Engine

Construction
Piston - Engine Construction
Spark - igniton and Diesel engines are similar in construction.
Both have cylinder blocks, cylinder heads, crankshaft and
bearings. Also both have pistons, connecting rods, and valve
trains. The main difference between spark ignition parts and
diesel engine parts is that diesel parts are usually heaviar and
stronger. This because the internal pressure are higher in diesel.
Cylinder Block

The cylinder block is the foundation of the engine. All other

parts are assmebled in or attached to the cyclinder block. Most
blocks are cast from gray iron (cast iron) or iron mixed with other
metals such as nickel and chronium. Some blocks are cast from
aluminum alloy.
The block is a casting that have large holes for the cylinder
bores. It also has water jackets and coolant passages. Water
jackets are the spaces between the cylinder bores and the outer
shell of the block. Coolant flows through these spaces to pick up
heat and carry it away from the engine.
Cylinder Block
Parts Attach to and Installed in Block
1. The crankshaft with main bearings, is attached to the bottom of
the block. The crankshaft fits into bearing in the main bearing
caps and block
2. The pistons, with rings installed and connecting rods attached,
are installed. The connecting rods are attached to the crankpins
on the crankshaft.
3. The cyclinder head with valves and camshaft (on OHC
engines) is assembled
4. After bearing adjustments and installation of the head and oil
pump, the oil pan is attached.
Crankshaft
The crankshaft is a one piece casting or forging of heated alloy steel.
Counter weights is placed opposite of the crankpins to balance the
crankshaft. The output end of the crankshaft has the flywheel or drive plate
attached. The front end has the gear or sprocket that drives the camshaft.
Main Bearing Cap
A bearing cap is a rigid, semi-circular part that fits around one
half of a bearing and secures it.
Thrust Bearing
Thrust bearing limits the crankshaft endplay. The thrust bearing
is one of the main bearings that has flanges on its two sides. Flanges
on the crankshaft fit close to the thrust bearing flanges. This limits
the forward and rearward movement on the crankshaft.
Thrust Washer
Thrust washers are long-wearing flat bearings in the shape of
a washer that transmit and resolve axial forces in rotating
mechanisms to keep components aligned along a shaft.
Flywheel
A heavy revolving wheel in a machine that is used to
increase the machine's momentum and thereby provide
greater stability or a reserve of available power during
interruptions in the delivery of power to the machine.
Oil Pump
The oil pump in an internal combustion engine circulates
engine oil under pressure to the rotating bearings, the sliding
pistons and the camshaft of the engine. This lubricates the
bearings, allows the use of higher-capacity fluid bearings and also
assists in cooling the engine.
Pistons
A piston is a cylindrical engine component that slides back
and forth in the cylinder bore by forces produced during the
combustion process. The piston acts as a movable end of the
combustion chamber. The stationary end of the combustion
chamber is the cylinder head.
Piston Component Parts
• Connecting Rod - One end of the connecting rod attaches to a crankpin
on the crankshaft. The other end attaches to the piston pin. The end of
the rod attached to the crankpin is the rod “Big end”. The other end is rod
“Small end”.

• Connecting Rod Cap - The rod cap is attached to the connecting rod
with two cap screws for installation and removal from the crankshaft.

• Piston Pin - Piston pin is a connecting link between piston and

connecting rod. It looks like a simple cylindrical shaft ,can be solid or
hollow. At ends , it has a chamfer.The piston pin is held in the piston by
circlips, while from the middle portion it is surrounded by the connecting
rod smaller bore end.
Component Parts of Piston
Piston Rings
Piston are fitted with piston rings. The two types of piston rings are
compression rings and oil - control rings .

• Compression rings - seal compression and combustion pressures in the

combustion chamber.

• Oil Control Rings - scrape oil from the cylinder.

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.
Cylinder Head
Camshaft
The camshaft is a mechanical component of an internal combustion
engine. It opens and closes the inlet and exhaust valves of the engine at
the right time, with the exact stroke and in a precisely defined sequence.
The camshaft is driven by the crankshaft by way of gearwheels, a toothed
belt or a timing chain.
Valves
Valve is a device to close and open a passage. In motor
vehicle engines, two engine valves are used for each cylinder-an
inlet or intake valve and an exhaust valve.
Valve Spring
A valve spring is a spring that returns a poppet valve to its closed
position. Valve springs play an important role in controlling the
breathing in internal combustion engines. The valves are mechanically
opened by a camshaft, via valve lifters or tappets, and closed by the
valve springs.
Rocker Arm
A rocking lever in an engine, especially one in an internal
combustion engine which serves to work a valve and is operated
by a pushrod from the camshaft. a lever that rocks about a pivot,
esp a lever in an internal-combustion engine that transmits the
motion of a pushrod or cam to a valve.
Push Rod & Valve lifter

A push rod in an overhead-valve engine that is part of the

linkage used to open and close the valves.

The valve lifter is the unit that makes contact with the valve
stem and the camshaft. It rides on the camshaft. When the cam
lobes push it upwards, it opens the valve.
Cylinder Head Gasket
A head gasket seals the joint between the cylinder head and
the cylinder block. The gasket is placed between head and the
block. Tightening the head bolts forces the soft material of the
gasket to fill irregularity. This seals the joint. Head gasket
installation becomes extremely important in sealing between an
aluminium head and a cast iron block.
Intake Manifold
The intake manifold is also a set of tubes. These tubes carry
air or air - fuel mixture from throttle valves to the intake ports in
the cylinder head. On inline engines, the intake manifold is
attaches to the side of the cylinder head. Some inline engines
have the intake and exhaust manifolds on the same side of the
cyclinder head. Other engines have manifolds on the opposite
side.
Exhaust Manifold and Exhaust System
The exhaust manifold is a set of tubes. It carries exhaust
gasses from the cylinder to the exhaust system. The manifold
attaches to the head so the exhaust ports in the head align with
the tube openings. An inlie engine needs one exhaust manifold.
V type and opposed cylinder engines have two exhaust manifold,
one for each type