Introduction

2103471 Internal Combustion Engine

 Definition of Engine
• Historically, the definition of ENGINE is any
machine that does work, no matter how it is
powered. This definition covers wind mills, water
wheels, muscle-operated machinery, etc. The
origin of the word engine is from Latin and
Greek roots meaning invention. In modern times,
the meaning has shifted to describe prime
movers that operate automatically and
continuously to convert some form of energy into
useful mechanical power.
 Heat Engine
• 1824 Sadi Carnot -Noted that work could be converted to heat
and vice versa and there must be a fixed ratio between the two.
However, the efficiency with which heat could be turned to work by
any engine was limited by the degree of heat. Thus, he has
essentially stated the first and second laws of thermodynamics.
• 1850 James Joule -Measured the fixed ratio between work and
heat thus defining the first law.
• 1889 Wm. Rankine -Having already developed Carnot's ideas to
lead to an "absolute" temperature scale, Rankine writes the first
formalized thermodynamics textbook thus defining the second law
• Alternatives to steam engines were being developed in the 19th
century (1800's).
 SEARCH FOR NEW ENGINES: Mid-19th century.
Steam was not satisfactory for all purposes, despite generally good
record of engineering development.
• Thermodynamics one reason. Allowed calculation of efficiency
against theoretical standard.
– a. Steam looked poor, < 12%
– b. Somewhat unfair, idealistic view.
• Opportunity presented by new fuel. "Gas" (from coking ovens) in
pipes.
– a. Supplied to cities as illuminant.
– b. Use as engine fuel tempting, but in steam engine?
• Market advantages. Steam required:
– a. Licensed operators.
– b. Lead & lag times for boilers.
– c. Fairly large size installations.
– d. Any machine avoiding these had possible market.
Stanley Steamer
 Hot air engine
• 1807 George Cayley Builds a working hot air engine, then goes off
and has a brilliant career in
• 1837 aerodynamics. In 1837, he patents an improved hot air engine
and it is commercially produced in the 1860's and 1870's. -basically,
the engine has an enclosed coal burner. Air is pumped into the
combustion chamber and, by burning with the coal, it expands to hot
combustion gases which raise engine pressure, forcing a piston up
its cylinder. This internal combustion engine suffers from serious
wear problems with coal cinders in the working cylinder.
 Hot air engine
• 1816 Robert Stirling Develops a working external combustion hot air
engine with a closed working fluid system (atmospheric air).
• 1840 The key to the success of this engine is an efficient
regenerative heat exchanger ... easy to imagine but difficult to build,
particularly in the early 1800's. Stirling built engines that produced up
to 45 hp and were more efficient than steam engines. However, the
materials did not allow a long life, particularly for the hot end of the
engine. Various successors, particularly in Germany and the US built
similar hot air engines with some applications such as powering fans
and church organ air compressors being almost exclusively supplied
by Stirling type machines.
 Hot air engine

• 1826 John Ericsson External combustion, open cycle hot air engine.
These engines were less efficient and noisier than the Stirling
engines but better marketed and were fairly successful, with engines
ranging from small portable to a 300 hp ship engine.
 Hot air engine
• The hot air engines were actually more efficient than steam engines
but were not sufficiently reliable and long lasting due to poor
materials for the hot end and poor lubricating & sealing materials for
metal/metal/air joints. Also, with atmospheric air as the working fluid,
it was hard to get high specific power.
 Why Internal Combustion?
• IC engines were thought to have a bleak
future when first invented

“You can’t get people to sit over an explosion”

“The automobile industry will surely

burgeon…but this motor will not be a factor.”
- Col. Albert A. Pope, largest
automobile manufacturer at the turn
of the century
 History of I.C. Engine
• 1794 Robert Street Patented a reciprocating IC
engine burning a gaseous fuel-air mixture (heated
turpentine / air)
• 1801-1860 Philippe Lebon, Samuel Morey, and many
others experimented with engines that burned fuel inside
the piston/cylinder arrangement to produce work. All of
their engines were failures but they gradually built up the
basic technology necessary for engines.
 EARLY ATTEMPTS.
• Most of the earilest practical internal combustion engine of
the 17th and 18th centuries can be classified as Atmospheric
Engine.

• It drew in the fuel-air mixture during the first half of the

stroke, then ignited the mixture which expanded during the
second half of the stroke.

• Gunpowder was often used as the fuel.

• The trapped exhaust products was allowed to cool. As the

gas cooled, it created a vacuum within the cylinder. This
caused a pressure differential across the piston. As the
piston move because of this pressure differential, it would
do work by being connected to an external system.
 Atmospheric Engine
Process 1-2: Fuel air mixture introduced into cylinder at
atmospheric pressure
Process 2-3: Constant pressure combustion (cylinder open
to atmosphere)
Process 3-4: Constant volume cooling (produces vacuum)
Process 4-5: Isentropic compression (vacuum pulls piston)
Process 5-1: Exhaust process

VALVE
Patm

2
Po 3
1
5
P
4

V
 EARLY ATTEMPTS.
• Lenoir in France produced the first practical internal
combustion engine in 1860.
• By firing in every stroke on the piston, an internal-
combustion engine on model of steam engine by Etienne
Lenoir (2-stroke) led to more efforts.
• Lenoir-cycle engines were not very efficient and because
the piston was double acting, and therefore was heated
from both sides, they were limited to relatively small sizes
that could be cooled by the cylinder water jacket.
 History of I.C. Engine
• 1860 Jean Joseph Lenoir The first commercially produced internal
combustion engine. -non-compression ... the engine sucked in air/fuel
mixture during half the intake stroke and then ignited it. The
expanding mixture shut the intake valve and produced enough
pressure to push the piston down, rotate the engine through its
exhaust stroke, and start the intake stroke again. In fact, the engine
was also double-acting with a combustion chamber on each side of
the piston. -due to lack of compression, his engines were very
inefficient ... including mechanical inefficiencies, the consumption was
given as 100 cu ft/ hp.hr of 500-600 btu/scf gas. This would be about
4 to 5 % efficient which was not bad compared to steam. (However,
remember it now used coal gas (a refined fuel) rather than raw coal.
Some energy had been used to produce the coal gas.)
 History of I.C. Engine

1860 Lenoir’s
engine (a converted
steam engine)
combusted natural
gas in a double
acting piston, using
electric ignition
 Two-stroke Lenoir Engine
Process 1-2: Fuel air mixture introduced into cylinder at
atmospheric pressure
Process 2-3: At half-stroke inlet valve closed and combustion
initiated constant volume due to heavy piston
producing high pressure products
Process 3-4: Products expand producing work
Process 4-5: At the end of the first stroke exhaust valve opens
and blowdown occurs
Process 5-1: Exhaust stroke

3
P

Po
1 2 5
V
 History of I.C. Engine
• 1876 Nikolaus Otto patented the 4 cycle engine; it used
gaseous fuel
• 1882 Gottlieb Daimler, an engineer for Daimler, left to
work on his own engine. His 1889 twin cylinder V was
the first engine to be produced in quantities. It used
liquid fuel and Venturi type carburetor, engine was
named “Mercedes” after the daughter of his major
distributor
• 1893 Rudolf Diesel built successful IC engine which
was 26% efficient (double the efficiency of any other
engine of its time)
 History of I.C. Engine
• The internal combustion
engine was first conceived
and developed in the late
1800’s
• The man who is considered
the inventor of the modern
IC engine and the founder
of the industry is pictured to
the right….Nikolaus Otto
(1832-1891).
• Otto developed a four-
stroke engine in 1876, most
often referred to as a Spark
Ignition, since a spark is
needed to ignite the fuel air
mixture.
 EARLY ATTEMPTS.
• Nicolaus August Otto, grocery salesman, impressed with
this Lenoir-cycle engines.
– a. Made working model for study.
– b. How to control explosive combustion?
• Otto's solution: Use combustion to heat cylinder, then cool
to allow atmospheric pressure to act on piston.
– a. Newcomen engine principle.
– b. Patented 1863.
• Otto formed partnership with Eugen Langen, sold 5000+
Otto & Langen engines.
• Design extremely limited. Poor power, fuel consumption,
space requirements, noise, etc. Market peaked and
declined.
 Two-stroke Otto-Langen Engine
Process 1-2: Fuel air mixture introduced into cylinder at
atmospheric pressure
Process 2-3: Early in the stroke inlet valve closed and
combustion initiated constant volume due to
heavy piston producing high pressure products
Process 3-4: Products expand accelerating a free piston
momentum generates a vacuum in the tube
Process 4-5: Atmospheric pressure pushes piston back,
piston rack engaged through clutch to output shaft
Process 5-1: Valve opens gas exhausted
Disengaged
output shaft

Engaged
output shaft
1885 Schleicher-Schumm Built in Philadelphia, PA by the
American licensee of Otto and the second oldest American,
operating internal combustion engine. Two-horsepower at 180
rpm, single-cylinder, horizontal design.
Historical IC Engines
 EARLY ATTEMPTS.
• The impact on society is quite obvious, all most all travel
and transportation is powered by the IC engine: trains,
automobiles, airplanes are just a few.
• The IC engine largely replaced the steam engine at the
turn of the century (1900’s)
• Another important cycle is the Diesel cycle developed by
Rudolph Diesel in 1897. This cycle is also known as a
compression ignition engine.
 EARLY ATTEMPTS : summary
Atmospheric engines
• Huygens proposed using gunpowder for providing
motive power (1680)
• Papin described an engine design to the Royal Society
of London (1688)
• Newcomen (1712) - first steam engine

Engines with compression

• Lenoir (1860)
• Otto and Langen (1866)
• Otto silent engine - four stroke (1876)
• Robson - two stroke (1877)
• Daimler - workable power-to-weight ratio (1884)
• Diesel - diesel engine (1892)
 Background on IC Engines

• “An internal combustion is defined as an engine

in which the chemical energy of the fuel is
released inside the engine and used directly for
mechanical work, as opposed to an external
combustion engine in which a separate
combustor is used to burn the fuel.”
• “IC engines can deliver power in the range from
0.01 kW to 20x10^3 kW, depending on their
displacement.”
 Background on IC Engines
Internal combustion engines are so called because the
heat required to drive them is released by burning a fuel
inside the engine itself.
This approach has advantages and disadvantages, but
is still the most popular for transport and small power
generation plant. We will be looking at some common
types of engine, examining some ways of analyzing their
performance parameters, and some of the problems
encountered in improving efficiency and output.
All the engines we will examine contain the same basic
activities:
• invest some work to compress a working fluid,
• inject heat into the fluid,
• recover a greater amount of work,
• return to initial conditions by removal of some heat.
 Background on IC Engines
Actual processes by which this is done vary. Internal
combustion engines "use up" the charge of working fluid
each cycle.
They therefore need to induce a fresh charge of working
fluid and get rid of the spent gases at the end of the
cycle.
Internal combustion engines vary, and include systems
which function like "closed" systems (e.g. petrol engines)
or as "open" systems (e.g. gas turbines). All essentially
perform the following basic processes
 Typical Processes
for an Internal Combustion Engine
Classification of Internal Combustion Engine
Internal Combustion Engine can be classified in number of different ways
1. Type of Ignition
2. Engine Cycle
3. Valve Location
4. Basic Design
5. Position and Number of Cylinders of Reciprocating Engines
6. Air Intake Process
7. Method of Fuel Input for SI Engine
8. Fuel Used
9. Application
10. Type of Cooling
Classification of Internal Combustion Engine
Type of Ignition
1. Spark Ignition
• Generally homogeneous mixture
• Ignition by external source such as a spark
• Orderly flame propagation-premixed flame
• Controlled energy release
• Intake air throttled
• Limited variation in A/F ratio
• Distinct fuel requirements
• Limitations on compression ratio
 Classification of Internal Combustion Engine

Type of Ignition
1. Spark Ignition
The Otto cycle SI engine has remained fundamentally unchanged,
besides slight improvements, for over 100 years. Its’ popularity has
continually increased because…
• Relatively low cost
• Favorable power to weight ratio
• High Efficiency
• Relative simple and robust operating characteristics
• Improvements are mainly lower emissions and higher fuel efficiency
Classification of Internal Combustion Engine
Type of Ignition
2. Compression Ignition
• Nonhomogeneous mixture
• Ignition due to high temperature
• May not have flame propagation
• Uncontrolled burning (varies for engines)
• No throttling of intake air
• Wide range of A/F ratio
• Distinct fuel requirements
• Needs high compression ratio
 Differences between design and operating
Characteristics of SI and Diesel Engine

Spark Ignition Diesel

1. Premixed charge drawn into cylinders Only air drawn into cylinders

2. Mixture formed in intake system Fuel injected into cylinder prior

to combustion

3. Load control by throttling Load control by fuel metering;

no throttling in diesel engines

4. Ignition by spark Spontaneous ignition of mixture;

no external ignition source

5. Generally volatile fuel (gasoline); Generally distillate oil. Must ignite

does not ignite spontaneously at at lower temperatures.
Lower temperatures.
 Differences between design and operating
Characteristics of SI and Diesel Engine

Spark Ignition Diesel

6. Lower compression ratio Higher compression ratio (as

(knock limited) high as 25, no knock limitation).

7. Turbocharged in high performance Usually turbocharged (except

engines in smaller size engines) to increase
power.

8. Lighter construction; higher rpm Heavier construction; limited rpm

9. Higher fuel consumption Lower fuel consumption

 Classification of Internal Combustion Engine
Engine Cycle
1. Four Stroke Cycle
• Four strokes to complete the thermodynamic cycle :
– Intake process - one stroke (fresh mixture inducted in, work done by piston to
induct mixture)
– Compression process - one stroke (mixture compressed almost adiabatically,
work done by piston on mixture; process Pv = constant)
– Combustion and expansion - one stroke (mixture is ignited and burned through
flame propagation in SI engine and the high pressure gases then expand
producing work. In CI engine, ignition occurs after fuel injetion and a delay
period, mixture is burned, and high pressure gases expand producing work
output)
– Exhaust process - one stroke (the burned gases are purged out by opening the
exhaust valve and moving the piston from BDC to TDC)
4-Stroke Engines intake exhaust
 Four stroke Spark Ignition (SI) Engine

Stroke 1: Fuel-air mixture introduced into cylinder through intake

valve
Stroke 2: Fuel-air mixture compressed
Stroke 3: Combustion (roughly constant volume) occurs and
product gases expand doing work
Stroke 4: Product gases pushed out of the cylinder through the
exhaust valve
FUEL
A
I Ignition
R

Fuel/Air
Mixture Combustion
Products

Intake Compression Power Exhaust

Stroke Stroke Stroke Stroke
 Four-Stroke SI Engine

Exhaust gas
residual

IVO - intake valve opens, IVC – intake valve closes

EVO – exhaust valve opens, EVC – exhaust valve opens
Xb – burned gas mole fraction
 Four stroke Compression Ignition (CI) Engine

Stroke 1: Air is introduced into cylinder through intake valve

Stroke 2: Air is compressed
Stroke 3: Combustion (roughly constant pressure) occurs and
product gases expand doing work
Stroke 4: Product gases pushed out of the cylinder through the
exhaust valve
A
I Fuel Injector
R

Air Combustion
Products

Intake Compression Power Exhaust

Stroke Stroke Stroke Stroke
 Four-Stroke CI Engine

SOI – start of injection

Fuel mass EOI – end of injection
flow rate
SOC – start of combustion
EOC – end of combustion

Fuel mass
burn rate
 Four stroke Compression Ignition (CI) Engine

Stroke 1: Air is introduced into cylinder through intake valve

Stroke 2: Air is compressed
Stroke 3: Combustion (roughly constant pressure) occurs and
product gases expand doing work
Stroke 4: Product gases pushed out of the cylinder through the
exhaust valve
A
I Fuel Injector
R

Air Combustion
Products

Intake Compression Power Exhaust

Stroke Stroke Stroke Stroke
Classification of Internal Combustion Engine
Engine Cycle
2. Two Stroke Cycle
• In a two-stroke engine all the processes are the same but the cycle
is completed in two strokes of the piston.
• Since there is one power stroke per revolution, one would expect the
power output of a 2-stroke engine to be twice that of a 4-stroke
engine for the same displacement.
 Two Stroke Spark Ignition Engine

Stroke 1: Fuel-air mixture is introduced into the cylinder and

is then compressed, combustion initiated at the end of
the stroke

Stroke 2: Combustion products expand doing work and then

exhausted

* Power delivered to the crankshaft on every revolution

2-StrokeEngines

intake

Reed
Valve
2-stroke
 Two Stroke Spark Ignition Engine

Exhaust
port

Fuel-air-oil
mixture
compressed

Check
valve
Expansion Exhaust Intake (“Scavenging”)
Crank
shaft

Fuel-air-oil
mixture

Compression Ignition
Scavenging in Two-Stroke Engine

Cross Loop Uniflow

 Two-Stroke CI Engine

EPO – exhaust port open

EPC – exhaust port closed
IPO – intake port open
IPC – intake port closed
scavenging

Exhaust area

Intake area
Advantages of the two stroke engine:

• Power to weight ratio is higher than the four stroke engine since there
is one power stroke per crank shaft revolution.
• Simple valve design

Most often used for small engine applications such as lawn mowers,
marine outboard engines, motorcycles….

Disadvantages of the two-stroke engine:

• Incomplete scavenging or to much scavenging

• Burns oil mixed in with the fuel

49
Classification of Internal Combustion Engine
Valve Location
• Valves in Head (overhead valve), also called I Head Engine.
• Valve in Block (Flat head), also called L Head Engine or T Head
Engine.
• One valve in Head and one valve in Block, also called F Head
engine.
Classification of Internal Combustion Engine
Inlet Valve and Head Configurations

‘L’ head Wedge chamber Hemispherical Head Blow-in-piston chamber

Bath-Tub Head Squish Zone Head May Fireball-high Turbulence chamber

Classification of Internal Combustion Engine
Basic Design
1. Reciprocating Engines
• Linear motion of piston in a cylinder and conversion of linear into
rotary motion using crankshaft.
• Advantages - better sealing of high pressure gases; ease of
lubrication; lower surface area; less wear on rings/seals.
• Disadvantages - reciprocating mass and force unbalance; vibrations,
lower power density (based on mass); larger physical size.
Classification of Internal Combustion Engine
Basic Design
2. Rotary
• Rotary motion of rotor-direct output at the shaft.
• Advantages - compact size power plant; higher power density;
smooth, vibration-free operation; lower height.
• Disadvantages - sealing of high pressure gases and leakage; cost
and durability of seals; lubrication of seals; larger surface area.
Wankel Engines
exhaust intake
+: No valves needed
Continuous motion
Æ less vibration

-: Leaks through
seals
Æ low compression
ratio
Æ pollution
(high levels of HC
and CO)
Classification of Internal Combustion Engine
Position and Number of Cylinders of Reciprocating Engines
• Single Cylinder.
• In-Line
• V Engine
• Opposed Cylinder Engine
• W Engine
• Opposed Piston Engine
• Radial Engine
 NUMBER OF CYLINDERS

Single-cylinder engine gives one power stroke per crank revolution

(2 stroke) or two revolutions (4 stroke). The torque pulses are widely
spaced, and engine vibration and smoothness are significant problems.
Used in small engine applications where engine size is more important

Multi-cylinder engines spread out the displacement volume amongst

multiple smaller cylinders. Increased frequency of power strokes
produces smoother torque characteristics. Engine balance (inertia forces
associated with accelerating and decelerating piston) better than single
cylinder.

Most common cylinder arrangements:

- In-line 4-cylinder
- In-line 6-cylinder
- V-6 and V-8
Classification of Internal Combustion Engine
Air Intake Process
• Naturally Aspirated
• Supercharged
• Turbocharged
• Crankcase Compressed
 Supercharger and Turbocharger

These devices are used to increase the power of an IC engine by raising

the intake pressure and thus allowing more fuel to be burned per cycle.

Knock or autoignition phenomenon limits the amount of precompression.

Superchargers are compressors that are mechanically driven by the engine

crankshaft and thus represent a parasitic load.

Pint > Patm

Patm

Compressor
Turbochargers couple a compressor with a turbine driven by the exhaust
gas. The compressor pressure is proportional to the engine speed

Compressor also raises the gas temperature, so aftercoolers are used

after the compressor to drop the temperature and thus increase the air
density.
The peak pressure in the exhaust system is only slightly greater than
atmospheric – small ΔP across turbine

In order to produce enough power to run compressor the turbine speed

must be very fast (100k-200k rev/min) – long term reliability an issue

It takes time for turbine to get up to speed so when the throttle is opened
suddenly there is a delay in achieving peak power - Turbo lag

Waste gate valve used to control the exhaust gas flow rate to the turbine
It is controlled by the intake manifold pressure

EXHAUST
FLOW

INTAKE
AIR
Classification of Internal Combustion Engine
Method of Fuel Input for SI Engine
• Carburetted
• Multipoint Port Fuel Injection
• Throttle Body Fuel Injection
 Fuel-Air Mixing

• In spark ignition engines the air and fuel are usually mixed prior to entry
into the cylinder.

• The ratio of mass flow of air to the mass flow of fuel must be held roughly
constant at about 15 for proper combustion.

• Initially a purely mechanical device known as a carburetor was used to

mix the fuel and the air

• Most modern cars use electronic fuel-injection systems

62
 Basic Carburetor

Air Flow

Venturi

Fuel
Throttle

Mixture to manifold
Sketch of a Carburetor
 Fuel Injection
System

Throttle

ECU: Electronic
Control Unit
 Fuel Injection System

Air intake
manifold

Throttle

Fuel tank

During start-up the components are cold so fuel evaporation is very slow, as a result
additional fuel is added through a second injecting valve
 Diesel Fuel Injection System

With diesel engines fuel is sprayed directly into the cylinders

power is varied by metering the amount of fuel added (no throttle)

Diesel fuel injection systems operate at high-pressure, e.g., 100 MPa

• fuel pressure must be greater than the compression pressure
• need high fuel jet speed to atomize droplets small enough for rapid
evaporation
 Direct Injection (DI) Engine
Hybrid engines that combines the best features of SI and CI engines:
• operate at optimum compression ratio (12-15) for efficiency by
injecting fuel directly into engine during compression (avoiding knock
associated with SI engines with premixed charge)
• ignite the fuel as it mixes (avoid fuel-quality requirement of diesel fuel)
• control engine power by fuel added (no throttling Æ no pumping work)

Need bowl in piston design with high

swirl in order to achieve rapid fuel-air
mixing
 Direct-Injection Stratified-Charge Engines

• Create easily ignitable fuel-air mixture at the spark plug and a leaner
fuel-air mixture in the rest of the cylinder.
• Lean burn results in lower emissions.

Following is an example of a torch or jet ignition engine

Classification of Internal Combustion Engine
Fuel Used
• Gasoline
• Diesel Oil of Fuel Oil
• Gas, Natural Gas, Methane
• LPG
• Alcohol – Ethyl, Methyl
• Dual Fuel
• Gasohol
Classification of Internal Combustion Engine
Application
• Automobile, Truck, Bus
• Locomotive
• Stationary
• Marine
• Aircraft
• Small Portable, Chain Saw, Model Airplane
Classification of Internal Combustion Engine
Type of Cooling
• Air Cooled.
• Liquid Cooled, Water Cooled.
 Introduction to the Internal Combustion
Engine’s Components

Keys components
• Combustion chamber
• Intake and exhaust
• Ignition
• Conversion to rotary motion
 I C Engine’s Components
Cylinder head
Air cleaner
Breather cap

Rocker arm
Choke
Valve spring
Valve guide
Throttle
Pushrod
Intake manifold Sparkplug
Exhaust manifold
Combustion chamber
Tappet
Piston rings Dipstick
Piston
Cam
Wrist pin
Cylinder block Camshaft
Connecting rod Water jacket
Oil gallery to piston Wet liner
Oil gallery to head
Connecting rod bearing
Crankcase
Crankpin
Crankshaft Main bearing

Oil pan or sump

CROSS SECTION OF OVERHEAD VALVE FOUR CYCLE SI ENGINE

 Air cleaner

Carburetor
Camshaft

Rocker arm

Intake valve
Cam sprocket Exhaust valve

Piston

Connecting rod
Timing belt

Timing belt
Crankshaft
tensor

Oil pump
Crank sprocket Oil pickup
 Crankshaft

• Originally steel forged; however,

large stiff crankshafts with relatively
low stresses allowed cast iron to be
substituted as a means to reduce
cost

• How is crankshaft supported?

 Piston Assembly

• Piston: aluminum, cast steel or cast iron

• Wrist pin: machined steel

• Connecting rod: forged-steel or cast iron

 Cylinder Head and Crankcase

• Crankcase and cylinder block are

usually cast iron; however, some
have been assembled from welded
steel plate Cylinder block

• Crankcase and cylinder are usually

Crank case
integral for greater rigidity

• How is cylinder head made?

 Cylinders

• How are cylinders fabricated?

– Gray cast iron with cylinder bores machined to meet tolerance

• Why must a new engine be “run-in / broken in”?

– Cast iron forms a hard glazed surface when subject to sliding friction
– When first assembled, slow speeds and light loads should be used to
facilitate forming this protective coating to give long engine life
Poppet Valve Actuation with Overhead Camshaft

Camshaft

Spring
Spark
plug Guide
Stem
Air manifold
Valve head
Valve seat

Piston
 Camshaft and Cams

• Camshaft and cams are usually made

from steel

• How are cams fastened?

Valves
• Intake valve: a chromium-nickel
alloy

• Exhaust valve: a silicon-chrome

alloy since it operates at higher
temperatures (about 1200oF)
 Engine Temperature Profiles
• What two purposes does
engine lubrication serve?
– minimize friction
– dissipate heat
How does your engine lubrication system work?

• An oil pan seals the

engine block, providing a
reservoir for lubricating oil
for most drivetrain Dip stick
components
Oil gallery
(for piston)
• How is oil pan fabricated? Oil gallery

Oil pan
 Automotive Fuel Needs

x1.1 x2.2 x2.5

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