M17-Combustion Engines (Zadco-AHRT)

ZIRKU ISLAND TRAINING
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MECHANICAL TRAINING SECTION
COMBUSTION
ENGINES
PART 1A
THE COMBUSTION ENGINE
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COMP. REF.: REVISION 01 PAGE 1 of 40
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TABLE OF CONTENTS
Para Page
1.0 OBJECTIVES
1.1 INTRODUCTION
1.2 THE PISTON ENGINE
1.2.1 The upper engine
1.2.2 The lower engine
1.2.3 The four-stroke process
1.2.4 The valve-timing system
1.2.5 Two-stroke engines
1.2.6 The diesel engine
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1.0 OBJECTIVES
The trainee will be able to:
 Name the parts of an internal combustion engine and state their

function.
1.1 INTRODUCTION
Over one hundred years ago a new type of engine was built. This new
engine was smaller and lighter than the normal steam engine. The steam
engine was the engine in use at that time, and needed a supply of coal
and water to operate. The new engine needed no water or coal. Instead,
it used a mixture of air and gas. It was in fact the first internal
combustion engine.
Today, the modern internal combustion engine powers nearly all the
world's cars, trucks and trains. It is also used in aeroplanes and industrial
machinery. The internal combustion engine started a revolution in
transportation and mechanisation. This revolution is still taking place.
1.2 THE PISTON ENGINE
An engine is an energy converter. That is, all engines convert, or change

chemical energy into mechanical energy. An engine frees chemical
energy in the fuel. Then the engine converts the fuel's energy into
mechanical motion. All engines convert fuel into motion. For example, a
car engine uses the energy from the petrol to turn the car's wheels.
Engines mix fuel with air. The mixture of fuel and air is burnt in the
engine. This burning is called combustion. Combustion releases the
fuel's chemical energy. All engines use combustion.
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In the internal combustion engine, combustion takes place inside the

engine. That is, combustion takes place internally. (see figure 1.1).
Figure 1-1.
Early engines, such as the steam engine, used external combustion.

However, modern piston engines are internal combustion engines.
Inside the piston engine, combustion creates pressure. This pressure

pushes against the piston. As a result, the piston moves. Pistons are made
of steel or aluminium alloy.
1.2.1 The upper engine
The main parts of the upper engine are the cylinder block and the
cylinder head.
The cylinder block is the largest piece of metal. The metal is usually
cast-iron, but sometimes aluminium is used. Holes are machined, or cut,
into the cylinder block. Moving parts operate inside these holes. The
holes in the cylinder block are cylinders. (see figure 1.2)
Figure 1-2.
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Each cylinder contains a piston. The piston reciprocates, or moves up or

down, inside the cylinder. Piston rings fill the gap between the piston
and the cylinder wall The piston rings stop the pressure of the
combustion from being released. (see figure 1.3).
Figure 1-3.
Combustion does not begin in the cylinder. Combustion begins in the

cylinder head. The cylinder head is a smaller block. It is attached to the
top of the cylinder block. (see figure 1.4).
Figure 1-4.
Ports, or holes, in the cylinder head allow fuel and air to enter the
combustion chamber. During combustion, gases are produced. After
combustion, these gases leave the combustion chamber through different
ports.
The upper engine contains, or controls, the combustion and uses it for
work. Inside the upper engine, chemical energy of fuel is converted into
the motion of the piston.
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1.2.2 The lower engine
Reciprocating motion is an up-and-down motion. Rotating motion is a

turning motion. (see figure 1.5).
Figure 1-5.
The lower engine changes the piston's reciprocating motion into rotating
motion. The lower engine does not itself convert energy. Instead, it
changes the piston's motion into a more useful form of motion.
The bottom of the piston is attached to an arm. This arm is called a

connecting rod. (see figure 1.6).
Figure 1-6.
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The end of the connecting rod is attached to the crankshaft. The

crankshaft is free to rotate. When the piston moves, the connecting rod
turns the crankshaft. (see figure 1.7).
Figure 1-7.
The turning crankshaft transfers the piston's energy outside the engine.
Each time the piston goes down, the connecting rod pushes the crankshaft
through 180º. This downward movement of the piston is called a stroke.
The crankshaft then rotates another 180º, and the piston returns to the top
of the cylinder. This upward movement is another stroke. Each time the
piston reciprocates, or moves through two strokes, the crankshaft turns
through 360º. (see figure 1.8).
Figure 1-8.
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1.2.3 The four-stroke process
Each time the piston reciprocates, it turns the crankshaft through 360º. In
most engines, the piston must reciprocate twice to produce mechanical
energy. In other words, the engine needs four piston strokes to convert
fuel into motion. This process is called the four-stroke process. Four -
stroke engines are the most popular type of piston engine.
The first stage of the four -stroke process is the intake stroke. During the
intake stroke, the piston descends, or goes down. As the piston descends,
a valve opens. This intake valve operates like a window. A window
opens to let air into a room. In much the same way, the intake valve
opens and shuts an intake port. It opens to let fuel mixture (fuel and air)
into the combustion chamber. As the piston descends, more fuel and air
are taken into the combustion chamber. During the intake stroke, the
piston turns the crankshaft through 180, but no new energy is converted.
(see figure 1.9)
Figure 1-9.
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During the next stroke, the piston returns to the top of the cylinder. As the
piston goes up, it pushes the fuel and air into a smaller space together.
This is called compression. During the compression stroke, the volume
of the fuel mixture is reduced, or made smaller. Pressure is increased
inside the combustion chamber. Under pressure, the temperature of the
mixture rises to about 300C (degrees Centigrade). As a result, the
mixture becomes explosive. After the intake stroke and the compression
stroke, the engine is ready for combustion. (see figure 1.10).
Figure 1-10.
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During the combustion stroke, the fuel mixture is ignited in the

combustion chamber. It is ignited by a sparking plug. The sparking plug
makes the compressed mixture explode. Hot, expanding gases push the
piston down. Thus chemical energy is converted into mechanical energy.
Work is done by the combustion stroke. In the four-stroke process only
the combustion stroke does work. For this reason the combustion stroke
is often called the power stroke. (see figure 1.11).
Figure 1-11.
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The exhaust stroke is the final stage of the four stroke process. A valve
opens the exhaust port over the combustion chamber. The piston rises,
and pushes exhaust gases out of the cylinder. These used gases are the
waste products of combustion. During the exhaust stroke, the piston also
sweeps, or cleans, the cylinder. This action is called scavenging. (see
figure 1.12).
Figure 1-12.
After the exhaust stroke, the piston begins the process again with the
intake stroke. The piston travels through four strokes. But it receives
energy during only one stroke. How, then does the piston continue to
move?
After combustion, the piston has kinetic energy, or energy of motion. It

transfers some of this energy to the crankshaft. As a result, the crankshaft
starts to rotate. At the end of the crankshaft is a heavy wheel, called a
flywheel. The flywheel rotates with the crankshaft. The weight of the
flywheel keeps the crankshaft in rotation. Other weights called
counterweights are situated along the crankshaft. These counterweights
also help to keep the crankshaft in rotation.
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During the combustion stroke, then, the piston moves the crankshaft. But
during the other three strokes, the turning crankshaft moves the piston. In
an engine with more than one cylinder, combustion stokes are more
frequent. As a result, the crankshaft operates more smoothly.
1.2.4 The valve-timing system
The valves must open at the correct time. They must also close at the
correct time. The second function of the crankshaft is to control the
timing of the valves. The crankshaft controls the valves by turning a
camshaft. (see figure 1.13).
Figure 1-13.
When the cams on the camshaft rotate, they move pushrods up and
down. (see figure 1.14).
Figure 1-14
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The pushrods then open the valves by operating rocker arms. The valves
are closed by springs. By means of the valve-timing system the lower
engine controls the valves in the upper engine. (see figure 1.15).
Figure 1-15.
Sometimes, in modern four-stroke engines, the camshaft is located in the

upper engine. The camshaft operates the rocker arms directly, without
pushrods. Engines of this type are called over-head camshaft engines or
OHCs.
1.2.5 Two-stroke engines
Not all piston engines use the four-stroke process. Many small piston
engines convert energy in a two-stroke process. These engines are called
two-stroke engines.
In two-stroke engines, intake and compression happen during the same

piston stroke. Combustion and exhaust happen during a second piston
stroke. In this way, two-stroke engines convert fuel into motion each time
the piston reciprocates. With each 360 of crankshaft rotation, the engine
converts energy.
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Inside the two-stroke engine, the piston rises during the first stroke. As it
rises, the piston compresses the fuel-air mixture above it. The volume of
the mixture is reduced. Pressure in the combustion chamber rises. This
compression phase is the first part of the first stroke. (see figure 1.16).
Figure 1-16.
As the piston continues to rise, it uncovers the intake port. The ports in
two-stroke engines are not located in the combustion chamber. They are
located in the cylinder wall. When the piston is up, the port is uncovered.
There is, therefore, no need for valves. When the intake port is
uncovered, fuel mixture enters the cylinder below the piston. Now there
is fuel both above and below the piston. The first stroke ends with this
intake phase. The piston is now at the top of the cylinder. (see figure
1.17).
Figure 1-17.
During the combustion phase the sparking plug ignites the compressed
mixture. The explosion pushes the piston down. At this point, the engine
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produces mechanical energy. As the piston descends, it uncovers the

exhaust port. The exhaust gases begin to escape from the engine. At the
same time, the new mixture below the piston is compressed. (see figure
1.18).
Figure 1-18.
In the last phase, the piston continues its downward movement. As the
piston descends, it uncovers the transfer port. The new fuel mixture
travels through the transfer port into the combustion chamber. This new
mixture pushes the remaining exhaust gases through the exhaust port.
This is the end of the transfer-exhaust phase. Then the piston rises,
compression takes place and the two-stroke process begins again. (see
figure 1.19).
Figure 1-19.
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Because they do not have valves or valve-timing systems, two-stroke

engines are lighter and simpler than four-stroke engines. Therefore, two-
stroke engines cost less to manufacture. They are normally used for small
boats, motorcycles, pumps etc. (see figure 1.20).
Figure 1-20.
Large two-stroke engines are not economical to operate. This is because

fuel is lost in the transfer-exhaust phase. During this phase, new mixture
escapes through the exhaust port. Heat is another problem with two-
stroke engines. In these engines, combustion occurs more frequently than
in four-stroke engines. Therefore two-stroke engines operate at higher
temperatures. As a result, they wear, or get old with use, more quickly.
1.2.6 The diesel engine
As pressure rises, temperature rises. Inside the engine, pistons compress

the fuel-air mixture. Therefore, the mixture’s temperature rises during
compression. Then the sparking plugs ignite the mixture. What happens
in an engine with no sparking plugs? If the pressure continues to rise, the
temperature of the mixture will continue to rise. At a certain temperature,
the mixture will ignite by itself.
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These ideas came to Rudolph Diesel at the end of the nineteenth century.
He built a new type of engine. These diesel engines were strong enough
to contain great pressure. In diesel engines, high temperature which is the
result of high pressure, ignites the fuel. Diesel engines use diesel fuel.
Diesel fuel is heavier than petrol.
The diesel engine is an internal combustion engine. Therefore, it needs a

fuel induction system. The fuel induction system in the diesel engine is
different from the fuel induction system in the petrol engine. This is
because diesel engines use the four-stroke process differently.
During the compression stroke, the petrol engine compresses fuel mixed
with air. But the diesel engine compresses only air . When the air is
compressed, it becomes very hot. A fuel injector then pushes fuel into
the combustion chamber. Combustion occurs immediately. Because the
fuel is mixed with air inside the cylinders, diesel engines do not need
carburettors. (see figure 1.21).
Figure 1-21.
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Diesel engines have to contain great pressure. Because of this, diesel

engines are heavier and more expensive than petrol engines. However,
diesel engines use less fuel. In addition, diesel fuel is cheaper than petrol.
The diesel engine is very economical to use.
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COMBUSTION
ENGINES
PART 1B
THE COMBUSTION ENGINE
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PARTS IN THIS COURSE
PART 01A THE COMBUSTION ENGINE
PART 01B THE COMBUSTION ENGINE
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TABLE OF CONTENTS
Para Page
1.3 SUPPORTING SYSTEMS
1.3.1 The Fuel Induction System
1.3.2 The Cooling System
1.3.3 The Lubrication System
1.3.4 The Exhaust System
1.3.5 Anti-Pollution Devices
1.3.6 Ignition System
1.4 OTHER TYPES OF INTERNAL COMBUSTION ENGINE
1.4.1 The Rotary Piston Engine
1.4.2 The Turbine Engine
1.5 MEASURING THE ENGINE
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1.3 SUPPORTING SYSTEMS
The basic piston engine cannot operate alone. The engine must be cooled.
Fuel must be brought to the engine. Electricity must arrive at the sparking
plug at the correct moment. Exhaust gases must be removed from the
engine. The engine’s supporting systems perform all these operations.
1.3.1 The Fuel Induction System
Fuel is brought to the engine through the fuel induction system. Fuel is
kept in a fuel tank. Because fuel is explosive and dangerous, the fuel
tank is placed away from the engine (see figure 1.22).
Figure 1-22
Fuel is pushed to the engine by the fuel pump. As the fuel is pumped to
the engine, it passes through a fuel filter. The fuel filter cleans the fuel
before it enters the engine.
Before entering the engine, fuel must be mixed with air. Combustion
cannot occur without oxygen from the air. The carburettor mixes fuel and
air (see figure 1.23).
Figure 1-23
Inside the carburettor the fuel first enters the float chamber. From the
float chamber the fuel passes through a fuel jet. The fuel jet is a very
small tube connecting the float chamber to the throat. Air enters the
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carburettor through the throat. In the throat the air moves past the fuel jet.
The air pulls fuel from the jet into the throat.
As the air pulls fuel from the jet, the fuel breaks up into tiny drops or
particles. These particles remain suspended in the air. Thus the fuel
enters the engine as a vapour.
Below the fuel jet, there is a valve. This valve is the throttle. It controls
the quantity of vapour passing into the engine. When the throttle opens,
engine speed increases (see figure 1.24).
Figure 1-24
A second valve is located at the top of the carburettor. This valve is

called the choke. The choke reduces the quantity of air in the mixture.
With less air, the mixture becomes ‘rich’ with fuel. A ‘rich’ mixture
helps a cold engine to start.
From the carburettor, the fuel mixture passes into the intake manifold.
The intake manifold distributes fuel mixture to the combustion chambers
(see figure 1.25).
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Figure 1-25
1.3.2 The Cooling System
The engine cannot convert all the energy from combustion into motion.
Some combustion energy is lost as heat. This heat is wasted. It does not
perform useful work. Instead, it heats the engine itself. Too much heat
will damage the engine. The heat must be removed. The cooling system
performs this operation.
Liquid-cooling systems are the most common. In these systems, a liquid

takes heat away from the engine. The liquid is called a coolant. A
water-pump pushes coolant around the engine. The coolant circulates
through water-jackets. As the coolant circulates, it becomes hot. It takes
heat from the engine. Then the coolant leaves the engine (see figure
1.26).
Figure 1-26
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After the coolant leaves the engine, it enters the radiator. The radiator
exposes hot coolant to the air. A fan draws more air through the radiator.
In this way, the coolant transfers its heat to the air (see figure 1.27).
Figure 1-27
Water may be used as a coolant. But in cold weather water freezes.

When water freezes, it expands. Expanding water can damage the engine.
Therefore, the coolant needs an anti-freeze, such as ethylene glycol.
Anti-freeze prevents the coolant from freezing.
In air-cooling systems, the heat of the engine is transferred directly to the

air. Some air cooled engines have fins (see figure 1.28).
Figure 1-28
These fins expose more of the engine surface to the air. Motorcycle and
aeroplane engines are normally exposed to air. Therefore, they often use
air-cooling systems.
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1.3.3 The Lubrication System
When one surface moves on another surface, heat is produced. This heat
is the result of friction between the two surfaces. Because piston engines
have many moving parts, friction heat is produced. Too much friction
heat will damage the engine.
Because of friction heat, the engine needs a lubricant, such as oil. The
lubricant reduces friction between the moving parts. The lubrication
system distributes oil around the engine.
Lubrication also saves energy. This is because lubricated parts move

more easily. In addition, lubrication gives the engine longer life because
the moving parts wear more slowly. Also, the lubricant takes heat away
from the engine. Finally, the lubricant removes dirt from the inside of the
engine.
In four-stroke engines, oil is kept below the crankshaft. The crankshaft

throws the oil into the upper engine. There it lubricates the pistons,
cylinders and other parts. Then the oil returns to the lower engine. A
four-stroke engine uses its oil again and again. A few litres of oil may be
used for many hours of operation (see figure 1.29).
Figure 1-29
In two-stroke engines, lubricant is added to the fuel. It is not used again

and again. After lubricating the engine, the oil is burnt during
combustion.
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1.3.4 The Exhaust System
Combustion produces waste gases. These gases are called exhaust.

During the exhaust stroke, the piston pushes these gases out of the engine.
Then the exhaust enters the atmosphere, or outside air.
But exhaust is harmful to health. Exhaust is full of carbon monoxide and

hydrocarbons. Carbon monoxide is poisonous, and hydrocarbons cause
disease. The operator must therefore be protected from exhaust. The
exhaust system removes exhaust to a safe distance from the operator (see
figure 1.30).
Figure 1-30
After leaving the engine, exhaust enters an exhaust manifold. The gases
pass through the manifold to the exhaust pipe. The exhaust pipe releases
the gases into the atmosphere.
The exhaust system also helps to reduce engine noise. The exhaust pipe is
connected to a box called a silencer. The silencer reduces the noise of
combustion.
1.3.5 Anti-Pollution Devices
The atmosphere is polluted, that is, dirtied and poisoned, by the carbon
monoxide and hydrocarbons in exhaust. In the 1960s, engine
manufacturers began to develop anti-pollution devices. Anti-pollution
systems reduce the dirt and poisons in exhaust.
Manifold reactors are one type of anti-pollution device. An air-pump

pushes oxygen through jets near each exhaust port. The oxygen raises the
temperature inside the manifold reactor to about 1300C. As a result of
this high temperature, the carbon monoxide and hydrocarbons combine
with oxygen. They are converted into carbon dioxide and water (see
figure 1.31).
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Figure 1-31
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Catalytic converters are a second type of anti-pollution device. They

contain a catalyst, such as platinum or alumina. (A catalyst causes a
chemical change, but does not change itself). The exhaust heats the
catalyst to about 500C. As in the manifold reactor, the hydrocarbons and
carbon monoxide are converted to carbon dioxide and water (see figure 1-
32).
Figure 1-32
Manifold reactors and catalytic converters are two types of anti-pollution

device. Manufactures of engines are developing other methods of
reducing pollution. Anti-pollution devices are not yet totally effective.
However, in the 1970s, new engines could convert 87% (percent) of their
hydrocarbon and 65% of their carbon monoxide.
1.3.6 Ignition System
What causes combustion? What makes the fuel-air mixture burn inside the
engine?
In the cylinder of the engine, the piston compresses the fuel-air mixture.
Following compression, the sparking plug provides an electric spark.
This spark ignites, or fires, the fuel-air mixture. This mixture explodes.
The firing of the fuel-air mixture is called ignition. An engine’s ignition
system distributes, or sends, electric current to the sparking plugs (see
figure 1.33).
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Figure 1-33
The ignition system needs a supply of electrical energy. An alternator

produces electric current for the engine. The electric current travels from
the alternator to the battery. The battery stores the electrical energy until
the ignition system needs it (see figure 1.34).
Figure 1-34
The ignition system must provide the electrical energy at a high voltage.
Voltage is a measure of a kind of electrical force. The sparking plugs
need electrical energy at voltages of up to 25,000 volts. But the alternator
does not produce a current at this high voltage. In fact, most alternators
produce electrical energy at only twelve volts. Twelve volts will not
cause a strong electric spark.
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Low voltage is converted into high voltage by the ignition coil. The coil
has two windings: a primary winding and a secondary winding. Electric
current is supplied to the primary winding from the battery. The current
travels through a circuit to the primary winding. In this circuit there are
two contact breaker points. The points open and close. When the points
are closed, the circuit is complete. Current travels through the primary
winding. When the points are open, the circuits is broken. The current
stops. When this happens, a high voltage is induced, or caused, in the
secondary winding of the coil. In this way, the coil produces high-voltage
electricity from low-voltage electricity (see figure 1.35).
Figure 1-35
If the engine has more than one cylinder, it will have more than one
sparking plug. The distributor distributes, or sends, the high-voltage
current from the coil to the correct sparking plug at the correct moment.
Inside the distributor is a rotor-arm. As the rotor-arm turns, it touches
metal points in the distributor cap. These points are connected to
sparking plug cables. The cables carry the high-voltage current to the
sparking plugs (see figure 1.36).
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Figure 1-36
Ignition must occur at the correct moment. The correct moment for
ignition is just before the piston reaches its highest point (Top Dead
Centre or TDC). Power is lost if ignition occurs either too early or too
late. When ignition does not occur at the correct moment, the ignition
timing must be adjusted, or changed. When the timing is advanced,
ignition occurs earlier. When the ignition is retarded, ignition occurs
later. Adjustments to the ignition timing are usually very small.
1.4 OTHER TYPES OF INTERNAL COMBUSTION ENGINE
1.4.1 The Rotary Piston Engine
In the Wankel engine or rotary piston engine, the piston does not go up
and down. Instead, the piston rotates.
A rotary piston has three sides. As it turns inside the engine, it forms
three moving chambers. The chambers move past an intake port, sparking
plugs and an exhaust port. In this way, fuel intake, compression and
combustion and exhaust, take place in a rotary cycle. The engine
produces useful mechanical energy without up-and-down strokes (see
figure 1.37).
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Figure 1-37
The rotary piston and its shaft are the only moving parts in the Wankel
engine. The rotary piston engine therefore weighs less than many other
piston engines.
1.4.2 The Turbine Engine
The turbine engine operates without a piston. There is no intake-

compression-combustion-exhaust cycle.
Instead, a compressor compresses air in a combustion chamber. Fuel is

pushed into the chamber continuously. Therefore, combustion occurs
continuously. Combustion produces expanding gases. These gases push
rotors or blades. The rotors turn a shaft. The shaft operates the
compressor. But the compressor only uses some of the energy from the
turbine. The rest of the turbine’s mechanical energy can be taken for
useful work (see figure 1.38).
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Figure 1-38
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1.5 MEASURING THE ENGINE
Piston engines are precision machines. The parts of a piston engine fit
together exactly. These parts operate at exact moments. Therefore,
precise engine measurements are needed. These engine measurements
give the piston engine’s size, power, efficiency, timing and speed.
The diameter of a cylinder is called the bore. The piston travels in the
cylinder. The length of the piston’s travel is the stroke. Bore times
stroke gives the piston’s displacement (see figure 1.39).
Figure 1-39
AREA OF THE BORE x STROKE = DISPLACEMENT
Displacement is the volume of air displaced, or pushed out, by the piston

stroke. Because it is a volume, displacement is measured in cubic inches,
cubic centimetres, or litres. Engine size is the total displacement of all
the engine’s pistons. Therefore, an engine with 4000cc (4 litre)
displacement is more powerful than an engine with 1600cc (1.6 litre).
Power
Engines convert energy to do work. Work causes the movement of an

object through space. Power is the measurement of work done in a
certain time. For example, one horsepower is the movement of a 33000
Ib (pound) object through one foot of space in one minute. Horsepower is
the measure of engine power.
The engine’s maximum horsepower is called theoretical horsepower.

But some horsepower is used to operate the engine’s supporting systems.
Some horsepower is lost through friction and heat. The remaining
horsepower can do useful work. This is known as the engine’s brake
horsepower.
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Engine Efficiency
The engine loses some theoretical horsepower through friction and heat.
Supporting systems, such as pumps, alternators and fans, also require
horsepower. The difference between theoretical horsepower and brake
horsepower shows the engine’s mechanical efficiency. Mechanical
efficiency is usually given as a percentage (X1/100).
Engine Timing
Inside the engine, events such as ignition, valve openings etc., must
happen at precise moments. Therefore, the timing of engine operations
must be precise. The rotation of the crankshaft is the measure of the
timing. Each rotation of the crankshaft is divided into 360. Different
operations occur at different moments during this rotation. The exact
moment can be given by the number of degrees (see figure 1.40).
Figure 1-40
Engine Speed
Engine speed is also measured by the rotation of the crankshaft. Each

crankshaft revolution, or rotation, in one minute equals one rpm
(revolution per minute). Rpm is the measure of engine speed. The
tachometer is an instrument for showing rpm. (see figure 1.41).
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Figure 1-41
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M17-Combustion Engines (Zadco-AHRT)

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M17-Combustion Engines (Zadco-AHRT)

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ZIRKU ISLAND TRAINING

THE COMBUSTION ENGINE

The trainee will be able to:

 Name the parts of an internal combustion engine and state their

1.2 THE PISTON ENGINE

An engine is an energy converter. That is, all engines convert, or change

In the internal combustion engine, combustion takes place inside the

Early engines, such as the steam engine, used external combustion.

Inside the piston engine, combustion creates pressure. This pressure

1.2.1 The upper engine

Each cylinder contains a piston. The piston reciprocates, or moves up or

Combustion does not begin in the cylinder. Combustion begins in the

1.2.2 The lower engine

Reciprocating motion is an up-and-down motion. Rotating motion is a

The bottom of the piston is attached to an arm. This arm is called a

The end of the connecting rod is attached to the crankshaft. The

1.2.3 The four-stroke process

During the combustion stroke, the fuel mixture is ignited in the

After combustion, the piston has kinetic energy, or energy of motion. It

1.2.4 The valve-timing system

Sometimes, in modern four-stroke engines, the camshaft is located in the

1.2.5 Two-stroke engines

In two-stroke engines, intake and compression happen during the same

produces mechanical energy. As the piston descends, it uncovers the

Because they do not have valves or valve-timing systems, two-stroke

Large two-stroke engines are not economical to operate. This is because

1.2.6 The diesel engine

As pressure rises, temperature rises. Inside the engine, pistons compress

The diesel engine is an internal combustion engine. Therefore, it needs a

Diesel engines have to contain great pressure. Because of this, diesel

THE COMBUSTION ENGINE

PARTS IN THIS COURSE

PART 01A THE COMBUSTION ENGINE

PART 01B THE COMBUSTION ENGINE

1.3 SUPPORTING SYSTEMS

1.3.1 The Fuel Induction System

A second valve is located at the top of the carburettor. This valve is

1.3.2 The Cooling System

Liquid-cooling systems are the most common. In these systems, a liquid

Water may be used as a coolant. But in cold weather water freezes.

In air-cooling systems, the heat of the engine is transferred directly to the

1.3.3 The Lubrication System

Lubrication also saves energy. This is because lubricated parts move

In four-stroke engines, oil is kept below the crankshaft. The crankshaft

In two-stroke engines, lubricant is added to the fuel. It is not used again

1.3.4 The Exhaust System

Combustion produces waste gases. These gases are called exhaust.

But exhaust is harmful to health. Exhaust is full of carbon monoxide and

1.3.5 Anti-Pollution Devices

Manifold reactors are one type of anti-pollution device. An air-pump

Catalytic converters are a second type of anti-pollution device. They

Manifold reactors and catalytic converters are two types of anti-pollution

1.3.6 Ignition System

The ignition system needs a supply of electrical energy. An alternator

1.4 OTHER TYPES OF INTERNAL COMBUSTION ENGINE

1.4.1 The Rotary Piston Engine

1.4.2 The Turbine Engine

The turbine engine operates without a piston. There is no intake-

Instead, a compressor compresses air in a combustion chamber. Fuel is

1.5 MEASURING THE ENGINE

AREA OF THE BORE x STROKE = DISPLACEMENT

Displacement is the volume of air displaced, or pushed out, by the piston