IC ENGINE & AUTOMOBILE

ME 283
Lecture Content
• Engine Construction
• Air Intake System, Exhaust System
• Turbocharger, Supercharger
• Cooling System
• Lubrication System
• Fuel Supply and Injection System
• Transmission System

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 Engine
a. A machine that converts energy into mechanical force or
motion.
b. Such a machine distinguished from an electric, spring-
driven, or hydraulic motor by its use of a fuel.

Heat Engine
 It can be defined as any engine that converts thermal
energy to mechanical work output.
Examples of heat engines include:
steam engine, diesel engine, and gasoline (petrol) engine.

 On the basis of how thermal energy is being delivered to

working fluid of the heat engine, heat engine can be
classified as an internal combustion engine and external
combustion engine.
Heat Engine

Heat Engine

External Combustion Internal Combustion

Engine Engine
 Internal Combustion Engine (IC Engine)

 Internal combustion engines are those engines

in which the combustion of fuel takes place inside
the engine cylinder.
Examples: Petrol, Diesel, Gas Engine

External combustion engine

 Combustion of an air-fuel mixture transfers heat
to a second fluid which becomes the motive
(working) fluid that produces power.
Example: Steam driven engine
 Classification of I.C. Engine
The internal combustion engine may be classified
in many ways:

1. According to the type of fuel used :

a. Petrol Engine
b. Diesel Engine
c. Gas Engine

2. According to the method of ignition of fuel:

a. Spark ignition engines (SI engine)
b. Compression ignition engines (CI engine)
 SI Engine

 Generally homogeneous air – fuel mixture is

used.
 Ignition by external source such as a spark.
SI Engine

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 CI Engine
 Generally Non-homogeneous mixture is used.
 Ignition due to high temp.
CI Engine

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3. According to the number of strokes per cycle :
a. Four Stroke cycle engines
b. Two stroke cycle engines
Four Stroke Cycle Engines

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4 Stroke Petrol Engine (Direct Injection)

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Two Stroke Cycle Engines

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4. According to the speed of the engine :
a. Slow speed engines
b. Medium speed engines
c. High speed engines
5. According to the cooling system:
a. Air-cooled engines
b. Water cooled engines
6. According to the method of fuel injection:
a. Carburetor engines
b. Air injection engines

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7. According to the number of cylinders:
a. Single cylinder engines
b. Multi-cylinder engines
8. According to the arrangement of cylinders:

a. Vertical Engines
b. Horizontal Engines
c. Radial engines
d. V-type multi-cylinder engines
e. In-line multi-cylinder engines
Vertical Engines Horizontal
Engines
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In-line multi-cylinder engines V-type multi-cylinder
engines

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Radial engines
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9. According to the type of lubricating
system:
a. Wet sump lubrication
b. Dry sump lubrication
c. Splash lubrication

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10. According to the cycle of operation:
a. Otto cycle
b. Diesel cycle
c. Duel or mixed cycle

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Construction details of IC Engine

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Construction details of IC Engine

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 Main Components of I.C. Engine

Cylinder block: The cylinder block is the foundation of

the engine. Usually made of cast iron; Contains
coolant passages.
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 Main Components of I.C. Engine

Cylinder Liner: It is a hole inside the cylinder block.

Wet or dry liner (wet if liner touch the cooling water).
Made Gray cast iron.

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 Main Components of I.C. Engine

Crankcase: Holds the cylinder and crankshaft of an IC

engine. Made of cast iron. Also serves as a sump for
the lubricating oil.
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 Main Components of I.C. Engine

Connecting Rod: Connecting rod is

used to transmit the motion from the
piston to the crankshaft. Made of
forged-steel or cast iron.

Crankshaft: It is considered as
the backbone of an engine. Its function is to
Convert reciprocating motion of the piston into
rotary motion with the help of connecting rod. Made of
forged steel.

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 Main Components of I.C. Engine

Cylinder Head: A detachable unit

of an engine bolted to the top of the
cylinder block. Contain valve
assemblies.

Piston: The piston is a cylindrical

plug that moves up and down in the
engine cylinder. Made of aluminum,
cast steel or cast iron. It contains
piston rings (oil & compression).

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Main Components of I.C. Engine

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 Main Components of I.C. Engine

Flywheel: Mounted on the crankshaft. To maintain

its speed const. Storing excess energy during the
power stroke, which is returned during other stroke.

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 Main Components of I.C. Engine

Intake and Exhaust Valve:

Intake valve usually made of a
chromium-nickel alloy and slightly
larger than exhaust valve for
higher volumetric efficiency and
also combustion. Exhaust valve
made of a silicon-chrome alloy
since it operates at higher temps
(about 1200oF).

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Comparison of Petrol and Diesel Engines
Sl Petrol (SI)Engine Diesel (CI)Engine
no
1 A petrol engine draws a A diesel engine draws only air
mixture of petrol and air during suction stroke.
during suction stroke.
2 The carburetor is employed The injector or atomizer is
to mix air and petrol in the employed to inject the fuel at
required proportion and to the end of compression
supply it to the engine stroke.
during suction stroke.
3 Pressure at the end of Pressure at the end of
compression is low. compression is high.
4 The charge is ignited with The fuel is injected in the
the help of sparking plug. form of fine spray . The
temperature of the
compressed air is sufficiently
high to ignite the fuel. 38
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Engine Terminologies

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 Engine Terminologies

Top Dead Center (TDC): Position of the piston when it

Stops at the furthest point away from the crankshaft.

 Top because this position is at the top of the

engines (not always), and dead because the piston
stops as this point

 When the piston is at TDC, the volume in the

cylinder is a minimum called the clearance volume

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 Engine Terminologies

Bottom Dead Center (BDC): Position of the piston

when it stops at the point closest to the crankshaft.
Stroke: Distance traveled by the piston from one
extreme position to the other : TDC to BDC or BDC
to TDC.
Bore: It is defined as cylinder diameter or piston
face diameter; piston face diameter is same as
cylinder diameter( minus small clearance).

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 Engine Terminologies

Swept volume/Displacement volume : Volume

displaced by the piston as it travels through one
stroke.
 Swept volume is defined as stroke times
bore.
 Displacement can be given for one
cylinder or entire engine (one cylinder times
number of cylinders).

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 Engine Terminologies

Clearance volume: It is the minimum volume of the cylinder

available for the charge (air or air fuel mixture) when the piston
reaches at its outermost point (top dead center or outer dead
Center)during compression stroke of the cycle.Minimum volume
of combustion chamber with piston at TDC.
Compression ratio: The ratio of total volume to clearance
volume of the cylinder is the compression ratio of the engine.
Typically compression ratio for SI engines varies form 8 to 12
and for CI engines it varies from 12 to 24.

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 2 Stroke Engine
Intake: The fuel/air mixture is first
drawn into the crankcase by the vacuum
that is created during the upward stroke
of the piston. The illustrated engine
features a poppet intake valve; however,
many engines use a rotary value
incorporated into the crankshaft.

Compression: The piston when rises,

driven by flywheel momentum,and compresses
the fuel mixture.
Power: At the top of the stroke, the spark plug ignites the
fuel mixture. The burning fuel expands, driving the piston
downward, to complete the cycle. (At the same time, another
crankcase compression stroke is happening beneath the
piston.)
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 2 Stroke Engine
Crank case Compression: During the
downward stroke, the poppet valve is forced
to closed by the increased crankcase
pressure. The fuel mixture is then compressed
in the crankcase during the remainder of the
stroke.
Transfer: Toward the end of the
stroke, the piston exposes the transfer port,
allowing the compressed fuel/air mixture in the crankcase to
escape around the piston into the main cylinder.
Exhaust: Fresh fuel air expels the exhaust gasses out the
exhaust port, usually located on the opposite side of the
cylinder. Unfortunately, some of the fresh fuel mixture is
usually expelled as well and some of the exhaust gas remain
in the cylinder.
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Four Stroke Cycle Engines Two Stroke Cycle Engines

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Comparison of 4 Stroke and 2 Stroke Engine

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Construction details of IC Engine

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Air Intake System
Intake Manifold
Takes air-fuel mixture from Carburetor/Mixer in to Cylinder

Objectives :
• Maintain the A/F ratio
• Fineness of atomization of fuel in carburetor
• Pressure drop (flow) in the manifold
• Temperature of mixture in the Manifold Uniform distribution of charge to all cylinders
• Pipe layout – Sharp bends (turbulent mixing)
• Improved volumetric efficiency
• Prevent induction robbery

Manufacturing
• Material : Al – good heat conductivity, ductility, light weight
• Process : Typically Casting.
• Shape : To keep the mixture composition unchanged and uniform as far as possible 51
Carburetor

Click to watch video

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Intake Manifold layouts for 4-Cylinder Inline Engines 53
Air Filter
• Ensures dust free air going in the engine
• Wet/Dry type
• Pleated structure of dry filter
• Reducing noise of air entering

Pleated Filter Structure

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Exhaust System
Exhaust manifold
Material – Cast Iron/ Steel (about 700-800oC) , has to be corrosion resistive
Layout – Prevent interference between cylinders, independent cylinders/ pair of cylinders

Exhaust pipe
Material – Steel pipe, corrosion protection
Construction – Pipe is generally rigid and fixed to the frame by flexible attachments to reduce vibration

Silencers (Mufflers)
Low frequency (Capacitive) Silencer – air suction/ motoring
High frequency (Absorption) Silencer – rapid expansion of exhaust gases
Combination type Silencer

• Back pressure developed – tuning

• Construction – Sheet metals
• Corrosion
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Exhaust System

Consists of-

• Exhaust Manifold
• Catalytic Converter
• Exhaust Pipe
• Muffler/ Silencer

Click to watch video

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Muffler

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Q. Why do engines produce black smoke?
• Incomplete combustion
• Excess fuel injection
• Too much fuel, but not enough air

Q. Why do engines produce white smoke?

• Gasket failure
• Cracked engine block
• Coolant leak and coolant loss

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Exhaust Gas Recirculation (EGR)

• When engine runs at high speed it produces high temperature

• In CI engine because of high compression ratio it develops excess
NOx at high temp.
(CH)n + N2 + O2 = CO2 + N2 + H2O+ Heat + CO + NOx

Necessity
• Reduces engine temperature
• Less amount of NOx because of low temp.
• Good for environment
• However, engine efficiency is reduced

Click to watch video

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Exhaust Gas Recirculation (EGR)
• Within modern, diesel internal combustion engines, Exhaust Gas
Recirculation (EGR) is a method to control NOx emissions
• Air from the environment is mostly a combination of Oxygen and
Nitrogen. When the air combines with fuel and ignites inside the
combustion chamber, temperatures increase and produce NOx
emissions
• The EGR system works by returning a small portion of an engine's
exhaust gas to the engine's combustion chambers through the intake
manifold, where it combines with fresh intake air.
• This lowers the Oxygen content and increases the water vapour
content to the combustion mixture which reduces peak combustion
temperature. Because more NOx is created as peak combustion
temperature rises, the EGR valve effectively reduces the amount of
NOx produced by the engine.

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Turbocharger
• The objective of a turbocharger is to
improve an engine’s efficiency by
increasing the density of the intake gas
(usually air), thereby allowing more
power per engine cycle.

• The turbocharger’s compressor draws

in ambient air and compresses it
before it enters into the intake
manifold at increased pressure. This
results in a greater mass of air entering
the cylinders on each intake stroke.
The power needed to spin the
centrifugal compressor is derived from
the kinetic energy of the engine’s
exhaust gases.
Click to watch video

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Turbocharger

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Supercharger

• It is fitted before the Intake valve of

the cylinder so that air can be
compressed in the supercharger and
allowed it to be forced into the
cylinder via the Intake valve. It is
used to increase engine power,
efficiency, torque by compressing the
air in multi-stages for increasing the
quantity of air, pressure, and
temperature.

Click to watch video

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• The greater mass flow-rate provides more oxygen to support combustion in the cylinder compared to
the naturally aspirated engine.
• Supercharger allows more fuel to be burned and thereby more work is said to be done per cycle which
increases the power output of the engine.
• The Power to the supercharger comes mechanically from the engine's crankshaft via a belt, gear,
shaft, or chain.
• Super Charger increases the pressure of the A/F mixture and supplies at a higher pressure than
atmospheric pressure.
• The supercharged engine produces higher power up to 40% to that of the normal engine

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Cooling System
PURPOSE OF COOLING
a. To keep the engine at its most efficient temp at all speeds and operating conditions.
b. To take away extra heat before it damages engine parts.
c. It also helps bring the engine up to normal operating temp as quickly as possible

Components
• Radiator – Water-Air Heat Exchanger, Large surface area, Cross flow from fan
• Pressure Cap – Maintains pressure, two-way valves
• Expansion Tank – Keeps radiator filled with water (hot and cold) controlling volume
• Hoses – Fabric reinforced Rubber
• Thermostatic Valve – Maintains water temperature in the water-jacket in certain desired
level - by controlling flow
• Water Jacket – Water filled space around cylinders
• Fan – Electrical/Mechanical Drive – Motor/Fan belt - advantage/ disadvantages
• Pump – Centrifugal type – low head
• Coolant Temperature Sensor

Click to watch video

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Engine Cooling system

Click to watch video

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Engine Cooling system

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Cooling system working principle
• The fluid circulates through pipes and passageways in the engine.
• As the liquid passes through the hot engine it absorbs heat, cooling the engine.
• After the fluid leaves the engine, it passes through a heat exchanger, or radiator, which transfers
the heat from the fluid to the air blowing through the exchanger.
• The liquid-cooling system for automobiles offers the most efficient cooling and it maintains an
optimum engine temp.
• The pump sends the fluid into the engine block, where it makes its way through passages in the
engine around the cylinders.
• Then it returns through the cylinder head of the engine.
• The thermostat is located where the fluid leaves the engine.
• The thermostat sends the fluid back to the pump directly if the thermostat is closed.
• If it is open, the fluid goes through the radiator first and then back to the pump.
• There is also a separate circuit for the heating system.
• This circuit takes fluid from the cylinder head and passes it through a heater core and then back
to the pump.

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Radiators

• A radiator is a heat
exchanger.
• Tube and fin style the
most popular.
• Made of copper and
brass or aluminum
and plastic.
• 3 (radiator,
evaporator, heater
core)
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Radiator Fans
Keeps air moving
through the radiator
when the car is not
moving.
Several types:
• rigid,
• flex (not used much
anymore),
• viscous clutch and
• electric.
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Radiator Cap

• The cap allows access to

the cooling system for
filling and testing.
• The cap has two valves:
a pressure relief valve
set at around 15 PSI and
a vacuum valve which is
needed when the engine
cools down.
• Raises boiling point of
fluid
• Able to take on more
heat
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Water Pump

• Centrifugal pump which

circulates coolant
around cooling system.
• Simple impeller design.
• Usually driven by drive
belt from crankshaft.

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Thermostat

• Controls coolant
temperature.
• Uses a temperature
sensor and a valve.
• Usually opens around
195 degrees F.

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Coolant Temperature Sensor (CTS)
• Reports to Engine Control
Unit (ECU)
• Gauges
• Location
• Block
• Head
• Radiator tank

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Water Jackets

• Surrounds the cylinders

with water passage.
• Absorbs heat from the
cylinder wall.
• Pump move water to
radiator where heat is
exchanged to the air.

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Coolant Recovery Tank
• Keeps the coolant level full in
the system at all times.
• Works in conjunction with the
radiator cap.
• When the engine heats up the
coolant expands and flows to
the recovery tank.
• When the engine coolant the
coolant contracts and creates a
vacuum and draws the fluid
back into the radiator.
• Reduces air in system
• Reduces rust
• Less need to open radiator

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Lubrication System
PURPOSE OF LUBRICATION
Primary Purposes
• Reduce friction between moving parts
• Reduce wear of the moving parts as far as possible
Secondary Purposes
• Provide cooling effect
• Provide cushioning effect
• Provide cleaning action
• Provide a sealing effect

LUBRICANTS
• Lubricants are required to protect undue wear wherever one rotates in another parts
• Different moving parts like the steering system, axle’s differential, transmission, brakes etc use
special type of lubricants

Lubricant properties
• Correct viscosity – less change in operating temp range (Viscosity Index), Multiple viscosity
• Resistance to – Oxidation, Carbon, Extreme pressure, Foam formation & Corrosion/Rust
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Lubricating System

Big end bearings ,

By Pass Crank connecting rod ,
Pressure
Valve shaft small end bearings ,
Relief
Valve Piston rings

Cam Rocker arm ,

Oil Filter Oil Main shaft valve and valve
Sump Strainer Pump Cooler oil spring
gallery

Timing gear
mechanism

Sump

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Lubricating System

Click to watch video

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Reasons of Loss of Lub oil
Leakage through valve stem-guide clearance Leakage through piston ring-cylinder Loss
through crankcase ventilation (PCV =Positive crankcase ventilation)

Checking the Lub oil

Oil volume – Dip stick (engine not running)
Oil pressure- Pressure switch/lamp (about 3-5 bar)

Oil change
Every 3000-5000 km run
Oil Flushing
Better to change the filter with oil

Designation of Lub Oil

SAE 30, SAE 40 (higher number more viscous)
SAE 10W-30, SAE 5W-20 (Multiple viscosity)

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Components

OIL PAN/ SUMP

 The oil pan / sump attaches to the crankcase.
 It serves as the reservoir for the engine oil.
 It is designed to hold the amount of oil that is needed to lubricate the engine when it is running , plus a reserve.
 The oil pan helps to cool the oil through its contact with the out side air.

OIL STRAINER
 It usually contains a filter screen, which is submerged in the oil at all times.
 The screen serves to keep large particles from reaching the oil pump.

OIL PUMP
• Circulate lubricating oil to different engine parts requiring lubrication
• Oil pump circulates oil under pressure through drilled passages and oil lines
• Located inside the engine crankcase and is submerged in the oil or is located outside the engine crankcase above
the oil level
• Generally driven by a worm gear of the camshaft

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Components
OIL FILTER
• Automotive engine-lubricating systems have an oil filter and oil from the oil pump circulates through this filter.
• In the filter there is a cartridge of filtering material that traps particles of foreign matter in addition to the
screens or strainers provided at the intake opening of the oil pump.
• Filters thus help to retard the formation of sludge in the sump.
• Oil filters are equipped with a spring loaded by-pass valve to allow oil to by pass the filter, if the filter is clogged.

OIL COOLER
• Oil coolers are simple heat exchangers. It is used to cool the oil and maintain its viscosity for smooth operation

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Fuel Supply and Injection System
Two ways
• Engine Carburetor
• Electronic Fuel Injection (EFI) System

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Engine Carburetor

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Electronic Fuel Injection (EFI) System

Click to watch video

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Carburetor and MPFI

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Electronic Fuel Injection (EFI) System

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PWM-controlled Fuel Injector

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What is EFI?
EFI is a way of delivering fuel to the engine by electronically controlling injection directly into the intake manifold
near the intake valve

Electronic Control System

This system consist of the:
Various engine SENSORS,
Electronic Control Unit (ECU),
Fuel injector assemblies, and related wiring

# The ECU determines precisely how much fuel needs to be delivered by the injector based on the engine
SENSORS output.
# Injector is turned On for the precise amount of time to deliver proper air/fuel ratio to the engine.

Basic Operation of ECU System

# Air enters the engine and then measured by the AIR FLOW METER,
# As the air flows into cylinder, fuel is mixed into the air by injector,
# ECU pulses the injector On and OFF. When it is ON just enough spraying of fuel occurs, to ensure ideal air/ fuel
ratio 14.7:1
# The ECU Control delivers precise amount of fuel to the engine,

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The injection quantity depend on variables such as:
# coolant temperature
# engine speed (rpm)
# throttle angle,
# exhaust oxygen content

SIMPLIFIED EFI SYSTEM

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Electronic Control Unit or ECU
# Small computer connected directly to engine
# Monitors engine parameters through the use of sensors
# Manages throttle control, ignition, fuel injection, and power

Crank Sensor
# Determines speed of engine
# Consists of toothed wheel and an inductive pickup
# Sensor pulses and creates a magnetic field
# Depending on location of wheel, changes magnetic field strength
# From magnetic strength the ECU can tell the exact crank position and speed

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Throttle Position Sensor
# Determines the load on the engine
# Two types:
1) Electronic accelerator pedal
Senses force applied to pedal and opens throttle body accordingly
2) Direct linkage
Uses a linkage between pedal and throttle

Mass Airflow Sensor

# Heated wire placed in venturi section and air flows over wire and cools
# Measures current required to keep at a constant temperature
# ECU converts voltage drops into mass airflow

Oxygen Sensor
# Mounted on the exhaust system before the catalytic converter.
# This device is important in fuel conservation and emissions control
# The amount of oxygen present in the exhaust stream is a direct result of the
air/fuel ratio
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Temperature Sensor
# Temperatures measured with a sensor known as a thermistor
# A thermistor is a resistor made of a semiconductor material whose
electrical resistance changes with temperature
Pressure Sensor
# Used to monitor intake manifold and ambient pressures
# Measured by semi-conducting silicon diaphragm that separates two
chambers
# Pressure change causes diaphragm to flex
# When diaphragm flexes cause resistance of material to change
# ECU monitors voltage change
Knock Sensor
# Sensors alert ECU when vibrations are detected in the cylinder
# Knock sensors contain a piezoelectric ( electricity resulting from
pressure)crystal
# Crystal produces an electric signal when subjected to physical stress due to
engine knock.
# ECU responds by retarding or advancing ignition time
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Types of Diesel Combustion System
 Direct-injection (DI) system. Have a single open combustion chamber into which fuel is injected
directly.
 Indirect-injection (IDI) system. Chamber is divided into two regions and the fuel is injected into
the “pre-chamber” which is connected to the main chamber via a nozzle, or one or more orifices.

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Transmission System

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 Transmission System

Engine Clutch Transfer Universal Propeller Final drive Rear drive

Universal Rear
Joint shaft /drive and axel/ half
Joint Wheel
shaft differential shaft

Front
drive axel

Front
wheel

Click to watch video

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