Automobile L 6

AHSANULLAH UNIVERSITY OF SCIENCE
AND TECHNOLOGY (AUST)
ME-4203: AUTOMOBILE ENGINEERING

BY
Dr. Abu Hamja
Assistant Professor, Dept. of MPE, AUST
Acknowledgment:
Fazlar Rahman; Asst. Prof.; AUST
ME-4203 (Automobile Engineering)
Engine Construction (Chapter ‐13):
 Piston Engine Construction (13‐1):
o SI and CI engines are similar in construction. The basic parts of engine
construction are:
 Cylinder blocks
 Cylinder heads
 Crankshafts
 Bearings
 Piston,
 Connecting rod
 Valve train
o CI (Diesel) engines are more heavier and stronger than SI engine due
to higher internal pressure in the combustion chamber.
 Cylinder Block (13‐2):
o Cylinder block is the foundation of the engine. All other parts of the
engine are assembled or attached to the cylinder block.
o Cylinder blocks are made of cast iron with nickel and chromium alloy
and some blocks are made of aluminum alloy.
2
o Cylinder blocks include large hole for cylinder bores and water jackets
and coolant passages. Water jackets are the spaces between cylinder
bores and the outer shell of the block.
3
Fig. 13‐2:
 Internal parts of a cylinder block for an inline four cylinder engine.
 Honda Motor Company, Inc
4
 The core clean‐out holes are used to facilitate removal of sand‐core for
water jacket during casting of cylinder blocks. The holes are sealed with
plugs during manufacturing which are called core plugs, freeze plugs or
expansion plugs. If coolant in the block starts to freeze, coolant expands
and pushes the plugs out. This provide some protection against crack of
block.
5
 Machining of Cylinder Block (13‐3):
 Holes are drilled for attaching various parts
 Cylinders are machined and finished.
 Camshaft‐bearing holes are bored.
 Surfaces to which parts are attach are machined and finished.
 Oil passages are drilled.
 Valve‐lifter bores are machined (for pushrod engines).
 Coolant passages are cleaned out.
 Parts Attached to and Installed in Block (13‐4):
 Following steps are followed to installed parts in the cylinder block:
 Crankshaft & main bearing are attached to the bottom of block.
 Piston, rings, piston pin are attached at small end of the
connecting rod.
 Big end of the connecting rod and rod bearing are attached to the
crankpin of the crankshaft by rod nuts.
 After installing all other parts, cylinder head, valves and camshaft
are assembled.
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 Parts Attached to and Installed in Block (continue):
 After adjustment of bearing and installation of head oil pump and
oil pan is attached.
Fig. 13‐4:
 Piston, Piston ring and connecting rod assembly.
 Honda Motor Company, Inc
7
 Oil Pan (13‐5):
 Oil pan is made of plastic or metal. It enclose the crankshaft and
bottom of cylinder block.
 Gasket is installed between the oil pan and block to seal the joint
and prevent oil leaks.
 It hold about 3 to 8 L of oil depending on size of the engine.
 Oil pump is normally installed in the oil pan to circulate oil from
the pan to the all moving parts.
 Some engine has acoustical oil pan. A damping material or
stamped‐steel inserts attach to the flat surfaces inside the pan,
which prevents vibration and noise from reaching to the
passengers.
(Fig. 13‐2)
8
 Oil Pan (13‐5): Continue
Fig. 13‐6:
 Acoustic oil pan.
 Plastic and stamped steel
insert absorb engine noise
and vibration.
 Chrysler Corporation.
9
 Aluminum Cylinder Block (13‐6):
 Most cylinder blocks are made of aluminum.
 Aluminum is also too soft to use as cylinder‐wall material.
 So a cast‐iron or aluminum alloy containing silicon particles is used as
cylinder liners to prevent wear of the cylinder wall.
 Cylinder liners are either cast into the block or installed later.
 The wet and dry liners are installed later.
 Dry liners are pressed in along full length of the cylinder bore.
 Wet liners touch the cylinder block only at the top and bottom. The rest of
the liners touches only the coolant.
 Both dry and wet liners can be replaced if they become worn or damaged.
 Aluminum is used to make most engine cylinder block. Because of
its light weight, good thermal conductivity; and it also improve fuel
efficiency.
10
 Aluminum Cylinder Block (13‐6): Continue
Fig. 13‐7:
 Wet cylinder liners uses in
Diesel engine.
 Peugeot Motors of America,
Inc.
11
 Aluminum Cylinder Block without liners (13‐7):
 Some manufacture such as Mercedes‐Benz, Porsche use aluminum cylinder
block without liners.
 Those manufacturer use silicon with aluminum to make cylinder block.
Silicon is very hard material. After casting the block, cylinders are honed.
 After honing, cylinders are treated with a chemical that eats away (or
etches) the aluminum surface and leaves only silicon in the cylinder wall.
 Piston and ring slide on the silicon particles with minimum wear.
Fig. 13‐8:
 Enlarged view of an aluminum
cylinder wall.
 Al is etched away, exposing only
silicon (hard particles) in the wall.
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 Cylinder Head (13‐8):
 Cylinder heads are cast from cast iron or aluminum alloy. After casting,
cylinder head is machined to installed various parts.
 Cylinder head forms the top of the combustion chamber and piston &
piston ring forms the bottom of the combustion chamber.
 There are some differences in shape and construction of cylinder head for
OHV (Over Head Valve) engine and OHC (Over Head Camshaft ) engine.
 The shape of upper combustion chamber has specific effect.
Fig. 13‐10: Shapes of combustion chamber.
13
 Cylinder Head (13‐8): Continue
Fig. 13‐5:
 Cylinder head for
an OHC four
cylinder engine.
 Mazda Motors of
America, Inc.
14
Fig. 13‐9:
 Cylinder head for an
OHV four cylinder
engine.
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 Wedge shape increases the turbulence of the burning mixture but it has high
exhaust emission.
 Hemispheric provides relatively slow burning .
 Cup or bowl‐in‐piston improves turbulence in diesel, turbocharged and high
performance engines. Cylinder head is flat.
 The height and shape of the crescent or pent‐roof is easily varied to change
the compression ratio and turbulence.
 Greater turbulence causes the air‐fuel mixture to burn faster.
16
Acoustic Cylinder head or valve covers:
 Valve covers or cylinder‐head covers are stamped from three‐layer sheets.
 Two outer layers is made of metal and middle layer is plastic.
 Noise from the engine causes the inside metal layer to vibrate and middle
plastic layers prevents noise and vibration from reaching the passengers
chamber.
Fig. 13‐11:
 Acoustic Valve Cover.
17
 Cylinder‐Head Casket (13‐9):
 Cylinder head gasket seals the joint between the cylinder head and the
cylinder block.
 Head‐gasket installation becomes extremely important in sealing between an
aluminum head and a cast‐iron block.
 Gasket ensured leak‐proof combustion chamber.
 Swirl‐Type Combustion Chamber (13‐10):
 Improve turbulence some engine uses a high‐swirl intake port and masked
intake‐valve seat.
 This arrangement causes the incoming air‐fuel mixture to move rapidly in a
circular pattern (Fig. 13‐12).
 Some engine uses a small jet valve or auxiliary intake valve which admits a jet
or stream of air into the combustion chamber. This creates additional
turbulence and reduces exhaust emissions (Fig. 13‐13).
18
 Swirl‐Type Combustion Chamber (13‐10): Continue
Fig. 13‐12:
 High‐swirl intake port.
 Mazda Motors of America, Inc.
Fig. 13‐13:
 Swirl action with auxiliary intake
valve or jet valve.
19
 Pre‐combustion Combustion Chamber (13‐11):
 Some engine use a pre‐combustion chamber which is a separate small
combustion chamber where combustion begins.
 Primary intake valve opens into the main combustion chamber and auxiliary
intake valve opens the pre‐combustion chamber. Both valve open at the same
time.
 Auxiliary valve admits rich mixture and primary valve admits a lean mixture.
 Spark plug installed in the pre‐combustion chamber which ignites the rich
mixture. It streams out and mixes with the lean mixture which causes high
turbulence and good combustion.
 Stratified‐charge engine:
 SI engine with pre‐combustion chamber is known as stratified‐charge
engine.
 Ignition begins in a layer or pocket of rich mixture which is surrounded
by leaner mixture (example only air in diesel engine).
 Leaner average air‐fuel ratio provides greater fuel economy and less
exhaust emissions.
 Diesel engine is an example of stratified‐charge engine.
20
 Pre‐combustion Combustion Chamber (13‐11): Continue
Fig. 13‐14:
 Stratified‐charge spark‐ignition
engine.
 Honda Motor Company, Inc.
21
 Exhaust Manifold and Exhaust System (13‐12):
 Exhaust manifold is a set of tubes which carries exhaust gas from the cylinder
head to the exhaust system.
 It is installed in between exhaust port of the cylinder head and exhaust pipe.
 In‐line engine required one exhaust manifold but V‐type and opposed‐
cylinder engine required two exhaust manifolds.
 In V‐type engine two exhaust manifolds are connected through a crossover
pipe.
 Exhaust gases are flow from the exhaust manifold to the muffler through a
catalytic converter.
 Muffler and resonator reduce the exhaust noise.
 Catalytic converter converts most of the pollutants in the exhaust gas to a
harmless gases.
Fig. 13‐15:
 Lower part of Fig. 13‐15
22
 Exhaust Manifold and Exhaust System (13‐12): Continue
Fig. 13‐16:
 Single exhaust system for V‐type engine with catalytic converter.
 Oldsmobile Division of General Motors corporation.
23
 Exhaust Manifold and Exhaust System (13‐12): Continue
Fig. 13‐17: Exhaust manifold for an inline six‐cylinder engines that uses a heat control valve.
24
 Intake Manifold (13‐13):
 A set of tubes which carry air or air‐fuel mixture from the throttle valves to
the intake ports in the cylinder head.
 In inline engines, the intake manifold attaches to the opposite side of the
cylinder head (Fig. 13‐9).
 Some engines have intake and exhaust manifold on the same side of the
engine (Fig. 13‐15).
 In V‐type engines, the intake manifold is between the two banks of cylinders
(Fig 12‐11).
 Some carbureted in‐line engines have a heat‐control valve in the exhaust
manifold which provides heat to the air‐fuel mixture in the intake manifold
while the engine is cold. This improves fuel vaporization for better cold‐engine
performance.
 Some V‐type engines have an exhaust‐gas passage that runs across the intake
manifold under the carburetor mounting pad. When engine is cold, heat
control valve forces exhaust gas to flow from the cylinder bank to the
passage. This heats the air‐fuel mixture entering the intake manifold (more in
section 21‐22).
25
 Intake Manifold (13‐13): Continue
Fig. 13‐9:
 Exhaust and intake manifolds are
opposite side of engine cylinder head.
converter.
26
Fig. 13‐15:
 Exhaust and intake manifolds are attached
on the same side of cylinder head.
 OHV Six cylinder engine.
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Fig. 12‐11 (Alternative):
 Intake manifolds in between two cylinder block.
 Exhaust manifolds on opposite side of cylinder head.
28
Fig. 13‐17:
 6 cylinders engine.
 Exhaust manifolds uses a heat‐control valve.
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 Crankshaft (13‐14):
 Crankshaft is made of one piece casting or forging of heat‐treated alloy steel
(Fig. 13‐2 & 13‐18).
 Counter‐weights placed opposite the cranks pins balance the crankshaft (Fig.
13‐19).
 Crankshaft of some V‐6 engines have spread out or splayed crankpins. A
splayed crankpin is split into two parts (Fig. 13‐19, top). Each connecting rod
has its own crankpin. This reduces out‐of‐balance conditions.
Fig. 13‐19, Bottom: Crankshaft. Fig. 13‐2: Crankshaft.
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 Crankshaft (13‐14): Continue
Fig. 13‐18:
 Oil holes drilled through Crankshaft to carry oil from the main bearing
to the connecting‐rod bearings.
 Toyota Motor Sales, USA, Inc.
31
Fig. 13‐19:
 Splayed Crankpins.
 Buick Division of General Motors
Corporation.
 A flywheel or drive plate is attached to the output end of crankshaft.

 Gear or sprocket (to drive camshaft), vibration damper and drive‐belt pulley
are attached with front end of crankshaft.
 Engines with a distributor less ignition system or an electronic engine control
(EEC) system have a notched plate or timing disc on the crankshaft. A
crankshaft sensor (Fig. 12‐3) signals the passing of the notches to the
computer in EEC system. The computer then uses this information to calculate
engine speed (crankshaft rpm) and piston position.
32
Fig. 13‐20:
 Crankshaft with vibration damper, flywheel or drive plate.
33
 Vibration Damper (13‐15):
 In each power stroke, thrust on crankpin may exceed 4000 pounds or 18000 N
which try to twist the crankshaft. This force tries to push the crankpin a head
of other portion of the crankshaft. Again, when force on the crankpin is
reduces, the crankshaft is untwists. This twist and untwist action repeats in
every power stroke. This action tends to create an oscillating (back and forth)
twisting in the crankshaft. This is called torsional vibration and it can break the
crankshaft.
 To reduced the torsional vibration in the crankshaft a vibration damper or

harmonic balancer is attached at front end of the crankshaft. This forms the
hub to which the crankshaft pulley attaches. The inertia ring is bonded
through the rubber ring to the pulley. The inertia ring has a damping effect
which tends to hold the crankshaft to a constant speed and cancels the twist‐
untwist action oscillating in the crankshaft (Fig. 13‐20).
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 Engine Bearing (13‐16):
 Bearings are installed in the engine, where rotary motion exists between two
engine parts. These bearings are usually sleeve bearings that fit like sleeves
around the rotating shaft. The part of the shaft that rotates in the bearing is a
journal.
 Crankshaft and connecting rod bearing are split into two parts. One haft of
connecting rod bearing fits into the connecting rod and other half into the rod
bearing cap (Fig. 13‐4 & 11‐8).
 One half of the crankshaft or main bearing fits into a semicircle machined in
the cylinder block and other half fits into the main bearing cap (Fig. 13‐23).
 Each bearing has a steel or bronze back with up to five linings of soft bearing
material. The bearing wears but not the more expensive crankshaft or other
parts. This reduces the cost of repair by allowing the reuse of the more
expensive parts.
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 Engine Bearing (13‐16): Continue [ See Fig. 13‐4 too].
Fig. 11‐7: Connecting Rod Bearing . Fig. 11‐8: Connecting Rod Bearing .
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 Engine Bearing (13‐16): Continue
Fig. 13‐23: Main Bearing of Crankshaft .
Fig. 13‐22: Connecting Rod & Main Bearing.
37
 Thrust Bearing (13‐17):
 Thrust bearing limits crankshaft endplay. Main bearing has flange on both
sides.
 Flanges on the crankshaft fit close to the thrust bearing flanges, which limits
the forward and rearward movement of the crankshaft.
Fig. 13‐22: Thrust type Main Bearing.
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AHSANULLAH UNIVERSITY OF SCIENCE

AND TECHNOLOGY (AUST)

ME-4203: AUTOMOBILE ENGINEERING

 A flywheel or drive plate is attached to the output end of crankshaft.

 To reduced the torsional vibration in the crankshaft a vibration damper or

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