INFORMATION SHEET NO.

1
INTRODUCTION TO INTERNAL COMBUSTION ENGINE

Learning Outcomes:
After reading this Information Sheet, you must be able to:
1. describe internal combustion engine;
2. explain the operating principle of an internal combustion engine;
3. identify the basic parts of an engine;
4. identify the various systems that supports engine operation; and
5. investigate the modern trends in engine technology.

What is an INTERNAL COMBUSTION ENGINE?

Figure 1. The combustion forces the cylindrical plug down forcing the crank mechanism to rotate.

An internal combustion engine is basically a machine that converts heat

energy into mechanical energy. It does so by burning fuel mixed with air inside
its cylinder. The combustion of the air-fuel mixture produces the force that
drives a cylindrical plug downwards. In addition, the cylindrical plug is
mechanically connected to a crank mechanism which is composed of series of
shafts and crankpins. As a result, the combustion force received by the
cylindrical plug is transferred to the shaft which in turn drives the vehicle.
According to Anjikar, Ramteke, and Zode (2017), the invention of the
engine, or even introducing its concept, was the most important scientific event
in the human history. The invention of the internal combustion engine has led
the way to the replacement of the horse carriage by automobiles and increased
the distance human beings can travel.

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 ACTIVITY #1
Evolution of the Internal Combustion Engine

Direction: Complete the timeline below. Use the link as your reference. Write
your answer on a clean sheet of paper. Take a clear picture of your
work and send it to pamulo.sp@mpc.edu.ph

REFERENCE LINK:
https://www.timetoast.com/timelines/evolution-of-the-internal-combustion-engine?
fbclid=IwAR2tiNhmlG1pY7xD3nhmYWgvvEDRNuqls39wtNC7561UeRj_Wy9IwmBQ7TA

Year Major Development in Internal Combustion Engine

April 1, 1680

April 1, 1820

April 1, 1860

April 1, 1866

April 1, 1885

April 22, 1889

April 22, 1891

April 1, 1897

April 1, 1957

April 1, 1999

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How does an Internal Combustion Engine works?
The internal combustion engine that we will discuss in our M1 class is a
reciprocating, four stroke, gasoline and diesel engine.
An engine is considered a reciprocating engine if it uses a cylindrical plug
that moves up and down inside the cylinder. The said cylindrical plug is called
the PISTON.
Moreover, the engine that we will talk about is also considered as a four
stroke cycle engine since it takes four movement of the piston, called STROKE,
to deliver the power necessary to propel the vehicle. The said stroke includes
INTAKE, COMPRESSION, POWER, and EXHAUST repeated in the same order
as the engine operates.
We will categorize the four stroke cycle into two- OTTO cycle and DIESEL
cycle. The OTTO cycle, which is used for gasoline/ petrol engines, was
conceptualized by Nikolaus August Otto. On the other hand, the DIESEL
CYCLE, which is used for Diesel engines, was conceptualized by Rudolf Diesel.
In a 4-stroke OTTO cycle engine, the piston is moving downward in its
INTAKE STROKE. This downward movement creates a vacuum which draws
the air-fuel mixture into the engine cylinder. The air-fuel mixture enters the
cylinder thru the open intake valve. This event is clearly illustrated in Figure 2.

Figure 2. During the INTAKE STROKE, the piston is moving down and the air-fuel mixture enters the cylinder thru the open
intake valve.

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During the COMPRESSION STROKE (Figure 3), the piston is moving up with
both the intake and exhaust valves close. Consequently the air-fuel mixture is
squeezed as the piston moves up. Before the piston reaches its top-most
position, the spark plug ignites the air-fuel mixture.

Figure 3. During the COMPRESSION STROKE, the piston is moving up squeezing the air-fuel mixture.

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 The force of combustion drives the piston downward during the POWER
STROKE. Because the connecting rod mechanically joins the piston and
crankshaft, the force applied to the piston is transferred to the crankshaft,
which then powers the vehicle.

Figure 4. During the POWER STROKE, the piston is driven downward due to the force of combustion.

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During the EXHAUST STROKE, the burned air-fuel combination exits the
cylinder through the open exhaust valve. The piston is rising at this point in
the 4-stroke Otto cycle in order to release the last of the exhaust gases. This
makes sure that the engine is once more prepared to take in fresh air and fuel.

Figure 5. During the EXHAUST STROKE, the piston is moving up. Burned gasses leaves the cylinder through the open exhaust
valve.

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 ACTIVITY #2
Operating Principle of the Internal Combustion Engine

Direction: Perform the following tasks. Write your answer on a clean sheet of
paper. Take a clear picture of your work and send it to
pamulo.sp@mpc.edu.ph

1. Go to https://www.youtube.com/watch?v=fTAUq6G9apg and use the video

as your reference. 15 points. Write a DETAILED discussion on what is
happening during the following timeline:
a. 00:08 to 00:30
b. 00:34 to 01:27
c. 01:28 to 02:08
d. 02:09 to 02:32
e. 02:34 to 03:06
f. 03:08 to 03:55

2. Investigate the DIFFERENCE and SIMILARITIES between a gasoline and

diesel engine. Write your findings on a similar table illustrated below.

DIESEL ENGINE GASOLINE ENGINE

DIFFERENCES (10
POINTS) in terms of:

 WEIGHT
 COMPRESSION
RATIO
 INTAKE STROKE
 METHOD OF
IGNITION




SIMILARITIES (10 
POINTS) 





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 To further understand how an internal combustion engine operates, an
understanding of its basic components and how they work together is
necessary. Figure 6 shows the cross section of a 4 cylinder, naturally aspirated,
gasoline engine from Honda. You will find that the basic parts of engines are
the same regardless of the manufacturer.

Figure 6. HONDA Engine

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 Let us start our discussion of engine parts with the PISTON (Figure 7).
As mentioned from our previous topic, a piston is a cylindrical plug that moves
up and down inside the cylinder.

Figure 7. PISTON

The piston serves several purposes. One of which is to create a vacuum

during the engine’s intake stroke. Also, the piston squeezes the air (for Diesel
engines) or air-fuel mixture (for Gasoline engines) during the compression
stroke. Moreover, during the power stroke, the piston transmits the force
generated during combustion to the crankshaft through a connecting rod. The
piston also pushes out the remaining burned gasses during the engine’s
exhaust stroke. Aside from the intake, compression, power, and exhaust
function, the piston also forms the lower part of the engine’s combustion
chamber. The combustion chamber is the space formed when the piston is at
its topmost travel. This enclosed space is where combustion takes place in an
engine.

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 Figure 8. Piston Parts

Figure 8 shows the parts of a piston. The CROWN/HEAD forms the top
surface of the piston and directly receives combustion pressure. Below the
crown are raised areas called RING LANDS that forms the sides of the ring
grooves. The RING GROOVES are recessed areas located around the perimeter
of the piston where the piston rings are inserted. Below the ring grooves is the
PISTON SKIRT. It acts as a guide as the piston goes up and down in the
cylinder. The WRIST PIN BOSS/ PISTON PIN BOSS is a bore that connects
the small end of the connecting rod to the piston by a wrist pin/ piston pin
(Figure 9).

Figure 9. The piston pin connects the small end of the connecting rod to the piston.

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 ACTIVITY #3
Types of Pistons
Direction: Complete the table below. Write your answer on a clean sheet of
paper. Take a clear picture of your work and send it to
pamulo.sp@mpc.edu.ph

DESCRIPTION
(Your answer must be based
TYPE REASON FOR THIS DESIGN
on the illustration found on
the first column)
CONICAL PISTON

OVAL PISTON

SLIPPER SKIRT PISTON

SOLID SKIRT PISTON

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 Pistons are equipped with PISTON RINGS (Figure 10). These are circular
metal rings that fit into the ring grooves of the piston. There are two types of
piston rings: COMPRESSION RING and OIL CONTROL RING. Pistons are
usually fitted with two compression rings in order to prevent the leakage of
compressed gas and high pressure burnt gas from the combustion chamber
into the crankcase. A three piece oil control ring is fitted to the piston’s ring
groove in order to regulate the film of oil on the cylinder wall.

Figure 10. Piston Rings

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 The CONNECTING ROD (Figure 11) connects the piston to the
crankshaft. It also converts the reciprocating motion of the piston into a
continuous rotary motion of the crankshaft.

Figure 11. CONNECTING ROD

As seen on Figure 11, the connecting rod is composed of the small end,
shank, big end, and connecting rod cap. Attached to it is the wrist pin/ piston
pin/ gudgeon pin and big end bearings inserts/ connecting rod bearing.
The small end connects the shank to the wrist pin. On the other hand,
the shank or rod connects the small end to the big end. It also transmits the
movement of the piston to the crankshaft. The big end part of the connecting
rod connects the shank to the crankshaft. The removal and installation of the
connecting rod to the crankshaft is made possible by the connecting rod cap.

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 The CRANKSHAFT (Figure 12) is the main rotating part of the engine.
Together with the connecting rod, it changes the reciprocating motion of the
piston into a continuous rotary motion.

Figure 12. CRANKSHAFT

A typical crankshaft used for a 4-cylinder engine is illustrated on Figure

13. It is composed of five MAIN JOURNAL/ CRANK JOURNAL (1), four
CONNECTING ROD JOURNAL/ CRANK PIN JOURNAL (2), eight CRANK ARMS
(3), and four COUNTERWEIGHTS (4).

Figure 13. Parts of a CRANKSHAFT.

The MAIN JOURNAL/ CRANK JOURNAL (1) makes up the main rotary
shaft. It is connected to the CONNECTING ROD JOURNAL/ CRANK PIN (2) by
the CRANK ARM (3). The CONNECTING ROD JOURNAL/ CRANK PIN (2) is the
part of the crankshaft that receives the force of combustion since it is
connected to the connecting rod. The COUNTERWEIGTHS (4) applies opposite
force in order to balance and stabilize the rotation of the crankshaft thereby
smoothing engine operation.
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 Another important part or group of parts that you need to be familiar
with is the VALVETRAIN MECHANISM. Figure 14 shows the valvetrain
mechanism for a V6, Overhead Valve (OHV), Diesel Engine. The valvetrain
mechanism transfers camshaft rotation to the valves. It is composed of the
CAMSHAFT (1), VALVE LIFTER/ CAM FOLLOWER (2), PUSHROD (3), ROCKER
ARM (4), and VALVES (5).
The CAMSHAFT (1) opens and closes the valves at the correct timing. It
is composed of a shaft with a series of cams. Riding directly above the cams of
the camshaft is the VALVE LIFTER/ CAM FOLLOWER (2) which changes the
rotational motion of the camshaft into reciprocating motion. Valve lifter
movement is transferred to the rocker arm by steel round rods called PUSH
RODS (3). The ROCKER ARM (4) receives the movement of the push rod at one
end and pushes the valve at its other end. VALVES (5) are devices that allow
the flow of gasses. A valve that allows the flow of air or air-fuel mixture into the
cylinder is called an INTAKE VALVE. While a valve that allows the release of
burnt gasses out of the cylinder is called an EXHAUST VALVE.

Figure 14. VALVETRAIN MECHANISM for a V6, OHV, Diesel Engine

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 There are basically 4 types of valvetrain mechanism. It includes
OVERHEAD VALVETRAIN (OHV), SINGLE OVERHEAD CAMSHAFT (SOHC),
COMPACT DOUBLE OVERHEAD CAMSHAFT (COMPACT DOHC), and
DOUBLE OVERHEAD CAMSHAFT (DOHC).
An Overhead Valvetrain Mechanism (Figure 14 and Figure 15) has its
camshaft located in the cylinder block while its valves are located in the
cylinder head. Camshaft movement is transferred to the valves through the
valve lifter, pushrod, and rocker arm.

Figure 15. OHV VALVETRAIN MECHANISM

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 A SINGLE OVERHEAD CAMSHAFT (SOHC) valvetrain mechanism (Figure
16) has its camshaft located in the cylinder head. With this arrangement, the
movement of the camshaft can be directly applied to the valves through a
rocker arm assembly or through a cam follower.

Figure 16. OHV with Rocker Arm

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 One of the most common type of valvetrain mechanism nowadays is the
DOUBLE OVERHEAD CAMSHAFT (DOHC) configuration (Figure 17). This type
has one camshaft for the intake valves and another camshaft for the exhaust
valves. Both are located in the cylinder head and are driven separately.

Figure 17. DOHC Valvetrain Mechanism

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 The COMPACT DOHC valvetrain mechanism (Figure 18) is similar to the
DOHC configuration since it also uses two camshafts. The only difference is
that in a COMPACT DOHC valve train mechanism, one camshaft is driven by
the other camshaft. For example, on Figure 18, the crankshaft drives the
intake camshaft through a timing belt (1) and the intake camshaft drives the
exhaust camshaft through gears (2).

Figure 18. COMPACT DOHC

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 It has been mentioned several times that the camshaft is driven by the
crankshaft. Remember that the camshaft turns half the speed of the
crankshaft. This means that the crankshaft must turn twice for the camshaft
to turn once.
There are three common methods of driving the camshaft. Figure 19
shows a GEAR DRIVEN camshaft. In this particular design, the timing gear of
the crankshaft (2) drives the camshaft timing gear (1) through an idler gear (3).

Figure 19. Gear driven camshaft.

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 Another common method of driving the camshaft is by chain. Figure 20
illustrates a CHAIN DRIVEN camshaft. Chain drives for camshafts are durable
and require less maintenance compared to belt driven camshafts.

Figure 20. CHAIN DRIVEN CAMSHAFT

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 Figure 21 shows a BELT DRIVEN camshaft. A reinforced rubber belt is
used to transfer crankshaft movement to the camshaft. Belt driven camshafts
are quitter than chain driven camshafts but requires replacement
approximately every 80,000 kilometers.

Figure 21. BELT DRIVEN CAMSHAFT

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 ACTIVITY #4
INVESTIGATING VALVETRAIN MECHANISMS

Direction: Look for the following engine code in the Internet and study the type
of valvetrain mechanism and camshaft drive used by each engine
and complete the table below by checking (/) the column appropriate
to the engine code. Write your answer on a clean sheet of paper.
Take a clear picture of your work and send it to
pamulo.sp@mpc.edu.ph. 40 points.

TYPE OF VALVETRAIN MECHANISM CAMSHAFT DRIVE

ENGINE
COMPAC
CODE OHV SOHC DOHC GEAR CHAIN BELT
T DOHC
TOYOTA 4A-
FE
TOYOTA
12R
TOYOTA
2E
TOYOTA
4K
TOYOTA
4A-GE
TOYOTA
1NZ-FE
HONDA
B16A
HONDA
F20C
HONDA
K20C
HONDA
K20A
HONDA
L13A
NISSAN
E13
NISSAN
GA16DE
NISSAN
RB20DE
MITSUBISHI
4D56
MITSUBISHI
4G63
MITSUBISHI
3A9
MITSUBISHI
4G16
MITSUBISHI
4M40
MITSUBISHI
4N15

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 ACTIVITY #5
OHV VALVETRAIN OPERATION

Direction: In reference to the illustrations on each item, explain in detail the

operation of the OHV valvetrain on items 1 & 2. Write your answer
on a clean sheet of paper. Use extra sheets of paper if necessary.
Take a clear picture of your work and send it to
pamulo.sp@mpc.edu.ph. 60 points.

1. VALVE OPEN

2. VALVE CLOSE

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 The largest stationary part of the engine is the CYLINDER BLOCK. It is
the structure which contains the CYLINDER and other components. Most
engine blocks contains the CRANKCASE or the part where the crankshaft is
mounted into the engine.

Figure 22. CYLINDER BLOCK

The cylinder has a cylindrical shape where the piston can slide up and
down. It also absorbs forces due to the pressure and heat generated during
combustion. Cylinders can be structurally classified into two (2) types- IN-
BLOCK/ CAST-IN and INSERTS/ LINER TYPE.
The IN-BLOCK/ CAST-IN LINER (Figure 22) are cylinder sleeves which
were installed during the casting process of the engine block. In effect, the
cylinder and the block are manufactured as a solid unit. For this reason, this
type is suitable for mass production. Currently, in-block cylinders are used
widely for gasoline engines with cast iron/ aluminum cylinder blocks.
In contrast, LINER TYPE cylinders are sleeves which are installed or
inserted into the cylinder bores after the engine block was manufactured.
There are basically two types of inserts/ liners- DRY CYLINDER LINERS and
WET CYLINDER LINERS.

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 Figure 23. DRY LINER

Dry liners are much thinner than their wet liner counterpart having a
wall thickness of only 1.5 mm to 3.0 mm and are used mostly for
reconditioning worn liners and cast-in liners. They are called “dry liners” since
they do not come into direct contact with the engine coolant. Moreover, dry
liners are made in the shape of a sleeve/ barrel having a flange at the top. The
flange keeps the liner in position in the cylinder bore of the engine block. The
dry liner fits accurately in the bore. The perfect contact and tight fitting of the
liner with the cylinder bore is necessary for the effective cooling of the liner. In
addition, the combined thickness of the liner and the bore helps the engine
block withstand the gas pressure, piston thrust and impact load during
combustion.

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 Figure 24. WET LINER

Wet liners (Figure 24) are called “wet” because they come in direct
contact with the engine coolant. They have thicker walls compared to their dry
liner counterparts. This liner is provided is provided with a flange at the top
which fits into the groove in the bore. To stop the coolant from leaking into the
crankcase, the lower end of the wet liner is sealed with the aid of rubber
sealing rings or packing rings.
The wall thickness of the wet liner is approximately 3mm to 6 mm. It is
better cooled than its dry liner counterparts. In addition, wet liners are easily
removed when it is worn or damaged.

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 Figure 25. CYLINDER HEAD (TOYOTA)

The last engine component worth discussing in the context of engine

overhauling is the CYLINDER HEAD (Figure 25). A cylinder head is the part of
the engine that covers the top of the cylinders and forms the top part of the
combustion chamber. In addition, the cylinder head houses the valves, valve
springs, valve guides, valve seats, intake and exhaust ports, water jacket, and
oil passages.

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 Figure 26. COMBUSTION CHAMBER

A COMBUSTION CHAMBER (Figure 26) is the space between the top of

the piston and the bottom of the cylinder head when the piston is at top dead
center. The said space is where the combustion of the air and fuel mixture
takes place.

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 Figure 27. INTAKE & EXHAUST VALVES

VALVES (Figure 26) are devices that allows and stops the flow of gasses
in and out of the cylinders. Specifically, the INTAKE VALVE opens during the
intake stroke to allow the entry of air or air-fuel mixture into the cylinder. On
the other hand, an EXHAUST VALVE opens a few degrees before the end of the
power stroke to release the burned gasses out of the cylinders. However, both
valve are close during the compression stroke to allow the piston to squeeze the
air or air and fuel mixture.
Figure 27 presents the parts of a valve.

Figure 28. Parts of a Valve. (1) TIP, (2) STEM, (3) FACE, (4) HEAD

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 A VALVE SPRING is a coil spring which keeps the valve closed tightly in
its seat. It is placed around the valve stem and is held in place by a retainer.
Most engines have one valve spring per valve. However, during high
engine revolutions, the number of valve openings and closings and the natural
frequency of the spring becomes equal. This causes the valve to vibrate
regardless of camshaft position. This is
called “SURGING” and it can cause engine
noise, valve spring damage, and the piston
hitting the valve.
In order to prevent surging, engines
uses UNEVEN PITCH VALVE SPRINGS or
DOUBLE VALVE SPRINGS. Figure 29
shows two types of uneven pitch valve
spring. Figure 29. UNEVEN PITCH SPRINGS (A)
SYMMETRICAL (B) ASYMMETRICAL
Illustration A on Figure 29 shows a
SYMMETRICAL valve spring. Observe that the spring pitch “a” and “c” are
equally narrower compared to spring pitch “b” which is wider.
Illustration B on Figure 29 shows an ASYMMETRICAL valve spring. It
can be seen that the spring pitch “e” is narrower than spring pitch “b”. This
type of valve springs must be installed with their wider pitch toward the top.
Most diesel engines uses double valve
springs in order to tightly close the valves by
using additional spring force (Figure 30).

Figure 30. DOUBLE VALVE SPRINGS

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 The VALVE GUIDE (Figure 31) is press-fitted into the cylinder head and
is constructed of cast iron. Its main purpose is to guide the movement of the
valve so that the valve face and valve seat can come into exact contact to each
other.
The contact surfaces of the valve guide and valve stem are lubricated
with engine oil. To prevent excess oil from entering the combustion chamber, a
VALVE SEAL (Figure 31) is fitted on the topside of the valve guide bushing.

Figure 31. (1) VALVE SEAL (2) VALVE GUIDE (3) VALVE STEM

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 The VALVE SEAT is a metal ring which is press fitted into the cylinder
head. It is the part where the valve face comes into contact when the valve is in
its close position in order to ensure that the combustion chamber is sealed or
airtight. In addition, the valve seat transfers the heat from the valve to the
cylinder head’s water jacket.

Figure 32. VALVE SEAT (In yellow)

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 Figure 33. INTAKE PORT (1), EXHAUST PORT (2)

PORTS are passages in the cylinder head that connects the manifold to
the engine cylinder. For example, the INTAKE PORT (Figure 33), being the final
part of the engine’s air intake system, connects the intake manifold to the
cylinder and are opened and closed by the intake valves. On the other hand,
the EXHAUST PORT (Figure 33) connects the cylinder to the exhaust manifold
and are opened and closed by the exhaust valve.

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 ACTIVITY #6
HOW CYLINDER BLOCKS ARE MADE?

Direction:
1. Watch the video “How it’s made-Engine Block” uploaded in our Google
Classroom.
2. Transcribe the discussion in each timeframe.
3. Use the format provided below.
4. Write your answer on a clean sheet of paper.
5. Take a picture of your work and send it as an attachment.
6. You will be graded accordingly:

CRITERIA SCORE
1-2-3-4-5-6-7-8-9-10
ACCURACY (50 points)
Note: Each number on the scale
Only words that are spoken in the video
corresponds to five (5) points. Each
file are written.
mistake under the ACCURACY
Phrases/ words were clearly
criteria corresponds to a five (5)
understood.
point deduction.
QUALITY OF SUBMITTED WORK (30 1-2-3-4-5-6-7-8-9-10
points) Note: Each number on the scale
Legibly written. corresponds to three (3) points.
Picture is clear and is in the correct, Each mistake under the QUALITY
readable orientation. criteria corresponds to a three (3)
point deduction.
1-2-3-4-5-6-7-8-9-10
CAPITALIZATION, PUNCTUATION, & Note: Each number on the scale
SPELLING (20 points) corresponds to two (2) points. Each
Proper capitalization, punctuation, and mistake under the WRITING
spelling were used CONVENTION criteria corresponds
to a two (2) point deduction.

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 FORMAT
Name:
Course, Year-Section:
ACTIVITY 6
How Cylinder Blocks are made
A. Timeframe- 00:00 to 00:19

B. Timeframe- 00:20 to 00:52

C. Timeframe- 00:54 to 01:10

D. Timeframe- 01:11 to 01:52

E. Timeframe- 01:53 to 02:06

F. Timeframe- 02:11 to 02:35

G. Timeframe- 02:38 to 03:02

H. Timeframe- 03:11 to 03:39

I. Timeframe 03:46 to 04:08

J. Timeframe 04:16 to 04:54

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