Petr l and diesel engines

Internal-combustion engine ICE

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 powertrain, 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.
Petrol engine and diesel engine parts

1. Cylinder block

It is the basic framework for the engine. and one of the main in engine parts. It
plays a key role in the lubrication, temperature control and stability of the engine
and it has to be of the highest quality so there is no room for short cuts.
A cylinder block consists of three parts:

1. The cylinder in which the piston slid up and down.

2. The port or opening for the valves.
3. The passages for the flow of cooling water.

• The cylinder block is usually made of grey cast iron or aluminum and its alloys.
• While the crankcase is fixed to its bottom. Apart from these other parts like
timing gear water pump, ignition distributor, flywheel, fuel pump etc., are also
attached to it.
• Passages are provided in the cylinder walls for the circulation of cooling water.
• Cylinder block also carries lubrication oil to various components through drilled
passages called oil galleries.
2. Cylinder head

A cylinder head is usually located on the top of the engine block. It serves as
a housing for components such as the intake and exhaust valves, springs and
lifters and the combustion chamber. This page covers the main function and
various designs of cylinder heads, and their causes and symptoms of failure.

The passages in the cylinder head allow air and fuel to flow inside the cylinder
while permitting the exhaust gases to flow out of it. The passages are otherwise
called ports or tracts. The cylinder head also channels the coolant into the
engine block, thereby cooling down the engine components. The cylinder head
uses a gasket that aids in preventing water or oil from leaking into the
combustion chambers.

3. Cam Shaft
• A camshaft has a number of cams along the length, two cams for each cylinder,
one to operate the inlet valve and the other the exhaust valve.
• In addition, the camshaft has an eccentric to operate the fuel pump and gear to
drive the ignition distributor and oil pump.
• The camshaft is driven by the crankshaft. The camshaft gear has twice as many
teeth as the gear on the crankshaft.
• Camshaft made from forged alloy steel.
This gives 1:2 gear ratio, the camshaft turns at half the speed of the crankshaft.
Thus, every two revolutions of the crankshaft produce one revolution of the
camshaft and one opening and closing of each valve, in the four-cylinder engine.
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What is the difference between OHV, OHC, SOHC and DOHC engines?
The main difference is in the placement of the camshaft. OHV means Over Head Valve.
Although almost all modern car engines have valves placed in the cylinder head, the term
OHV is used to describe a pushrod engine, with the camshaft placed in the cylinder block.
OHC stands for Over Head Cam, or the camshaft is installed in the cylinder head. SOHC
means Single Overhead Cam, while DOHC means Double Overhead Cam.

OHV (Over Head Valve)

In an OHV engine, the camshaft is placed inside the block and the valves are operated
through lifters, pushrods and rocker arms. This mechanism is called a valve train. An OHV
design has been successfully used for many years. Most early American cars had OHV
engines and they are still used in trucks and sports cars.
The downside of an OHV design is that it requires many moving components to operate
the valves. Each component adds weight. This results in higher valve train inertia, making
it difficult to control the valve timing at higher RPMs This means that a small OHV engine
will not be very efficient. The OHV design is more suitable for larger V6 and V8 engines;
you won't find an OHV engine in a modern compact car
Advantages of an OHV engine include a lower cost, higher low-end torque and more
compact size

OHC (Over Head Cam)

OHC simply means Over Head Cam, while SOHC means Single Over Head Cam or Single
Cam.

In a SOHC engine the camshaft is installed in the cylinder head, and valves are operated
either by the rocker arms or directly through the lifters. The advantage of the OHC design
is that valves are operated almost directly by the camshaft, which makes it easier to
maintain precise timing at higher rpms. It's also possible to install three or four valves per
cylinder
The downside of an OHC engine is that it requires a timing belt or chain with a tensioner
and other related components. A timing belt must also be replaced at regular intervals. The
timing chain lasts longer, but it too might need to be replaced if stretched. Another
downside is that it's more difficult to implement variable valve timing separately for
exhaust and intake valves; something that can be easily done in a DOHC engine.
DOHC (Double Over Head Cam)

DOHC means Double Over Head Cam. A DOHC engine design is often called Twin Cam
or Dual Cam. The majority of modern cars have a DOHC engine. A typical DOHC engine
has two camshafts and four valves per cylinder, like the one in this animation. One
camshaft operates intake valves, while another camshaft controls exhaust valves on the
opposite side.
In a DOHC engine, camshafts can be installed farther apart from each other. This allows
the intake valves to be at a larger angle from the exhaust valves, which results in a more
direct air flow through the engine. In other words, a DOHC engine can "breathe" better,
which means it can produce more horsepower out of a smaller engine volume.

4. Oil Pan
The bottom half of the crankcase is called the oil pan or sump. It is attached to the crankcase
through set screws and with a gasket to make the joint leak proof. The oil pan serves as a
reservoir for the storage, cooling and ventilation of engine lubricating oil.
At the bottom of the oil sump, a drain plug is provided to drain out the dirty oil at the time
of oil replacement. Generally, the sump is made of pressed steel sheet or aluminum alloy
casting is used.

The various functions of the oil pan as follows

• To store the oil for the engine lubrication system.
• Oil pan used to collect the return oil draining
• To serve as a container for impurities or foreign matters
• Oil pan provides for cooling of the hot oil in the sump.

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1. Oil filler pipe 2. Fuel pump

3. Oil supply pipe 4. Oil outlet pipe
5. Centrifugal oil filter 6. Oil filter
7. Oil pressure indicator 8. Oil filter bypass valve
9. Radiator tap 10. Radiators
11. Differential valve 12. Safety valve for radiator section
13. Oil sump 14. Suction pipe with intake
15. Oil pump radiator section 16. Supply section of the oil pump
17. Reducing valve of the delivery section 18. Cavity for additional centrifugal oil cleaning
PURPOSE OF THE ENGINE LUBRICATION SYSTEM

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.
DEVICE, PRINCIPLE OF OPERATION OF THE LUBRICATION SYSTEM
The classic system has the following structure:

• Hole on top of the motor for replenishing the lubricant volume;

• The drip tray in which all the oil collects. There is a plug at the bottom that is
designed to drain the oil during replacement or repair;

• The pump creates pressure in the oil line;

• Oil intake, presented in the form of a pipe, put on the pump connection. Often it has a
small mesh for coarse oil cleaning;

• The filter removes microscopic particles from the lubricant. Thanks to this, the
internal combustion engine receives high-quality lubrication;

• Sensors (temperature and pressure);

• Overflow valves. Prevents oil from returning to the reservoir without completing a
lubrication cycle;
• Highway. In most cases, it is made in the form of grooves in the crankcase and some
parts (for example, holes in the crankshaft).

‫توجد عدة عوامل مختلفه في محركات الديزل عن البنزين‬

‫تتعرض الحمال وضغوطات اعلي من محركات البنزين‬ •

‫درجة حرارة التشغيل في الديزل اعلي من البنزين‬ •

‫الرواسب الكربونيه في الديزل اعلي من محركات البنزين‬ •

:‫لذلك نظام التزييت توجد بعض االضافات في حالة محرك البنزين مثل‬

• Radiator. It is found in many modern dry sump motors. It serves to cool the used oil
more efficiently. In most budget cars, this function is performed by the oil pan;

• Piston oil jet Piston cooling nozzles/jets play several crucial

roles in the power cylinder of an internal combustion engine.
Primarily, they help with the thermal management of the
piston and provide lubrication to the cylinder liner and the
piston’s wrist pin

• Filters it may be more than one filter in diesel engines

5. Manifolds

There are separate sets of pipes attached to the cylinder head which carry the air-fuel
mixture and the exhaust gases, these are called manifolds. It is generally made of cast
iron so that it is able to withstand the high temperature of the exhaust gases.

Working

• The air goes into the air intake travels through, throttle body into the intake
manifold and from there it goes into the engine through the cylinder head.
• The inlet manifold carries the air-fuel mixture from the carburetor to the cylinders
for petrol engines and just air for diesel engines.
• The exhaust manifold is the set of pipes carrying exhaust gases from the cylinder
head to the exhaust system.

6. Gaskets
These are used to provide a tight fitting joint between two surfaces.

Gaskets are found in

• the joint between the cylinder head and the cylinder block

• Between crankcase and oil pan.

• Between the cylinder block and manifold.

Materials used for gaskets are

• Cork
• Asbestos
• Rubber

Requirement/properties of the gasket as follows

• Conformity: The gaskets should conform to the mating surfaces which may have
roughness or warpage.

• Resistance: It should have resistance to high pressures, extreme temperature and

vibrations.

• Resistance to chemical attack: the gasket should have resistant to the chemicals
such as fuel, products of combustion, coolant and engine oil.
7. Pistons

Pitons are most important engine parts compared to others. The piston is a cylindrical
plug that moves up and down in the cylinder.

It helps to convert pressure energy obtained by the combustion of fuel into useful
mechanical power and it transfer this power to the crankshaft through the connecting
rod.

• The highest position of the piston reaches in the cylinder is called the Top Dead
Centre(TDC) and

• The lowest position it reaches is called the Bottom Dead Centre(BDC).

It is provided with pistons ring about 3 to 5 provide a good seal between the cylinder
wall and piston. The efficiency and economy of the engine primarily depend on the
working of the piston.
8. piston Rings

The piston rings are fitted into the grooves of the piston to maintain a good seal between
the piston and the cylinder wall.

The number of piston rings used is about 2 to 4 compression rings and 1 to 2 oil
control ring was used but in modern design the number if rings usually three out of
which one is the oil control ring.

The function of piston rings

• To form a seal for the high pressures gases from the combustion chamber entering
into the crankcase.

• The piston ring provides easy passage for heat flow from the piston crown to the
cylinder walls.

• To maintain sufficient lubrication oil on cylinder walls throughout the entire length
the piston travel, hence it minimizes the cylinder wear.
9. Connecting Rod
Fig showed a connecting rod. It is fitted in between the p iston and crankshaft.

The main function of the connecting rod is to convert the reciprocating motion of
the piston into the rotary motion of the crankshaft.

It must be light and strong enough to withstand stress and twisting forces.

10. Crankshafts
The crankshaft is the engine component from which the power is taken. It is one
of the main power transmission sources in all engine parts.

The Crankshaft is the first part of the power transmission system in which the
reciprocating motion of the piston is converted into the rotating motion with the
help of connecting rod.

The front end of the crankshaft carries three devices that

• A gear that drives the camshaft,

• The vibration damper to control torsional vibration, and

• The fan belt pulley. This pulley drives the engine fan, water pump, and
generator with a V-belt.

The rear end of the crankshaft carries flywheel. The flywheel tends to keep the
crankshaft running at constant.

Next, to the rear end, the main journal and oil seal is fitted. In some engine, oil
return threads are provided which return the lubricating oil to the sump.

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11. Turbo vs supercharger

‫يستخدم بشكل اساسي في محركات البنزيل بسبب طبيعية عمل المحرك باحتياجه لكم هواء اكبر وسعه اكبر‬
‫وقد يوجد احيانا في محركات البنزين‬
Turbo

In simple terms a turbo is an air pump that enables more air to be pumped into the engine
at higher pressure. This replicates the effect of having a larger cylinder but with more
efficiency. The turbo is made up of two distinct sections; the compressor end and the
turbine end. The compressor end (or cold end) is often made from aluminum and
experiences temperatures of up to 70°C. Ambient air is drawn into the compressor
housing and a compressor wheel compresses the air and accelerates it to very high
speeds.
The turbine end (or hot end), is made from cast iron or stainless steel and can reach
temperatures of up to 960°C, as the exhaust gases rotate the turbine wheel at speeds of
up to 280,000 rpm. The turbine housing directs exhaust gas from the engine onto the
turbine wheel blades, and once it has passed through the turbine wheel, the gas then
passes out through the exhaust system as with normally aspirated vehicles.
Once the combustion process starts, this creates a continuous cycle and the turbo makes
use of waste energy from the exhaust gases. More air in the cylinder also enables more
fuel flow through to the cylinder and therefore achieves more power.

Supercharger

supercharger is mechanically driven by the engine and increases the amount of air
through intake by compressing the air above atmospheric pressure, without creating a
vacuum. This forces more air into the engine, providing a boost, which in turn allows more
fuel to be added to the charge, and therefore increases the power of the engine. There
are two main types of superchargers. Positive Displacement superchargers produce a
fixed amount of pressure that doesn’t increase much as the engine increases its RPM.
Dynamic Compressors, as the name suggest, produce more pressure as the engine’s
RPM increases.
Some pictures from the training in AL MUQAQLIN training center

Fiat 8210 engine

Fiat 124
GM