LV06 Engines

Engines (1) LV06
LV06 Engine - Copyright © Automotive Skills 2003 Ltd. All rights reserved.
Introduction
On completion of this module you will be expected to
effectively:
• describe the operating principles of petrol engines
• describe the operating principles of diesel engines
• identify the components used in petrol engines
• identify the components used in diesel engines
• describe the features of petrol engines
• describe the features of diesel engines
The Engine
Main Engine Components
The Engine
Main Engine Components:
• Inlet Valve:
Opens at the correct time to allow the air/fuel mixture into the cylinder.
• Exhaust Valve:
Opens at the correct time to allow the burnt exhaust gasses out of the cylinder.
• Spark Plug:
Ignites the air/fuel mixture in the cylinder which creates rapid burning producing
tremendous pressure in the cylinder - this pressure is transferred to the piston.
• Piston:
The piston travels up and down the cylinder. The pressure on the piston is then
transferred to the crankshaft.
• Crankshaft
The pressure on the piston is transferred to the crankshaft via the connecting rod, which
converts reciprocating action of the piston to rotary motion of the crankshaft.
Progress check 1
Component Function

1 Spark plug Ignites the air/fuel mixture in the cylinder

Opens at the correct time to allow the air/fuel mixture into the
2 Inlet valve
cylinder

Exhaust Valve
3 Opens at the correct time to allow the burnt exhaust gasses out

of the cylinder

4 Piston Moves up and down the cylinder and forms one portion of
the combustion chamber

5 Piston rings A gas tight seal is formed between the piston and the cylinder

bore

6 Connecting The pressure on the piston is transferred to the crankshaft

Rod

7 Crankshaft Converts reciprocating action of the piston to rotary motion

via the connecting rod

8 Flywheel Stores kinetic energy to keep the engine running during none

power strokes.

Four Stroke Petrol Engine
The Petrol Engine Four Stroke Cycle
N. A. OTTO
Nicolaus August Otto invented the four stroke cycle. He

was born on 14 June 1832 in Holzhausen (Germany) and
died on 26 Jan 1891 aged 59 in Cologne.
Otto began his first experiments with four-stroke engines
and in 1864 together with Eugen Langen he founded the
first engine company N. A Otto and Cie. He was elected to
the Automotive Hall of Fame in 1996.
The basic operating principles of the four-stroke engine
have been around for more than 100 years. Rest assured
that under all those sensors and electronics the same basic
principles of engine operation still exist.
The Petrol Engine
Four Stroke Cycle
The Operating Principle of a

Petrol Engine
Four Stroke Cycle
The Induction Stroke
Inlet Valve Exhaust valve
Induction
The inlet valve is

open and the piston
is moving down the
cylinder Piston
Connecting rod
Crank shaft
Four Stroke Cycle
The Compression Stroke
Compression
Both valves are

closed and the piston
is moving up the
cylinder compressing
the fuel/air mixture
Four Stroke Cycle
The Power Stroke
Power
The piston is forced
down the cylinder
due to the burning
and expanding gas
Four Stroke Cycle
The Exhaust Stroke
Exhaust
The exhaust valve is open
and the piston is moving
up the cylinder
Four Stroke Cycle
Summary of Operation
Induction Compression Power Exhaust

stroke stroke stroke stroke
Four Stroke Cycle
Progress check 2
Stroke Piston Travel Intake Valve Exhaust Valve
Induction Down Intake air/fuel is enters the Open Close

cylinder from the atmosphere
Compression Up
The intake of air/fuel is
Closed
Closed
compressed
Power Down
The compressed air/fuel is Closed

Closed
ignited
Exhaust Up
The burnt mixture (exhaust)
Closed Open
is discharged from the
cylinder to the atmosphere
Four Stroke Cycle
Progress check 2
When the spark plug ignites the new mixture that has entered the
cylinder which component is the energy transferred to?
a) Piston
b) Piston rings
c) Exhaust valve
d) Inlet valve
The Four Stroke Cycle
Progress check 2
The induction stroke:

opens
On the induction stroke, the inlet valve ____________ piston
and the ____________
moving down, creates a depression (this is a pressure which is less than
atmospheric pressure) mixture of air/fuel, which has become ____________
vaporised is
being pushed into the cylinder via the open ____________
inlet valve by atmospheric
pressure (a high pressure always flows to a low pressure trying to make pressure
equal again).
The compression stroke:
upwards
When the piston reaches its lowest limit of travel it then moves ____________ as
this happens the inlet valve ____________The
closes exhaust valve remains closed, so
the cylinder is sealed, nothing can get out or in. As the piston moves upward the
air/fuel mixture (a gas) is ____________
compressed to about one tenth its original volume.
Thus the compression of the mixture increases the ____________
pressure and
____________
temperature in the cylinder.
The Four Stroke Cycle
Progress check 2
The power stroke:
top
As the piston reaches the ____________ compression
of its travel on the ____________stroke, a
ignites
spark from the spark plug ____________ the mixture, the mixture burns very rapidly
increases to approximately 40 times atmospheric
and the cylinder pressure ____________
pressure. All of this pressure acting against the piston forces it down the cylinder.
power
The ____________ is transmitted through the connecting rod to the crankshaft, which
rotated
is ____________due to the force acting on it.

The exhaust stroke:

bottom
As the piston reaches the ____________of exhaust valve
its travel (stroke) the ____________
opens, the expanding gas escapes to atmosphere via the exhaust valve port, the
up
piston then starts to move ____________ the cylinder forcing the remaining burnt
gasses out through the exhaust valve port, when the piston reaches the top of its
exhaust valve closes and the inlet valve opens again, the ____________
travel the ____________ four strokes
continue to repeat during engine operation.
Compression Ratio
Bore and Stroke
Compression Ratio
Calculating
Example:

V1 + V2 =
Note: V1
Combustion chamber
32 cc + 315 cc
volume is often 32 cc
referred to as the
Compression Ratio
clearance volume
(V1) = 10.8 : 1
Cylinder Volume is
often referred to as
the piston swept
volume (V2)
Four Stroke Diesel Engine
The Diesel Four Stroke Cycle
Rudolf Christian Karl Diesel
Rudolf Christian Karl Diesel

Born in Paris and was the son of an Augsburg Craftsman. Diesel was
surrounded by poverty almost all his life. He patented the cycle of
operation (four-strokes) of the compression-ignition engine in 1892/
1893. It was 1897 before he got one working. He spent the rest of his
life introducing his invention to the world.
Diesel had many problems with manufacturing, licensing and financial
stability. Once the engine had been proven he was a rich man
becoming a millionaire in 1898 from the sale of the rights to his
engine.
Rudolf Diesel 1853 -
His invention is widely used today in all types of transport and 1913
manufacturing.

Diesel Engines
A Typical Modern Diesel Engine
Diesel Engines
Pressure = 30kg/cm2 = 500/800°C
Progress check 3
Spark Ignition (Petrol) Compression Ignition (Diesel)

Power and speed are controlled by Power and speed are controlled by
varying the quantity of fuel and air varying the quantity of fuel injected
entering the cylinder
The engine can be made lighter due to Due to high pressures and vibration
less vibration and pressure heavier components are used
Fuel vaporises readily in the Fuel is safer to handle, is less volatile

atmosphere, therefore is more volatile and flammable, takes time to reach flash
point (ignition point)
Compression ratios are usually in the Compression ratios are 16:1 or more
region of 10:1, can be higher in special
cases but is limited by pre-ignition
A spark plug is used to ignite the fuel Compressing the in the cylinder causes
a rise in temperature, this in turn causes
the fuel to ignite
Fuel and air is normally mixed before Air only enters the cylinder
entering the cylinder. Fuel may be
injected directly into the cylinder.
The Petrol Engines Four Stroke Cycle
Progress check 3
On a four-stroke engine, during the compression phase, which
statement is correct?
Pressure will increase but temperature will remain constant

Pressure and temperature will remain constant
Pressure will remain constant but temperature will increase
Pressure and temperature will increase in the cylinder
How many revolutions will the camshaft do if the crankshaft rotates

80 times?
100
160
80
40
Two Stroke Petrol Engine
The Petrol Engine
Two Stroke Cycle
Developed by Dugald Clerk a Scotsman.
Joseph Day modified Clerk’s engine.
The two-stroke has fewer moving parts. No valves or camshaft.
Lubrication is achieved by mixing oil with the petrol.
The complete cycle of operation is carried out in only two-strokes

of the piston
A lighter flywheel can be used.
Lower efficiency than the four-stoke engine.
Poor scavenging
The Petrol Engine
Two Stroke Cycle
Compression
Exhaust
leaving the
cylinder
Crankcase
induction
Inlet port
closed
Transfer of
air/fuel
mixture into
the cylinder
The Petrol Engine
Two Stroke Cycle
Power Exhaust
Crankcase
induction
Crankcase
compression
A inlet port
B exhaust port
C transfer port
Two Stroke Cycle
Progress check 4

Answer the following questions:

1. One complete cycle is completed in ________degrees

360 of crankshaft
rotation
2. The crankcase is sealed in order to:

Ensure pressure is created below the piston which forces the mixture up
the transfer port into the cylinder
3. Advantages of a two-stroke engine over the four-stroke are:

a) Complete cycle of operation is carried out in only two strokes
b) A lighter flywheel can be used
c) Fewer moving parts
Four Stroke Cycle
Progress check 4
4. A four cylinder four stroke engine has a firing order of 1,3,4,2

firing. If the piston in number 2 cylinder is at TDC on the firing
stroke in which position is the piston in number 1 cylinder?
(a) TDC on the induction stroke

(b) BDC on the firing stroke
(c) TDC on the compression stroke
(d) BDC on the compression stroke
Two Stroke Diesel Engine
The Diesel Engine
Two Stroke Cycle
Exhaust
valves
Injector
Inlet ports Supercharger

(blower)
Air intake
Air box Air box
Progress Check 5
1. Complete the following:

compression
Heat to ignite the fuel in a diesel engine is produced by_______________

small
The combustion chamber in a diesel engine is _______because high
a _________
compression ratio is required

exhaust
The two-stroke petrol engine has a high loss of mixture through the ________

but the two-stroke diesel does not suffer this disadvantage because
air only is admitted

___________________
In the two stroke diesel engine the fresh charge of air is delivered by the use
supercharger
of a ____________
Progress Check 5
2. What is the turbo charger driven by?
• The intake air

• Drive belt
• Drive gear
• The exhaust gases
Rotary Engine
The Rotary Engine
Felix Wankel
The Wankel Engine

Felix Wankel conceived the idea of a rotary engine in 1924
and attempted a patent in 1926.
Prior to 1910, 2000 patents for rotary engines were filed.
There were also designs of rotary engines by Hornblower,
Murdoch, Bramah, Flint, Poole, Wright, Marriot, Trotter and at
least a dozen others.
Felix Wankel 1902 - 1988
The Rotary Engine
Reverse Rotary Engine
An example of an
alternative design of
rotary engine.
The next slides show

the one that has been
adopted for use in
modern times.
The Rotary Engine
A Typical Wankel Engine
The engine consists

of a rotor which is
free to rotate in a
oval chamber of a
special shape,
which is known as a
epitrochoidal.
Eccentric shaft gear is

not shown
The Rotary Engine
Main components
Apex
Rotor
Eccentric shaft and gear
Spark plug
Epitrochoidal shaped rotor
Rotor housing
The Rotary Engine
Position of the ports
Exhaust Port
Inlet Port
The Rotary Engine
The Induction Stroke
Induction
Inlet takes place

on a rotary engine
when the intake
Rotation anti-clockwise
ports are uncovered
by the rotor at
which time the
chamber open to
the port will be
increasing in
volume
The Rotary Engine
The Compression Stroke
Compression
Compression is
achieved on a
rotary engine as a
result of the rotor
moving in its
housing so that the
volume of the Compression
closed chamber is
decreased. The
decreasing volume
describes the
compression cycle.
The Rotary Engine
The Power Stroke
Power/Expansion
The force of the

Power/Expansion
expanding gas
pushes on the
rotor and in the
process rotates
the eccentric
shaft
The Rotary Engine
The Exhaust Stroke
Exhaust
The exhaust cycle

clears the contents of Exhaust
the chamber. The
leading apex of the
combustion chamber
uncovers the exhaust
port in the rotor
housing through which
the spent gas is
discharged.
The Rotary Engine
Summary
Fresh air/fuel
mixture is being
induced into
chamber A, from Start of exhaust
the inlet port. C
Chamber B is
decreasing in
size and is
approaching the
end of the Start of induction
Compression
compression
stroke. A B
Chamber C is at
the beginning of
the exhaust
stroke, and this
chamber is just
opening to the
exhaust port.
Progress check 6
1. Sketch the position of the rotor when on the power

stroke. State what is happening in the other two
chambers.
Progress check 6
2. In comparison to a reciprocating engine a Wankel engine

has:
a) More engine parts

b) Less engine parts
c) The same
d) The design of both engine types is the same
Valve Operating Mechanism
Valve Mechanism
Valves are the

greatest restriction
in the intake
system
Valve Operating Mechanisms
Push rod operated valves
Overhead Camshaft
Narrow valve stems

reduce intake and
exhaust resistance and
reduces weight
Overhead Camshaft
Twin Overhead Camshaft (DOHC)
Valve Train Operation
Chain drive
Chain drive
A silent chain with a 6.35mm pitch

makes the engine more compact
The chain tensioner uses spring and

oil pressure to maintain correct chain
tension
A ratchet type non-return mechanism

is used
An inspection port is provided to

release the tensioner
Gear drive
Belt drive
‘G’ Type ‘F’ Type
The scissor gear (sub-gear)
Petrol Engine Valve Timing
Valve Timing
Valve Timing
Valve overlap
Valve
inserts
Valve
seat
Inlet and Cylinder

exhaust valve head gasket
slightly open
at the same
time
Engine Valves
Overhead valve tappet clearance
The gap between the

valve and its operating
mechanism is known as
the valve clearance.
Valve clearance affects
valve timing - it is
necessary due to
expansion of engine
parts due to heat
Engine Valves
Overhead cam valve clearance
Cam
Feeler gauge
Checking Valve Timing
Belt driven camshaft
Install the crankshaft

pulley bolt and turn the
crankshaft two
revolutions clockwise
from number 1cylinder
(tdc to tdc)
Check the valve timing

ensure that both pulleys
line up with the marks as
shown
Checking Valve Timing
Belt driven camshaft
Direction
arrow
These match
marks must be
aligned
If the timing belt is removed to be re-used draw a direction

arrow on the belt to ensure correct direction of travel. Place
match marks on the pulley and belt as shown. Don’t forget that
correct timing belt tension is very important.
Multi-Valve Arrangements
Engine Layout and Components
Two and three valve layout
Exhaust port
Nissan three valve combustion

chamber, one exhaust port and
two inlet ports
Inlet port
Two valve wedge combustion

chamber
Exhaust port
Four and five valve layout
Inlet ports
Five valve combustion chamber.
Three intake ports at the top and
two larger exhaust valves are at
the bottom
Inlet ports
Exhaust ports
Four valve layout
Exhaust ports
Petrol Engine
Progress check 7
1. The main components of the piston and connecting rod (excluding the
piston and Inlet
connecting
ports rod assembly are:
Piston rings, combustion chamber, small end, big end, piston bosses
Gudgeon pin, main bearing, small end, piston bosses, crankshaft web
Piston rings, gudgeon pin, big end, small end, crankshaft journal
Inlet ports
Piston rings, gudgeon pin, big end, small end, piston bosses
2. In a 2 stroke motorcycle engine, what is the purpose of the piston
Exhaust ports
ring:
Prevent oil leaks

Seal the small clearance between the crankshaft journal and main bearing
Seal the small clearance between the gudgeon pin and small end
Seal the small clearance between the piston and the cylinder wall
Exhaust ports
Petrol Engine
Progress check 7
3. Which one of theports

Inlet following statements in relation to the four-stroke cycle
is FALSE
The inlet valve opens on the exhaust stroke

The exhaust valve opens on the firing stroke
Valve overlap occurs when both inlet and exhaustInlet ports
valves are open
The inlet valve opens on the induction stroke
Exhaust ports
Exhaust ports
Engine Configurations
Engine Configuration
The flat engine VW (air cooled)
‘Vee’ V-type engine
Square four engine
Crankshafts
Crankshaft connecting gear
Less conventional cylinder arrangements
Some less familiar cylinder
arrangements
Horizontal in-line
Radial Twin radial
Inverted in-line Triple in-line or Quad opposed

double ‘V’ cylinder
Multi-cylinder Engines
Single cylinder engines
When operating in the four-stroke cycle there is one

power stroke every 720 degrees.
When operating in the two-stroke cycle there is one

power stroke for every 360 degrees
The crankshaft torque is uneven and a heavy flywheel is

required to carry the crankshaft over the idle (non-
power) strokes. The power rapidly falls off between the
power strokes.
Multi-cylinder engines
The two-cylinder engine
The crankshaft torque is smoother that that of the single

cylinder when operated in the four-stroke cycle.
There is a power stroke every 360 degrees of crankshaft

rotation. This arrangement is often used for motor cycle
engines.
Multi-cylinder Engines
The four cylinder engine
This is the most popular arrangement, the cylinders are

arranged above the crankshaft in a line.
Pistons one and four are at top dead centre while piston two
and three are at bottom dead centre.
There is a power stroke every 180 degrees of crankshaft

rotation.
Torque output is smoother due to as one power stroke

ending another is beginning
Flywheel is lighter, balance is good, lighter pistons and

connecting rods can be used
Combustion Chambers
Type of Combustion Chambers
Hemispherical combustion chamber
This type has a very small

surface area thus heat loss
is kept to a minimum and
therefore a higher thermal
efficiency is achieved.
Larger valves can be used
but the mechanism is more
complicated.
Wedge type combustion chamber
There is less thermal

loss with this type of
combustion chamber
and the valve
mechanism is simpler
than that of the
hemispherical type
Bath tub combustion chamber
Simple construction and

least expensive - valve
diameter is limited and
efficiency is poor
Penthouse roof type combustion chamber
Exhaust
valves
Inlet valves
Exercise
Form three groups and ask each group carry out the tasks listed
below. Elect a representative to feedback to the groups
Group A
Discuss the relative merits of using DOHC valve arrangements over other
conventional systems, identify advantages and disadvantages.
Group B
Discuss why correct valve timing is essential and the problems that would be
caused if the valve timing was incorrect. Provide reasons for valve overlap.
Group C
Discuss multi-valve engines, provide reasons why manufacturers are
favouring four valves per cylinder over the conventional two valve system.
Petrol Engine Main
Components
Cylinder Block
Cylinder Liners
Cylinder block
without liners
Dry liner Wet liner
Cylinder Liner and Seals
Wet type
Cylinder liner
Cylinder block
Water jacket
Seals
Cylinder Head Layout
Four valves per cylinder
Tightening The Cylinder Head
(a) Torque each bolt to 29nm /

22 ft.-lb.
The Cylinder Head Gasket
Gasket cross-section
A typical piston
Piston construction
Piston Taper
Piston rings
Piston rings (operation)
Compression
rings prevent loss
of pressure during
compression and
combustion
Oil control rings

return the oil back
to the sump (oil
pan)
Piston pin
Piston pin as
viewed from
underneath the
piston
Semi and fully floating piston pins
Fixed type Fully floating type
Bolted type Press-fit type
Main Components of an Engine
A typical connecting rod
Big end
Little end
Main Components of an Engine
Connecting rod construction
Just before TDC, the position of the

crankshaft pin journal oil hole and the oil
jet coincide and oil is sprayed out
through the oil jet.
If the connecting rod is assembled with

the front and back reversed, the cylinder
will receive insufficient lubrication.
Crankshaft and bearings
Crankshaft
webs
Five main
bearings
Crankshaft Oil Seal
The lip type seal

as shown is
normally fitted at
the front and Lip seal
rear of the
crankshaft
Flywheel
Ring
gear
Clutch
face
Crankshaft
mounting
bolts
Clutch
pressure
plate dowels
Diesel Engine Main
Components
Diesel Engines
Direct injection chamber types
Multi-spherical Hemispherical Spherical
Diesel Engine Combustion Chambers
Direct injection type
Pre-combustion chamber
Swirl chamber type
Diesel Engine
Main components
Diesel Engine Combustion Chamber
Position of injector and glow plug
Glow plug
Injector
Swirl
chamber
Injector
Glow plug
Combustion
chamber
Diesel engine pistons
Direct injection type Indirect injection type
Diesel Engine Valve Timing
Diesel Engine
Timing gear valve train
Diesel Engine
Timing gear type valve train
Diesel Engine
Timing belt type valve train
Valve Operating Mechanism
Valve timing
Diesel Engine
Valve timing diagram
ve
Progress check 8
Diesel Engine Advantages and Disadvantages
Advantages of the diesel engine Disadvantages of the diesel engine
Greater thermal efficiency Greater noise level and vibration
More economical More expensive stronger structure
Does not require an ignition system Heavier
Torque (output power) remains virtually Require careful maintenance and

unchanged over a wide speed range, servicing due to a precise high pressure
low speed high torque fuel injection system
Suitable for commercial vehicles High compression pressures demand

better starter systems e.g. bigger
batteries
Published by Automotive Skills
201 Great Portland Street, London W1W 5AB
Tel: 020 7436 6373, Fax: 020 7436 5108
www.automotive-skills.org.uk
Automotive Skills wishes to thank the Sector Skills Development

Agency (SSDA) and the Learning and Skills Council (LSC) for
supporting the development of this Technical Certificate Learning
Material. It was produced in association with PROAUTO Ltd.
No part of this learning material may be produced, reproduced, stored

in any retrieval system or transmitted in any form or by any means,
electronic, photocopying, recording or otherwise without the prior
written permission of Automotive Skills.
Copyright © Automotive Skills 2003. All rights reserved.

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Engines (1) LV06

Nicolaus August Otto invented the four stroke cycle. He

The Operating Principle of a

The inlet valve is

Both valves are

Induction Compression Power Exhaust

Stroke Piston Travel Intake Valve Exhaust Valve

Induction Down Intake air/fuel is enters the Open Close

The compression stroke:

Rudolf Christian Karl Diesel

Pressure = 30kg/cm2 = 500/800°C

Fuel vaporises readily in the Fuel is safer to handle, is less volatile

Pressure will increase but temperature will remain constant

How many revolutions will the camshaft do if the crankshaft rotates

Joseph Day modified Clerk’s engine.

The two-stroke has fewer moving parts. No valves or camshaft.

Lubrication is achieved by mixing oil with the petrol.

The complete cycle of operation is carried out in only two-strokes

A lighter flywheel can be used.

Lower efficiency than the four-stoke engine.

1. One complete cycle is completed in ________degrees

2. The crankcase is sealed in order to:

3. Advantages of a two-stroke engine over the four-stroke are:

b) A lighter flywheel can be used

c) Fewer moving parts

4. A four cylinder four stroke engine has a firing order of 1,3,4,2

(a) TDC on the induction stroke

Inlet ports Supercharger

Air box Air box

1. Complete the following:

compression ratio is required

air only is admitted

2. What is the turbo charger driven by?

• The intake air

The Wankel Engine

Felix Wankel 1902 - 1988

The next slides show

The engine consists

Eccentric shaft gear is

Eccentric shaft and gear

Epitrochoidal shaped rotor

Inlet takes place

The force of the

The exhaust cycle

1. Sketch the position of the rotor when on the power

2. In comparison to a reciprocating engine a Wankel engine

a) More engine parts

Valves are the

Narrow valve stems

A silent chain with a 6.35mm pitch

The chain tensioner uses spring and

A ratchet type non-return mechanism

An inspection port is provided to

Inlet and Cylinder

The gap between the

Install the crankshaft

Check the valve timing

If the timing belt is removed to be re-used draw a direction

Nissan three valve combustion

Two valve wedge combustion

Four valve layout

Prevent oil leaks

3. Which one of theports

The inlet valve opens on the exhaust stroke