Basic workshop skills &

Engine systems
Name: Bapoo Shailen
Automotive Mechanics and Electronics (Level 4)
Table of contents

1. Demonstrate good work habits and perform safe work practices

2. Select and use hand tools and workshop equipment
3. Measure linear and angular dimensions
4. Explain the operation of two and four stroke petrol and diesel engines
5. Dismantle and reassemble a four-stroke petrol engine
1.Demonstrate good work habits and perform safe
work practices

Safety equipment used in an automotive workshop:

 Safety Glasses – Defense against eye injuries
 Fire extinguishers – Cools burning materials
 Safety gloves – protection against cuts or burns
 First aid boxes – Supply for medical treatment
 Face shields – protect wearer’s entire face
Safety signs and posters

 Prohibition signs- It is a safety sign preventing behaviour likely to cause a risk

to health and safety.
 Mandatory signs- It specifies that an instruction must be carried out.
 Safe condition sign- An emergency escape of first aid sign giving information
for rescue
 Hazard sign- A hazard is any source of potential damage, harm or adverse
health effects on something or someone.
Precautions to be taken while handling
sharp tools
 Carry all sharp tools in sheath or holsters
 Tag worn, damaged or defective tools “Out of service” and do not use
them.
 Transport hand tools only I tool boxes or tool belts
 Do not throw tool from one location to another or from one employee
 Do not perform “make-shift” repairs to tools
Safety regulations prescribed by the authorities for
safety in an automotive workshop

 A well ventilated workplace

 Easy access and exit to workshop
 First aid facilities
 Accident reporting
 Protective clothing
 Observe cleanliness
 Dispose used chemicals without causing environmental pollution
 No smoking
 No long hairs, necklace, watches and rings
 Follow instructions carefully
2.Select and use hand tools and workshop equipment

 Hand tools- They are fairly simple tools which are used with hands, and which
are usually not powered
 Power tools- They are tools that are actuated by an additional power source
and mechanism other than the solely manual labour
3. Measure linear and angular dimensions

 The need for accurate measurements

1. To ascertain the amount of wear
2. To have better finish
3. To avoid wastage in terms of materials, time and money
S.I units- Systeme Internationale d’Unites :
4. Explain the operation of two and four stroke petrol
and diesel engines

 In a motor vehicle the engine develops power to propel the vehicle. It

converts the heat energy of the fuel into mechanical energy. Various types of
engines are used in present day vehicles.
 Types of heat engines:
Difference between spark ignition
engine and compression ignition engine
Spark Ignition
 It works on OTTO Cycle or constant
volume heat addition.
 During the intake or suction process,
air and fuel are used.
 The fuel used Petrol which is highly
volatile. Self Ignition temperature is
high.
 The fuel is supplied by Carburetor.
 High speed because due to
lightweight and homogeneous
combustion.
Compression Ignition
 It works on DIESEL Cycle or constant
pressure heat addition.
 During the intake or suction process,
only air used.
 The fuel used Diesel which is low
volatile. Self-ignition temperature is
low.
 The fuel is supplied by Carburetor.
 Comparatively low speed because
due to heavyweight and
heterogeneous combustion.
Difference between a two stroke engine
and a four stroke engine
Two stroke engine
 1. When the piston reaches the top of the cylinder,
the spark plug ignites the air/fuel mixture, which
explodes, driving the piston downward.
2. Expanding gases force the piston down and
escape out the exhaust valve as it is exposed. The
piston forces the next air/fuel charge below it up
through transfer ports to the area opening above it.
3. When the piston is at the bottom of the stroke, the
transfer port's top is exposed to let the air/fuel charge
into the cylinder above the piston.
4. As the piston heads back up, it creates a vacuum
beneath it that sucks the next air/fuel charge in
through the one-way reed valve system. The piston
also compresses the charge above it to be ready to
explode when the spark plug ignites again.
Four stroke engine
 1. When the piston reaches the top of the cylinder the
spark plug ignites the air/fuel mixture, driving the piston
down on the power stroke. All valves are closed.
2. The piston reaches the bottom of the cylinder and
starts back up on the exhaust stroke. A cam pushes the
exhaust valves slightly open into the cylinder and the
piston forces the exhaust gases out.
3. The piston reaches the top then starts down on the
intake stroke. The spark plug does not fire. Now the
intake valves are pushed open by the cam, and the
vacuum created by the piston sucks in a fresh air/fuel
charge.
4. The piston reaches the bottom and starts back up on
the compression stroke. All the valves are closed. At the
top, the spark plug will ignite the air/fuel mixture to
cause the next power stroke.
5.Dismantle and reassemble a four-stroke petrol
engine

 Service a cylinder head

The cylinder head forms the top of the combustion chamber. It includes the
valves, valves guides, valve seats, ports, combustion chambers, and water
jackets, threaded holes for spark plugs.
The engine valves are responsible for the flow of gases in and out og the
cylinder. There are two types of valves, inlet and exhaust valves. The inlet valve
allows the flow in the fresh mixture for S.I engine. The exhaust valve allows the
flow of burnt gases to escape outside the cylinder head.
Service piston and piston rings

 Piston
The function of piston in an engine is to transmit the power produced by the
burning fuel to the crankshaft. The nurning of fuel produces a very high pressure
in the combustion chamber. The high pressure acts on the piston head and forces
it downward in the cylinder. The piston should be strong enough to withstand
high temperatures and pressures and also a good conductor of heat.
 Piston rings
A piston ring is a metallic split ring that is attached to the outer diameter of a
piston in an internal combustion engine or steam engine.
Service of a connecting rod

 Function of a connecting rod

1. It connects the piston to the crankshaft
2. It transmits the piston force to the crankshaft
3. It converts the linear movement of the piston into rotary movement of the
crankshaft
The connecting rod converts the linear up and down movement of the piston into
the circular motion of the crankshaft and is therefore subject to tension,
compression, bending and buckling.
Service of a crankshaft

 The crankshaft changes the downward power pulses from the connecting rod
into rotary motion. It also drives the camshaft and supports the flywheel, and
contains passages through which oil flows.
 The camshaft converts the rotary motion into reciprocating motion with the
help of cam lobe. It operates the inlet and outlet valves
 The crankcase is the lower part of the engine block which accommodates the
crankshaft
 The flywheel stores energy produced during power stroke and supplies it to
the crankshaft during the idling strokes.
Perform Valve timing

 Valve timing is the process of connecting the crankshaft to the camshaft in

such a way that the valves open close in relation to piston movement.
The valve timing diagram shows the angle at which the valves open and close. It
is used to check wear of the camshaft lobes.