2nd.

Quarter
Lesson 4.2

COMMON ENGINE
TERMS & ENGINE
COMPONENTS
Engine Terms
Bore and Stroke

Bore
inside diameter of the engine cylinder

Stroke
distance travelled by the
piston inside the cylinder
 Types of Engine Bore and Stroke
Long Stroke Type
This type of cylinder is
suitable for running in
urban areas
Stroke > Bore A larger torque is
generated even during
low-speed rotation

Commonly used in
large engines
Square Stroke Type

Stroke = Bore

This type of
cylinder is suitable
for passenger cars
and small engines
Short Stroke
Type

Stroke < Bore

This type of
cylinder is suitable
for running in high
speed

Larger torque is
generated during
high-speed rotation
Engine Displacement
Total volume displaced per cylinder multiplied
by the number of cylinders
Bore
Sample Computations:

Stroke 1 2 3 4 Given: 4JJ1 engine

Bore = 95.4 mm (9.54
cm)
Stroke = 104.9 mm
(10.49 cm)
V = π / 4 x (bore)2 x stroke x no. of cylinders

V = π / 4 x (9.54cm)2 x 10.49 cm x 4

V = 3.1416 / 4 x 91.01cm2 x 10.49 cm x 4

V = 2,999.32 cm3 ~
2.99 L or 3.0 L
since, 1000 cm³
= 1 liter

V = 3.0 liters
Compression Ratio
it is the measure of how much air is being
compressed during the compression stroke
it is the ratio between the volume of
combustion chamber and volume of air intake
during intake process per cylinder

TDC V2

V1

BDC
 Formulas:
Volume 1 (V1)
Compression Ratio =
Volume 2 (V2)
Compression Ratio
Low
High Compression Compression
Ratio Ratio
(Diesel Engine) (Gasoline
Engine)

a. Better engine
starting a. Low engine
Advantages
b. Improved fuel noise
combustion

a. Difficult engine
Disadvantag a. Louder engine starting
es noise b. Poor fuel
combustion
Engine Power
- Power is the ability from the crankshaft to
do work
- Engine power indicates the vehicle’s top
speed
- The higher the engine can provide, the
faster the vehicle can be
 hp stands for horsepower it is the amount of power
a horse uses to lift an item weighing 75kgs to a height
of 1 meter in 1 second (metric) or 33,000 lb to a
height of 1 ft in 1 second (english)

PS stands for Pferdestarke, it is a German unit that

is commonly used in Europe, South America and Japan
especially by the automotive and motorcycle industry
Engine Torque
it is the amount of turning or twisting force
generated by an engine
it is a force that the passenger feels when
you accelerate in a vehicle. Torque is the
force that determines the acceleration rate
and pulling capacity of the vehicle
Engine Performance Curve
Engine performance curve represents how
engine works at specific engine speed (rpm)
Example 1:
When engine rpm reaches 3,500
rpm,
a.Max. output (power) = 70 Ps
70 b.Engine Torque = 17.5 kg-m
60
c.Fuel Consumption = 185 gm/hr

50 20
Example 2:
40 15 When engine rpm 4,500
30 10 rpm,
a.Max. output (power) =
250
20
58 Ps
10 Specific Fuel Consumption Curve 200 b.Engine Torque = 10
kg-m
150
1000 1500 2000 2500 3000 3500 4000 c.Fuel Consumption =
Engine Speed (rpm) 230 gm/hr
 Engine
Components
Cylinder
- is a long round and barrel type shape in
which the piston moves up and down.
- the air and fuel mixture always enters in the
cylinder and goes out after burning.
Classification of Cylinder:
a. In-Block Cylinder
- the cylinder and the block are
manufactured as a solid unit
- there is no cylinder liner and has
fewer parts than liner type cylinder
- widely used in gasoline engine
and is made up of cast iron
material In-block
Cylinder
Dry Liner Type Wet Liner Type
- liner is surrounded by the
- outer surface of the
walls of cylinder block, so it
liner comes directly in
never comes into direct
contact with the cooling
contact with the engine
water
cooling water.
- has a better cooling
- can be inserted easily by
efficiency
slip fitting into the cylinder
block - easy to manufacture
and assemble than dry
liners

Dry Liner Type Wet Liner

Cylinder Block
- basic framework of the engine wherein
other parts of the engine is attached
Cylinder Block Structure

1. Cylinder- pistons are moving in

reciprocal motion
2. Water Jacket - passage for the
cooling water used to cool off the heat
generated by the engine
3. Crankshaft bearings - holds the
crankshaft by the bearings
4. Oil gallery- passage for oil drawn in
by the oil pump
5. Oil pan and gear train mountings
Classification of Cylinder Block
1.Deep Skirt Type - the skirt end is 50 – 70
mm from the center of the crankshaft
- good design enough to strongly hold the
transmission case
2. Half Skirt Type – the skirt ends near the
center of the crankshaft
- relatively used for small engines
Cylinder Head Gasket
- mounted between the cylinder block and
the cylinder head to prevent gas leakage
between them and to prevent the entry of air
from the outside.
 Handling of Cylinder Head Gasket

Do not carry a cylinder head gasket by both

1 ends. It may curve and the asbestos in the
middle may be cracked

Do not damage or deform the gasket. Do

2
not store it under a heavy object

Do not immerse the gasket in liquid,

3
because the asbestos will be damaged

4 Mount the gasket on the correct side

Pistons
- round metallic component which moves up
and down inside the cylinder
- absorb and transmit the pressure generated
by combustion to the crankshaft through the
connecting rod
 Piston Structure

Piston Head / Crown – top most part of the

1 piston that directly receives the combustion
pressure
Piston Ring Land – portion where piston
2
rings are inserted

Oil Drain Hole – passage of the oil that was

3
scraped by the oil ring

Piston Skirt – part below the piston pin

4
center
Piston Pin
- used to connect the piston and the
connecting rod
- made up of special steel and is abrasion
resistant because of carburizing treatment
 Classification of Piston Pin
1. Fixed Type – piston pin is fixed to a
piston boss by a set of screw
2. Half Floating Type – piston pin is fixed
to the small end of the connecting rod to
enable movement in the piston hole
3. Full Floating Type – piston pin can move
freely because it is not fixed. A snap ring is
inserted at both ends to prevent shifting from
the pin hole.
Pistons Ring
- wheel shape steel surrounding the head part
of the piston
- seals in compression, transfer heat, clean
the cylinder walls, withstand high pressure
Top
compression
ring

Second
compression ring

Oil ring ring

Pistons Ring Operation

Piston Ring
Oil
Piston
Cylinder

Intake Stroke Compression Stroke

During intake stroke, During compression stroke,
pressure of the combustion the oil that is scraped up by
chamber is lower than the the compression ring (1st
crankcase. With this, the oil ring) is scattered into the
will sucked up from the combustion chamber.
small clearance between
the rings, piston and
cylinder to form oil film at
the cylinder wall.
Pistons Ring Handling
When mounting a ring on the piston, do not open the end gap
1 more than necessary, it may broke or reduce its tensile force.

2 Mount the rings in the specified direction and shift the end gap
of each ring by 180°.
3 Make sure that the upper surface of the ring faces up and the
lower surface of the ring faces down.

For proper inspection of the piston rings, check

the following:
1. Piston ring width

2. End gap of piston ring

3. Clearance between piston ring

and ring groove
Connecting Rod
- connecting link or arm between the piston
and the crankshaft
- converts the up-and-down (reciprocating)
motion of the piston into a circular (rotary)
motion of the spinning crankshaft
small end

connecting rod

connecting rod bolt

big end

connecting rod bolt nut

connecting rod cap
Crankshaft
- main rotating shaft inside the engine
- receives the pressure applied to the pistons
through the connecting rods and changes this
reciprocating motion into rotary motion
needed to power the driveline of the vehicle

Crank
Journal Crank Oil Balance Crank
Pin Holes Weight Arm
 Crankshaft Structure
Description Function
• connect the connecting rods through bearing
Crank Pin metals
• directly receive the force from combustion

• major component of the rotary shaft

• directly mounted to the cylinder block through
Crank Journal bearing metals
• distance between crank journal center and crank
pin center is equal to ½ of piston stroke

• connects the crank pin and the crank journal

Crank Arm
• oval shape because of large bending stress

• mounted to crankshaft for smooth operation

Balance Weight • decrease abrasion on the crank journals and
bearings

• lubricants sent to the crank journals is supplied to

Oil Holes
the crank pins from the oil holes
Flywheel
- a rotary plate made of high grade cast iron
and is mounted at the rear end of a
crankshaft
- Engine produces power during
combustion or power stroke only. To sustain
its operation smoothly flywheel is used.
Functions of Flywheel
1. A flywheel for a car with manual
transmission is very heavy and can help
smooth engine operation
2. The flywheel connects the engine
crankshaft to the transmission. Either the
manual clutch or the automatic transmission
torque converter bolts to the flywheel

3. A large ring gear, usually on the flywheel,

is used to start the engine. A small gear on
the starting motor engages the flywheel ring
gear and turns it.
Cylinder Head
- detachable metal cap that is bolted to cover
the top of the cylinders
- it forms part of the combustion chamber
- has water and oil passages for cooling and
lubrication
Components attached on Cylinder Head
Camshaft

Valve
Spring

Intake Valve
Manifold
Exhaust
Manifold
Camshaft
- other rotating shaft inside the engine
- main function is to drive the opening and closing of
the valves
Camshaft components:
Cam Journal – functions as bearings for mounting the
camshaft on the engine
Cam lobe – determines the lift and timing of valve
opening/closing

Cam lobe Cam Journal

Rocker Arm
- used to transfer motion on all engine
valves

Rocker
Arm
Valves
- Engine valves open and close the ports in the cylinder
head
- Intake valve is the larger valve because it controls the flow
of air (diesel) or fuel mixture (gasoline) into the
combustion chamber
- Exhaust valve is the smaller valve and it controls the flow
of exhaust gases out of the cylinder
Stem End

Valve Stem

Valve Face
Seat Width

Valve Head
Valve Spring
Valve spring is used to maintain the valve
stay close after it has been open by the
camshaft to maintain air tightness in the
cylinder
Valve Spring Inspection

Free Length Measurement

Valve length should be check, if it is
shorter than specified limit, replace
the spring
Valve Spring
Squareness

Use surface plate

and a square to Valve Spring
measure the Tension
Use spring tester to test
squareness of the
the tension of the
spring. If value
compressed spring. If
exceeds the limit,
value is lower than the
replace the spring.
limit, replace the spring.