Introduction

of
Automobile
Engineering

1:10
CONTENTS

I. Introduction to Automobile
II. Engine Construction and Operation

III. Fuel System of SI Engine

IV. Fuel System of CI Engine

V. Engine Lubrication System

VI. Engine Cooling System

2:10
1. Introduction to Automobile

1-1. History of Development

1-2. Classification of Motor Vehicles
1-3. Components of Automobile
1-4. Introduction of Automobile Engines

3:10
1-1. History of Development

■ Steam Powered Vehicle INDUSTRIAL

 1779 Josheph Cugnot REVOLUTION

■ Electric Vehicle
 1873 Robert D. John

■ Early Internal Combustion Engine

Vehicle by Gas(Hydrogen)
 1887 Carl Benz

4:10
1-1. History of Development
■ Internal Combustion Engine Vehicle by Liquid
 Vehicle Fueled Biofuel(Ethanol, Peanut Oil)
 Vehicle Fueled Petroleum(Petrol, Diesel)

Advent of Petroleum Fuels

WORLD WAR I (1914)

1915 Model T 1923 Mercedes Benz

Mass Production System First Diesel Truck
5:10
1-1. History of Development

1926 Bugatti Type35 1932 Ford V8 (Model B)

Racing car V8 Engine

1934 Citroen Traction Avante 1936 Rolls Royce Phantom III

Front-Wheel Drive V12 Engine
6:10
1-1. History of Development

1936 Benz 260D 1938 Volkswagen Beetle

First Diesel Passenger Vehicle

OIL
SHOCK
1973

1966 Toyoda Collora 2008 Tata Nano

7:10
1-1. History of Development
■ Alternative Vehicle
 Hybrid Vehicle
 Plug-in Electric Vehicle
 Fuel Cell Vehicle
 Hydrogen Vehicle

PROTOCOL
1997

CO2 Regulation
1997 Toyoda Prius 2008 Tesla Roadster
Hybrid Electric All Electric

8:10
1-1. History of Development

Mega-Transition from Carbon to Hydrogen

C/H RATIO FUEL TYPE HARDWARE

10 WOOD(solid)
Steam Engine

2 COAL(solid)

0.5 CRUDE OIL (liquid)

Internal Combustion
Engine
0.25 NATURAL GAS (gas)

0 HYDROGEN (gas) Fuel Cell

9:10
1-2. Classification of Motor Vehicles
■ by Purpose
 Passenger Vehicle
by Body Style
 Sedan
 Hatchbag
 Convertible Sedan Hatchbag
 SUV(Sports Utility Vehicle)
 Wagon
 Van

 Commercial Vehicle
By Load Capacity
Convertible SUV
 Light Duty Vehicle
 Heavy Duty Vehicle

 Special Vehicle
 Ambulance
 Fire Engine
 Etc.
Wagon Van
10:10
1-2. Classification of Motor Vehicles
■ by Fuel
 Petrol(Gasoline) Vehicle
 Diesel Vehicle
 EV(Electric Vehicle)
 FCV(Fuel Cell Vehicle)
 Hydrogen Vehicle
■ by Steering Wheel
 Left-hand Drive
 Right-Hand Drive
■ by Number of Wheels
 Two Wheeler
 Three Wheeler
 Four Wheeler
 Six Wheeler
■ by Type of Transmission
 MTM(Manual Transmission)
 ATM(Automatic Transmission)

■ By Type of Drive
 4WD(4 Wheel Drive)/
AWD(All Wheel Drive)
 2WD(2 Wheel Drive)
 FWD(Front Wheel Drive)
 RWD(Rear Wheel Drive)
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1-3. Components of Automobile
■ Power Train
 Engine
 Transmission
 Axle

12:10
1-3. Components of Automobile
■ Chassis
 Body and Frame
 Suspension System
 Steering System
 Brake System

13:10
1-3. Components of Automobile
■ Electrics and Electronics
 Battery System
 Starting System
 Charging System
 Lightning System
 Control Modules and Sensors

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1-4. Introduction of Automobile Engine

“Automobile Engine is a device which convert

chemical energy to mechanical energy to drive
Vehicles”

■ 1877 Gasoline Engine N. Otto → 1887 Gasoline Vehicle K. Benz

■ 1894 Diesel Engine R. Diesel → 1923 Diesel Truck Mercedes Benz

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2. Engine Construction and
Operation
2-1. Classification of Automobile Engine
2-2. Operation of 4 Stroke and 2 Stroke Engine
2-3. Construction and Working Principle of SI & CI Engine
2-4. Major Engine Components
Cylinder Head
Cylinder Block
Crankcase
Piston
Crankshaft
Connecting Rod
Flywheel
Etc.
2-5. Valve Mechanism & Valve Timing Diagram
16:10
2-1. Classification Automobile Engines
■ Basic Engine Design
 Reciprocating Engine
 In-Line Engine
 V-Engine
 Opposite Piston Engine
 Radial Engine

In-Line V Opposite Piston Radial

 Rotary Engine
 Wankel Engine

Wankel
17:10
2-1. Classification Automobile Engines
■ Working Cycle
 2 Stroke Cycle Engine
 4 Stroke Cycle Engine
■ Method of Ignition
 SI(Spark Ignition) Engine
 CI(Compression Ignition) Engine
■ Method of Cooling
 Air Cooled Engine
 Water Cooled Engine
■ Fuel Used
 Gasoline(Petrol) Engine
Diesel Engine
Gas(LNG, CNG, LPG) Engine
Dual Fuel Engine
Hydrogen Engine
Hybrid 18:10
Fuel Cell
2-1. Classification Automobile Engines
■ Application
 Motorcycles, 0.75 – 70 kW, SI, 2 and 4-stroke, air-cooled
 Outboard motor, 0.75 – 50 kW, SI, 2-stroke, water-cooled
 Passenger cars, 15 – 200 kW, SI and CI, 4-stroke, water-cooled
 Light commercial vehicles, 35 – 150 kW, SI and CI, 4-stroke, water-
cooled
 Heavy commercial vehicles, 120 – 400 kW, CI, 4-stroke, water-cooled
 Locomotives, 400 – 3 000 kW, CI, 4-stroke, water-cooled
 Ships, 3 500 – 22 000 kW, CI, 2- and 4-stroke, water-cooled
 Airplanes, 45 – 3 000 kW, SI, 4-stroke, air-cooled
 Stationary engines, 10 – 20 000 kW, CI, 2- and 4-stroke, water-cooled

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2-2. Operation of 4 Stroke
and 2 Stroke Engine.

1 = Intake 1 = Intake/Compression
2 = Compression 2 = Power/ Exhaust
3 = Power
4 = Exhaust
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2-2. Operation of 4 Stroke
and 2 Stroke Engine

1 = Intake/Compression 2 = Power/ Exhaust

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2-2. Operation of 4 Stroke
and 2 Stroke Engine

Gasoline 2 Stroke Engine Diesel 2 Stroke Engine

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2-2. Operation of 4 Stroke and
2 Stroke Engine
4 Stroke Engine
One power stroke for every 2 revolution of crankshaft
Heaver flywheel due to unbalanced engine run
Heavy
Design complicated due to valve mechanism
More cost
Less mechanical efficiency due to more friction parts
More output due to full fresh charge intake & full
burnt gases exhaust
Engine run cooler
Less fuel consumption & Complete burning of fuel
Required more space
Complicate lubricating system
Less noise
Intake & exhaust valves
More thermal efficiency
Less engine oil consumption
Less wear of moving parts
Mainly used in cars, buses, trucks
2 Stroke Engine
One power stroke for each revolution of crankshaft
Lighter flywheel due to relatively balanced engine run
Light
Design simple due to absence of valve mechanism
Less cost
More mechanical efficiency due to less friction parts
Less output due to mixing of fresh charge with hot
burnt gases
Engine run hotter
More fuel consumption & fresh charge mixed with
exhaust gas
Required less space
Simple lubricating system
More noise
Intake & exhaust ports
Less thermal efficiency
More engine oil consumption
More wear of moving parts
Mainly used in mopeds,23:10
outboards, lawnmower
(gasoline0 & marine engine(diesel)
2-3. Construction and Working
Principle of SI & CI Engine
SI Engine

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2-3. Construction and Working
Principle of SI & CI Engine
■ CI(Compression Ignition) Engine Working Principle

25:10
2-3. Construction and Working
Principle of SI & CI Engine
Compression Ratio

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2-4. Major Engine Components
Ignition Coil & Spark Plug
Three Way Catalyst
Fuel Injector

Cylinder Head

Intake Manifold

Alternator Cylinder Block

Cam Shaft

Piston

Flywheel

Connecting Rod

Crankcase Crankshaft 27:10

2-4. Major Engine Components
■ Cylinder Head
 Contain valve driving mechanism
 Camshaft(OHC), Valve train
 Installed Intake and Exhaust Manifold
 Consist upper part of combustion chamber
 Material : Cast Iron, Aluminum Alloy

28:10
2-4. Major Engine Components
■ Cylinder Block
 Contain Piston assembly
 Embedded water jacket for cooling system and oil gallery for lubricating
system
 Installed water pump, alternator, starting motor, compressor, etc.
 Consist upper part of crankcase
 Material : Cast Iron, Aluminum Alloy

29:10
2-4. Major Engine Components
 Cylinder Head Gasket & Head Bolt
 Cylinder head and cylinder block are fabricated by cylinder head bolts
 Sealed by head gasket between cylinder head and block

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2-4. Major Engine Components
■ Crankcase
 Contain oil pump and strainer, engine oil
 Mount lower part of main journal bearing
 Consist of lower part of crankcase
 Material : cast iron, steel alloy, aluminum alloy

31:10
2-4. Major Engine Components
■ Piston Head
 Change thermal energy to mechanical energy
thru connecting rod to crankshaft
 Mount piston rings
 Consist lower part of combustion chamber
 Material :Cast Iron, Aluminum Alloy

Piston Top

32:10
2-4. Major Engine Components
Piston Ring

Top Ring

2nd Ring

Oil Ring

33:10
2-4. Major Engine Components
Combustion Chamber (Gasoline Engine)

Wedge Bathtub
Hemispherical

34:10
2-4. Major Engine Components
■ Connecting Rod
 Transmit force from piston to crankshaft
 Connected with piston and crankshaft by pins
 Material : nickel, chrome, chrome
vanadium steel, aluminum

35:10
2-4. Major Engine
Components
■ Crankshaft
 Change reciprocating of piston movement
to rotating movement
 Different configuration depending number
of cylinder for balance
 Mount crankshaft sprocket and flywheel
 Material : cast iron, nickel alloy

36:10
2-4. Major Engine Components
■ Flywheel
 Energy storage device.
 Provide balance for crankshaft
 Mount clutch/transmission
 Meshed with starter motor’s pinion
gear on outer gear
 Material : cast iron

37:10
2-4. Major Engine Components
■ Piston + Connecting Rod + Crankshaft +Flywheel

Connecting
Rod Piston
Flywheel

Crankshaft

38:10
2-4. Major Engine Components
■ Camshaft
 Operate valve mechanism (open and
close intake and exhaust valves
 Mounted cam sprocket
 Connected crankshaft sprocket by timing
chain or belt
 Chilled cast iron

39:10
2-5. Valve Mechanism & Valve Timing
Diagram
Cam Shaft in Cylinder Block

Side-Valve Overhead-Valve
Cam Shaft in Cylinder Head

40:10

SOHC w/cam follower SOHC w/Rocker DOHC w/Tappet SOHC w/Tappet

Valve Timing Diagram

41:10
2-5. Valve Mechanism & Valve Timing
Diagram
Effect of Valve Timing
Opening Closing
Valve
Early Late Early Late
Dilution with Reduce Volume Increase Cylinder Reduce Cylinder
Intake Exhaust gas Efficiency Pressure Pressure
Power Reduce Volume
Exhaust Reduction
Pumping Loss
Efficiency
Reduce Vacuum

42:10

VVC(Variable Valve Control)

3-1. Engine Lubrication System & Type

■ Purpose of Engine Lubrication

 Reducing Friction
 Preventing Wear of Moving Engine Parts
 Sealing Combustion Gas
 Maintaining Engine Cleanliness
 Cooling Engine Parts
 Permitting Easy Start
 Extending Engine Life

43:10
3-1. Engine Lubrication System & Type
■ Engine Lubrication System

44:10
3-1. Engine Lubrication System & Type
 Pressure Feed Lubrication
Mechanical pump supply oil under pressure(200~400kPa) to parts such as bearings,
cams, piston rings etc.

Oil Pump
45:10
3-1. Engine Lubrication System & its
Types
 Splash Lubrication
Consists of a scoop fitted at the lower end
of connecting rod . As the engine runs, sco
op splashes oil from trough by centrifugal
force to all engine part.

scoop

Oil Tank

Splash Lubrication

 Dry Sump Lubricating System

• Additional pump(s) and remote oil tank
• Marine Diesel Engine, Racing car, motor bilk
Oil Pump 46:10
3-2. Properties of Lubricants.
■ Viscosity
Viscosity, by definition, is an oil’s resistance to flow and shear. The most common
unit of measure for viscosity is the Kinematic viscosity and this is usually quoted i
n data sheets at 40°C and 100°C. The commonly used unit of measure is centisto
kes but the correct SI unit of measure is mm2/s
■ Viscosity Index
Viscosity index (VI) is an arbitrary measure for the change of viscosity with variatio
ns in temperature. The lower the VI, the greater the change of viscosity of the oil
with temperature and vice versa. It is used to characterise viscosity changes with r
elation to temperature in lubricating oil
■ Oxidation Stability
The ability of a lubricant to withstand the presence of oxygen. The rate of oxidati
on is accelerated by high temperatures, water, acids and catalysts such as copper.
Oxidation will lead to an increase in the oil's viscosity and deposits of varnish and
sludge. The rate of oxidation doubles with every 10º C rise in temperature
■ Pour Point
The pour point of an oil is the lowest temperature at which it will pour when cool
ed under defined conditions.
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3-3. Types of Lubricant & Additives.
■ Base oil & Additives for Engine Oil
 Engine Oil Composition

48:10
3-4. Grading of Lubricants.
■ Classification by Viscosity
 SAE(Society of Automotive Engineers)

49:10
3-4. Grading of Lubricants.
■ Classification by Performance
 API(American Petroleum Institute
Gasoline Engine Oil

50:10
3-4. Grading of Lubricants.
■ Classification by Performance
 API(American Petroleum Institute
Diesel Engine Oil

51:10
3-5. Grading of Lubricants.
■ Package Marking Grade of Engine Oil

API

ACEA

SAE

52:10
3-5. Grading of Lubricants.
■ Classification by Performance
 OEMs (Original Equipment Manufacturers)

ILSAC

OEM
GM Desos2

13:32
53:10
26:02
4. Engine Cooling System

4-1. Air and Water Cooling System

4-2. Working Principles of Air & Water Cooling System
4-3. Variation of Gas Temperature
4-4. Components of Water Cooling System

54:10
4-1. Air and Water Cooling System
■ Engine Cooling System
 Prevent Overheating
 Excess Heat generated in engine
 Peak temperatures exceed melting point of metal
 Cooling removes excess heat
 Regulate Temperature
 Allow engine to warm up in cool weather
 Cold engine less efficient
 Cold engine allow corrosive compounds to form
 Maintain engine in optimum range

55:10
4-1. Air and Water Cooling System
 CONSEQUENCES OF ENGINE RUNNING TOO HOT
 Pre-ignition
 Detonation
 Knock
- All result in very high pressure rise and possible damage to engine
 Heat fatigue of components
- Burnt pistons
- Burnt valves
 Failure of lubrication system
- Oil breakdown
- Oil film at cylinder destroyed at 200°C
 fracture of components

56:10
4-1. Air and Water Cooling System
 CONSEQUENCES OF ENGINE RUNNING TOO COLD
 Unnecessary wear
 Poor fuel economy
- Incomplete combustion
- Lower coolant temperature
 More energy transferred out of cylinder
 Energy is wasted & not available for work (Power)
 Promotes corrosive conditions in engine
- Water of combustion reacts with sulfur oxides in exhaust
 Forms acids
- Allows water & sludge to accumulate in crankcase
- Over time, fuel diluting the oil will accumulate
 Normally lighter volatile fuel will evaporate as temp. rises

57:10
 4-2. Working Principles of Air &Water
Cooling System
■ Air Cooling System
 Heat is transferred from cylinder block and head to air directly
 Use many fins on cylinder block and head for effective heat transfer
to the surrounding air
 Heat Transfer depend on;
1) Temperature Difference
2) Heat Transfer Area
3) Hear Transfer Coefficient
 Normally cylinder and heat temperature in an air-cooled engine is
about twice that of a comparable water-cooled engine
 Equipped Oil Cooler and use high viscosity oil
 Heat transfer coefficient between metal to water is about 100 times better than
metal to air
 Therefore, either the metal to air surface area or the temperature difference or
combination of two should be 100 times larger in air-cooled engine to obtain
same amount of heat transfer 58:10
4-2. Working Principles of Air &Water
Cooling System
Air-Cooling Diesel Engine

Air-cooling system for Air-cooling system for

an in-line four-cylinder a horizontally
59:10 opposed
engine four-cylinder engine
4-2. Working Principles of Air &Water
Cooling System
Gasoline Engine(VW Beetle)

Gasoline Engine(Motorbike)
60:10
4-2. Working Principles of Air &Water
Cooling System
■ Water Cooling System

61:10
4-3. Variation of Gas Temperature

Heat Distribution

Heat transfer
62:10
4-4. Components of Water Cooling
System.
■ Water Cooling System
 Components
 Radiator
 Radiator Cooling Fans
 Pressure Cap & Reserve Tank
 Water Pump
 Thermostat
 Freeze Plugs
 Heater Core

63:10
4-4. Components of Water Cooling
System.
 Radiator
• Heat exchanger to air
• Coolant reservoir

 Pressure Cap & Reserve Tank

• Hold pressure on modern
closed cooling system
• Pressure relief into overflow
chamber at high temp &
pressure

64:10
4-4. Components of Water Cooling
System.
 Radiator Cooling Fans
• Forces air through radiator
• Electric Fan/Clutch Fan/Flex Fan

65:10
4-4. Components of Water Cooling
System.
 Water Pump
• Circulate coolant thru out cooling system
• Centrifugal Pump (housing & Impeller)

 Thermostat
• Maintain proper engine temperature
• Sealed copper cup that contained wax and metal pellet
• As the thermostat heats up, the hot wax expands, pushing a piston against
spring pressure to open the valve and allow coolant to circulate

66:10
4-4. Components of Water Cooling
System.
 Freeze Plugs
• When coolant freeze, pressure of water
freezing and expanding forced the freeze
-out plugs to pop out, relieving pressure
and saving engine block from cracking

 Heater Core
• provide heat to the interior of vehicle
when needed

67:10
4-4. Components of Water Cooling
System.
 Antifreeze Coolant
• Lower freezing point of a water-based
coolant
• Mixture freezing-point depressor for cold
environments, boiling-point elevator for
higher coolant temperature and additives
(rust/corrosion inhibitor)
• Normally Ethylene/Propylene Glycol base

 Maintenance of Cooling System

• Visual inspection of all cooling system components, including belts and hoses
• Radiator pressure cap test to check for the recommended system pressure level
• Thermostat check for proper opening and closing
• Pressure test to identify any external leaks to cooling system parts; including
radiator, water pump, engine coolant passages, radiator and heater hoses and
heater core
• Internal leak test to check for combustion gas leakage into cooling system
• Engine fan test for proper operation
• System power flush and refill with car manufacturer's recommended
concentration of coolant
68:10
5.1. Engine Performance
Tests

5-1. Performance Parameters

5-2. Engine Power, BHP, Fuel
Consumption, Air Consumption

69:10
5-1. Performance Parameters

70:10
5-1. Performance Parameters.
■ Calorific Value of Fuel (CV)
■ Clearance Volume (Vc)
■ Engine Swept Volume (Vd)
■ Compression Ratio (CR)
■ Engine Indicated Torque (Ti)
■ Engine Torque (Te)
■ Indicated Power (Pi)
■ Friction Power (Pf)
■ Brake Power (Pb)
■ Engine Specific Fuel Consumption (SFC)
 Brake Specific Fuel Consumption (bsfc)
 Indicated Specific Fuel Consumption (isfc)
71:10
5-1. Performance Parameters.
 mep (Mean Effective Pressure)
 mep is a fictitious constant pressure that would produce the same
work per cycle if it acted on the piston during the power stroke
 imep (Indicated Mean Effective Pressure)
 bmep (Brake Mean Effective Pressure)
 bmep = ηmㆍimep
 Used for comparing different engines
 imep is a better parameter
than torque to compare
engines for design and
output because it is inde-
pendent of engine speed(N)
and engine size(Ve)
imep

72:10
5-2. Engine Power, BHP, Fuel
Consumption, Air Consumption.

73:10
74:10