INTERNAL

COMBUSTION
ENGINES

SECTION 3

AUXILIARIES OF THE
INTERNAL COMBUSTION
ENGINE

AUXILIARIES OF THE INTERNAL

COMBUSTION ENGINE
The Cooling System
1.
Combustion releases energy.
It also produces excess .which must be removed.
Heat
2.
Alternate heating and cooling of gas causes metal parts to expand and
contract.
This constant expansion and contraction of the metal cause stress which can
..the metal.
Weaken, Damage
3.

To minimize damage to the engine, excess heat must be .

Removed

4.

Large, stationary engines are usually water cooled.

The engine block is hollowed out to form a

Water jacket
5.
A pump forces water to circulate through this water jacket.
If the water is cool, it absorbs from the cylinders and other hot
parts.
Heat

6.
Now this heated water can be drained off and fresh, cool water
pumped into the water jacket.

This method water.

Wastes
7.
To save water, the hot water leaving the engine is .and then
recirculated through the engine.
Cooled

8.

A radiator is a heat exchanger.

Hot water from the engine flows into the tubes.

Radiator
9.

The hot water from the engine flows (Around / Through) the tubes.
Through

10.

A fan forcesto circulate around the tubes.

Air

11.

The air absorbs the heat and the blows it away.

Fan

12. Then the pump forces this cooled water back through the to
absorb more heat from the engine.
Water jacket

13. Engines have a temperature at which operation is most efficient.

At startup, the temperature (Is / Is not) high enough for the engine to run
safely and efficiently.
Is not
14. If the cooling system operates fully from startup, the engine takes too
.to reach the most efficient temperature.
Long
15. To warm the engine up quickly, the water jacket is closed off from the
radiator by means of a thermostat.
The water is circulated only within the water jacket until the engine reaches
its temperature.
Efficient
16.

The drawing shows a cooling system with the thermostat in operation.

While the engine is cold, the thermostat valve closes the radiator off from
the ...
Water jacket
17. Cold water circulates through the (Water jacket and radiator / Only
through the water jacket)
Only through the water jacket
18. When the engine reaches the operating temperature, the thermostat
valve ..and allows water to circulate through both the radiator and the
water jacket.
Opens
19. The water temperature taken at the engine outlet is indicated on a
temperature gage usually located on the .panel.
Instrument

20. Each manufacture specifies a range of operating temperatures for his

specific engine.
In this operating range and above it, the thermostat stays (Open / Closed)
and (Restricts /Does not restrict) the flow of water.
Open, Does not restrict
21. When water temperature rises above the operating range, an alarm
usually goes off.
If the temperature still rises, a safety switch may automatically .the
engine,
Stop
22. Cooling systems may operate at atmospheric pressure or at high
pressure to permit a higher operating temperature.
Higher pressure permits the water to absorb more heat and (Increases /
Decreases) the efficiency of the cooling system.
Increases
23. Even under pressure, ordinary radiator cooling systems may not cool a
heavy industrial engine enough to keep it from overheating.
If the cooling water overheats, the .. itself overheats.
Engine
24. The capacity of the cooling system may be increased by running the
cooling water through a large, industrial heat exchanger.
This heat exchanger transfers heat from the hot water from the engine to the
.. water in the heat exchanger tubes.
Cool
25.

A radiator transfers heat from water to air.

The large heat exchanger transfer heat
from hot water to
Cold water
26. Water absorbs heat better than
air does.

The water in the heat exchanger tubes can absorb more heat from water than
..can.
Air
27. Evaporative coolers cool even more efficiently than heat exchangers
or radiators.

They use both .and.as cooling agents.

Air, Water
28.

Water from the evaporating cooler is sprayed on a ..coil.

Cooling

29.

As this water absorbs heat, it starts to ..

Evaporate / Vaporize

30. A fan forces these hot vapors out of the cooler, and the water being
sent back to the engine is .
Cooler / Cold
31. An engine may also be cooled by this high temperature cooling
system.

Part of the hot water coming to the cooler from the engine, flashes to
.in the flash tank.

Steam
32.

It does this by taking out of the water.

Heat

33. This steam removes the heat from the rest of the water, which is then
recirculated back through the ..
Engine
34. If the cooling water flows too slowly, it may carry pockets of steam
into the engine which may interfere with water circulation.
The flow of water must be .enough to maintain continuous
circulation and even cooling.
Fast
35. Fresh water or condensate from the system is continually supplied to
make up for .lost to the atmosphere from the flash tank.
Steam
36. Impurities in the cooling water form scale deposits on the walls of
water jacket.
If not prevented or removed, scale deposits interfere with cooling and cause
the engine to .
Overheat
37. Cooling water must be clean and free from materials which can form
deposits.
Distilled water or condensate from steam lines usually contains little or
nothing that forms ..
Scale / Deposits
38. The amount of pure water available usually determines whether the
cooling system is an open system or a .system.
Closed / Recirculating
39. In recirculating systems, an antifreeze solution is added to the cooling
water to keep it from ..if the engine operates in a cold climate.
Freezing
40. Lets Review

Heat exchangers work by transferring heat from a substance to a

.. substance.
Hotter, Cooler
A radiator (Is / Is not) a kind of heat exchanger.
Is
The main source of heat in the engine comes from .
Combustion / Burning

The Lubricating System

What is friction?
41. The sides of a piston and the cylinder in the engine look like this
(although you cannot see this without a microscope).

The metal appears to be (Smooth / Rough).

Rough
42. When two pieces of this rough metal rub together, the peaks on the
surfaces will probably ..off.
Break, Wear
43. These broken off particles act like sandpaper.
They .friction, which increases temperature.
Cause / Increase
44.

They can also .away metal surfaces.

Wear

45. Roughness and dryness resist the movement of metal surfaces against
one another.

Friction is the term for this.to movement.

Resistance
46.

Engine efficiency (Increases / Decreases) as friction increases.

Decreases

47.

Look at this drawing.

Oil on this piston separates the two metal surfaces so that they do not
..together.
Rub
48. In an IC engine, oil is used to reduce ..between moving parts.
It is also used to remove caused by this friction.
Friction, Heat
49. Oil has other functions, too.
We know that when two surfaces rub together, small bits of metal ..
Break off
50.

These small bits are carried away by the

Oil

51.

Look at these two pistons.

Because there is an open space between the piston and the cylinder wall,
combustion gases can.between the piston and the wall.
Leak
52. Since oil fills the space at B, the . prevents the leaking of gases
past the piston.

Oil
The acts as a seal.

53.

Oil
54.

The functions of oil in an engine are to:

decrease
remove small bits of ..
cool the engine by removing .caused by friction, and
prevent gas from..around the piston.
Friction, Metal, Heat, Leaking

Lubricating the Engine

55. Oil must be delivered to all metal parts of the engine that
against other parts.
Rub
56.

The .system delivers the oil to these moving parts.

Lubricating

57. Here is an example of a splash lubricating system used on some small

engines.

When the engine is not operating, the oil collects at the (Top / Bottom) of
the engine.
Bottom
58.

Oil collects in the .

Crankcase

59. Connected to the crankshaft is a dipper.

As the crankshaft turns, the dipper dips into the ..in the crankcase.

Oil
60. Since the crankshaft rotates very fast, the dipper moves through the oil
with great force, splashing oil over the engine parts.
The oil splashes up against the walls of the ..
Cylinders
61.

The dipper also splashes oil on the bearings and the turning ..
Crankshaft

62. Some of the oil is splashed inside the piston and up to the tops of the
connecting rod and its .pin.
Wrist
63. The oil is sent to the piston where it lubricates and seals the space
between the piston and the ..wall.
Cylinder
64. After lubricating the cylinder wall and bearings, the oil drips down to
the ..again.
Crankcase
65. Some of the oil from the dipper is splashed into grooves on the upper
block.
This oil lubricates the valve rocker arm parts and the camshaft before
returning to the ..
Crankcase
66. In large industrial engines, since the splash system is not large enough
to lubricate all moving parts, a forced lubricating system is used.
Because oil will not flow up by itself, an oil forces the oil to
circulate.
Pump

67.

The whole length of this crankshaft has channels bored into it.

These channels carry the ..to the different engine parts.

Oil
68.

The forces the oil through these channels.

Pump

69. Some of the oil passes through channels in the crankshaft to the
..which support the crankshaft.
Bearings
70. From the crankshaft, oil is forced up through the connecting rods to
the .
Wrist pins
71. The oil in the piston flows out of the piston and down the
..wall.
Cylinder
72. The pump also forces oil through the channels to the top of the engine
to lubricate the rocker arm parts and the
Valves

73.

This is a typical oil pump.

It consists of rotating ..
74.

Gears
The pump is driven by the
Camshaft

75.

The inlet to the pump is connected to a ..

Strainer

76. Lubricating oil returning from the engine parts gather in the
crankcase.
Heavy particles of dirt, collected during circulation through the engine settle
to the of the crankcase.
Bottom
77.

Therefore, the oil at the (Top / Bottom) of the crankcase is cleaner.

Top

78. A float on the .makes sure that only surface oil goes into the
pump.
Strainer
[

79. Dirt, water and sludge on the bottom of the crankcase are prevented
from getting into the oil pump by this floating
Strainer
80. Sometimes dirt, sand, and small metal particles remain in the
circulating oil.
The impurities are ..from the oil by oil filters.
Removed

81. Many engines use a filter in the lubricating system, through which all
of the oil from the pump must go before going to the engine parts.
This is called (Partial flow / Full flow) system.
Full flow
82. When a by-pass filter is used, only a small part of the lubricating oil
passes through the filter each time the oil is circulated through the engine.
All of the oil (Has to / Does not have to) pass through the filter in this
system.
Does not have to
83. After engines have been in operation for a while, oil filters may pick
up enough impurities to fill them.
Then these filters must be either ..or ..
Cleaned / Replaced
84. Some cleanable filters only have to have a handle on them turned
every few hours to keep them .
Clean
85. Lubricating oil after continuous use, breaks down chemically into
acids, tars, and sludge.
The oil must be .at regular intervals to keep the oil fresh.
Changed
86. Oil treatment systems remove undesirable chemicals from the oil.
By treating the lubricating oil, the number of oil changes needed is
(Increased / Reduced).
Reduced

Oil Cooling
87. In small engines enough heat escapes through the outside engine parts
to cool the lubricating oil adequately.
For example, the metal crankcase draws heat from the oil and the outside
removes heat from the crankcase.
Air

88. In larger systems, this arrangement (Can / Cannot) remove enough

heat to keep the oil at a safe temperature.
Cannot
89.

This drawing shows an oil cooling system for a large engine.

Excess heat from the oil is removed by a .exchanger.

Heat
90.

Water flows through the heat exchanger and around the .

Oil

91.

This is (An air cooled / A water cooled) system.

A water cooled

Oil Pressure
92. The lubrication system must build up enough to force oil
through engine parts.
Pressure
93. Excessively low pressure is undesirable.
The engine may not get .oil.
Enough
94. Excessively high oil pressure also indicates trouble.
A clogged filter causes oil pressure to (Increase / Decrease).
Increase
95. Oil that is too thick does not flow properly.
Pressure in the system ..
Increases

96.

This is a simplified drawing of an oil pressure safety valve or switch.

The oil .operates this valve.

Pressure
97.

Lubricating oil enters at the .of the valve.

Top

98. Oil pressure pushes down on the piston.

A ..pushes up on the piston against the oil pressure pushing down.
Spring
99. The piston is connected to a shut off valve.
The shut off valve shuts off the (Oil / Fuel) supply.
Fuel
100. As long as the oil pressure is high enough, it holds the shut off valve

Open
101. If the oil pressure falls too low, the spring the shut off valve.
Closes
102. Closing the shut off valve stops the engine by cutting off its
.supply.
Fuel
103. Lubricating systems usually have a gage on the instrument panel which
indicates oil .
Pressure

Air Cleaners
104. The air that ventilates the crankcase must be clean when it enters the
engine.
An air filter at the entrance to the crankcase dirt and other impurities
from the air.
Removes
105. The primary use of air in an IC engine is to mix with fuel for
combustion.
The air must also be
Clean
106. Dirty air can clog valves or carburetor parts.
Air must be cleaned (Before / After) it enters the carburetor.
Before
107. Engines use large amounts of air.
The air filter must be .enough to supply enough clean air to support
combustion.
Large
108. Impurities may be removed by passing the air through copper gauze
baffles and a felt filter.

This filtering system would most likely to be found at point (A / B / C).

A

109. An oil bath cleaner is an effective air filter.

As air comes into the cleaner, it is first forced to come into contact with the

Oil
110. Heavy particles stay suspended in the oil.
Then the air is forced up through the
Filter
111. The filter removes the (Smaller / Larger) particles from the air.
Smaller
112. Lets Review
Metal parts are lubricated to prevent between parts.
Friction
Friction generates which can harm the engine.
Heat
Oil lubricates and
Cools
A small engine may have splash lubrication system: this splash system (Can
/ Cannot) lubricate all the parts of a large engine.
Cannot
In a large engine, oil is forced to flow by an oil
Pump
Oil filters are used to keep oil ..

Clean

Chargers
113. Large amounts of air are needed to support combustion.
Air usually enters the ..at atmospheric pressure.
Carburetor
114. The amount of air entering the carburetor can be increased by
(Increasing / Decreasing) the air pressure.
Increasing
115. A supercharger is a compressor.

Or, a supercharger is a machine which increases

Pressure
116. The amount of fuel burned is limited by the amount of air available to
combine with the fuel.
Supercharging provides more air to burn more fuel, so that a supercharger
engine develops more power than one which operates at a ..pressure.
Atmospheric
117. At high elevations, Atmospheric pressure is lower than at sea level.
As engine operating at atmospheric pressure at high elevations develops
(More / Less) power than one operating at a lower elevation.
Less
118. Supercharging can produce high intake air ..at even high
elevations.
Pressure

119. In 2-cycle engines, supercharging supplies high pressure air.

High air pressure provides more complete removal of exhaust gases and
more intake air to combine with fuel for increased ..output.
Power
120. If air pressure decreases, power output (Increases / Decreases).
Decreases
121. To prevent inefficient operation, supercharge systems are equipped
with shutdown devices.

The shutdown device operates if pressure

Decreases
122. Air pressure from two sources acts on the .
Piston
123. As long as air pressure in the supercharger is (Higher / Lower) than the
set pressure, the piston keeps its valves .
Higher, Open
124. If the supercharger air pressure decreases, air from the set pressure
pushes up on the .
Piston
125. This pressure is strong enough to the valve.
Close
126. Then the engine.
Stops

Exhaust Systems
127. As power is produced by the engine, the burning fuel forms combustion
gases.
Exhaust gases leave the engine under enough pressure to keep a load
explosive .
Sound / Noise
128. This explosive sound is decreased by (Increasing / Decreasing) the
pressure of the exhaust gases before they are discharged.
Decreasing
129. A muffler between the exhaust manifold and the end of the exhaust
pipe the pressure, by allowing the exhaust gases to expand.
Decreases
130. Restricting the escaping exhaust gases too much reduces the power and
speed of the engine by creating a backpressure.
To be efficient, the muffler must let exhaust gases escape without much
restriction or without much .
Noise
131. Exhaust gases contain carbon monoxide, a deadly poison.
When engines are operated in closed buildings, the exhaust must carry all
exhaust gas to the .
Outside

REVIEW AND SUMMARY

132. Name the lettered parts of the drawing.

A.
Channels
B.
Oil pump / Oil lines
C.
Strainer / Float & Strainer
133. It represents a (Lubricating / Cooling) system.
Lubricating
134. Oil is forced through channels by the oil ..
Pump
135. The oil system shown would probably be found in a (Large / Small)
engine.
Large
136. Look at this drawing.

This is the system for an industrial engine.

Cooling
137. Heat is transferred from the engine to the ..water in the jacket.
Cool
138. The amount of air available for combustion can be increased by
increasing the of the air.
Pressure
139. Increasing air pressure can be done with a ..
Supercharger
140. Engine exhaust (Is / Is not) poisonous.
Is