TARGET THE E-STEP COURSE

To enable technician to perform the lubrication, PDI and periodic inspection operation To help technicians have a basic knowledge of the major components like engine, and understand the configuration and function. To help technicians understand the mounting position and functions of the various types of electrical and electronic devices. To help technicians learn how to use measuring instruments required for the routine operations.

To help technicians acquire the basic knowledge needed for handling a higher level system.

ENERGY CONVERSION

Energy is define as the ability to do work

Power is defined as a measure of the work being done. Energy can take on one of six forms, they include a. Chemical b. Electrical c. Radiant d. Mechanical e. Nuclear f. Thermal forms of energy

ENERGY CONVERSION
Example how energy conversion happen :

CLASSIFICATION OF ENGINE
Internal Combustion Engine

Change Thermal Energy to Mechanical Energy

CLASSIFICATION OF ENGINE
External Combustion Engine

Change Thermal Energy to Mechanical Energy Burning process occur outside combustion chamber

CLASSIFICATION OF ENGINE
Reciprocating Engine

Changing motion upward and downward

CLASSIFICATION OF ENGINE
Classification Of Engine

Stroke Cycle Operation

Combustion

Cooling

Valve Mechanism

Cylinder Arrangement

Four Stroke Cycle Engine Two Stroke Cycle Engine

Spark Ignition Engine .Petrol Compression Ignition.Diesel

Water Cooled Air Cooled

OverHead Valve OverHead Cams

In-Line V Type

Horizontally Opposed Type

Horizontally Mounted Type

BASIC ENGINE TERMINOLOGY

1. 2. 3. 4. Cylinder Block Cylinder Piston

Connecting rod and crankshaft 5. 6. Cylinder head

Combustion chamber 7. 8. 9. Valves Camshaft Flywheel

COMBUSTION REQUIREMENTS
There is three condition are required to run the engine smoothly :

1. 2. 3.

Proper Compression Proper Air/Fuel Mixture Proper Sparking

COMBUSTION REQUIREMENTS
Air Fuel Ratio

Proper Ratio mixing air and fuel for better engine operation Stoichiometric Ratio 14.7 : 1

COMBUSTION REQUIREMENTS
Rich And Lean Mixture

Fuel Requirement base on engine condition

COMBUSTION REQUIREMENTS
TDC And BDC

Piston position during travel inside cylinder

COMBUSTION REQUIREMENTS
Bore And Stroke

To Identify engine size Difference Bore and Stroke will effect engine capability

COMBUSTION REQUIREMENTS
Type SQUARE Engine

Under Square, stroke greater than bore Square, Bore and stroke same size Over Square, Bore larger than stroke

COMBUSTION REQUIREMENTS
Engine Displacement
The volume which the piston displaces as it moves from BDC to TDC is called stroke volume. The total displacement of the engine would be the stroke volume multiplied by the number of cylinder in the engine. The displacement is generally expressed is cc or liter. Total Displacement = 0.7854 x Stroke X Cylinder The larger displacement, greater the amount airfuel mixture drawn in. Since combustion pressure increase, greater output become possible.

COMBUSTION REQUIREMENTS
Compression Ratio

How much air and fuel have been compressed Ratio = Cylinder Volume + Combustion Chamber Volume Combustion Chamber Volume Less or much will effect engine efficiency.

ENGINE REQUIREMENTS
Types Of Horsepower When discussing of engine capability, Horsepower was used. Many type of horsepower will used to measured the capability example : a. Road Horsepower b. Frictional Horsepower c. Brake Horsepower d. Indicated Horsepower etc. To do this, the term WORK must first be discussed.

ENGINE REQUIREMENTS
Work

Work is defined as the result of applying a force.

ENGINE REQUIREMENTS
Torque

One Way to measured work Its define as twisting force

ENGINE REQUIREMENTS
Horsepower Define

Its define capability of engine to do work within a certain time Measured have be done on straight line Torque will be measured in a rotary direction

ENGINE REQUIREMENTS
Other Define of Horsepower

Brake Horsepower Used to compare capability of difference engine

Indicate Horsepower
To measured efficiency of engine Frictional Horsepower

To measured internal frictional that effect engine efficiency

ENGINE REQUIREMENTS
Four Cycle Engine Design

Its design to get better engine performance. Performance will be effect if : Intake stroke Compression stroke Power stroke Exhaust stroke Not perform as a required

FOUR STROKE CYCLE

Intake Stroke

Intake valve open to allow air/fuel get in combustion chamber

FOUR STROKE CYCLE

Compression Stroke

Both intake & exhaust valve close Air/Fuel started be compressed

FOUR STROKE CYCLE

Power Stroke

Air/fuel start to be explode. Spark will be occur near TDC

FOUR STROKE CYCLE

Exhaust Stroke

Exhaust valve Start open Weight from flywheel will help upward motion

FOUR STROKE CYCLE

Timing Diagram

Location exactly of crankshaft, piston, valve, camshaft base actual timing

FOUR STROKE CYCLE

Four Stroke Timing Diagram

Sample Timing Diagram

FOUR STROKE CYCLE

Advance & Retard Timing Diagram

DIESEL ENGINE PRINCIPLE

Diesel Compression Ratio

Fuel was inject end of compression stroke

DIESEL ENGINE PRINCIPLE

Comparison Diesel and Gasoline engine
COMPARISON BETWEEN GASOLINE AND DIESEL ENGINES

GASOLINE

DIESEL

Intake Compression

Air-Fuel 8-10 to 1 130 psi 545 F Carburetor or before intake valve with fuel injection. Spark Ignition 464 psi

Air 16 20 to 1 400 600 psi 1,000 F Near Top Dead Centre by Injection.

Air-Fuel Mixing Point

Combustion Power

Compression Ignition 1,200 psi

Exhaust

1,300 - 1,800F CO = 3%

700 - 900F CO = 0.5%

CHARACTERISTIC OF AIR POLLUTION

Definition Of Pollution Pollution is defined as the contamination of the environment by harmful products. Many sources forms of pollutions example : a. Chemical b. Thermal Radiation c. Air d. Water etc. In Automobile pollution will produce by product of the combustion process example : a. Coal b. Oil and Gas burned.

POLLUTION EMISSION CONTROL SYSTEM

Introduction In automobile pollution came from : a. Fuel Tank b. Exhaust Gases c. Engine operation process To minimum the pollutants three system have been create : a. The Positive Crankcase Ventilation System b. The Evaporative Emission Control c. The Intake And Exhaust Emission Control System

POLLUTION EMISSION CONTROL SYSTEM

Positive Crankcase Ventilation System

Open Crankcase Ventilation System

POLLUTION EMISSION CONTROL SYSTEM

Positive Crankcase Ventilation System

Purposely to control Co & Hc

Close Crankcase Ventilation System

POLLUTION EMISSION CONTROL SYSTEM

Evaporative Emission Control (E.E.C)

Purposely to Control Hydrocarbon Liquid Vapor Separator / Fuel Cut of Valve Charcoal Carbon Canister. Variable Purge / Purge Control Fuel Tank Tank Filler Cap

POLLUTION EMISSION CONTROL SYSTEM

Intake And Exhaust Emission Control

To reduce Pollution came from Low Intake Temperature a. b. c. Operate at Warm up condition Operate at cold start Control by vacuum and Bi-metal concept.

POLLUTION EMISSION CONTROL SYSTEM

Intake And Exhaust Emission Control

Cold Weather Operation

POLLUTION EMISSION CONTROL SYSTEM

Intake And Exhaust Emission Control

Warm up Operation

POLLUTION EMISSION CONTROL SYSTEM

Exhaust Gas Recirculating System (E.G.R)

Control By Vacuum Valve (Mechanical) Reduce Nox.

POLLUTION EMISSION CONTROL SYSTEM

Exhaust Gas Recirculating System (E.G.R)

Control By Solenoid Valve (Electrical) Reduce Nox.

POLLUTION EMISSION CONTROL SYSTEM

Catalytic Converter

Reduce Nox, Co & HC Oxidizing gases using Platinum, Palladium and rhodium

STRUCTURE AND FUNCTION OF ENGINE

CYLINDER AND ARRANGEMENT

In-line Engine

Designed as an In-Line style

Advantages Easy manufacture More cheaper Disadvantages Cannot change aerodynamic

CYLINDER AND ARRANGEMENT

V Configuration Engine

V type design, angle 60-90

CYLINDER AND ARRANGEMENT

Slant Cylinder Engine

Engine Design like In line Its design to reduce distance TDC to BDC Slanting type can be design more aerodynamically

CYLINDER AND ARRANGEMENT

Opposed Cylinder Engine

Used Two Cylinder Head The angle between two cylinder was 180 Normally its used in smaller vehicles

CYLINDER AND ARRANGEMENT

Radial Cylinder Engine

Cylinder are set in a circles Normally this type used for high performance engine

VALVE AND HEAD ARRANGEMENT

I Head Design

Air and Fuel can move easily into combustion chamber This process improved volumetric efficiency.

VALVE AND HEAD ARRANGEMENT

L Head Design

Valve located at block Inlet and Outlet port small

VALVE AND HEAD ARRANGEMENT

F & T Head Design

Valve located inside cylinder block Used more than one crankshaft Too costing

CYLINDER AND ARRANGEMENT

In Block Camshaft

Most modern engine not use this type camshaft This system used too much linkages.

CYLINDER AND ARRANGEMENT

Overhead Camshaft

The camshaft is mounted on top of cylinder head

CYLINDER AND ARRANGEMENT

Dual Camshaft (DOHC)

Certain engine used Double Overhead Cam. Its drive by chain or belt

CYLINDER AND ARRANGEMENT

Four Valve Engine

Some engine used for better air/fuel efficiency

CYLINDER BLOCK
Block Manufacturing Design

The main structure of engine. All other engine parts attached to cylinder block

CYLINDER BLOCK
Block Core Plug

Used to protect block if any happen to coolant liquid

CYLINDER BLOCK
Cylinder Sleeves

The sleeve was machined or inserted into block after manufactured. There are two type for insert sleeves.

SECONDARY VIBRATION
How to reduce secondary Vibration

Can be cancel by applying vibration of same magnitude in opposite direction

CRANKSHAFT ASSEMBLY
Crankshaft Design

Two type manufactured

a. Forged Steel b. Cast Iron

BEARING ASSEMBLY
Bearing And Bearing Cap

Main bearing cap are used to hold crankshaft

BEARING ASSEMBLY
Bearing Design

BEARING ASSEMBLY
Thrust Bearing

To absorb axial or thrust motion

BEARING ASSEMBLY
Bearing Clearance

Bearing clearance determine how much oil will flow past and out To small or much clearance will effect engine condition and performance

PISTON ASSEMBLY
Piston And Rod Assembly

Piston and rod are used to transmit the power from combustion to the crankshaft

PISTON ASSEMBLY
Piston Parts

Most piston made from hollow aluminum alloy. Its design to operate under severe temperature

PISTON ASSEMBLY
Head Shape

The shape of piston head will effect engine performance

PISTON ASSEMBLY
Piston Skirt

A slipper skirt is used to make connecting road shorter, smaller and lighter Grooves are used for improved wall lubrication

PISTON ASSEMBLY
Piston Ring

Blow by is defined as combustion gases that escape past the rings and into the crankcase area.

PISTON ASSEMBLY
Piston Ring Gap

Small or big gap will effect engine condition Eng gap can be checked with feeler gauge

PISTON ASSEMBLY
Compression Ring Design

Chromium and Molybdenum layer is placed to improve wearing

PISTON ASSEMBLY
Oil Ring Design

The oil being scraped off the cylinder wall, through the ring and back to crankcase

PISTON ASSEMBLY
Cylinder Wear

Over a period of time, the ring on the piston wear the cylinder to a tapered shape

PISTON ASSEMBLY
Piston Thrust Surfaces

Major and minor thrust surfaces are built to absorb piston thrust

PISTON ASSEMBLY
Connecting Rod

Purposely to change energy motion As a lubrication system component

CYLINDER HEAD
Cylinder Head Design and Manufacturing

It is used for sealing Head design example Valve port, combustion chamber coolant passage and material will effect system operation

CYLINDER HEAD
Gasoline Combustion Chamber

Placed Air/Fuel mixing and explode

Type of combustion chamber and head shape will change engine performance. Turbulence cause better combustion Quench area will get better turbulence efficiency and for cooling system Type of combustion chamber are commonly used a. Hemispherical type b. Wedge Shaped Type c. Pent roof type

CYLINDER HEAD
Type Of Combustion Chamber

CYLINDER HEAD
Diesel Combustion Chamber

VALVE ASSEMBLY
Valve Parts

It is made of very strong metal with nickel, chromium and other material

VALVE ASSEMBLY
Valve Parts

Type shape of valve head is refer to type of combustion chamber

VALVE ASSEMBLY
Valve Guide

The Valve Guide Helps to dissipate heat from the valve

VALVE ASSEMBLY
Valve Seat

Valve seat help the valve seal to cylinder block or head

VALVE ASSEMBLY
Valve Spring

Valve keeper or log was used to keep the valve spring and retainer in place

CAMSHAFT ASSEMBLY
Camshaft Design

Cam lobes are machined on the camshaft to lift the valves open at the right time

CAMSHAFT ASSEMBLY
Rocker Arm

Rocker arm are used to change the direction of motion on the valve operation

LUBRICATING SYSTEM OPERATION

Lubricating system was most importance thing on engine operation The system composed of several parts include : a. Oil Pan b. Oil Pump c. Main Oil Gallery d. Oil Filter e. Pressure Regulator f. Oil Cooler g. Oil Sensor

LUBRICATING SYSTEM OPERATION

Oil Flow System

Oil flow from oil pan, through the pump and into the main gallery

LUBRICATING SYSTEM OPERATION

Oil Flow System

Oil from main gallery is sent through passages into the crankshaft.

LUBRICATING SYSTEM OPERATION

Oil Pump System

Oil pump was direct drive by crankshaft, belt or change Three type commonly used are : a. Gear Type b. Eccentric Type c. Trochoid Type

LUBRICATING SYSTEM OPERATION

Oil Pressure Regulating Valve

Purposely to maintain, increase and reduce oil pressure to main oil gallery

LUBRICATING SYSTEM OPERATION

Oil Filter

Purposely to Filter all dust, dirt and sludge particles from the oil Two type filter filtering a. By Pass Filter b. Full Flow Filter

LUBRICATING SYSTEM OPERATION

By Pass Filter

A small volume oil is filtered on the system

LUBRICATING SYSTEM OPERATION

Full Flow Filter

All of the oil must go through the filter

COOLING SYSTEM OPERATION

Purpose Of Cooling System

To maintain operating temperature. To remove Excess heat

To bring working temperature.

COOLING SYSTEM OPERATION

Heat Transfers

To maintain, control and reduce temperature, cooling system used heat transfer principle :

a. b. c.

Conduction (Pengaliran) Convection (Pemanasan) Radiation (Pemeluapan)

COOLING SYSTEM OPERATION

Liquid Cooled Engine

Coolant is pumped from water pump, through the block and head, thermostats into radiator.

COOLING SYSTEM OPERATION

Water Pump And Water Jacket

COOLING SYSTEM OPERATION

Thermostat

COOLING SYSTEM OPERATION

Jiggle Valve

FUEL SYSTEM PETROL AND DIESEL ENGINE

GASOLINE PROPERTIES
Knocking

Detonation is a result of having two flame fronts hit each other

GASOLINE PROPERTIES
Chemical Changes

Combustion brings about chemical change

GASOLINE PROPERTIES
Gasoline Tank

Construction of a typical gasoline tank

GASOLINE PROPERTIES
Mechanical Fuel Pump

Air chamber, diaphragm, pull rod and return spring in assemble parts

GASOLINE PROPERTIES
How Does It Work

Air chamber, diaphragm, pull rod and return spring in assemble parts

GASOLINE PROPERTIES
Rocker Arm And Link

GASOLINE PROPERTIES
Electrical pump

Electrical Fuel pump Utilizing a bellows to produce the pumping acting

CARBURETOR
Air Horn

Air horn was indicate flow of air through horn, into manifold and cylinder

CARBURETOR
Fuel Bowl

CARBURETOR
Main Discharge Tube

Main discharge tube, note fuel level in discharge tube

CARBURETOR
Venturi

Venturi will increase vacuum, three condition air speed process

CARBURETOR
Air Flow Direction

Side draft carburetor

Down Draft, widely used

Updraft carburetor

CARBURETOR
Function And Construction

Fuel Inlet System

CARBURETOR
Function And Construction

Primary Metering System

CARBURETOR
Function And Construction

Secondary Metering System

CARBURETOR
Function And Construction

Accelerating Pump

CARBURETOR
Function And Construction

Enrichment System

CARBURETOR
Function And Construction

Fuel Cut Off Solenoid

MULTIPOINT INJECTION SYSTEM

What is MPI System In Engine

Multi Point Injection(MPI) was a system which controls and manages the engine efficiently. The system consists of an Electronic Control Unit (ECU) which is programmed to control the sensors and actuators. The need of the system is to meet the ever increasing demand of exhaust emissions, allows better fuel economy, without sacrificing the performance.

MULTIPOINT INJECTION SYSTEM

Fuel System

MULTIPOINT INJECTION SYSTEM

Fuel Passage

MULTIPOINT INJECTION SYSTEM

Fuel Pump

Check valve Relief valve

Motor

Brush

Armature Magnet

Impeller

Casing Filter

MULTIPOINT INJECTION SYSTEM

Fuel Pressure Regulator

ENGINE ELECTRICAL SYSTEM

ENGINE ELECTRICAL
Alternator

To supply current and voltage to electrical device and battery

ENGINE ELECTRICAL
Alternator

Also used to create vacuum, supply for brake booster system

ENGINE ELECTRICAL
Glow Plug

To heating air at combustion chamber

ENGINE ELECTRICAL
Starter

To support crankshaft for 4 stroke operation

ENGINE ELECTRICAL
Ignition Coil System

ENGINE ELECTRICAL
Coil System

ENGINE SERVICE

ENGINE SERVICE
Belt Inspection

ENGINE SERVICE
Belt Inspection

ENGINE SERVICE
All Hoses Inspection

ENGINE SERVICE
Coolant Inspection

ENGINE SERVICE
Air Filter Inspection

ENGINE SERVICE
Ignition System

ENGINE SERVICE
Valve Clearance Inspection

ENGINE SERVICE
Ignition Timing Inspection

ENGINE SERVICE
Idle Mixture Adjustment

ENGINE SERVICE
Idle Mixture Adjustment

ENGINE SERVICE
Idle Mixture Adjustment