Basic Engine Components

Service Training Center

ENGINE COMPONENTS
After completing this topic, you will able to identify the

components in the block, cylinder head, and gear train assemblies
and understand the function of each components.

ENGINE COMPONENTS
ENGINE BLOCK
In this segment, you will learn about each component in the

block assembly and be able to describe the function of each
components.

ENGINE COMPONENTS
ENGINE BLOCK
The block assembly is where the power is created. Lets look at

each of the block assembly components and how they work together
to make the engine operate.

ENGINE COMPONENTS
ENGINE BLOCK
The engine block is the

structure that supports all the
components for the engine.

ENGINE COMPONENTS
ENGINE BLOCK
The engine blocks come in

different deigns. In-line engines
have the cylinders all in one row.
V-type engines separate the
cylinders into two rows, and the
block has a “V” shape.

ENGINE COMPONENTS
ENGINE BLOCK
The engine blocks are

normally gray cast iron.
Coolant(1) and Lubricant(2)
passages are cast into the block.
The water passages are

usually called the water jacket.

ENGINE COMPONENTS
CYLINDERS
The cylinders are hole in
the engine block. They perform a
number of tasks:
1. House the pistons
2. Form the combustion
chambers
3. Move heat away from
the pistons
In both in-line and “V”
engine designs, the cylinders can
be cast into the block or may be
replaceable cylinder liners.
ENGINE COMPONENTS
CYLINDERS
Cylinders can be cast

permanently into the block called
a PARENT BORE(1), or they may
be removable CYLINDER
LINERS(2)

ENGINE COMPONENTS
CYLINDERS
PARENT BORE ENGINE

- Engines without cylinder
liner.
CYLINDER LINER
- Form the water jacket
wall between the coolant and the
pistons.

ENGINE COMPONENTS
CYLINDERS
CYLINDER LINER
- there are two types of Cylinder Liners:
Wet Liners Dry Liners

- often used to
- have O-ring
repair or”sleeve”
seals and form parent bore engine
the walls of the should a cylinder
combustion fail. It is called
chamber and “dry” because it fits
the walls of the against pre-existing
cylinder bore walls
water jacket in in the block.
the block.
ENGINE COMPONENTS
CYLINDERS
CYLINDER LINER
- is made of cast iron. A typical wet cylinder liner has several parts:

Inside surface – holds the piston, also called the bore
Fire dam - seals the combustion chamber
Flange – supports the liner in the block
Filler Band Groove – hold the filler band which helps the
liner fit into the bore and reduces liner vibration
Outside surface - forms the water jacket wall
O-ring Grooves – hold O-rings which seal the water

jacket

ENGINE COMPONENTS
PISTONS
The piston fits inside each
cylinder and moves up and down
during combustion. The top of the
piston forms the bottom of the
combustion chamber.
- it performs three primary
job:
1. Transmit force of
combustion to connecting rod and
crankshaft
2. Seal the combustion
chamber
3. Transmit excess heat away
from the combustion chamber

ENGINE COMPONENTS
PISTONS
The piston which transmit

the force of combustion, is made
up of many parts:

Piston Crown –
contains the
combustion
chamber
Piston Ring 6 Piston Ring Lands – are the
spaces between the rings
Grooves – holds the
compression and oil Thrust Skirt – carry off side
control rings. loads on the piston and help
transfer heat away from the
Wrist Pin Bore – piston
contains a pin
Wrist Pin – connects the
7 piston to the connecting
rod
Retaining Ring – keeps the wrist pin
inside the wrist bore.

ENGINE COMPONENTS
PISTONS
Undercrown and Cooling Gallery
There is an under crown

area(1) on the inside of the
piston.
Some pistons contain oil

cooling galleries(2) inside the
piston crown which cannot be
seen.

ENGINE COMPONENTS
PISTONS

ENGINE COMPONENTS
PISTONS
Pistons Styles
2 There are two styles of

pistons which relate to fuel system
and combustion chamber design.
1
1. Precombustion pistons
have a heat plug in the crown.
2. Direct Injection pistons

do not have a heat plug.

ENGINE COMPONENTS
PISTON RINGS
Each piston has two or more

rings that fit into grooves on the
piston. They have three primary
jobs:
1. Seal the combustion
chamber.
2. Control lubrication of the
cylinder walls.
3. Transfer some of the
heat generated by combustion.

ENGINE COMPONENTS
PISTON RINGS
Piston Ring Types
There are two types of

piston rings: (1)compression rings
and (2)oil control rings.
All rings have a hard facing
to increase ring life.
Compression rings seal the

bottom of the combustion chamber
by preventing combustion gases
from leaking out past the piston.
ENGINE COMPONENTS
PISTON RINGS
Oil Control Ring
There is usually one control

ring below the compression rings.
Oil control rings lubricate the walls
of the cylinder liner as the piston
moves up and down. The oil film
reduces wear on the cylinder liner
and piston.

ENGINE COMPONENTS
PISTON RINGS
Every piston ring has a gap between the two ends of the ring.
Ring gaps should not line up when installed.
Because of the high combustion temperatures and constant

motion, piston rings will eventually wear and are designed to be
replaced as a needed.

ENGINE COMPONENTS
PISTON COOLING JETS
Some engines use piston

cooling jets. It spray oil to the
underside of each piston, and help
lubricate the cylinder walls.

ENGINE COMPONENTS
CONNECTING RODS
- it transmit the force of

- is attached to every
the combustion to the crankshaft,
piston via piston pin. It link the
and transforms reciprocating
piston to the crankshaft.
motion to rotary motion.

ENGINE COMPONENTS
4. Bore and Cap – are the

1. Rod Eye – holds the piston
large end of the con-rod. They
pin bushing.
surround the crankshaft’s rod bearing
2. Piston Pin Bushing – is journal and attach the con-rod to the
inside the rod eye. Bushings are a crankshaft.
type of bearing which distributes load 5. Rod Bolts and Nuts –
and can be repaired when worn. secure the con-rod to the crankshaft.
3. Shank – extends the length This is called the “crank-end” or “big
of the con-rod. It is an I-beam shape end”. 6. Con-Rod Bearing – are in
for strength and rigidity.. the crank end of the con-rod. The
crankshaft turn inside the con-rod
bearings which carry the load.
ENGINE COMPONENTS
CONNECTING RODS
Bearings
The top half of the con-rod bearing fits in the rod and is called
the upper half shall. The other half fits in the cap, and is called the
lower half shell.
Generally the upper half shell carries more load..
Con-Rod Bearings will eventually wear. They are checked on a
regular basis and replaced as needed
ENGINE COMPONENTS
CRANKSHAFT
- is located in the bottom of the engine block. The Con-Rods

are attached to the crankshaft.
- match engine design. In-line crankshaft look different than
V-crankshafts.
ENGINE COMPONENTS
CRANKSHAFT
- it transmit rotary motion to the flywheel which provides

energy suitable for work. A crank is an L-shaped part for converting
reciprocating to rotary motion.
- have different parts. The main and rod journals are the load
carrying components of the crankshaft.
1. Rod Bearing Journal – determines the position of the
pistons. It convert reciprocating to rotary motions.
2. Web – hold together the rod and main journal.
3. Main Bearing Journal – support the crankshaft in the block.

Main bearings and main bearing journals are in line with each other.
4. Counterweight – help balance the crankshaft. It may be
part of the crankshaft forging or in some cases they are bolted on.

Fillet – the radius
between the web and the
Thrust Main Bearing Journal – one journal.
main bearing journal is a thrust main
bearing with wide ground sidewalls
on the web.
Drilled Oil Passages – The crankshaft

has drilled oil holes to get oil from the
main bearings to the con-rod
Lightening Holes – some con-rod bearings . Drilled oil passages are
journals have lightening holes to plugged at one end by a cup plug or
reduce the weight and balance the set screw.
crankshaft.
Thrust Bearing – there are two
types of thrust bearing (1) insert Lower Half – fits into the main
and (2) flanged. bearing cap.
Upper Half – fits into the main

bearing bore in the block.
Oil Hole – usually a slot so lubricating

oil is continuously fed into the oil hole
in the main journal. Main Bearings
Main Bearing Assembly
The crankshaft turns inside the main bearings that are tightly
clamped in bores located at the bottom of the block.
Main Bearings will wear faster than other parts of the
crankshaft because they support most of the load. Bearings are
designed to be replaced when necessary.

ENGINE COMPONENTS
FLYWHEEL
- is bolted to the rear of the
crankshaft in the flywheel housing. It
performs three jobs:
1. Stores energy for momentum
between power stroke.
2.Smoothes out the speed of
the crankshaft.
3.Supplies the brake horsepower
perform work.
MOMENTUM – the crankshaft turns
the flywheel on the power stroke, and
the flywheel’s momentum keeps the
crankshaft turning smoothly during the
other stroke.
ENGINE COMPONENTS
FLYWHEEL Assembly
- has several components:
1.Flywheel.
2. Ring Gear – fits on the

outer edge of the flywheel. It is
used for starting the engine
3.Flywheel Housing – houses

the flywheel.

ENGINE COMPONENTS
VIBRATION DAMPER
- is resembles a miniature
flywheel that is either pressed on or
bolted to the front of the
crankshaft.
Purpose:
- control torsional or
twisting vibrations of the
crankshaft.

ENGINE COMPONENTS
VIBRATION DAMPER
- there are two common types of vibration damper.
RUBBER DAMPERS VISCOUS DAMPERS

- use dense rubber to - use heavy oil encase in the
absorb the vibration. housing to absorb the vibration.

ENGINE COMPONENTS
CAMSHAFT
- is driven by a gear on the
crankshaft. The camshaft gets its
name from the egg shaped lobes
called cams.
Purpose:
- the motion of the
camshaft controls the opening and
closing of the intake and exhaust
valve. On some engines the
camshaft controls fuel injector
operation.

ENGINE COMPONENTS
CAMSHAFT
How Camshaft Operates.
As the camshaft rotates the cam lobes

turns. Valve train components linked to the
camshaft follow the motion, moving up and
down. When the nose of the lobe faces up, the
valve is all the way open. The camshaft turns at
the half the speed of the crankshaft so that the
valves open and close at the correct time during
the combustion cycle.

ENGINE COMPONENTS
CAMSHAFT
Parts of Camshaft
All camshaft have Bearing Journal (1) and Cam Lobes (2).

ENGINE COMPONENTS
CAMSHAFT
Camshaft Bearing
The Camshaft Journals

ride in the bearing.
The Camshaft bearings are

pressed fit into the bores in the
engine block. They contain an oil
hole that lines with an oil passage
in the block.

ENGINE COMPONENTS
CAMSHAFT
Types of Camshaft
Separate lobes operate the

intake and exhaust valves for
every cylinder.
Some Cams have fuel

injection lobes which operate unit
injectors. These control when fuel
is injected into the cylinder.

1. Intake 3. Injection Pump 2. Exhaust
1. Intake 2. Exhaust

ENGINE COMPONENTS
CAMSHAFT
Parts of Cam Lobes
1.Base Circle
2. Lift – the distance from the base circle

diameter to the top of the nose. It determines
how far valves are opened.
( RAMPS) – the shape of the opening and
closing ramps determine how fast the valves open
and close.
3. Nose – the shape of the nose
determines how long the valve is fully opened..

ENGINE COMPONENTS
CAMSHAFT
Valve Lifter
- a valve lifter or cam
followers rests on each cam lobe
of the camshaft. As the camshaft
turns the lifter follows the shape
of the lobe.
Purpose:
- transmits the motion of
the camshaft to the push rod.
-there are two types of

valve lifter:

ENGINE COMPONENTS
CAMSHAFT
Valve Lifter
1. Roller Follower – Have a
hardened steel roller that rolls on
the camshaft lobe. It slide up and
down in bores in the engine block
and are kept aligned by special
clips.
2. Slipper Follower – are
usually one piece castings with a
wear face that contacts the lobe.
It slide up and down in bores in
the engine block, and rotate
slowly while the engine is
operating.
ENGINE COMPONENTS
CAMSHAFT
Push Rods
- are steel tubes with seats
on both ends. The camshaft moves
the push rod causing it to lift the
rocker arms.
Purpose:
- transmits motion from the
valve lifter to the rocker arms The
lower end of it contacts the valve
lifter and the upper contacts the
rocker arm.

ENGINE COMPONENTS
REPLACEALE PARTS
- some components which

are most susceptible to wear are
designed to be replaced. These
include cylinder liners, piston rings,
main and con-rod bearings.

ENGINE COMPONENTS
CYLINDER HEAD
In this segment, you will learn about cylinder head and the
function of each component. You will also learn how an overhead cam
engine operates and how its valve train differs from a push rod
engine.

ENGINE COMPONENTS
CYLINDER HEAD
The cylinder head is a separate casting which separate casting

which seals the top of the engine block and holds the valve, injector
or precombustion chamber in place.
The cylinder head also houses the valve train, some fuel
system components and water passages for cooling the parts.

ENGINE COMPONENTS
CYLINDER HEAD
Gasket, Spacer Plate, Cylinder Head and Bolts or Stud .
The cylinder head(1) is

sealed to the engine block with
gasket(2) a spacer plates(3)
either by bolts or studs and nuts.

ENGINE COMPONENTS
CYLINDER HEAD
Cylinder Head Casting
Depending on the engine

design, cylinder head can either
be a single casting that fits over
the block, or each cylinder or
group of cylinders can use its own
cylinder head.
Valve covers fit on top of
cylinder head and seal the top of
the engine. Many engines have
more than one valve cover.

ENGINE COMPONENTS
CYLINDER HEAD
Valve Train Assembly .

Bridges
Rocker Arms
Valve Cover
Valve Spring
Assembly
Valve Guides Cylinder Head
Valve Seat Valves

Inserts

ENGINE COMPONENTS
CYLINDER HEAD
Rocker Arms
As the push rod in the

block pushes up on the end of the
rocker arm, it pivots on the rocker
arm shaft and pushes and pushes
down on the valve mechanism
causing the valve to open.
- links the valves to the
As the camshaft continues
camshafts.
turning, the push rod lowers, and
- change the rotary motion the force of the valve spring
of the camshaft to reciprocating closes the valve.
motion in the valves.
Rocker Arm Shaft – ( not shown ) – rocker arm pivots on a rocker arm shaft
that is usually fastened to the cylinder head.
Adjusting Screw –
adjust valve lash Lock nut – locks screw in place to
maintain lash
Rocker Shaft Bushing – provides a bearing Wear Seat – hardened

between the rocker arm and the shaft. insert to prevent
rocker arm wear

ENGINE COMPONENTS
CYLINDER HEAD
Rocker Arms Equals Cam Lobes
- the number of rocker arms on an engine equals the number

of cma lobes on the camshaft.

ENGINE COMPONENTS
CYLINDER HEAD
Valve Lash
The rocker arm pivots on a
shaft that is usually fastened to
the cylinder head. When the cam
lobe starts to move the push rod
upwards there is usually a little
gap or clearance between the
rocker arm and valve bridge that
assures the valve is able to close
completely. This is called valve
lash and is one on the more critical
adjustments that must be made on
the valve train.

ENGINE COMPONENTS
CYLINDER HEAD
Bridges
- are if a cylinder has

multiple intake and exhaust
valves.
- the bridge assembly
transmits rocker arm motion to
all the intake or exhaust valves
on a cylinder simultaneously.
- has different parts and
functions:

Adjusting Screw – is used to
compensate for the
Wear Seat – is the contact point for differences in the height of
the rocker arm. valve stem.
Lock Nut – secures the adjusting

screw to maintain proper
adjustment.
Bore – fits over the bridge
dowel and holds the bridge in
place.
Bridge Dowel – fits on bridge

dowels. It is fit into the bores in
the cylinder head.
ENGINE COMPONENTS
CYLINDER HEAD
Valves
- every cylinder has at

least one intake and exhaust
valve which fit in the cylinder
head.
Purpose:
- control the flow of air
and exhaust gases through the
combustion chamber.
- has different parts and
functions:
Keeper Grooves – keepers fit into it on the
valve. Keepers hold the valve spring on to the
valve stem.
Valve Stem – extend the length of the valve.
Fillet Radius – joins the head to the stem.

Valve Seat – has a hard facing which reduces
wear and seals the combustion chamber.
Valve Face – the flat portion of the valve.

Valve Head – is ground to fit into the cylinder head.

ENGINE COMPONENTS
CYLINDER HEAD
Valve Seat Inserts
To completely seal the
combustion chamber, every
valve has a valve seat insert
located in the cylinder head.
Purpose:
- when the valve closes
the valve seat contacts the valve
seat insert, sealing the
combustion chamber.
- on most engines, the
valve seat inserts are
replaceable.
ENGINE COMPONENTS
CYLINDER HEAD
Valve Guides
Valves move up and
down inside valve guides which
are mounted in the cylinder
head.
Purpose:
- keep the valves
traveling in a straight line. The
valve stem extends out of the
guide on top of the cylinder
head.

ENGINE COMPONENTS
CYLINDER HEAD
Valve Spring Assembly
Valves Spring keep the
valve closed. Valve springs fit
over the valves
- are held in place by a

combination of keepers(1) and
either a retainer(2) or rotator.

ENGINE COMPONENTS
CYLINDER HEAD
Spring Retainer
Valves Spring Retainer(2)

fit on the end of the valve stem.
Retainers lock the keepers into
the grooves in the valve, and
provide a seat for the valve
spring to press against.

ENGINE COMPONENTS
CYLINDER HEAD
Keepers
Valves keepers(1) fit into

the keeper grooves on the valve
inside the circumference of the
valve spring. Keepers keep the
valve spring on the valve stem.

ENGINE COMPONENTS
CYLINDER HEAD
Valve Rotators
- are located on the end

of the valve stem if the valve
does not use retainer. It turns
the valves to prevent excessive
wear in one spot.

ENGINE COMPONENTS
CYLINDER HEAD
MAJOR WEAR ITEMS
- the valves, valve seat

insert and valve guides
experience the most wear
because of the high combustion
temperatures and pressures.All
are replaceable components.

ENGINE COMPONENTS
CYLINDER HEAD
Fuel Nozzles
- fuel nozzles or unit

injectors are also located in the
head.

ENGINE COMPONENTS
CYLINDER HEAD
Fuel Nozzle Mount
- fuel nozzles are held in

place with a sleeve, washers,
adapters and keepers.

ENGINE COMPONENTS
VALVE TRAIN DESIGN
- different
engine models use
different valve
train designs.
1. Push Rod Engine
2. Overhead cam
Engine
3. Cam in Head
Engine

ENGINE COMPONENTS
VALVE TRAIN DESIGN

1. Push Rod Engine
-engines which use

camshaft, valve lifter, push rod
and rocker arm are often called
“push rod” engines.

ENGINE COMPONENTS
VALVE TRAIN DESIGN

2. Overhead Cam Engine
- have a camshaft in the
cylinder head. Valve lifters are
linked to the top of the valve
stem.As the cam lobe rotates ,
the lifter follows the motions
and opens the valve. As the cam
continue to rotate, valve spring
force close the valve
- does not require push
rods.

ENGINE COMPONENTS
VALVE TRAIN DESIGN

3. Cam-in-Head Engine
- the camshaft is located

in the cylinder head. Rocker
arms ride on the lobes. As the
camshaft turns, the rocker push
the valves open.

ENGINE COMPONENTS
GEAR TRAIN ASSEMBLY
In this segment, you will learn about the component in the

gear train and the function of each components.

ENGINE COMPONENTS
GEAR TRAIN ASSEMBLY
- is a series of gears that

transfer power from the
crankshaft to other major
components in engine. Gear
trains may be located on the
front and back of the engine.
The gear train shown here is
located on the front of the
engine between the backing
plate and timing gear housing.

ENGINE COMPONENTS
GEAR TRAIN ASSEMBLY

- synchronizes all the
components in the engine so
they work together during each
stroke of the combustion cycle.
- consists of a rear plate
which bolts to the engine block,
the timing and idler gears, and a
timing gear cover.
- Typical gear train have

different components:

Water Pump Air Compressor
Idler Camshaft
Crankshaft Fuel Injection

Pump
Oil Pump

ENGINE COMPONENTS
GEAR TRAIN ASSEMBLY
1. CRANKSHAFT GEAR
- is mounted on the
crankshaft. As the crankshaft
turns, the gear turns as well. All
other components are timed and
driven by the crankshaft and
crankshaft gear.

ENGINE COMPONENTS
GEAR TRAIN ASSEMBLY
2. IDLER GEAR
- keep the camshaft gear

turning the same direction as
the crankshaft gear. The gear
ratios that ensure that the
camshaft turns at ½ the speed
of the crankshaft.

ENGINE COMPONENTS
GEAR TRAIN ASSEMBLY
3. CAMSHAFT GEAR
- is meshes with the idler

gear.It turn a half the speed of
the crankshaft to make sure the
intake and exhaust valves open
and close on the correct stroke.

ENGINE COMPONENTS
GEAR TRAIN ASSEMBLY

4. FUEL PUMP GEAR
- is driven by the
camshaft gear. Since they are
the same size, they both turn at
the same speed. The fuel pump
gear turns the fuel pump
camshaft,which works with the
fuel system components to
deliver fuel to the engine at the
proper time.

ENGINE COMPONENTS
GEAR TRAIN ASSEMBLY
5. OIL PUMP GEAR
- is driven by the
crankshaft gear. It circulates oil
throughout the engine.

ENGINE COMPONENTS
GEAR TRAIN ASSEMBLY
6. WATER PUMP GEAR
- water pump is driven by

the water pump gear and
circulates coolant throughout
the engine. It is usually driven at
the same speed as the
crankshaft.

ENGINE COMPONENTS
GEAR TRAIN ASSEMBLY
7. AIR COMPRESSOR GEAR
- some engines use an air

compressor to supply air to
brakes and other components.
The air compressor is driven
from the gears in the gear train.
A.C. gear meshes with the idler
gears and turns at the speed
recommended by the
manufacturer.

ENGINE COMPONENTS
GEAR TRAIN ASSEMBLY

TIMING MARKS
- are used to align the

gears and help ensure proper
timing.

ENGINE COMPONENTS
GEAR TRAIN ASSEMBLY

BALANCE GEAR
- some engine models use

it. The shafts are driven from the
crankshaft. In this example,
there is a balance shaft on each
side of the engine. The balance
shaft eliminates excess vibration
of the crankshaft.

ENGINE COMPONENTS
GEAR TRAIN ASSEMBLY

PULLEY ASSEMBLY
- attached to the
crankshaft drives drives other
components like fans or
alternator.

ENGINE COMPONENTS
GEAR TRAIN ASSEMBLY

TIMING GEAR HOUSING
All The timing gear are

protected by the timing gear
housing. The timing gear
housing seals the front of the
engine block.

ENGINE COMPONENTS


Basic Engine Components

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Service Training Center

Service Training Center

After completing this topic, you will able to identify the

Service Training Center

In this segment, you will learn about each component in the

Service Training Center

The block assembly is where the power is created. Lets look at

Service Training Center

The engine block is the

Service Training Center

The engine blocks come in

Service Training Center

The engine blocks are

The water passages are

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Cylinders can be cast

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PARENT BORE ENGINE

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Wet Liners Dry Liners

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Fire dam - seals the combustion chamber

Flange – supports the liner in the block

Outside surface - forms the water jacket wall

O-ring Grooves – hold O-rings which seal the water

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The piston which transmit

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There is an under crown

Some pistons contain oil

Service Training Center

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2 There are two styles of

2. Direct Injection pistons

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Each piston has two or more

Service Training Center

There are two types of

Compression rings seal the

There is usually one control

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Because of the high combustion temperatures and constant

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PISTON COOLING JETS

Some engines use piston

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- it transmit the force of

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4. Bore and Cap – are the

- is located in the bottom of the engine block. The Con-Rods

- it transmit rotary motion to the flywheel which provides

2. Web – hold together the rod and main journal.

3. Main Bearing Journal – support the crankshaft in the block.

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Drilled Oil Passages – The crankshaft

Upper Half – fits into the main

Oil Hole – usually a slot so lubricating

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2. Ring Gear – fits on the

3.Flywheel Housing – houses

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