ENGINE CONSTRUCTION

ENGINE
• Is a machine that converts heat energy into mechanical energy. The
heat from burning a fuel produces power which moves the vehicle.
INTERNAL COMBUSTION ENGINE
• The fuel that runs them is burned internally, or inside the engines.
TWO TYPES OF INTERNAL
COMBUSTION ENGINE
RECIPROCATING (PISTON ENGINE)

• Means moving up and down, or back and forth. They have pistons
that move up and down or reciprocate in cylinders
ROTARY ENGINE
• Have rotors that spin, or rotate.
TWO KINDS OF PISTON ENGINE
 SPARK-IGNITION ENGINE (GASOLINE
ENGINE)
• Usually runs on a liquid fuel such as gasoline or an alcohol blend. Heat from an
electric spark produced by the ignition system sets fire to, or ignites the air and fuel
mixture.
 COMPRESSION IGNITION ENGINE (DIESEL
ENGINE)
• The fuel mixes with air after it enters the engine cylinders. The hot air or heat of
compression ignites the fuel. Method of ignition by heat of compression.
ENGINE CONSTRUCTION
GASOLINE ENGINE AND DIESEL ENGINE ARE
SIMILAR IN CONSTRUCTION

• Both have cylinders blocks, cylinder heads, crankshafts, and bearings.

Also both have pistons, connecting rods, valve trains. The main
difference between spark ignition parts and diesel engine parts is that
diesel parts are usually heavier and stronger. This is because the
internal pressure are higher in diesel engines.
CYLINDER BLOCK

• Is the foundation of the engine. All other engine parts are assembled
in or attached to the cylinder block. The block is a casting that has
large holes for the cylinder bores, it also has water jackets and coolant
passages.
Water jackets - are the spaces between the cylinder bore and the outer
shell of the block. Coolant flows through these spaces to pick up heat
and carry it away from the engine.
PARTS ATTACHED TO AND INSTALLED IN
BLOCK
CRANKSHAFT WITH MAIN BEARINGS.
• The crankshaft fits into bearings in the main bearing caps and block.
 PISTONS, WITH RINGS INSTALLED AND
CONNECTING RODS.
• The connecting rods, with rod bearings, are attached to the crankpins on the
crankshaft.
CYLINDER HEAD WITH VALVES AND CAMSHAFT
• OHC ENGINES
CYLINDER HEAD
• Forms the top of the combustion chamber. Heads are cast iron or
aluminum alloy.
 OIL PUMP
• Sends oil from the oil pan to the moving engine parts.
 OIL PAN
• Is plastic or metal. It is shaped to fill on the bottom of the block. A gasket is installed
between the pan and block to seal the joint and prevent oil leaks.
COMBUSTION CHAMBER
COMBUSTION CHAMBER

• The space between the top of the piston and the cylinder head, in
which the fuel is burned.
 WEDGE TYPE

• Increases the turbulence of the burning mixture, but has high exhaust emissions
HEMISPHERIC TYPE
• Provides relatively slow burning
CUP OR BOWL-IN-PISTON
• Improves turbulence in diesel, turbocharged, and high-performance
engines.
CRESCENT OR PENT-ROOF
• Is easily varied to change the compression ratio and turbulence.
Greater turbulence causes the air-fuel mixture to burn faster.
 SWIRL-TYPE- COMBUSTION CHAMBER
• Another way to improve turbulence is to use a high-swirl intake port and a masked
intake-valve seat.
 PRE COMBUSTION CHAMBER
• Is a separate small combustion chamber where combustion begins.
• Spark-ignition engine using a pre-combustion chamber is a stratified-charge engine.
“Stratified” means in layers. Ignition begins in a layer or pocket of rich mixture which is
surrounded by a learner mixture .
 CYLINDER-HEAD
GASKET
Seals the joint between the cylinder
head and the cylinder block.
Tightening the head bolts forces
the soft material of the head gasket
to fill any irregularity. This seals the
joint.
 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.
 EXHAUST MANIFOLD
Is a set of tubes. It carries exhaust
gas from the cylinder head to the
exhaust system. The manifold
attaches to the head so the
exhaust ports in the head align with
the tube openings.
 CRANKSHAFT
Is a one-piece casting or forging of
heat-treated alloy steel. Counter
weights placed opposite the
crankpins balance the crankshaft.
 VIBRATION DAMPER
Helps control torsional vibration.
The damper mounts on the front
end of the crankshaft. This forms
the hub to which the crankshaft
pulley attaches
 ENGINE BEARINGS
Are placed in the engine where
there is rotary motion between
engine parts. These bearings are
usually sleeve bearings that fi like
sleeves around the rotating shafts.
The part of the shaft rotates in the
bearing is a journal.
 THRUST BEARINGS
Limits crankshaft endplay. The
thrust 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 of the crankshaft.
 BEARING OIL
CLEARANCE
Oil clearance varies, with
0.0015 inch typical for new
bearings.
 CONNECTING RODS
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
“rod big end”. The other end is the
rod “small end”.
 PISTONS
are made of aluminum alloy
(aluminum mixed with other
metals). The piston is slightly
smaller than the cylinder, which
allows the piston to slide up and
down. This is a sliding fit.
 PISTON RINGS
to prevent excessive blow
by, piston rings are installed on the
piston.
TWO TYPES OF PISTON RINGS
1. COMPRESSION RING
these form a sliding seal
between the piston and the cylinder
wall.
2. OIL-CONTROL RINGS
these scrape off most of the
lubricating oil splashed on the
cylinder wall, and return the oil to
the crankcase.
 ENGINE VALVES
are plugs with long stems
that open and close the ports in the
cylinder head.
 INTAKE VALVES
opens during intake stroke
and then the air and fuel mixture
can pass through the port.
 EXHAUST VALVE
open during exhaust stroke
and then the burn gasses will exit
through the port.
Arrangement of Cylinders
Three, four, five, six, eight and twelve cylinders are used in car engines. Buses and
trucks
use twelve and sixteen cylinder engines. The engine cylinders can be arranged in the
following
ways (Fig. 2.12).
(a) In a row (in-line)
(6) In two rows or banks set at an angle (V-type)
(c) In two rows, opposing each other (flat, or pancake)
Introduction to the engine valvetrain
The valve train refers to the assembly of components designed to open and close the
intake and exhaust valves. Most new engines have overhead cam assemblies like the
one shown. Other designs locate the camshaft lower in the engine and use push rods
to move valve assemblies. The camshaft is rotated by a timing belt, timing chain or
direct gear.
Camshaft:
The camshaft (1) is manufactured with precisely machined lobes (2) which control
valve opening. The number of lobes on a shaft is determined by the number of
valves the shaft controls. Some engines use one shaft to control both intake and
exhaust valves. Others have dedicated camshafts for each valve type. Engines
designed with four valves per cylinder are normally equipped with dual camshafts
for each row of cylinders.
Cam Lobe:
Cam lobes (2) are precisely machined into shapes which determine when the valve
opens in relation to piston position, how far the valve is displaced, and the length of
time the valve remains open. The distance between the end point of the base radius
and the nose controls valve displacement. The geometry of the sides (flank) and
nose determine how long the valve remains open.
Cam Follower:
The cam follower (3) is seated on top of the valve stem and spring (4)
and is the surface upon which the cam lobe pushes to open the valve. The
follower slides up and down within a bore machined in the cylinder head.
Push Rod:
Engines designed with the camshaft located in the engine block use push
rods (2), acting on rocker arms (3), to open valves. Push rods are seated
on valve lifters (1) or tappets which ride on the camshaft lobes.
Hydraulic Lifters:
Hydraulic lifters are used most often since they can reduce valve train noise by
maintaining zero valve clearance (no spacing between valve train components.) The
oil filled lifters adjust automatically for changes brought on by temperature
variations and wear of parts. Engine motor oil fills the inside of the lifter, pushing
the lifter plunger up until all the play in the valve train is removed.
Mechanical Lifters:
Mechanical lifters, also called solid lifters, simply transfer cam lobe action to the
push rod. They do not contain oil and are not self adjusting. As a result, they require
periodic adjusting. Valve trains using mechanical lifters are prone to a clicking or
clattering noise as the valves open and close. This is why hydraulic lifters are more
common.
Roller Lifters:
Roller lifters are either mechanical or hydraulic. Designed into
the lifter is a roller that rides the cam lobe, reducing friction
between the camshaft and lifter. Friction between these two
components is one of the highest friction points in an engine.
Spring Retainer:
The spring retainer is designed to hold in place the valve stem
tip. This allows the rocker arm to act directly on the valve.
Timing Chain:
Timing chains are becoming the standard for turning both the intake and exhaust
camshafts. The chains are located on the engine's front end, and are pulled by a
drive sprocket (1), which is turned by the engine's crankshaft. Timing chains are
required for both the intake cam sprocket (2) and the exhaust cam sprocket (3). A
chain guide (4) is also provided. Some engines still use belts instead of chains. In
either case, excess slack or play will degrade engine performance.
Timing Belt:
A timing belt instead of
a timing chain may be
used to turn the
camshafts. The inner
side of the belt is
designed with square
(cogged) teeth which
prevent the belt from
slipping. The belt should
be checked periodically
for wear and proper
Belt Tensioner:
The belt tensioner is a spring-
loaded wheel which keeps the
timing belt in tension and
aligned with the cam sprocket.
The smooth side of the timing
belt rides over the tensioner. The
tensioner applies a force on the
backside of the belt. This keeps
the belt in tension. Whenever the
belt needs to be removed, the
tensioner can be pulled away,
freeing the belt.
Valves:
Each cylinder has at least one intake
valve (1) and one exhaust valve (2).
Some engines are designed with two sets
of valves per cylinder as shown in the
photo. The intake valve has a larger
diameter than the exhaust valve, which
maximizes air flow to the cylinder. The
exhaust valve must withstand higher
temperatures than the intake valve since
the air flowing past the intake valve
keeps the intake valve at a lower
temperature. However, both intake and
exhaust valves must transfer their heat to
the cylinder head otherwise they will
burn.
Valve Springs:
Valve springs (4) provide a resisting force that returns displaced valves to
their closed position. The spring may be a one-coil design or a two-coil
design which has inner and outer coils. The second coil increases the
amount of force holding the valve closed.