving conditions. The injectors
particularly the injector nozzles – exist in an environment where tremendous heat is
generated. The burning of the fuel leaves carbon deposits on piston valves and fuel injector
nozzles that interfere with the spray pattern and flow of fuel. Cleaning the fuel injectors on a
regular scheduled maintenance program removes these deposits.

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How does a Fuel Injection Cleaning help my vehicle?
At Precision Tune Auto Care, we introduce a liquid cleaning agent into the injection nozzle. This
removes the carbon deposits and restores proper fuel flow into the combustion chamber, which will:
 Increase fuel efficiency.
 Increase performance.
 Reduce harmful emissions.
 Extend engine and fuel injector life.

Here are the 5 most common symptoms of faulty diesel fuel injectors.

 Trouble starting the vehicle or uneven idling. The engine cranks but doesn't start unless you
crank it for a long time
 Misfire
 Smell of fuel
 Dirty emissions
 Increased fuel consumption and poor miles per gallon

Diesel fuel injectors- generally have a shorter lifespan than their predecessors, meaning they need to
be replaced more frequently for optimal performance. The life expectancy of a good
quality diesel fuel injector is around 150,000 kilometers. They should be checked out by a
professional at around this time.

Activity 8.1

Name:________________________________ Date: ______________________________

Strand:_________________________________ Score: ______________________________

Direction: Explain the following.

1. What is fuel injector and explain its operation?

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__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
2. Differentiate the mechanical and electronic fuel injector
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
3. What are the types of injection nozzle?
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
4. Why do we need to service fuel injector?
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
5. When do we need to change fuel injector?
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
6. What is the acceptable spray of fuel injector?
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
7. Give the benefits injector cleaning and common symptoms of bad fuel injector and explain. Use the
table below.

Benefits of injector cleaning Symptoms of bad fuel injector

Activity 8.2

Name:________________________________ Date: ______________________________

Strand:_________________________________ Score: ______________________________

Direction: Draw and label the parts of Fuel Injector.

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 Learning Module in BTVTE-Automotive
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Lesson 9

Learning Objectives:
a. Identify what is supercharger and turbocharger,
b. Explain the operation of supercharger and turbocharger,
c. Differentiate the supercharger and turbocharger,
d.. Draw and label the parts of supercharger and turbocharger.

Supercharger and Turbocharger

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INTAKE SUPERCHARGER
 Is an air compressor that increases the pressure or density of air supplied to an internal
combustion engine.
 This give each intake cycle of the engine more oxygen letting it burn more fuel and do more
work, thus increasing power.
 Power for the supercharger can be provided mechanically by means of belt, gear, shaft, or
chain connected to the engine’s crankshaft.
A basic engine with the additional of a supercharger
 1. The piston moves down.
 2. This create a vacuum.
 3. Air and atmospheric pressure is sucked into the combustion chamber.
Once air drawn into the engine, it must be combined with fuel to form the charge, a packet of
potential energy that can be turned to useful kinetic energy through a chemical reaction
known as combustion.
Superchargers increase intake by compressing air above atmospheric pressure without creating
vacuum. This forces more air into the engine, providing boost with the additional air in the boost,
more fuel can be added to the charge and the power of the engine is increased. Supercharging adds an
average of 46 percent more horsepower and 31 percent more torque.

In high altitude situations, where engine performance deteriorates because the air has low density and
pressure, a supercharger delivers higher pressure air to the engine so it can operate optimally

TYPES OF SUPERCHARGER
There are three types of superchargers: Roots, twin-screw and centrifugal. The main difference is how
they move air to the intake manifold of the engine. Roots and twin-screw superchargers use different
types of meshing lobes, and a centrifugal supercharger uses an impeller, which draws air in.

 CENTRIFUGAL SUPERCHARGER

Is made up of several key components, each working together to compress

air and boost the engine’s performance by increasing airflow through the
engine.
The main components for any centrifugal supercharger include the:
1. Impeller
2. Gears
3. Pulley
4. Bearings
5. Housing
6. Aeration oil pump

 ROOT
TYPE

 SCREW TYPE

Parts of Centrifugal Supercharger

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Advantages of Supercharger
 Self-contained
 Easy to install
 Less pieces in general
 Set it and forget it for boost
 Great for a beginner who is
learning

Disadvantages of Supercharger
 Less tuning capabilities
 Less power under the curve

Maintenance Tips

Since superchargers eat up gas, be sure to check fuel levels. A supercharger belt has a life expectancy
of 80,000-110,000 km, and should be replaced before reaching this point. Oil should be changed after
every 160,000 km (a harder working engine requires more protection!)

TURBOCHARGER
 Known as a turbo
 Is a turbine-driven force induction device that increase an internal combustion engine’s
efficiency and power output by forcing extra compressed air into combustion chamber.
 Originally known as turbo supercharger when all forced induction device were classified as
superchargers.
 Today the term “supercharger” is typically applied only to mechanically driven forced
induction devices.
 Turbocharger are commonly used on truck, car, train, aircraft and construction equipment
engines.
PARTS OF TURBOCHARGER
 Compression Housing
 Compressor Wheel
 Turbine Shaft
 Turbine wheel
 Turbine Housing

ADVANTAGES OF
TURBOCHARGER
 Increase Horsepower of
Engine
 Better Fuel Economy
 Size and Weight
 Increase Overall Efficiency of
Engine

Disadvantages of Turbocharger
 Turbo Lag
 Excessive Heat
 Expensive Addition to the
System
 More Maintenance Required

Intake Supercharger Diagram

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Exhaust Turbocharger Diagram

Activity 9.1

Name:________________________________ Date: ______________________________

Strand:_________________________________ Score: ______________________________

Direction: Explain the following.

1. Explain the operation of supercharger and turbocharger.

__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
2. What are the advantages of supercharger and explain.
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
3. As a automotive student which one do you prefer? Supercharger or turbocharger? Depend your
answer.
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________

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__________________________________________________________________________________________
__________________________________________________________________________________________
4. Differentiate the supercharger and turbo charger. Use the table below.

Supercharger Turbo charger

Activity 9.2

Name:________________________________ Date: ______________________________

Strand:_________________________________ Score: ______________________________

Direction: Draw and label the parts of supercharger and turbo charger.

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References :
Pulkrabek,W. (2007). Engineering Fundamentals of the Internal Engine Combustion
Crouse- Anglin Auto Mechanics 10th edition

-------------------------------------------------End of Module 1---------------------------------------- -------

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