ICE ( Internal-combustion engine )

Fig. 1 an inline four spark-ignition engine with over head camshaft

Internal means inside, while Combustion, also known as burning, is the basic chemical process
of releasing energy from a fuel and air mixture. In an internal combustion engine (ICE), the
ignition and combustion of the fuel occurs within the engine itself. The engine then partially
converts the energy from the combustion to work. The engine consists of a fixed cylinder and a
moving piston. The expanding combustion gases push the piston, which in turn rotates the
crankshaft. Ultimately, through a system of gears in the power train, this motion drives the
vehicle’s wheels.

There are two kinds of internal combustion engines currently in production: the spark ignition
gasoline engine and the compression ignition diesel engine. Most of these are four-stroke cycle
engines, meaning four piston strokes are needed to complete a cycle. The cycle includes four
distinct processes: intake, compression, combustion and power stroke, and exhaust.

Spark ignition gasoline and compression ignition diesel engines differ in how they supply and
ignite the fuel. In a spark ignition engine, the fuel is mixed with air and then inducted into the
cylinder during the intake process. After the piston compresses the fuel-air mixture, the spark
ignites it, causing combustion. The expansion of the combustion gases pushes the piston during
the power stroke. In a diesel engine, only air is inducted into the engine and then compressed.
Diesel engines then spray the fuel into the hot compressed air at a suitable, measured rate,
causing it to ignite.

The most common internal-combustion engine is the four-stroke, gasoline-powered,

homogeneous-charge, spark-ignition engine. This is because of its outstanding performance as a
prime mover in the ground transportation industry.

TYPES OF INTERNAL COMBUSTION ENGINE

 TWO KINDS OF PISTON ENGINE

The two kinds of piston engines are the spark-ignition engine and the compression- ignition
(diesel) engine. The difference between them are:

 The type of fuel used.

 The way the fuel gets into the cylinders.
 The way the fuel is ignited.

The main difference between gasoline and diesel is in the way these explosions happen. In
a gasoline engine, air mixes with the fuel, which is then compressed by pistons and ignited by
the sparks from spark plugs. In a diesel engine, the air is compressed first, and then the fuel is
injected

Engine construction ( Fig. 1)

Spark -ignition and compression- ignition piston engine are similar in construction. Both have
the main parts this are: (a) the engine block; (b) the cylinder; (c) cylinder head, usually
holding in-let and exhaust valves; (d) the piston; the connecting rod; (f) the crankshaft; (g)
the crankshaft or main and connecting-rod bearing; and (h) the fuel pump and fuel injector

Pistons and piston rings.

Pistons are commonly made of a cast aluminum alloy (aluminum mixed with other metal) the
piston is slightly smaller than the cylinder, which allows the piston to slide up and down. This is
a sliding fit.
 To prevent excessive blow by, piston rings are installed on the piston.

There are two types of piston rings:

1. Compression rings these form a sliding seal between piston and the cylinder wall.
2. Oil-control rings (or oil rings) These scrape off most the lubricating oil splashes on the
cylinder wall, and return the oil to the crankcase.

RECIPROCATING TO ROTARY MOTION

The reciprocating motion of the piston must be changed to rotary motion to turn the drive
wheels. A connecting rod and crank on the crankshaft make this conversion.
ENGINE VALVES

Engine valves are mechanical components used in internal combustion engines to allow or
restrict the flow of fluid or gas to and from the combustion chambers or cylinders
during engine operation.

Engine Valve Nomenclature

Most engine valves are designed as poppet style valves because of their up and down popping
motion and feature a conical profile valve head that fits against a machined valve seat to seal off
the passage of gases. They are also called mushroom valves because of the distinctive shape of
the valve head. Figure 1 shows the nomenclature for the different elements in a typical engine
valve.

Figure 1 - Nomenclature for a standard poppet style engine valve.

Image credit: https://dieselnet.com

The two primary elements are the valve stem and the valve head. The head contains a fillet that
leads into a seat face that is machined at a specified angle to match the machining of the valve
seat to which it will match. The seating of the valve face to the valve seat is what provides the
seal for the valve against combustion pressure.

The valve stem connects the valve to the mechanical elements in the engine that operate the
valve by creating a force to move the stem against the seating pressure provided by a valve
spring. The keeper groove is used to hold the spring in position, and the tip of the valve stem is
repeatedly contacted by a rocker arm, tappet, or lifter that actuates the valve.
Engine Operation
Four stoke or four-cycle internal combustion engines make use of two primary types of valves –
the intake valve and the exhaust valve. Intake valves are opened to allow the flow of an air/fuel
mixture into the engine’s cylinders prior to compression and ignition, while exhaust valves open
to permit the expulsion of exhaust gases from the combustion process after ignition has occurred.

In normal operation, a crankshaft in the engine to which the pistons are attached is tied to a
camshaft as part of a valve train arrangement for the engine. The movement of the crankshaft
transfers motion to the camshaft through a timing chain, timing belt, or other geared mechanism.
The timing and alignment between the position of the crankshaft (which establishes the position
of the piston in the cylinder) and the position of the camshaft (which determines the position of
the valves for the cylinder) is critical not only for peak engine performance but also to preclude
interference between pistons and valves in high compression engines.

In the intake cycle, the intake cylinder piston cycles downwards as the intake valve opens. The
piston movement creates negative pressure that helps draw the air/fuel mixture into the cylinder.
Just after the piston reaches the lowest position in the cylinder (known as bottom dead center),
the intake valve closes. In the compression cycle, the intake valve is closed to seal off the
cylinder as the piston rises in the cylinder to the highest position (known as top dead center),
which compresses the air/fuel mixture to a small volume. This compression action serves to
provide a higher pressure against the piston when the fuel is ignited as well as pre-heating the
mixture to assist with an efficient burning of the fuel. In the power cycle, the air/fuel mixture is
ignited which creates an explosion that forces the piston back down to the lowest position and
transfers the chemical energy released by burning the air/fuel mixture into the rotational motion
of the crankshaft. The exhaust cycle has the piston again rising upward in the cylinder while the
intake valve remains closed and the exhaust valve is now open. The pressure created by the
piston helps force the exhaust gases out of the cylinder through the exhaust valve and into the
exhaust manifold. Connected to the exhaust manifold are the exhaust system, a set of pipes that
includes a muffler to reduce acoustical noise, and a catalytic converter system to manage
emissions from the engine combustion. Once the piston reaches the top of the cylinder in the
exhaust cycle, the exhaust valve begins to close and the intake valve starts to open, beginning the
process over again. Note that the cylinder pressure on intake helps to keep the intake valve
opened and the high pressure in the compression cycle helps to keep both valves closed.
In engines that have multiple cylinders, the same four cycles repeat in each one of the cylinders
but sequenced so that the engine proves smooth power and minimizes noise and vibration. The
sequencing of piston movement, valve movement, and ignition is accomplished through the
precise mechanical design and electrical timing of ignition signals to the spark plugs that ignite
the air/fuel mixture.

FOUR STROKE CYCLE OF A GASOLINE ENGINE

FOUR STROKE CYCLE OF DIESEL ENGINE

SUPPORTING ENGINE OPERATION

BASIC ENGINE SYSTEM

A spark-ignition engine requires four basic systems to run. A diesel engine requires three of this
systems.

This are:

1. Fuel system
2. Electric ignition system (except diesel)
3. Lubricating system
4. Cooling system

FUEL SYSTEM

The function of the fuel system is to store and supply fuel to the engine and cylinder
chambers. There, it can be mixed with air, vaporized, and then burned to produce the energy.

A vehicle's fuel system comprises components that deliver fuel from the tank to the engine,
including a fuel pump, fuel lines, a fuel-pressure regulator, fuel filter and fuel injectors. Fuel
system components are built to last, so the fuel filter is the only part that's likely to require
replacement on a schedule.
 The fuel injection types used in newer cars include four basic types:
 Single-point or throttle body injection.

THROTTLE BODY INJECTION SYSTEM

The throttle body injection (TBI) system (fig. 4-46) uses one or two injector valves mounted in a throttle body
assembly. The injectors spray fuel into the top of the throttle body air horn The TBI fuel spray mixes with the air
flowing through the air horn. The mixture is then pulled into the engine by intake manifold vacuum. The throttle
body injection assembly typically consists of the following: throttle body housing, fuel injectors, fuel pressure
regulator, throttle positioner, throttle position sensor, and throttle plates.

 Port or multipoint fuel injection.

 Sequential fuel injection. * Direct injection.
two basic types of fuel injection systems used on passenger cars and light trucks,
multiport fuel injection and throttle body fuel injection or TBI.
 FUEL SYSTEM OF A DIESEL ENGINE

Here are three of the top fuel delivery issues your car could suffer from.
 Clogged Fuel Filter. One of the simplest fuel issues to repair is a clogged fuel filter. ...
 Dirty of Malfunctioning Fuel Injectors. The fuel injectors are what spray the proper amount
of gas into the combustion chamber. ...
 Failed Fuel Pump.
IGNITION SYSTEM

The ignition system in an internal-combustion engine that produces the spark to ignite the
mixture of fuel and air: includes the battery, ignition coil, distributor, spark plugs, and
associated switches and wiring.
The ignition system is the system, which consists of devices that serve to
create an electric spark of high voltage. The ignition system is generating a very
high voltage (from 20 to 30 thousand volts) from the car’s 12Volt battery. This
voltage is necessary to igniting the fuel-air mixture in the engine ‘s combustion
chambers. The spark plugs are supplying a high voltage spark to the combustion
chambers in determine time.

What are the type of ignition system ?

Currently, we recognize four types of ignition systems used in most cars and trucks: contact
-point ignitions, electronic ignitions, distributor-less ignition and coil-on-plug ignitions.
LUBRICATING SYSTEM

The job of the lubrication system is to distribute oil to the moving parts to reduce friction
between surfaces which rub against each other

Purpose of the engine lubrication system

A car engine is the main unit that drives a vehicle. It consists of hundreds of interacting parts.
Almost all of its elements are exposed to strong heating and frictional forces.

Without proper lubrication, any motor will quickly break down. Its purpose is a combination of
several factors:

 Lubricate parts to reduce wear on their surface during friction;

 Cool hot parts;
 Clean the surface of parts from small chips and carbon deposits;
 Prevent oxidation of metal elements in contact with air;
 In some unit modifications, oil is a working fluid for adjusting hydraulic lifters, timing
belt tensioners and other systems.

What are the component parts of Lubricating system ?

The main components of lubrication system consist of an oil pump, filter, and heat exchanger.
The crankcase of the compressor acts as the oil sump.

Why is lubricating system important in the engine

The job of the lubrication system is to distribute oil to the moving parts to reduce friction
between surfaces which rub against each other. ... The oil is pumped to the top of the engine,
at the right, inside a feed line. Small holes in the feed line allow the oil to drip inside the
crankcase.
ENGINE LUBRICATING SYSTEM COMPONBENTS

Oil pan: This is where Oliver hangs out when the engine isn't doing anything; the oil lounge, if
you will. In most cars, this pan holds about 4 to 6 quarts of oil.

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Pickup tube: When the engine is switched on, it needs oil immediately. Oliver and his oil
buddies get sucked up by the pickup tube and lined up for action.

Oil pump: The pump does the sucking so that Oliver can slide up that tube against gravity and
then pressurizes the oil. Oliver and his little oil friends get jammed in together even closer. Let's
hope Oliver remembered to put on deodorant today.

Pressure relief valve: If Oliver and his friends get too close they start to plan a riot, this relief
valve gives them a bit of much-needed breathing space. It's the lubrication system's way of
saying, "Settle down, kids."

Oil filter: While Oliver and his friends are allowed to pass into the engine, the filter stops any
dirt and debris the oil may have picked up on its last pass through the system.

Spurt holes and galleries: Oliver giggles every time he says "spurt holes." He's really immature.
These are the little holes drilled in the crankshaft or other parts of the system that allow the oil to
coat the bearings and cylinders that need to stay lubricated.

Sump: After doing his job to keep the moving parts of the engine moving, an exhausted Oliver
slides all the way down into the oil pan again, also known as the sump, to hang out until he's
sucked back up the pickup tube -- and he's back on the job.

COOLING SYSTEM

What is a cooling system in an engine?

A cooling system works by sending a liquid coolant through passages in the engine block
and heads. As the coolant flows through these passages, it picks up heat from the engine.
The heated fluid then makes its way through a rubber hose to the radiator in the front of the
car.
What are the types of engine cooling system?

What are the types of engine cooling system?

There are two types of cooling systems:

1. Air cooling system and

2. Water-cooling system. In this type of cooling system, the heat, which is conducted to
the outer parts of the engine, is radiated and conducted away by the stream of air,
which is obtained from the atmosphere.

What is the function of the cooling system?

The cooling system serves three important functions. First, it removes excess heat
from the engine; second, it maintains the engine operating temperature where it works
most efficiently; and finally, it brings the engine up to the right operating temperature
as quickly as possible.
What are the main parts of the cooling system?

The major components of the cooling system are the water pump, freeze plugs, the
thermostat, the radiator, cooling fans, the heater core, the pressure cap, the overflow
tank and the hoses.

WATER COOLING SYSTEM

AIR COOLING SYSTEM

OTHER ENGINE SYSTEM

An exhaust system is usually piping used to guide reaction exhaust gases away from a
controlled combustion inside an engine or stove. The entire system conveys burnt gases from
the engine and includes one or more exhaust pipes. ... A turbocharger to increase engine
power. A catalytic converter to reduce air pollution.

What are the three function of an exhaust system?

The exhaust system collects the exhaust gases from the cylinders, removes harmful
substances, reduces the level of noise and discharges the purified exhaust gases at a suitable
point of the vehicle away from its occupants. The exhaust system can consist of one or two
channels depending on the engine.
Emission control system

Emission control system, in automobiles, means employed to limit the discharge of noxious
gases from the internal-combustion engine and other components. There are three main
sources of these gases: the engine exhaust, the crankcase, and the fuel tank and carburetor.

What is the function of Emission control system?

Your vehicle's exhaust system is designed to take care of toxic emissions your car produces.
It will 1) direct harmful hydrocarbons away from the driver and passengers, and 2) reduce
the air polution your car releases into the environment, helping keep the air clean.
 EVAPORATIVE EMISSION CONTROL SYSTEM

What are the emission from a diesel engine

The four main pollutant emissions from diesel engines (carbon monoxide-CO,
hydrocarbons-HC, particulate matter-PM and nitrogen oxides-NOx) and control systems for
these emissions (diesel oxidation catalyst, diesel particulate filter and selective catalytic
reduction)