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THE PETROL ENGINE An engine convert (chenges ) energy stored in fuel in to mechanical energy.

An engine is source of power to drive the vehicle forward. ENGINE TERMES. 1- TOP DEAD CENTRE. ( T D C ) This is the point where the position of Crankshaft when the piston is has reached it s nerast point to the cylinder head. ENGINE TERMES ( B D C ) Bottom dead centre. 2- This is the lowest point the piston can reach. STROKE: This is distance between top dead centre (T D C )and bottom dead centre (B D C ). CYLINDER BORE: This is the diameter of the cylinder bore. ENGINE CAPACITY: This is total volume of or total piston displacement of all cylinder. The engine capacity =volume of one cylinder x number of cylinder. VOLUME. Of cylinder = AREA of the cylinder x stroke ( hight ). Area of cylinder = TTr2 = TTr2 x L = TTr2L Eg. Swept of one cylinder is 375cm3 ( CC) .cubic centre meter and the engine has 4 cylinders then the engine capacity is 375cm3 x 4 = 15000 or 1.5 litters. Nb 1 litter = 1000cm3 ( CC ). OPERATING PRINCIPLE: The 4 stroke engine ( petrol ). The following order of events is reaped at all the time when the engine is running. 1- The induction stroke: during this the piston moves down from T D C to B D C, inlet valve opens takes in mixture of air and petrol in to the cylinder. 2- Compression stroke: during this both valves are closed piston moves up and down from B D C to T D C compressing the mixture in to the combustion chamber. 3- Power stroke: during this the piston is forced down by resulting pressure of the burning gases. the pressure is due to the ignition of the mixture immediately by the spark plug before the end of compression stroke. 4- Exhaust stroke: during this the exhaust valve opens and the products of combustion (exhaust gases) are allowed out or cleared out of the cylinder.

THE ENGINE PARTS 1- Cylinder Block and Crank case . The cylinder block contains cylinders for the piston to operate in. The water jackets for lubricating the parts of the engine. The crankcase forms an enclosure. 2- Piston and Rings: it transmits (takes) the force of the burning gases to the crankshaft to rotating it. The piston Rings have the following functions. Function 1 . To maintain the gas tight seal between the piston and the cylinder wal under all normal temperatures, pressure and piston speeds Function 2 . To prevent the pasge of the lubricating oil to the combustion chamber. Function 3. To transfer heat from piston crankcase to the cooled cylinder wals TYPES OF PISTON RINGS. 1- Compression rings 2- Oil Rings Compression ring are used to prevent leakage of gases in to the crankcase. The two types of gases 1- Exhaust gases. 2-Mixture of petrol and Air. The leakage of gases in to crankcase is called BLOW-BY. OIL RINGS: To prevent oil being passed up to the combustion chambers and burnt. Rings are made of Cast iron Piston are made of Cast iron or Aluminum Alloy. THE DIFFERENT BETWEEN PETROL ENGINE AND DISEAL ENGINE. DISEAL ENGINE. It uses diseal as fuel It has an injector pump to build inject pressure. As injector, has injectors to injuect fuel into the cylinder or combustion chambers Takes inside air only Compresses air only to a high temperature when fuel is injected into the ignition takes place.

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PETROL ENGINE. 1- It uses petrol as fuel. 2- It has carburetor or [ E F I ] Electronic fuel injection. 3- It has spark plugs for ignition the mixture. THE FLYWHEEL. 1- The function of the flywheel is to keep crankshaft rotating smoothly.

2- The flywheel also forms one driving face of the clutch assemble. 3- It act as a gear for the engagement of the starter motor. VALVES. The valve is used to control the flow of gases in to and out of the cylinder and combustion chambers. Usually there is one inlet valve and outlet [Exhaust] but the engine with two valves of each type are also available. CAM SHAFT. The camshaft is to open the valves at the correct time hold it open for correct time in relation to the movement of piston. The camshaft is driven by crankshaft at half engine speed .eg. if the engine speed is 3000 revolutions per minute [ REV/ MIN or R.P.M.] The two position of the camshaft. 1- Over head Camshaft Place on to of the valves and drives the directly. 2- Side camshaft Placed in side the cylinder block push rods and rocker arms VALVE TIMING. This is an operation carried out to insure that the valve open in relation the crankshaft position. 1- Positioning the crankshaft 2- Positioning the camshaft 3- Connecting the two together. POSITIONING THE CRANKSHAFT [ ENGINE TIMING ]. 1- Turn the engine until number one [1] cylinder is on T D C compression by aligning the timing the marks on the crankshaft pulley and the timing cover. 2- Positioning the camshaft after timing the crankshaft timing aligned on the pulley. 3- Connect timing belt or chain. VALVES CLEARANCE. This is the clearance between the valve tip and the rocker arm, or the clearance between the cam lob and tappet the valve. Clearance is given to make sure that valve is fully closed by its springs under all working temperatures i.e to allow for expanion. The valve clearance is set with help of feeler gauges. And varies different engine. it may also vary between inlet and exhaust valves of the same engine eg. Inlet 0.30mm and exhaust 0.35mm. Valve clearance can be set when the engine is hot or cold. Too small valve clearance, the valve is not fully close this will couse . 1- The valves to be burnt 2- Loss of compression and power.

Too big valve clearance will lead to 1- Engine been noisy 2- Extra wear valves 3- Loss of power. CLEARANCE SETTING. Before setting clearance inlet and exhaust valves must be identified first. Because they have different clearances they are several motherds of carrying out valves adjustment. 1- One by Nine 2- Over lap motherds 3- Over run motherds. ONE BY NINE [ add one to the total number of valves ] If the clearance of number one is to be set, rotating the crankshaft until number eight [8] valve is fully open. If number two next the crankshaft is rotating number seven [7] valve is fully opened.

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Adjust Adjust Adjust Adjust Adjust Adjust Adjust Adjust number number number number number number number number 1 2 3 4 5 6 7 8 when when when when when when when when 8 7 6 5 4 3 2 1 is fully open is fully open is fully open is fully open is fully open is fully open is fully open is fully oprn

OVER LAP MOTHERD.

Overlap means both valves are open Overlap cylinder number four [4] and adjust number one [1] cylinder valve Overlap number two [2] adjust number three [3] Overlap number four [4] adjust number one [1].

OVER RUN MOTHERD Set the crankshaft to T D C compression adjust all the valves which are fully closed. Turn the crankshaft through one revolution and adjust all the valves which are closed.

CYLINDER HEAD. Cylinder head is made from Aluminium Alloy or cast iron it contains the valves . The head is attarched to the cylinder block by bolts or studs which must be tightened to the correct torgue in the correct order [sequence] this will prevent the head from bending [warping] or distorting.

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In tightening begins from middle out words. During loosing you start from out words eg. The reverse of tightening. The reason, the removal of the cylinder . 1- To replace the gasket 2- To decarbonized the cylinder head [to remove the carbon]. 3- To check the cylinder for cranks warping. To remove the cylinder head from the engine, remove or disconnect all the attarchement the cylinder head. 1- Drain the cooling system [ water ] 2- Remove the cylinder head cover

3- Remove the spark plugs/ injector 4- Loosen the bolts starting from out side working to the centre ie opposite to the tighten sequence. 5- Remove the cylinder from the cylinder block. 6- Using a suitable spring compressure compress each valves spring in turn and remove the valve retaining collects or locks 7- Remove all the valves from the cylinder head 8- Clean the cylinder head and the valves thoroughly. INSPECTION. 1- Check the cylinder head for cranks and corrosion [rest ]. 2- Check the head for warpage [bending ] using a straight edge and feeler gauge diagonally lengthwise. 3- If the cylinder is bent it can be resurfaced to bring it back to the serviced condtion. LUBRICATION SYSTEM. The function of engine system lubricatin is to reduce or minimize wear in engine moving part coused by friction.

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THE PARTS OF LUBRICATION SYSTEM Sump or tank A pump or pumps A pressure relief valve or bleed A pressure gauge or warning lamp switch A system of pipes or duts to the direct oil to filters A system of crankcase venting reduce the formation of Acids in the oil

PROPERTIES OF ENGINE OIL Viscosity is the oil resistance to flow . Thick oil flows very slowly and has high viscosity. Thin oil has a low viscosity and flows quickly

OILNESS OR BODY This is ability of the to maintain an unbroken film of the oil between two surface under all normal condition of speed and load . Oilness it is the oils resistance to been squeezed out by high pressure.

FLOW This is the ability of oil to sprayed over the surfaces and pass easly through small holes and clearances

GRADES OF ENGINE OIL Oils are graded according to the S A E / A P I . S A E Means society Automotive Engineers. A P I. Means American petroleum Institutes, The S A E number indicates the viscosity of oil Engine S A E grades are given below S A E 40 S A E 50 AND S A E 60 . Transimition oil are S A E 75, 80, 90, 140, and 250.

MULTI GRADE OIL. Oil contain an additive which reduces the effect of temperature on there viscosity ie thick an less when Cool and thin less Hot a multi grade oil has a letter W eg. 10 W / 30 which means the oil a viscosity of 10 at negative 18c and 30 grade 99c.

LUBRICATION SYSTEM FAULTYS. 123456No oil in the sump Fault warning lamp Blocked oil filter or dirty oil Oil pump not working Chocked / blocked oil ways Gauge broken.

( NO PRESSURE SHOWN )

LOW PRESSURE GAUGE READING 1234Faulty gauge Oil too thin or Engine too hot Pump filter partly chocked Low oil level.

SERVICING AND REPLACEMENT PROCCEDURE

1- Check the oil level use dip stick 2- Replacing the engine oil at given period of time or after given mileage eg. Every 5000km. CHANGING ENGINE OIL. 12345678910111213Park the vehicle on level ground ,pit or lift. Worm the Engine to normal working temperature. Put a container under the Engine ( sump ) Open the drain plug and remove it Remove the oil filer cap Remove the oil filter Allow the oil drain completely from the Engine Fit the oil filter Replace the drain plug Fil the Engine with a oil of correct grade Put back the filer cap Run the Engine for some time Check the oil level and an oil leak around the filter.

THE COOLING SYSTEM. The function of the cooling system is to remove excess heat from the Engine quickly and continuously the normal working temperature of an Engine is 75 to 90c the are two types of cooling system. 1- AIR COOLED 2- WATER COOLED AIR COOLING ( direct cooling ) Air cooling is used in motorcycles and Aircraft Engines. The cylinder heads and cylinder blocks are heavily finned to increase the dissipating area, Air coold engine cylinder head and block are made from Aluminum Alloys because they are good conductor of heat. Air cooled Engines run at higher temperature than water cooled Engines and they are more noisy

WATER COOLED ENGINES The simple cooling system consist of Water jackets, Radiator, water Pump, Thermostat, Hoses, Radiator cap and Fan

RADIATOR. The function of the Radiator is to expose the to the flowing air streem. THERMOSTAT. The function of thermostat is to control the flowing of water through Radiator when the Engine is cold it prevents water leave the water jackets ( thermostat open) in some vehicles it controls flow of air through the Radiator, the air flow is controlled by opening and closing a set of shutters in front of Radiator.

FUEL SYSTEM The fuel system consist of fuel tank, connecting pipes, fuel pump and carburetor. Petrol tank are made of steel pressing treated with un anticorrosive finish; One of the latest techniques being the electro point the tank with a very thin layers

Of water based point surging the fuel due to accelerating, breaking and conering is reduced by battled plates that divide the tank into interconnected compartments . The bottom of the tank is usually recsssed to create a dirts or sediment trap and screweel into this recess or dipression which is the loest point 1- Function of fuel tank is to store fuel. They are made still or plastic surging of the fuel due to accelerating vented ( hole ) in the cup to allow in air and to allow fuel vapour to escape. FUNCTION OF THE CARBURATOR The function of the carburetor is to mix the air and petrol completely atomize, or break up the fuel into

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