1. What is an IC engine?

The internal combustion engine (ICE) is an engine where the combustion of a fuel occurs with air
inside the combustion chamber.

2. Draw the P-V & T-S diagram of CI engine?

3. Define octane number and cetane number?

Octane number denotes the percentage (by volume) of iso-octane (a type of octane) in a
combustible mixture of iso-octane and normal-heptane.

Cetane number denotes the percentage (by volume) of cetane (chemical name Hexadecane) in
a combustible mixture of cetane and alpha (1)-methylnaphthalene.

4. What do you mean by SI & CI engine?

SI engine means spark ignition engine that is petrol engine.
CI engine means compression ignition engine that is diesel engine.

5. Explain four strokes of Diesel engine?

The four strokes are:

 Intake stroke -- The intake valve opens up, letting in air and moving the piston down.
 Compression stroke -- The piston moves back up and compresses the air.
 Combustion stroke -- As the piston reaches the top, fuel is injected at just the right moment and
ignited, forcing the piston back down.
 Exhaust stroke -- The piston moves back to the top, pushing out the exhaust created from the
combustion out of the exhaust valve.

6. Draw the valve timing diagram?

7. What is overlap?
Valve overlap is the period during the valve timing where both the intake and exhaust valves are
open.

8. What is detonation?
Detonation occurs because of increased ignition delay - if ignition delay is more than more fuel
will accumulate till ignition starts hence ignition of more fuel instantaneously leads to pressure
rise called detonation/knocking .

9. What is a Turbo charger?

A turbocharger is a device driven by exhaust gases that increases engine power by pumping air
into the combustion chambers.

10. Difference between turbo charger & super charger?

The key difference between a turbocharger and a supercharger is its power supply. In a
supercharger, there is a belt that connects directly to the engine. In a turbocharger, gets its
power from the exhaust gas. The exhaust runs through a turbine.

11. What is an after-cooler?

After-cooler is a kind of inter-cooler which reduces the temperature of compressed air before
entering the combustion chamber.

12. Why do we use after-cooler?

It is used to improve their volumetric efficiency by increasing intake air-charge density through
isochoric cooling.

13. What is a Radiator?

Radiators are heat exchangers used for cooling internal combustion engines. Internal
combustion engines are often cooled by circulating a liquid called engine coolant through the
engine block, where it is heated, then through a radiator where it loses heat to the atmosphere,
and then returned to the engine. Engine coolant is usually water-based.

14. What is coolant?

A coolant is a fluid which flows through or around a device to prevent its overheating,
transferring the heat produced by the device to other devices that use or dissipate it.

15. What is the purpose of cooling system?

The cooling system keeps the engine at its most efficient temperature at all speeds and
operating conditions. Burning fuel in the engine produces heat. Some of this heat must be taken
away before it damages engine parts.

16. What is thermostat?

A thermostatic valve is called a thermostat which controls coolant flow.

17. What is a unit injector?

Unit injector is an integrated direct fuel injection system for diesel engines, combining the
injector nozzle and the injection pump in a single component.
18. What are water jackets?
The cylinder block and cylinder head have internal passages which are called water jackets that
surround the cylinder and combustion chamber.

19. What are the functions of radiator pressure cap?

Cooling systems are sealed and pressurized by a radiator pressure cap. Sealing reduces coolant
loss from evaporation. Pressurizing raises the boiling temperature of the coolant, thereby
increasing the cooling efficiency.

20. What is lube oil? What are multi-grade oils?

Lube oil is a substance introduced to reduce friction between surfaces in mutual contact.

A multi-grade oils generally possesses the following characteristics:

 high boiling point and low freezing point (in order to stay liquid within a wide range of
temperature)
 high viscosity index
 thermal stability
 hydraulic stability
 corrosion prevention
 High resistance to oxidation.

21. Write down the lubrication system of IC engine?

Multi-grade oils are those oils that have two numbers on the grade, indicating that the oil is able
to maintain engine performance in high and low temperatures. A multi-grade lubricant
minimizes viscosity differences under temperature variations.

22. What does SAE 15W-40 for lube oil means?

SAE stands for Society of Automotive Engineers which is a U.S.-based, globally active
professional association and standards organization for engineering professionals in various
industries.
The numbers indicate the viscosity index of lube oil. There are two numbers, so it is multi-grade
oil. This lube oil will behave as single grade oil of SAE 15W in winter and SAE 40 in summer.

23. Write down causes of low oil pressure?

 A weak or broken pressure relief valve
 A worn oil pump
 A broken or cracked oil line
 An obstruction in the oil line
 Insufficient or thin oil
 Worn engine bearings
 A leaking oil filter, oil filters gasket, or oil-pressure sending unit.

24. What are the functions of piston rings?

Compression rings: These form a sliding seal between the piston and the cylinder wall.
Oil-control rings (or oil rings): These scrape off most of the lubricating oil splashed on the
cylinder wall and return the oil to the crankcase.
25. What is a cylinder liner and why is it used?
A cylinder liner is a cylindrical part to be fitted into an engine block to form a cylinder.
The main reason for using cylinder liner is to protect the cylinder block (which is quite expensive
to replace) from wear. If a cylinder liner is damaged, it can be replaced.

26. What is honing?

Honing is an abrasive machining process that produces a precision surface on a metal work
piece by scrubbing an abrasive stone against it along a controlled path.

27. What is blow by? Write down the causes of blow by?
Blow-by occurs when the explosion that occurs in your engine’s combustion chamber causes
fuel, air and moisture to be forced past the rings into the crankcase.
The causes of blow-by: wear, soot and deposits.

28. What is scavenging?

Scavenging is the process of pushing exhausted gas-charge out of the cylinder and drawing in a
fresh draught of air or fuel/air mixture for the next cycle.

29. What is a pump? Write down the classification?

A pump is a device that moves fluids (liquids or gases) by mechanical action. Pumps can be
classified into three major groups according to the method they use to move the fluid: direct lift,
displacement, and gravity pumps.

30. What are the functions of lube oil?

 Controls friction between load-bearing surfaces
 Reduces wear by preventing metal-to-metal contact between moving parts
 Limits the temperature by carrying away heat from fluid friction and combustion of fuel
 Reduces corrosion by coating metal parts and by flushing debris from between moving
parts
 Dampers mechanical shock in gears
 Forms a seal on the walls of the cylinders

31. What is tappet clearance?

Tappet clearance is a space between the top of the valve stem and the rocker arm (Intake 0.5
mm and Exhaust 1 mm). Its purpose is to allow for some mechanical expansion and lengthening
of valve stem and push rods as the engine warms up. This clearance is also called valve lash.

32. Why camshaft is used?

In internal combustion engines with pistons, the camshaft is used to operate poppet valves.

33. What is the function of crankshaft?

The crankshaft is part of an engine that converts reciprocating linear piston motion into
rotation. The crankshaft is often connected to the flywheel thus reducing the pulsation of the
four-stroke cycle.

34. What is the function of counter weight?

 A counterweight is used to reduce vibrations due to imbalance load in the crankshaft due to the
power stroke of piston.

35. What is the function of vibration damper?

Is a device connected to the crankshaft of an engine to reduce torsional vibration and serves as
a pulley for drive belts.

36. What is a cam? Write down the name of different type of cam follower?
A cam is a rotating or sliding piece in a mechanical linkage used especially in transforming rotary
motion into linear motion or vice versa.
o Knife edge follower
o Roller follower
o Flat-face follower
o Spherical-face follower.
37. What is indicated mean effective pressure (MEP)?
Mean effective pressure of an IC engine is the average piston pressure during the power stroke.

38. What is calorific value of fuel? What is HHV & LHV?

The calorific value of a substance, usually a fuel is the amount of heat released during the
combustion of a specified amount of it. Its unit is btu/lb or KJ/Kg
HHV= Higher Heating Value
LHV= Lower Heating Value
1 btu/lb = 2.326 KJ/Kg

39. What specific fuel consumption (sfc)?

It is the rate of fuel consumption divided by the power produced.

40. What is fuel system? What type of fuel system is used in your engine?
Fuel system means how fuel is supplied to the injector to burn the compressed air. Electronic
fuel injection (EFI) system is used in our engine.

41. What is a rocker arm?

A rocker arm of an internal combustion engine is an oscillating lever that conveys radial
movement from the cam lobe into linear movement at the poppet valve to open it.

42. What is a push rod?

Push rod is a device which delivers the rotational motion of cam into linear motion to the rocker
arm to open or close the poppet valve.

43. Write down the different parts of valve assemble?

o Cam
o Push rod
o Rocker arm
o Lock and retainer
o Valve stem
o Valve spring (inner and outer)
o Valve guide
o Valve seat
 o Insert

44. What is the function of inner and outer spring of valve?

The function of valve spring is to close the valve when the pressure of rocker arm is released.

45. How do you find out the inlet and exhaust valve?
Inlet valve head is large as compared with the exhaust valve head. Because air intake into the
combustion chamber in normal atm. pressure where combustion product has a large pressure
to exhaust.

46. What is a flywheel?

A flywheel is a rotating mechanical device that is used to store rotational energy. It provides
continuous energy when the energy source is discontinuous. For example, flywheels are used in
reciprocating engines because the energy source, torque from the engine, is intermittent.

47. What is a connecting rod?

The connecting rod connects the piston to the crank or crankshaft. Together with the crank,
they form a simple mechanism that converts reciprocating motion into rotating motion.

48. What is a piston?

A piston is a component of reciprocating engines, reciprocating pumps. It is the moving
component that is contained by a cylinder and is made gas-tight by piston rings. In an engine, its
purpose is to transfer force from expanding gas in the cylinder to the crankshaft via a piston rod
or connecting rod.

49. What is piston pin?

A piston pin, also known as a gudgeon pin, is a hardened steel pin which connects an engine's
piston to a connecting rod.

50. What is compression ratio?

The compression ratio of an internal-combustion engine or external combustion engine is a
value that represents the ratio of the volume of its combustion chamber from its largest
capacity to its smallest capacity.

51. What is overhauling? Types of overhauling?

Overhauling is a process (such as tests, measurements, replacements, adjustments and repairs)
intended to retain or restore a functional unit in or to a specified state in which the unit can
perform its required functions.
o Top overhauling- Valve, Valve spring, Valve seat, Retainer, Seal.
o In-frame overhauling- Piston, Piston ring, Big end bearing, Liner, Seal and gasket.
o Major overhauling- Main bearing, Big end bearing, Thrust bearing, Liner, Piston etc.

52. What is schedule maintenance, preventive maintenance and corrective maintenance?

Schedule maintenance is a planning maintenance to ensure that an item of equipment is
operating correctly and therefore avoid any unscheduled breakdown and downtime.
Preventive maintenance tends to follow planned guidelines from time-to-time to prevent
equipment and machinery from breakdown.
 Corrective maintenance is a maintenance task performed to identify, isolate, and rectify a fault
so that the failed equipment, machine, or system can be restored to an operational condition.

53. What is bearing? Write down the Classification of bearing?

A bearing is a machine element that constrains relative motion to only the desired motion, and
reduces friction between moving parts.
o Plain bearing-Journal bearing
o Rolling-element bearing-Ball bearing, Roller bearing.

54. What is the function of main bearing?

Main bearing holds the crankshaft in place and prevent the forces created by the piston and
transmitted to the crankshaft by the connecting rods.

55. What is the function of thrust bearing?

Function of thrust bearing is to supporting the axial loads and preventing movements of
crankshaft along the crankshaft axis.

56. Where the big-end bearing used?

Connecting rod bearings (Big end bearing) are mounted in the Big end of the connecting rod.

57. What is auto ignition temperature?

The auto ignition temperature or kindling point of a substance is the lowest temperature at
which it will spontaneously ignite in a normal atmosphere without an external source of ignition,
such as a flame or spark.

58. What is a flash point?

The flash point of a volatile material is the lowest temperature at which it can vaporize to form
an ignitable mixture in air. Measuring a flash point requires an ignition source.

59. What are the functions of crankcase pressure relief valves?

Crankcase pressure relief valves have two functions-
 To relieve excess pressure inside the crankcase thereby normalizing the pressure
 To prevent the flames inside the crankcase from coming out and causing further damage.

60. Why is compression ratio of diesel engine high?

Diesel fuel is injected under much higher pressure into the cylinders than gasoline. Diesel
engines do not rely on spark to combust the fuel as do gasoline engines. They rely on
compression for ignition.

61. Why exhaust valve clearance is greater than inlet valve?

Due to high temp in exhaust valve more thermal expansion is required. That’s why exhaust valve
clearance is more than inlet valve.

62. How the Governor work?

A governor is a mechanical device in the injection pump on older diesels. The accelerator pedal
does not control the amount of fuel into the engine - it commands the engine to run at a certain
 speed. The governor controls the position of the fuel rack in the pump to control the volume of
fuel injected in each cylinder. Newer diesels do the same thing in software. No mechanical
governor exists. The pedal is connected to a position sensor; the injectors are computer
controlled. The engine and vehicle speed limiters are in software also.

63. What is the effect of blow by in diesel engine?

Blow by cause’s excessive crankcase pressure.

64. Why white smoke comes from the exhaust of diesel engine?
o Due to the presence of water in fuel.
o Lean mixture (un burn fuel)
o Water/Coolant in cylinder head.
o Incorrect timing.
o Incorrect valve clearance.
o Faulty injector.
o Poor fuel quality.

65. Why black smoke comes from the exhaust of diesel engine?
o Rich mixture (air-fuel ratio).
o Oil in cylinder head due to faulty liner, piston and piston ring.
o Incorrect timing.
o Incorrect valve clearance.
o Faulty injector.
o Poor fuel quality.

66. What are the reasons of engine RPM fluctuation?

o Air in fuel
o Fuel pressure too low.
o Speed governor faulty.
o Governor control linkage jammed.

67. What are the reasons of high bearing temp?

o Bearing Damaged/faulty lubrication.
o Alignment /foundation faulty.
o Sensor defective.

68. What are the reasons for high lube Oil temp?
o Air in cooling water system.
o Lube oil level low.
o Lube oil pumping problem.
o Cooling water pump faulty.
o Temperature control faulty.
o Pre heating device active.
69. What are the reasons for high jacket water temp?
o Radiator dirty.
o Faulty thermostat valve.
o Coolant leakage or low coolant level.
o Jacket water pump problem.
o Faulty radiator pressure cap.
o Sensor defective.

70. What are the reasons for high after cooler temp?
o Radiator dirty.
o After cooler dirty.
o After cooler pump problem.
o Intake air temperature high.
o Air filters differential pressure high.
o Sensor defective.

71. What are the reasons for high exhaust temp?

o Intake air temperature high.
o Incomplete combustion.
o Cooling system faulty.
o Sensor defective.
o Faulty injector.

72. What are the reasons for high cylinder temp?

o Faulty injector.
o J/W temp. high.
o Incorrect valve clearance.
o Lean mixture.
o Intake air temperature high.
o Sensor defective.

73. What are the reasons for low cylinder temp?

o Faulty injector.
o Incorrect valve clearance.
o Fuel pressure low.
o Sensor defective.

74. Causes of failure of engine to start?

o Lack of fuel
o Ignition switch off
o Incorrect throttle setting
o Cold oil
o Defective battery
o Dirty or defective injector
o Water in fuel
o Incorrect valve and/or ignition timing
 o Incorrect valve clearance
o Defective priming system
o Intake manifold air leaks
o Defective camshaft
o Internal engine failure

75. Write down the factors effect injector damaged?

o Poor fuel quality.
o Dirt in intake air.
o Improper valve clearance.
o Lean or Rich mixture.
o Poor cooling system.

76. Write down the factors effect TC damaged?

o Exhaust temp. high.
o Dirt in intake air.
o Defective lubrication.
o Faulty bearing.
o Improper TC blade clearance.
o Misalignment of Compressor and turbine.

77. Write down the factors effect low power output?

o Low injection pressure.
o High intake air temp.
o Poor cooling system.
o Poor fuel quality.
o Air in fuel system.
o Poor lubrication system.

78. What is plant load factor?

In electrical engineering the load factor is defined as the average load divided by the peak
load in a specified time period.

79. What is plant Capacity factor?

The net capacity factor of a power plant is the ratio of its actual output over a period of time,
to its potential output if it were possible for it to operate at full nameplate indefinitely. To
calculate the capacity factor, take the total amount of energy the plant produced during a
period of time and divide by the amount of energy the plant would have produced at full
capacity. Capacity factors vary greatly depending on the type of fuel that is used and the
design of the plant.
80. What is plant demand factor?
In electrical engineering the demand factor is taken as a time independent quantity where the
numerator is taken as the maximum demand in the specified time period instead of the
averaged or instantaneous demand. the possible

81. What is plant Diversity factor?

Diversity Factor is ratio of the sum of the individual maximum demands of the various sub
circuit of a system to the maximum demand of the whole system.
Diversity Factor = Sum of Individual Maximum Demands / Maximum Demand of the System.