1.

Cylinder Block

Material – Cast iron or Aluminium alloy

The cylinder block is the main supporting structure for the various components. The
cylinder of a multicylinder engine is cast as a single unit, called cylinder block. The
cylinder head is mounted on the cylinder block. The cylinder head and cylinder block are
provided with water jackets in the case of water-cooling with cooling fins in the case of
air-cooling. Cylinder head gasket is incorporated between the cylinder block and cylinder
head. The cylinder head is held tight to the cylinder block by number of bolts or studs. The
bottom portion of the cylinder block is called crankcase. A cover called crankcase, which
becomes a sump for lubricating oil is fastened to the bottom of the crankcase. The inner
surface of the cylinder block, which is machined and finished accurately to cylindrical
shape, is called bore or face. An engine block is the structure which contains the cylinders,
and other parts, of an internal combustion engine. In an early automotive engine, the engine
block consisted of just the cylinder block, to which a separate crankcase was attached.
Modern engine blocks typically have the crankcase integrated with the cylinder block as a
single component. Engine blocks often also include elements such as coolant passages and
oil galleries.

2. Cylinder

Material – Cast iron or Aluminum

A cylinder is the central working part of a reciprocating engine or pump, the space in
which a piston travels. Multiple cylinders are commonly arranged side by side in a bank,
or engine block, which is typically cast from aluminum or cast iron before receiving
precision machine work. Cylinders may be sleeved (lined with a harder metal)
or sleeveless with a wear-resistant coating.. A sleeveless engine may also be referred to as
a "parent-bore engine". A cylinder's displacement, or swept volume, can be calculated by
multiplying its cross-sectional area (the square of half the bore by pi) by the distance of
 piston travels within the cylinder (the stroke). The engine displacement can be calculated
by multiplying the swept volume of one cylinder by the number of cylinders.

3. Piston
Material – Aluminum alloy
It is a cylindrical component fitted into the cylinder forming the moving boundary of the
combustion system. It fits perfectly (snugly) into the cylinder providing a gas-tight space
with the piston rings and the lubricant. It forms the first link in transmitting the gas forces
to the output shaft. It is a part inside the cylinder bore probably made up of cast iron, which
reciprocates linearly to suck the air and fuel mixture during suction stroke , pressurizes the
mixture during compression stroke by reducing the space available for mixture inside the
cylinder bore , transfers some amount of energy to the crank shaft through connecting rod
during the expansion stroke and again reduces the volume to send out the burnt
mixture(exhaust stroke) in a four stroke engine (in two revolutions of crank shaft).If it is a
two stroke one it can perform all the four strokes in one revolution of crank shaft. Piston
features include the piston head, piston pin bore, piston pin, skirt, ring grooves, ring lands,
and piston rings. The piston head is the top surface (closest to the cylinder head) of the
piston which is subjected to tremendous forces and heat during normal engine operation.

4. Piston Rings
Material – Cast Iron
Piston rings commonly used on small engines include the compression ring, wiper ring,
and oil ring. A compression ring is the piston ring located in the ring groove closest to the
piston head. The compression ring seals the combustion chamber from any leakage during
the combustion process. When the air-fuel mixture is ignited, pressure from combustion
gases is applied to the piston head, forcing the piston toward the crankshaft. The
pressurized gases travel through the gap between the cylinder wall and the piston and into
the piston ring groove. Combustion gas pressure forces the piston ring against the cylinder
wall to form a seal. Pressure applied to the piston ring is approximately proportional to the
combustion gas pressure.
 An oil ring is the piston ring located in the ring groove closest to the crankcase. The oil
ring is used to wipe excess oil from the cylinder wall during piston movement. Excess oil
is returned through ring openings to the oil reservoir in the engine block. Two-stroke cycle
engines do not require oil rings because lubrication is supplied by mixing oil in the
gasoline, and an oil reservoir is not required.

5. Combustion Chamber
The space enclosed in the upper part of the cylinder, by the cylinder head and the piston
top during the combustion process, is called the combustion chamber. The combustion of
fuel and the consequent release of thermal energy results in the building up of pressure in
this part of the cylinder.

6. Connecting rod
Material – Steel or Aluminum alloy
It interconnects the piston and the crankshaft and transmits the gas forces from the piston
to the crankshaft. The two ends of the connecting rod are called as small end and the big
end. Small end is connected to the piston by gudgeon pin and the big end is connected to
the crankshaft by crankpin. The small end attaches to the piston pin, gudgeon pin or wrist
pin, which is currently most often press fit into the connecting rod but can swivel in the
piston, a "floating wrist pin" design. The big end connects to the crankpin (bearing journal)
on the crank throw, in most engines running on replaceable bearing shells accessible via
the connecting rod bolts which hold the bearing "cap" onto the big end. Typically there is
a pinhole bored through the bearing on the big end of the connecting rod so that
pressurized lubricating motor oil squirts out onto the thrust side of the cylinder wall to
lubricate the travel of the pistons and piston rings.

7. Crank Shaft
Material – Medium Carbon steel
It converts the reciprocating motion of the piston into useful rotary motion of the output
shaft. In the crankshaft of a single cylinder engine there is pair of crank arms and balance
weights. The balance weights are provided for static and dynamic balancing of the rotating
 system. The crankshaft is enclosed in a crankcase. A crankpin or crank journal is
a journal in an engine or mechanical device. That is, the part of a shaft or axle that rests
on bearings.
In a reciprocating engine, the crankpin is the part of a crankshaft where the lower end of
a connecting rod attaches.

8. Gudgeon pin
Material – Steel
It forms the link between the small end of the connecting rod and the piston. The gudgeon
pin has to operate under some of the highest temperatures experienced in the engine, with
difficulties in lubrication due to its location.

9. Cam shaft
Material – Chilled cast iron
The camshaft is a mechanical component of an internal combustion engine. It opens and
closes the inlet and exhaust valves of the engine at the right time, with the exact stroke and
in a precisely defined sequence. The camshaft is driven by the crankshaft by way of
gearwheels, a toothed belt or a timing chain. With a transmission ratio of 2:1, the rate of
rotation of the camshaft is half that of the crankshaft.

10. Rocker Arm

Material – Carbon steel
A rocker arm is an oscillating lever that conveys radial movement from the cam lobe into
linear movement at the poppet valve to open it. One end is raised and lowered by a rotating
lobe of the camshaft (either directly or via a tappet (lifter) and pushrod) while the other end
acts on the valve stem. When the camshaft lobe raises the outside of the arm, the inside
presses down on the valve stem, opening the valve. When the outside of the arm is
permitted to return due to the camshafts rotation, the inside rises, allowing the valve spring
to close the valve.
11.Inlet and exhaust valves
Material – Carbon steel alloy
The intake valve takes in the fuel/air mixture or air (in the case of a Diesel) while the
exhaust valve vent the products of combustion. The intake valve is usually larger in
diameter for normally aspirated engines, while the exhaust valve is made for higher
temperature resistance, sometimes even sodium filled for added heat transfer.

12. Inlet manifold

Material – Aluminum or cast iron
The pipe which connects the intake system to the inlet valve of the engine and through
which air or airfuel mixture is drawn into the cylinder is called the inlet manifold. The
primary function of the intake manifold is to evenly distribute the combustion mixture (or
just air in a direct injection engine) to each intake port in the cylinder head. Even
distribution is important to optimize the efficiency and performance of the engine. It may
also serve as a mount for the carburetor, throttle body, fuel injectors and other components
of the engine.

13. Exhaust Manifold

Material – Cast iron or stainless steel
The pipe that connects the exhaust system to the exhaust valve of the engine and through
which the products of combustion escape into the atmosphere is called the exhaust
manifold. An exhaust manifold collects the exhaust gases from multiple cylinders into one
pipe. Exhaust manifolds are generally simple cast iron or stainless steel units which collect
engine exhaust gas from multiple cylinders and deliver it to the exhaust pipe. For many
engines, there are aftermarket tubular exhaust manifolds known as headers.

14. Spark Plug

Material – Aluminium oxide ceramic
A spark plug is a device for delivering electric current from an ignition system to
the combustion chamber of a spark-ignition engine to ignite the compressed fuel/air
 mixture by an electric spark, while containing combustion pressure within the engine. A
spark plug has a metal threaded shell, electrically isolated from a central electrode by
a porcelain insulator. The central electrode, which may contain a resistor, is connected by
a heavily insulated wire to the output terminal of an ignition coil or magneto. The spark
plug's metal shell is screwed into the engine's cylinder head and thus electrically grounded.
The central electrode protrudes through the porcelain insulator into the combustion
chamber, forming one or more spark gaps between the inner end of the central electrode
and usually one or more protuberances or structures attached to the inner end of the
threaded shell and designated the side, earth, or ground electrodes.

15. Flywheel
Material – steel
A flywheel is a mechanical device specifically designed to efficiently store rotational
energy (kinetic energy). Flywheels resist changes in rotational speed by their moment of
inertia. The amount of energy stored in a flywheel is proportional to the square of
its rotational speed and its mass. It is directly connected to the crank shaft.

16. Engine bearing

Material – Bronze
Everywhere there is rotary action in the engine, bearings are needed. Bearings are used to
support the moving parts. The crankshaft is supported by bearing. The connecting rod big
end is attached to the crank pin on the crank of the crankshaft by a bearing. A piston pin at
the small end is used to attach the rod to the piston is also rides in bearings. The main
function of bearings is to reduce friction between these moving parts. In an IC engine
sliding and rolling types of bearing used. The sliding type bearing which are sometime
called bush is use to attach the connecting rod to the piston and crankshaft. They are split
in order to permit their assembly into the engine. The rolling and ball bearing is
used to support crankshaft so it can rotate freely.
17.Fuel Pump
Fuel pumps pump gasoline from the vehicle's fuel tank to the engine and also
distribute fuel under low pressure to the carburetor or to the fuel injection system under
higher pressure. Carburetor engines utilize low pressure pumps, which are located outside
of the fuel tank.