CHAPTER 1

ENGINE
COMPONENTS &
CLASSIFICATION

SUMMARY

The topic covers basic theoretical knowledge

and understanding of engine components,
classifications and terminologies. Areas
involving engine construction, operating
principles and valve train

SYLLABUS

Understand engine construction

Explain

various types of internal combustion

engines construction and operation:

two-stroke petrol and diesel

four-stroke petrol and diesel
rotary/Wankel

Understand basic engine terminologies

Explain

basic engine terminologies such as

TDC, BDC, stroke, bore, displacement,
compression ratio etc.

Understand cylinder head and valve train

construction
State

the purpose of cylinder head

Describe various type of valve train:

OHV
OHC
Multivalve

Explain

typical valve timing diagram

Explain basic operating principles of:

VTEC
MIVEC
VVTI
CPS
DVVT

INTRODUCTION TO ENGINES

Engine provides the power to drive the vehicles

wheel.
Biggest part of the engine is the cylinder block.
The cylinder block is a large casting of metal
that is drilled with holes to allow for the
passage of lubricants and coolant through the
block and provide spaces for movement of
mechanical parts.
The block contains the cylinders, which are
round passageways fitted with pistons.
The block houses or holds the major mechanical
parts of the engine.

The cylinder head fits on top of the cylinder

block to close off and seal the top of the
cylinder.
The combustion chamber is an area into which
the air-fuel mixture is compressed and burned.
The cylinder head contains all or most of the
combustion chamber.
The cylinder head also contains ports through
which the air-fuel mixture enters and burned
gases exit the cylinder and the bore for the
sparkplug.

The valve train is a series of parts used to

open and close the intake and exhaust ports.
A valve is a movable part that opens and
closes the ports.
A camshaft controls the movement of the
valves.
Springs are used to help close the valves.

The up-and-down motion of the pistons must be

converted to rotary motion before it can drive
the wheels of a vehicle.
This conversion is achieved by linking the piston
to a crankshaft with a connecting rod.
The upper end of the connecting rod moves
with the piston.
The lower end of the connecting rod is attached
to the crankshaft and moves in a circle.
The end of the crankshaft is connected to the
flywheel.

ENGINE CLASSIFICATIONS

Operational cycles. (4 stroke or 2 stroke)

Number of cylinders. (3,4,5,6,8,10,12
cylinders)
Cylinder arrangement. (Flat, inline, V-type)
Valve train type. (OHC,OHV, DOHC)
Ignition type (Spark, Compression)
Fuel type (gasoline, natural gas, methanol,
diesel, propane, fuel cell, electric, hybrid)

ENGINE CONSTRUCTION

Types of internal combustion engines

construction:
4

Stroke petrol and diesel

2 Stroke petrol and diesel
Rotary/wankel

4 STROKE PETROL
Intake Stroke

Compression
Stroke

Power Stroke

Exhaust
Stroke

INTAKE STROKE

The first stroke of the cycle is the intake stroke.

As the piston moves away from top dead center (TDC), the intake
valve opens.
The downward movement of the piston increases the volume of the
cylinder above it, reducing the pressure in the cylinder. Low
pressure (engine vacuum) causes the atmospheric pressure to push a
mixture of air and fuel through the open intake valve.
As the piston reaches the bottom of its stroke, the reduction in
pressure stops, causing the intake of air-fuel mixture to slow down.
It does not stop because of the weight and movement of the air-fuel
mixture.
It continues to enter the cylinder until the intake valve closes. The
intake valve closes after the piston has reached bottom dead
center (BDC).
This delayed closing of the valve increases the volumetric efficiency
of the cylinder by packing as much air and fuel into it as possible.

COMPRESSION STROKE

The compression stroke begins as the piston starts to

move from BDC.
The intake valve closes, trapping the air-fuel
mixture in the cylinder.
The upward movement of the piston compresses the
air-fuel mixture, thus heating it up.
At TDC, the piston and cylinder walls form a
combustion chamber in which the fuel will be
burned.
The volume of the cylinder with the piston at BDC
compared to the volume of the cylinder with the
piston at TDC determines the compression ratio of
the engine.

POWER STROKE

The power stroke begins as the compressed fuel

mixture is ignited.
With the valves still closed, an electrical spark
across the electrodes of a spark plug ignites the
air-fuel mixture.
The burning fuel rapidly expands, creating a
very high pressure against the top of the piston.
This drives the piston down toward BDC. The
downward movement of the piston is
transmitted through the connecting rod to the
crankshaft.

EXHAUST STROKE

The exhaust valve opens just before the piston

reaches BDC on the power stroke.
Pressure within the cylinder causes the exhaust gas to
rush past the open valve and into the exhaust system.
Movement of the piston from BDC pushes most of the
remaining exhaust gas from the cylinder.
As the piston nears TDC, the exhaust valve begins to
close as the intake valve starts to open.
The exhaust stroke completes the four-stroke cycle.
The opening of the intake valve begins the cycle
again.
This cycle occurs in each cylinder and is repeated
over and over, as long as the engine is running.

It takes two full revolutions of the crankshaft

to complete the four-stroke cycle.
One full revolution of the crankshaft is equal
to 360 degrees of rotation; therefore, it
takes 720 degrees to complete the fourstroke cycle.
During one piston stroke, the crankshaft
rotates 180 degrees.

4 STROKE DIESEL

The operation of a diesel engine is comparable to a gasoline

engine.
They also have a number of components in common, (crankshaft,
pistons, valves, camshaft, and water and oil pumps.
However, diesel engines have compression ignition systems. Rather
than relying on a spark for ignition, a diesel engine uses the heat
produced by compressing air in the combustion chamber to ignite
the fuel.
The compression ratio of diesel engines is typically three times (as
high as 25:1) that of a gasoline engine.
As intake air is compressed, its temperature rises to 700C to
900C. Just before the air is fully compressed, a fuel injector
sprays a small amount of diesel fuel into the cylinder. The high
temperature of the compressed air instantly ignites the fuel.
The combustion causes increased heat in the cylinder and the
resulting high pressure moves the piston down on its power stroke.

4 STROKE DIESEL ENGINE

2 STROKE ENGINE

This engine requires only two strokes of the piston to

complete all four operations: intake, compression,
power, and exhaust.
This is accomplished as follows:
Movement

of the piston from BDC to TDC completes both

intake and compression.
When the piston nears TDC, the compressed air/fuel
mixture is ignited, causing an expansion of the gases.
During this time, the intake and exhaust ports are closed.
Expanding gases in the cylinder force the piston down,
rotating the crankshaft.
With the piston at BDC, the intake and exhaust ports are
both open, allowing exhaust gases to leave the cylinder
and air-fuel mixture to enter.

2 STROKE ENGINE

2 STROKE ENGINE

Although the two-stroke-cycle engine is

simple in design and lightweight because it
lacks a valve train, it has not been widely
used in automobiles.
It tends to be less fuel efficient and releases
more pollutants into the atmosphere than
four-stroke engines.

ROTARY/WANKEL ENGINE

The rotary engine, or Wankel engine, is

similar to the standard piston engine in that
it is a spark ignition, internal combustion
engine.
Its design, however, is quite different. For
one thing, the rotary engine uses a rotating
motion rather than a reciprocating motion.
In addition, it uses ports rather than valves
for controlling the intake of the air-fuel
mixture and the exhaust of the combusted
charge.

ROTARY/WANKEL ENGINE

CHARACTERISTICS OF ROTARY
ENGINE

The rotating combustion chamber engine is

small and light for the amount of power it
produces, which makes it attractive for use
in automobiles.
However, the rotary engine at present cannot
compete with a piston gasoline engine in
terms of durability, exhaust emissions, and
economy.

BASIC ENGINE TERMINOLOGIES

Bore cylinder diameter measured in inches(in) or

milimeters (mm).
Stroke length of the piston travel between TDC
& BDC.
TDC Top dead center
BDC Bottom dead center
If bore = stroke, the engine is called a square
engine.
If bore > stroke, the engine is called a oversquare
engine.
If bore < stroke, the engine is called a
undersquare engine.

Cylinder Displacement volume of the cylinder

when the piston is at BDC.
Engine displacement sum/total of the
displacement of each of the engine cylidners.
Typically, an engine with a larger displacement
produces more torque than a smaller
displacement engine.
Compression ratio comparison of a cylinders
volume when the piston is at BDC to the
cylinders volume when the piston is at TDC.
The

higher the compression ratio, the more power

an engine theoretically can produce.

ENGINE EFFICIENCY

Volumetric efficiency describes the engines

ability to have its cylinders filled with airfuel mixture.
If the engines cylinders are able to be filled
with air-fuel mixture during its intake stroke,
the engine has a volumetric efficiency of
100%.
Typically, engines have a volumetric
efficiency of 80% to 100%.

CYLINDER HEAD & VALVE TRAIN

Purpose of cylinder head

The

cylinder head fits on top of the cylinder

block to close off and seal the top of the
cylinder.
The cylinder head also contains ports through
which the air-fuel mixture enters and burned
gases exit the cylinder and the bore for the
sparkplug.

TYPE OF VALVE TRAIN

Overhead Valve (OHV)

Overhead Cam (OHC)
Multivalve

OVERHEAD VALVE (OHV)

The intake and exhaust valves in an OHV engine

are mounted in the cylinder head and are operated
by a camshaft located in the cylinder block.
This arrangement requires the use of valve lifters,
pushrods, and rocker arms to transfer camshaft
rotation to valve movement.

OVERHEAD CAM (OHC)

An OHC engine also has the intake and exhaust valves

located in the cylinder head.
But the cam is located in the cylinder head.
In an OHC engine, the valves are operated directly by
the camshaft or through cam followers or tappets.
Engines with one camshaft above a cylinder are often
referred to as single overhead camshaft (SOHC)
engines.

MULTIVALVE

A multivalve design typically has three, four, or

five valves per cylinder to achieve improved
performance.
Any four-stroke internal combustion engine
needs at least two valves per cylinder: one for
intake of air and fuel, and another for exhaust
of combustion gases.
Multi-valve engines tend to have smaller valves
have

lower reciprocating mass,

can reduce wear on each cam lobe,
more power from higher RPM without the danger of
valve bounce.

MULTIVALVE

Three-valve cylinder head

This

has a single large exhaust valve and two

smaller intake valves

Four-valve cylinder head

This

is the most common type of multi-valve

head, with two exhaust valves and two similar
(or slightly larger) inlet valves.

Five-valve cylinder head

Less

common is the five-valve head, with two

exhaust valves and three inlet valves. All five
valves are similar in size.

VALVE TIMING

Valve timing is the precise timing of the opening and closing of

the valves.
One way to look at this diagram is to think of these events in
terms of the position of the crankshaft and 360 degrees rotation.

VALVE TIMING

With traditional fixed valve timing, an engine will have a period

of valve overlap at the end of the exhaust stroke, when both
the intake and exhaust valves are open.

The intake valve is opened BTDC because to give enough time for
air-fuel mixture to get into the cylinder.

The intake valve is allowed open ABDC because to get advantages

of inertia created by velocity assists in drawing in the fresh
charge.

The exhaust valve is opened BBDC because the gases inside the
cylinder posses a higher pressure even after the expansion
stroke. This higher pressure enables it to reduce the work that
needs to be done by the engine piston in pushing out these gases.

The exhaust valve close ATDC because to give sufficient time for
exhaust gas exit through the exhaust valve. If the exhaust valve
is closed like in actual timing diagram, a certain amount of
exhaust gases will get compressed and remain inside the cylinder
and will be carried to the next cycle also.

VARIABLES VALVE TIMING

At low speed, a little valve lift already sufficient for

air/fuel to enter the cylinder.
The fuel consumption is better and enough for
cruising and low speed.
But at high speed, the valve need to open and close
very fast and need more longer time for air/fuel to
enter the cylinder.
Therefore, the valve lift must be higher and the
timing is longer.
If the engine has fixed valve lift and valve timing, the
performance will be bad.
To increase the performance of the engine and better
fuel consumption, variable valve timing is introduced.

VARIABLES VALVE TIMING

How it works?
As

the camshaft spins, the lobes open and close

the intake and exhaust valves in time with the
motion of the piston.
VVT is the process of altering the timing of a
valve lift event, and is often used to improve
performance, fuel economy or emissions.
Some cars use a device that can advance the
valve timing. This does not keep the valves open
longer; instead, it opens them later and closes
them later.
VIDEO

VARIABLES VALVE TIMING

Type of variables valve timing

VTEC

(Honda)
MIVEC (Mitsubishi)
VVTI (Toyota)
CPS (Proton)
DVVT (Perodua)

VIDEO

How an Engine Works - Comprehensive Tutoria

l Animation featuring Toyota Engine Technol
ogies

EXERCISE
1.
2.
3.
4.
5.

6.
7.

Explain how 4-stroke engine works?

Compare 2-stroke and 4-stroke engines.
Compare petrol and diesel engine.
Sketch and explain 4 process in the rotary
engine.
An engine has 4 cylinders. Each cylinder has
a bore of 5.15cm and its stroke is 6cm.
Calculate the engine displacements.
Draw and explain a typical valve timing
diagram for 4-stroke petrol engine.
What is valve overlap?

QUIZ 1
Chapter 1
9 July 2013 (Tuesday)

THANK YOU