DERPARTMENT OF MECHANICAL ENGINEERING

B.TECH. (MECHANICAL) (II YEAR / IV SEMESTER)

SKILL DEVELOPMENT COURSE III

FOUR WHEELER TROUBLESHOOTING (U20MES403)

 INTRODUCTION
1 Internal Combustion Engine:

The internal combustion engine is an engine in which the combustion of a fuel

(normallya fossil fuel) occurs with an oxidizer (usually air) in a combustion chamber that is
an integral part of the working fluid flow circuit. In an internal combustion engine (ICE)
the expansion of the high-temperature and high-pressure gases produced by
combustion apply direct force to some component of the engine. The force is applied
typically to pistons, turbine blades, or a nozzle. This force moves the component over a
distance, transforming chemical energy into useful mechanical energy.

1.1 Classifications of Internal Combustion Engine:

Internal combustion engines can be classified in many ways on following basis:

1.1.1 Basic Design

According to the design, the internal combustion engines are of two types.

1.1.2 Reciprocating:
Engine has one or more cylinders in which pistons reciprocate back and forth. The
combustion chamber is located in the closed end of each cylinder. Power is delivered to a
rotating output crankshaft by mechanical linkage with the pistons.

1.1.3 Rotary:
Engine is made of a block (stator) built around a large non-concentric rotor and crankshaft.
The combustion chambers are built into the non-rotating block. A number of experimental
engines have been tested using this concept, but the only design that has ever
becomecommon in an automobile is the Wankel engine in several Mazda models. Mazda
builds rotary automobile engines with one, two, and three rotors.

1.2 Types of ignition

According to type of ignition the internal combustion engines are of following types.

1.2.1 Spark Ignition (SI):

An SI engine starts the combustion process in each cycle by use of a spark plug. The spark
plug gives a high voltage electrical discharge between two electrodes, which ignites the
air
fuel mixture in the combustion chamber surrounding the plug. In early engine development,
before the inventor of electric spark plug, many forms of torch holes were used to initiate
combustion from an external flame.

1.2.2 Compression Ignition (CI):

The combustion process in a CI engine starts when the air-fuel mixture self-ignites due to
high temperature in the combustion chamber caused by high compression.

1.3 Engine Working Cycle

There are basically two types of working cycles on which the internal combustion engines
operates. These cycles are explained below.

1.3.1 Four-stroke cycle:

A four-stroke cycle has four piston movements over two engine revolutions for each cycle.
The four strokes are Intake, compression, Expansion and Exhaust.

Figure 1.1: Four strokes of four stroke engine

1.3.2 Two-stroke cycle:

A two-stroke cycle has two piston movements over one revolution for each cycle. A two-
stroke, two-cycle, or two-cycle engine is a type of internal combustion engine which
completes a power cycle in only one crankshaft revolution and with two strokes, or up and
down movements, of the piston in comparison to a "four-stroke engine", which uses four
strokes to do so. This is accomplished by the end of the combustion stroke and the beginning
of the compression stroke happening simultaneously and performing the intake and exhaust
(or scavenging) functions at the same time.
 Figure 1.2.: Strokes of two strokes engine

1.4 Number of cylinders

The Internal combustion engines have different types according to the number of cylinders in
the engine as explained bellow.

1.4.1 Single Cylinder:

Engine has one cylinder and piston connected to the crankshaft.

1.4.2 Multi-cylinder Engine:

Some Internal Combustion Engines contain more than one cylinder. These multi-cylinder
engines have different types according to the arrangement of cylinders.

1.4.2.1 In-Line:
Cylinders are positioned in a straight line, one behind the other along the length of the
crankshaft. They can consist of 2 to 11 cylinders or possibly more. In-line four-cylinder
engines are very common for automobile and other applications. In-line six and eight
cylinders are historically common automobile engines In-line engines are sometimes called
Straight (e.g., straight six or straight eight).

1.4.2.2 V Engine:
V engines usually have even numbers of cylinders from 2 to 20 or more. V6s and V8s re
common automobile engines, with V12s and V16s (historic) found in some luxury and high-
performance vehicles. Large ship and stationery engines have anywhere from 8 to 20
cylinders.
1.4.2.3 Opposed Cylinder Engine:
Two banks of cylinders opposite to each other on a single crankshaft. These are common on
small aircraft and some automobiles with an even number of cylinders from two to eight or
more. These engines are often called flat engines (e.g., flat four).

1.4.2.4 W engine:
Engines of two different cylinder arrangements have been classified as W engines in the
technical literature. One type is the same as a V engine except with three banks of cylinders
on the same crankshaft. They are not common, but some race cars of 1930 s and some luxury
cars of the 1990s had such engines either with 12 cylinders or 18 cylinders. Another type of
W engine is the modern 16-cylinder engine made for the Bugatti automobile (W16). This
engine is essentially two V8 engines connected together on a single crankshaft.

1.4.2.5 Opposed piston engine:

Two pistons in each cylinder with the combustion chamber in the centre between the pistons.
A single combustion process causes two power strokes at the same time, with each piston
being pushed away from the centre and delivering power to a separate crankshaft at each end
of the cylinder. Engine output is either on two rotating crankshafts or on one crankshaft
incorporating a complex mechanical linkage. These engines are generally of large
displacement, used for power plants, ships, or submarines.

1.5 Governing cycles of SI and CI engines:

1.5.1 Otto Cycle:
An Otto cycle is an idealized thermodynamic cycle which describes the functioning of a
typical spark ignition reciprocating piston engine, the thermodynamic cycle most commonly
found in automobile engines.
1.5.2 Diesel cycle:
The Diesel cycle is the thermodynamic cycle which approximates the pressure and volume of
the combustion chamber of the Diesel engine, invented by Rudolph Diesel in 1897. It is
assumed to have constant pressure during the first part of the "combustion" phase (V_2 to
V_3 in the diagram, below). This is an idealized mathematical model: real physical Diesels
do have an increase in pressure during this period, but it is less pronounced than in the Otto
cycle.

Figure 1.4: P-V diagram of Diesel cycle

Labelled diagram of Diesel Engine

Figure 2.1 Labelled diagram of 4-stroke diesel engine

2.1 Description of main parts
2.5.1 Cylinder block
Cylinder block or Cylinder are main part of an engine. It is a
part in which combustion of fuel takes place. All other parts
like piston, connecting rod, crankshaft, water jacket etc. are
bolted on it.

Figure 2.2 Cylinder Block

2.5.2 Piston
Piston is placed in the cylinder and transmits thrust to the
connecting rod. It is free to move. It compresses the air fuel
mixture and convert the fuel energy into mechanical energy. It
transmits the power to the crankshaft.

Figure 2.3 Piston

2.5.3 Cylinder Head

Cylinder head is fitted on the top of cylinder block and the
function of the cylinder head is to seal the working end of
cylinder and not to permit entry and exit of gases on cover
head valves of the engine. The valves, spark plug, camshaft
etc are fitted on it.
Figure 2.1 Cylinder Head

2.5.4 Connecting Rod

It connects piston to the crank shaft and transmit the motion and
thrust of piston to crankshaft. The lower end of connecting rod is
connected to the piston and the bigger is connected to the crank
shaft.

Figure.2.2 Connecting Rod

2.5.5 Crankshaft
It is located in the bottom end of cylinder block. It transmits the
reciprocating motion of piston into rotary motion. This rotary
motion used to rotate wheels of the vehicle.

Figure 2.3 Crankshaft

2.5.6 Oil Sump
It is bolted at the lower end of the cylinder block. All the oil for
lubricating the movable parts is placed in it.

Figure .2.4 Oil Sump

2.5.7 Camshaft
It is fitted either in the cylinder head or at the bottom of the cylinder
block. It is use to open or close valves at proper timing in multi-
cylinder engine.

Figure.2.5 Camshaft

2.5.8 Valves
It is fitted on the cylinder head. It regulates the flow of air fuel mixture
inside the cylinder and exhaust gas outside the cylinder block. When
both inlet and exhaust valves are closed no pressure can go inside or
outside of cylinder block.

Figure 2.6 Valves

2.5.9 Spark Plug

It is used in Petrol engine (Spark Ignition Engine). It is fitted on the
cylinder head. It is used to ignite the air fuel mixture inside the cylinder at
the end of each compression stroke.

Figure.2.7 Spark Plug

2.5.10 Injector
It is used in Diesel engine (Compression Ignition Engine). It is fitted on
the cylinder head. It is used to inject fuel in spray form inside the
cylinder at the end of compression stroke.

Figure 2.8 Injector

2.5.11 Push Rod
It is used when the camshaft is situated in the bottom of the cylinder
head. It regulates the timing of valves open and close through rocker
arm and camshaft.

Figure 2.9 Push Rods

2.5.12 Manifold
It is bolted on the cylinder head one each for intake and exhaust.
Its function is to evenly distribute air-fuel mixture for intake &
collects the exhaust gases from all cylinders.

Figure 2.10 Manifold

2.5.13 Piston Rings

It provides the good sealing fit and less friction resistance
between piston and cylinder. It is split at one point so it can be
easily installed into the grooves cut in the piston.

Figure 2.11 Piston Rings

2.5.14 Gaskets
It is used to seal the cylinder head and cylinder so no pressure is
allowed to escape. It is placed between the cylinder block and
cylinder head.

Figure 2.12 Gasket

2.5.15 Gudgeon Pin (Piston Pin)

It is the parallel spindles fitted through the piston boss and connecting
rod small end. It connects the piston to the connecting rod.

Figure 2.13 Gudgeon Pin

3.3.1 Parts of Otto Engine:
1. Cylinder head
2. Piston
3. ECU
4. Cylinder
5. Connecting Rod
6. Gunging pin
7. Crank shaft
8. Rocker arm
9. Valves
10. Spark plug
11. Carburetor
12. Butterfly valve
13. Water Jacket

Figure 3.2: Parts of petrol engine

3.3.4.1 Cylinder head:
The head which consist of inlet and outlet valves, piston and cylinder.
3.3.4.2 Piston:
Piston is used to compress the fuel and to produce the power.
3.3.4.3 ECU:
Electronic control unit controls the amount of air and fuel required for power
generation.
3.3.4.4 Cylinder:
The internal part of engine in which piston can slide up and down to produce the
power required for the engine working.
3.3.4.5 Connecting Rod:
Connecting rod connects the piston with crank shaft. The basic purpose of connecting
rod is to convert the rotatory motion of crank shaft in to translational motion of piston.
3.3.4.6 Gunging pin:
The pin which connects the piston and connecting rod.
3.3.4.7 Crank shaft:
The shaft which is connected with the piston and transfer the power from piston to
flywheel.
3.3.4.8 Rocker arm:
Rocker arm is used to open and close the inlet and outlet valves by the crank rotation.
3.3.4.9 Valves:
There are two valves. The first valve is inlet valve, from which the fuel air mixture is
enter. The second valve is outlet valve which is responsible for the removal of exhaust gasses
from the piston which is produced after the end of combustion process.
3.3.4.10 Spark plug:
Spark plug is responsible for the burning of fuel. It produces a little spark which is
enough to burn the fuel completely.
3.3.4.11 Carburetor:
It controls the Air Fuel ratio according to the load.
3.3.4.12 Butterfly valve:
The valve which controls the quantity of air required to complete burn the fuel
according to the load variation.