IC Engine Tutorial

03/12/2025 BY: Yonathan M. 1

 1. Understanding IC Engines
characteristics and selection

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 The purpose of internal combustion engines is the production of
mechanical power from the chemical energy contained in the fuel.
 In internal combustion engines, this energy is released by burning
or oxidizing the fuel inside the engine (usually called a Heat
Engine).
 The actual working fluids are the fuel-air mixture before
combustion and the burned products after combustion.
 The work transfers which provide the desired power output occur
directly between these working fluids and the mechanical
components of the engine.

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 …Cont
 The internal combustion engines which are the subject of
this course are spark-ignition engines (sometimes called
Otto engines, or gasoline or petrol engines, though other
fuels can be used) and compression-ignition or diesel
engines.
 Because of their simplicity, strength and high
power/weight ratio, these two types of engine have found
wide application in transportation (land, sea, and air) and
power generation.

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 The Characteristics of Engines
•Stability: the ability to keep running at high speeds without consuming an excessive
amount of fuel or electrical energy.

•Power: the work engines generate in a certain amount of time at a specific speed.

•Performance: the output obtained between the useful power of the engines and the
power absorbed.

•Engine torque: the moment of force that affects the axis of the engines and which
determines their rotation.

•Rated speed: the number of revolutions per minute at which the engines spin
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Specifications for selecting combustion engines
The most important specifications to consider when selecting
combustion engines are torque, horsepower, and RPM (shaft
speed), which are all interdependent.
For internal combustion engines, displacement and the number
of cylinders are also important to consider.

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 …cont.
 Torque (τ) is a measure of the rotational force generated on engine's shaft
during the power stroke. It defines the amount of physical load the engine can
generate.
 RPM or shaft speed is the speed at which the shaft, disc, or rotor in the
engine rotates measured in rpm (rotations per minute).
 Horsepower (hp) is a derived specification which indicates an engine's
performance. Specifically, it defines the rate of energy transfer in the engine.
 Displacement is the volume displaced by all the pistons in an internal
combustion engine during one stroke.
 The number of cylinders describes the amount of combustion cylinders in an
internal combustion engine.

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 Fuel consumption - Fuel consumption defines the amount of fuel consumed
 Engine efficiency Energy efficiency describes the amount of energy from the fuel
used by the engine to do useful work.
 Emissions - Gaseous emissions of pollutants and particulates are released in
the exhaust streams of combustion engines after the fuel is burned.
 Weight - The weight of the engine is important in terms of portability and
placement.
 Dimensions - The dimensions of the engine must fit within the requirements
of the corresponding system or environment.
 Compression ratio - The ratio of an engine's combustion chamber volume at
its largest to the volume at its smallest.

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 2. Understand processes and
performance w.r.t power, efficiency
and emission by application of first
principles in thermodynamics,
chemistry, heat transfer, fluid flow,
and mechanical dynamics.
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 BASIC ENGINE CYCLES
 Most internal combustion engines, both spark ignition and compression
ignition, operate on either a four-stroke cycle or a two-stroke cycle.
 These basic cycles are fairly standard for all engines, with only slight
variations found in individual designs.

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 OTTO CYCLE
This ideal air-standard cycle is called an Otto cycle,
named after one of the early developers of this type
of engine.
The intake stroke of the Otto cycle starts with the
piston at TDC and is a constant-pressure process at
an inlet pressure of one atmosphere (process 6-1).

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 OTTO CYCLE

Ideal air standard Otto cycle,

6-1-2-3-4-5-6, which
approximates the four-stroke
cycle of an SI engine on P-V
coordinates.

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 DIESEL CYCLE

Early CI engines injected fuel into the combustion chamber very

late in the compression stroke
Due to ignition delay and the finite time required to inject the
fuel, combustion lasted into the expansion stroke. This kept the
pressure at peak levels well past TDC.
This combustion process is best approximated as a constant-
pressure heat input in an air-standard cycle.
The rest of the cycle is similar to the air-standard Otto cycle.
The diesel cycle is sometimes called a Constant Pressure cycle.

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 …Cont

Air-standard diesel cycle, 6-1-2-3-4-5-6, (a) pressure-specific

volume coordinates, (b) temperature-entropy coordinates.
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 DUAL CYCLE
It is a dual cycle because the heat input process of combustion can best be
approximated by a dual process of constant volume followed by constant
pressure.
It can also be considered a modified Otto cycle with a limited upper
pressure.

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 DUAL CYCLE

 Comparison of air-standard Otto cycle, Dual cycle

 Air-standard Dual cycle, 6-1-2-x-3-4-5-
and Diesel cycle . All engines have the same cylinder
6 pressure-specific volume input conditions and same maximum temperature
coordinates and pressure.
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 ENGINE PERFORMANCE

 Engine performance is an indication of the degree of success of the

engine performs its assigned task, i.e. the conversion of the chemical
energy contained in the fuel into the useful mechanical work.
 The important factors to an engine user are:
1. The engine's performance over its operating range
2. The engine's fuel consumption within this operating range and the
cost of the required fuel
3. The engine's noise and air pollutant emissions within this operating
range
4. The initial cost of the engine and its installation
5. The reliability and durability of the engine, its maintenance
requirements, and how these affect engine availability and operating
costs
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 …Cont
 The performance of an engine is evaluated on the basis of the
following :
(a) Specific Fuel Consumption.
(b) Brake Mean Effective Pressure.
(c) Specific Power Output.
(d) Specific Weight.
(e) Exhaust Smoke and Other Emissions.
The particular application of the engine decides the relative
importance of these performance parameters.

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 Power
The main purpose of running an engine is to obtain mechanical power.
Power is defined as the rate of doing work and is equal to the product of force
and linear velocity or the product of torque and angular velocity.
Thus, the measurement of power involves the measurement of force (or torque)
as well as speed.
The force or torque is measured with the help of a dynamometer and the speed
by a tachometer.
The power developed by an engine and measured at the output shaft is called
the brake power (bp) and is given by,

where, T is torque in N-m and N is the rotational speed in revolutions per minute.
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 Power
There is a maximum in the brake power versus engine speed called the rated
brake power (RBP).
At higher speeds brake power decreases as friction power becomes
significant compared to the indicated power.
There is a maximum in the torque versus speed called maximum brake
torque (MBT).
Brake torque drops off:
 at lower speeds do to heat losses
 at higher speeds it becomes more difficult to ingest a full charge of air.

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 INDICATED POWER
It is the actual rate of work done by the working fluid on the piston.
It is the power developed in the cylinder and thus, forms the basis
of evaluation of combustion efficiency or the heat release in the
cylinder.

where, Pim= Mean effective pressure, N/m2 ,

L = Length of the stroke, m,
A = Area of the piston, m2 ,
N = Rotational speed of the engine, rpm (It is N/2 for four stroke
engine), and
k = Number of cylinders.
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MECHANICAL EFFICIENCY
The difference between the ip and bp is the indication of the power lost in the
mechanical components of the engine (due to friction) and forms the basis of
mechanical efficiency;
Mechanical efficiency is defined as the ratio of brake power (delivered power) to
the indicated power (power provided to the piston).

FRICTION POWER:
The difference between ip and bp is called friction power (fp). Friction
power is that power required to overcome the frictional resistance of the
engine parts,

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 MEAN EFFECTIVE PRESSURE AND TORQUE
Mean effective pressure is defined as a
hypothetical/average pressure which is assumed to be
acting on the piston throughout the power stroke.
Therefore,

If the mean effective pressure is based on bp it is called

the brake mean effective pressure (bmep, Pmb), and if
based on ip it is called indicated mean effective pressure
(imep).
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SPECIFIC FUEL CONSUMPTION (SFC)
Specific fuel consumption is defined as the amount of fuel consumed for
each unit of brake power developed per hour.
It is a clear indication of the efficiency with which the engine develops power
from fuel.
It is an important parameter that reflects how good the engine performance
is inversely proportional to the thermal efficiency of the engine.
Indicated specific fuel consumption (isfc) = fuel mass flow rate/ip ,
Brake specific fuel consumption (bsfc) = fuel mass flow rate/bp
ηm = bsfc / isfc

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 THERMAL EFFICIENCY AND HEAT BALANCE
Thermal efficiency of an engine is defined as the ratio of the output to that
of the chemical energy input in the form of fuel supply. It may be based on
brake or indicated output.
It is the true indication of the efficiency with which the chemical energy of
fuel (input) is converted into mechanical work.
Thermal efficiency also accounts for combustion efficiency, i.e., for the fact
that whole of the chemical energy of the fuel is not converted into heat
energy during combustion.
Indicated Thermal Efficiency (ηith)
Indicated thermal efficiency is the ratio of energy in the indicated power, to
the input fuel energy in appropriate units.

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Brake Thermal Efficiency (η bth)
 A relatively small portion of the energy liberated from the fuel
burnet inside the internal combustion engine is obtained as a
brake power (20-30%).
 Brake thermal efficiency is the ratio of energy in the brake power,
to the input fuel energy in appropriate units.

where, Cv = Calorific value of fuel, kJ/kg, and

mf = Mass of fuel supplied, kg/sec.
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EXHAUST SMOKE AND OTHER EMISSIONS
Smoke and other exhaust emissions such as oxides of nitrogen, unburned hydrocarbons, etc.
are nuisance for the public environment.
With increasing emphasis on air pollution control all efforts are being made to keep them as
minimum as it could be.
Smoke is an indication of incomplete combustion. It limits the output of an engine if air
pollution control is the consideration.
Exhaust emissions have of late become a matter of grave concern and with the enforcement
of legislation on air pollution in many countries; it has become necessary to view them as
performance parameters.
SPECIFIC WEIGHT
Specific weight is defined as the weight of the engine in kilogram for each brake power
developed and is an indication of the engine bulk.
Specific weight plays an important role in applications such as power plants for aircrafts

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 ENGINE PERFORMANCE PARAMETERS
 The practical engine performance parameters of interest are
power, torque, and specific fuel consumption.
 The maximum bmep is obtained at WOT at a particular engine
speed. Closing the throttle decreases the bmep.
 For a given displacement, a higher maximum bmep means
more torque.
 The specific fuel consumption, sfc, is a measure of how
efficiently the fuel supplied to the engine is used to produce
power.
 Clearly a low value for sfc is desirable since for a given power
level the lesser the fuel consumed the better it is.
03/12/2025 BY: Yonathan M. 28
 …cont.
There is a minimum in the bsfc versus engine speed curve.
At high speeds the bsfc increases due to increased friction.
At lower speeds the bsfc increases due to increased time for heat
losses from the gas to the cylinder and piston wall.
Bsfc increases with compression ratio due to higher thermal efficiency.
Bsfc decreases with engine size due to reduced heat losses from gas to
cylinder wall (cylinder surface to volume ratio decreases with bore
diameter).
The friction losses increase with the increase of the engine speed (N).
Thermal or heat transfer losses to the cooling system and engine parts
increase with the decrease of N.
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 …Cont
The graph shows
the operation and
performance
characteristics as
a function of
engine speed for
a typical engine

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3. Describe and explain engine heat
transfer and its relation to thermal
loading of engine components and
cooling.

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• Heat transfer passes through the cylinder wall surfaces of the
engine, in which the heat transfer process is carried out from
the working fluid to the coolant.
• There two aspects heat transfer within internal combustion
engines.
• Firstly there is heat transfer from within combustion
chamber to its boundaries, and
• secondly there is heat transfer from the combustion
chamber to its cooling media.

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 Cooling System
 Get the engine up to optimum operating Temperature as
quickly as possible and maintains it at that temperature.
 Controls the heat produced in combustion chamber, so
that the engine parts are not damaged & the oil does not
break down.
TOTAL FUEL BURNED

 1/3 cooling system

 1/3 Exhaust system

 1/3 Propels the vehicle

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 Cooling System
Two Types of Cooling System.

1. AIR COOLED
 Have metal FINS on the outer
perimeter of the engine.

 Heat is transferred from the

engine, through these fins, into
the atmosphere

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 2. LIQUID COOLED
 A liquid (coolant) is circulated around the cylinders and absorb
heat from the cylinder walls and cylinder head.
COOLANT is a mixture of antifreeze (Ethylene Glycol) and
Water (some Aluminum radiators have special antifreeze)
 Coolant absorbs heat as it passes through the engine and also
lubricates the water pump.
 Hot coolant enters the radiator in which
the heat is passed on to air that is
flowing through the radiator.
 Prevents rust and corrosion from the
water jackets.

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 Components of Liquid Cooled Cooling System
Water Jackets
 Designed to keep engine block and cylinder
head cool.
 Open spaces between the outside of cylinder
and inside of cylinder block and head.
 When engine is running at normal operating
temperature, the coolant is forced through the
water jackets in the engine block, through the
head gasket, into the head, and back to the
radiator.

Cylinder head gasket sits between the short block and cylinder
head.
•If damaged, the coolant enters the combustion chamber and
the combustion into the cooling system. It will allow acids to form.
(WHITE SMOKE)

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 Water Pump (Impeller Type)
 Draws the coolant from the
radiator, through the lower
radiator hose, and then forces it
through the water jackets, back
into the radiator.
 If the clutch fan can be wiggled up
and down, most likely the water
pump needs to be replaced.

 Water pumps gasket is placed between the

water pump and the engine block to prevent
leakage, if left loose it might leak and if
tightened too much it might crack).

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  Water pump is driven by the crankshaft through
 Timing Belt (Keeps Cam and Crank shafts in time)
 Drive/accessory Belt (Runs alternator, power-
steering pump, AC, etc.)

V-Belt
Serpentine Belt

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 Engine Fan draws air through the radiator at low speeds (i.e.
Traffic)
Clutch fan is mounted on the water pump
and is driven by the drive belt.
 It slips at higher speed, in turn slowing
the fan speed down.
 It locks up at slow speeds, in turn
speeding up the fan RPMs.

 Should be able to turn when the engine is turned off.

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 Electric fan is mounted on the
radiator and is operated by battery
power.
 Is controlled by the thermostat
switch.
 Is located on Thermostat housing,
Block, or Radiator.
 Some modern cars have the range
between 193º to 207º F (89 to 97º C)
 On AC equipped cars, a second fan
is mounted, and it runs any time AC
is turned on.
CAUTION Electric fan may run while the
engine is turned off.

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 Radiator is a heat exchanger that removes heat from the
coolant passing through it.
 Vertical or Horizontal core

 Vehicles equipped with automatic

transmission have transmission cooler
build into the radiator.

 Some vehicles (towing purposes) have

oil cooler mounted to “or” build into the
radiator.

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 Thermostat placed between the cylinder head and top
radiator hose.
 Purpose is to close off this passage when
engine is cold.
 The temperature that the thermostat
opens is called thermostat rating.
 Higher temperature thermostats are
used on the modern vehicles.
 If thermostat is stuck open the engine will
run cool, and if the thermostat is stuck
closed the engine will Overheat.
 Can be checked by placing in the boiling
water.

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42
 Radiator Pressure cap seals the cooling
system and pressurize it.
 Most caps insert 12-16 lbs of pressure.
 Each pound of pressure inserted increases
the boiling point of coolant by 1.8º C (3º F).
 Boiling point of water is 100º C (212º F).
 Has a built in pressure relief valve to prevent excessive pressure
build-up.
 Has a vacuum vent valve (when engine is shut off and it cools, the
coolant volume is reduced)
 Excess coolant goes to the expansion tank.
CAUTION never open the radiator cap if you
can’t squeeze the top radiator hose.

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BY: Yonathan M. 43
 Hoses
 Top Radiator hose brings the coolant
back to the radiator and are molded
Specifically for individual make and
model.

 Lower radiator hose draws the

coolant into the engine, from the
radiator and is attached to the
water pump. (sometimes a spring
is inserted in order to prevent
collapsing)
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 BLOCK HEATER
 Fitted into the block to keep the engine
warm during extremely cold weather.
(Diesel Engines)

FREEZE PLUG
 Prevents engine block cracking
if water freezes inside.

 Common cause of freeze plug

failure is rust.

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 4. Describe and explain engine
friction, wear and lubrication

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Engine friction:
 Forces acting between surfaces in relative motion.
 In engines, frictional losses are mainly due to sliding as well as rotating
parts.
Wear
 Wear results from contact between a surface and body or substance that
is moving relative to it.
 Wear is progressive in that it increase with usage or increasing amounts
of motion , and it ultimately results in the loss of material from a surface
or the transfer of material between surface.
Lubrication
 The action of applying substance such as oil or grease to an engine or
component so as to minimize friction and allow smooth movement.
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 Purpose of Lubrication System

•Lubricate
Reduces Friction by creating a thin film(Clearance)
between moving parts (Bearings and journals)
•Seals
The oil helps form a gastight seal between piston
rings
and cylinder walls Reduces Blow-By)
Internal oil leak (blow-by) will result in
BLUE SMOKE at the tale pipe.

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 Purpose of Lubrication System
•Cleans
As it circulates through the engine, the oil picks up
metal
•Cools
particles and carbon, and brings them back down to
the pan.
Picks up heat when moving through the
engine and then drops into the cooler oil pan,
giving up some of this heat.

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 Purpose of Lubrication System
•Absorbs shock
When heavy loads are imposed on the bearings, the oil
helps to cushion the load.

•Absorbs Contaminants

The additives in oil helps in absorbing the contaminants

that enter the lubrication system.

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 Parts
Oil Pumps Driven by camshaft, crankshaft (Rarely
rebuild by an auto technician)

•Rotor Pump(Two star shaped rotors

pumps the oil)

•Gear oil Pump

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 Parts
Oil Pan
Stores the oil and helps in cooling the oil
Pan gasket splits if over tightened.

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 Parts
Pressure Relief Valve to prevent the buildup of high
Pressure (Causes the oil filter to bulge, but not a common
problem).

Good oil pressure is

40-60 psi

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 Parts
Oil Pressure Indicator
•Light or a Gauge
The light turns on or gauge reads low when
the pressure drops below 10psi.
•Good oil pressure is 40-60 psi.
Common causes of low oil pressure are:
•Low oil level
•Worn out pump
Low oil pressure Safety system will shuts down the car by
cutting the ignition System(Spark).

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 Parts
Oil Filter filters the oil
Some particles are too small for the filter Element(paper
in the filter ) to trap.

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 Parts
Oil Galleries

 Deliver the oil to top

end and returning it
To the oil pan.

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 Parts
Positive Crankcase ventilation Valve

•Pollution prevention
•Blow-by back into the intake
•Prevent sludge in the engine.

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 Parts
Oil Pressure sending unit electrically sends the
signal to the Light or Gauge mounted on the dash.

If the wires get shorted the light will come on or

the gauge will read high.

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 OIL CHANGE

•Every 5000Km

•3 months

Ignoring regular oil change intervals will shorten

engine life and performance.

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 5. Sufficient knowledge on Engine
management systems

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Engine Management System (EMS):

 consisting of a wide range of electronic and electrical components such as

sensors, relays, actuators, and an Engine Control Unit.
 They work together to provide the Engine Management System with vital data
parameters.
 These are essential for governing various engine functions effectively.

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Engine Management System (EMS):

 ECU stands for Engine Control Unit and ECM for Engine Control Module. Both
are the same. However, it is also a generic term for any Electronic Control
Unit/Module.
 The Engine Control Unit is a central part of the Engine Management System,
virtually the ‘Brain’ of the engine.
 It plays a vital role in collecting, analyzing, processing, and executing the data
it receives from various sub-systems.
 Furthermore, an ECU comprises a computer that uses a microchip to process
the inputs from multiple engine sensors in real-time.

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How an ECU Works?

 Based on this data input, the ECU precisely calculates and delivers
the ideal air-fuel mixture.
 It also regulates the engine’s idle speed and limits the top speed of
a vehicle.
 This system is also widely referred to as an ”Electronic Engine
Management System” or the EMS.
 Furthermore, it is possible to customize the modern-day ECUs to
suit different vehicular applications and varying customer
demands.
 Also, some cars have an individual’ ‘Control Module” for all major
systems.
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Sensors: are electro-mechanical devices that monitor
various engine parameters.
 The car sensors convert the light, electricity,
temperature, pressure, time, position, and other
information in the car operation in to electrical signal,
which are then input to onboard computer system.
 An engine uses different types of sensors such as
thermocouples, resistance, temperature detectors and
hall effect sensors.

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• Actuators: used to convert energy in a physical action or
force.
• Most actuators are motors powered by electricity,
others are mechanical and actuated by air flow or fluid
pressure.
• Electric actuators take their orders from
microprocessors that manage the various electronic
systems in the vehicle.

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 6. Describe methods for reduction
of exhaust emissions, and their
relations to fuel quality and engine
performance

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 What is Emission Control System?
 The emission control system reduces the emissions, which are harmful
to the environment and human beings produced by automobiles.
 The term emission gas in automobile refers the evaporated fuel from the
fuel tank and the blow-by gas, which passes between the piston and the
cylinder wall, including the exhaust gas.
 The emission gas is harmful to the environment and human beings
because it includes such harmful substances as CO (carbon monoxide),
HC (hydrocarbon) and NOx (nitrous oxides).
 Vehicles equipped with diesel engines emit not only gases such as CO,
HC, NOx but also carbon particles, which also affect the environment
and human beings.
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 Harmful Gases Produced by Automobiles
1. CO (carbon monoxide)
 CO is generated when an insufficient amount of oxygen is taken the combustion chamber
(incomplete combustion).
2. HC (hydrocarbon)
 HC is generated during incomplete combustion in the same way as CO. Also, HC is
generated in the
following cases:
1. When the temperature of the quenching zone is low, it does not reach the combustion
temperature.
2. The intake gas blows through when the valve timing overlaps.
 The richer the air-fuel mixture is, the more HC is generated. The leaner it is, the less HC is
generated.

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 Harmful Gases Produced by Automobiles
3. NOx (nitrous oxides)
 NOx is generated by the nitrogen and oxygen in the air of the air-fuel
mixture when the temperature of the combustion chamber rises
above about 1,800°C (3,272 0F).
 The higher the combustion temperature rises, the more NOx is
generated.
 When the air-fuel mixture is lean, more NOx is generated because the
ratio of oxygen in the air-fuel mixture is too high.
 Therefore, NOx is generated according to the two factors of the
combustion temperature and oxygen concentration.
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 Emission Control System

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 1. Improvement of Engine
Adoption of squish area B. Generation of swirl

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 1. Improvement of Engine
C. Adoption of EFI, ESA and DIS
 Burns the air-fuel mixture completely and decreases the exhaust gas
due to the adoption of EFI (Electronic Fuel Injection), which always
makes the proper air-fuel mixture, and ESA (Electronic Spark Advance)
and DIS (Direct Ignition System), which finely regulates the ignition
timing depending on the driving condition.

03/12/2025 BY: Yonathan M. 73

 2. Devices
Catalytic Converters
 The catalytic converter makes harmful substances (CO, HC and NOx) react
chemically with harmless ones (H2O, CO2, N2) according to the exhaust gas passed.
 Generally platinum, palladium, iridium and rhodium, etc., are used as catalysts for
automobiles.
Types of catalyst
 Oxidation catalyst: Oxidize HC or CO and form nonpolluting H2O or CO2.
 Deoxidization catalyst: Remove oxygen from NOx and form non-polluting N2.
 Oxidation/Deoxidization catalyst: Perform above two functions at the same time.
(Oxidation/Deoxidization catalyst for automobiles is called "Three-Way Catalytic
Converter (TWC)“ because three harmful substances, CO/HC/NOx, are transformed
into non-polluting substances at the same time. it is used for most automobiles
nowadays.
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Three-Way Catalyst (TWC) system
 The TWC is the system that oxidizes CO and HC in the exhaust gas and deoxidizes NOx
at the same time, to purify them into CO2, H2O and N2. Recently the monolithic type is
used as shown in the illustration.
 Alumina or catalytic substances coat the grated pattern of monolith which has many
holes. The harmful substances are purified by passing through the holes.

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Dash Pot (DP) System
 When the throttle valve closes at high engine speed, a strong vacuum is
generated inside the intake manifold.
Some of the fuel adhering to the internal walls of the manifold evaporates,
causing the air- fuel mixture to become too rich temporarily.
At the same time, since the intake air volume decreases, the incomplete
combustion or misfiring occurs, and a great amount of incombustible gas is
emitted in the exhaust.
To prevent the incomplete combustion or misfiring, the dash pot is used to
keep the throttle valve from closing too suddenly.

03/12/2025 BY: Yonathan M. 76

Deceleration Fuel Cut-off System
This system stops the fuel injection during
the deceleration part of driving, and
decreases the amounts of CO and HC.
Also it prevents after-burning in the
exhaust pipe, and effectively decreases the
amount of the fuel consumed during
deceleration.
Operation
The engine ECU stops the fuel injection of
the injector according to the engine speed
and throttle valve opening.

03/12/2025 BY: Yonathan M. 77

Exhaust Gas Recirculation (EGR) System
The Exhaust Gas Recirculation (EGR) System
recirculates some of the exhaust gases to the
intake air system.
The flame propagation becomes slow during
the combustion when the exhaust gases are
mixed with the air-fuel mixture because most
of them are the inert (incombustible) gases.
Also the combustion temperature drops to
reduce the Nox generation because the inert
(incombustible) gas absorbs the heat
generated by burning.

03/12/2025 BY: Yonathan M. 78

 3. Blowby gas
Positive Crankcase Ventilation (PCV) System
 Blow-by gas includes a large amount of unburned gas, which leaks out from
the gap between the piston ring and cylinder wall into the crankcase.
 The Positive Crankcase Ventilation (PCV) system forces the blowby gas into
the air intake system and re-burns it.
 Using the vacuum of the intake manifold, blow-by gas is drawn in.
 Therefore, the PCV valve is installed between the intake manifold and
cylinder head cover.

03/12/2025 BY: Yonathan M. 79

Positive Crankcase
Ventilation (PCV) System
 Generally the generated
volume of the blow-by gas
becomes greater when the
engine load is large (the manifold
vacuum is small).
 On the other hand, it becomes
less when the engine load is
small (the manifold vacuum is
large).

03/12/2025 BY: Yonathan M. 80

 4. Fuel Evaporative Gas
Fuel Evaporative Emission Control (EVAP) System
The Fuel Evaporative Emission Control (EVAP) System temporarily
absorbs the evaporated gas in the charcoal canister and channels it
to the engine for burning, in order to prevent the fuel, which is
evaporated from the fuel tank, from escaping into the atmosphere.

03/12/2025 BY: Yonathan M. 81

Fuel Evaporative Emission Control (EVAP) System
 When opening fuel tank cap  During refueling
The atmosphere is drawn into the chamber The ORVR valve opens and the evaporated
located in the upper of the ORVR valve (on- gas flows into the canister when the
board refueling pressure in the tank
vapor recovery valve). increases by refueling.

03/12/2025 BY: Yonathan M. 82

 7. Sufficient knowledge on engine
Trouble-shooting

03/12/2025 BY: Yonathan M. 83

 The three common engine problems.
 ENGINE PROBLEM #1: ENGINE WON'T START
You can usually conclude it’s a battery problem if the engine is clicking but there’s
no crank. When there’s a crank, but still not start, you are looking at a fuel or
ignition problem.
Some other typical reasons engines fail to start include:
• low or discharged battery
• corroded or loose battery cables
• starter motor relay failure
• ignition switch failure
• faulty fuel pump
• clogged or dirty fuel filter
• neglecting oil and filter changes
• catalytic
03/12/2025 converter failure BY: Yonathan M. 84
 ENGINE PROBLEM #2: SERVICE ENGINE SOON LIGHT: most vehicle is
equipped with a “Service Engine Soon” light to let you know if any fault has
been detected by one of the sensors connected to the emission, engine, or
powertrain controls.
 Some other typical reasons SERVICE ENGINE SOON LIGHT include:
• loose or missing gas cap
• worn out and damaged spark plugs or wires
• electronic control module failure
• defective distributor or coil packs
• emissions control fault – such as the oxygen sensor
• poor fuel quality

03/12/2025 BY: Yonathan M. 85

 ENGINE PROBLEM #3: ENGINE OVERHEATING: Most cars come with some
kind of temperature gauges or warning lights to tell the driver if the engine
is in danger of overheating.
 Overheating is most frequently caused by the following problems:
• damaged or broken thermostat
• dirty or low coolant level
• non-functioning cooling fan
• failed radiator hose
• internal or external coolant leaks
• defective radiator cap

03/12/2025 BY: Yonathan M. 86

 Common Engine Problems
• Worn out or broken piston Rings
• Cracks or holes in Pistons
• Bent or broken Conrods
• Noisy, worn Big End conrod bearings
• Low oil pressure, worn Main Bearings
• Worn Camshaft lobes
• Cracked or broken Crankshafts
• Blown cylinder Head gasket
• Burnt out exhaust Valves
• Worn, cracked Cylinder Block
• Engine
03/12/2025Problem Symptoms BY: Yonathan M. 87
 Common Engine Problems
• Engine using Oil
• Blowing smoke
• Bearing noise
• Knocking noise
• Oil in water
• Water in oil
• Loosing water / coolant
• Decreased performance
• Lacking power
• Rough idle
• Overheating high engine temperatures
•03/12/2025
Oil light on BY: Yonathan M. 88
 Major causes of engine failure is due to Overheating, Improper Lubrication
& Detonation.
 Overheating usually happens due to coolant loss that can be a result of a
bad radiator, thermostat, hose, water pump or a faulty cooling fan. It is
important to have these items regularly inspected, serviced or replaced.
 Improper Lubrication of all moving parts (pistons, rings, bearings, bushes,
shaft & gears) can cause severe damage to your engine.
 Detonation is caused by abnormal combustion inside the engine, which
produces excessive heat & pressure inside the combustion chambers. Over
advanced Ignition timing or fuel with a low octane rating can create a
knocking noise, also known as “pinging”.
03/12/2025 BY: Yonathan M. 89
 THANK YOU !!!

GOOD LUCK !

03/12/2025 BY: Yonathan M. 90