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Trade Theory
Engine
85 Pages
Trade Theory
Nikolaus August Otto
1832 - 1891
First functioning four-stroke
Otto-engine in 1876
Engine
History of Piston Engine
Engine pioneers
After Steam-Engines the Gas-Engine were developed already in 1824 by the
French Physicians Leonard Sadi Carnot. It was first a theoretical process
discribed. The first functioning Gas-Engine was developed by the British
engineer Samuel Brown. The atmopheric engine was patented on 04.12.1823
under patent number 4874. In 1826 the American engineer Samuel Morey
got a patent for his Gas-Engine with carburettor.
1838 developed the British engineer Wellman Wright also a Gas-Engine.
1838 got the British engineer William Barnett patent 7615 for his Gas-Engine.
All this engines were on experimental base, not economical and lasted not long.
The belgian Autodidact Jean Joseph Etienne Lenoir developed 1860 a
Gas-Engine which was patented in France on 01.01.1860. The principle was
similar to the steam-engine and reached only the experimental stage too.
The business man Nikolaus August Otto and his brother Wilhelm Otto in Cologne
developed according to the principle of the Lenoir-Engine an engine driven by
alcohol. A patent for this engine was refused, because it was similar to the
principle of the Lenoir-Engine.
Otto and his mechanic M.J. Zons developed than a modern four-stroke Gas-Engine
which was well functioning. For producing this Gas-Engine Otto founded together
with the engineer Eugen Langen on 31.03.1864 a new company “N.A.Otto & CIE”
in Cologne-Deutz. The engine was continously improved and was a best-seller for
all pruposes. The principle of this engine is still in use today and was patented on
05.01.1872. The engine was named “Otto-Engine”.
Trade Theory Engine

Classification of Engines

Engine
according to

Working Layout of Mixure Engine

Duty cycle Fuel Ignition Cooling
principle cylinders formation filling

Reciprocating Induction Spark Suction

Four stroke In-line Petrol Water
piston system ignition engine

Exterior
Rotary Compression Charged
Two stroke V Diesel mixture Air
piston ignition engine
formation

Oposed
Turbine Gas
cylinder

VR

Star
Trade Theory Engine

Crankshaft Rotation

 In-line Engine

1
2
3
4

Front of Engine Flywheel Pulley Flywheel

Direction of crankshaft rotation

- Standard is clockwise (seen oppisite of flywheel)
- Some manufacturer have also anticlockwise (Peugeot)
Trade Theory Engine

Cylinder Arrangement

In-line Engine Numbering of cylinders

- Standard is =
1 Cylinder 1 is opposite
2 of
flywheel
3 - Some manufacturer
4 have also cylinder 1
on flywheel side
(Peugeot)
Flywheel

V-Engine
Cylinder bank 1
(60 – 90 Cylinder bank 2

5 1
6 2
7 3
8 4
Numbering of cylinders
- Standard is =
Cylinder bank 1 is opposite right of flywheel
- Standard is =
Cylinder 1 is right opposite of flywheel

Flywheel
Trade Theory Engine
Cylinder Arrangement
VR-Engine (15 Cylinder bank 2 Cylinder bank 1

6
1
Example : 5
2
- VW 4
3
- AUDI
Flywheel

Cylinder bank 3 Cylinder bank 1

W-Engine
Cylinder bank 4 Cylinder bank 2

Example : 10 7 1 4
- VW 11 8 2 5
- AUDI 12 9 3 6
Flywheel

Opposed Cylinder Type Engine Flywheel

Example : 3 1
VW Beetle
4 2

(Boxer)
Trade Theory Engine

Cylinder Arrangement

7 1 Before the gas turbine and jet were invented

the star engine are used mostly as aircraft
engine. Few star engine were used as boat
6 engine and one type of tank in the US army
2 had a star engine.

Star engines with 5, 7, 9 up to 27 cylinders

in few levels were constructed.
5 3
The firing order of this engine is :
4 1–3–5–7–2–4-6
Trade Theory Engine

Basics of Engine

Cylinder Head
Cylinder Head Gasket

TDC Combustion
(Top Dead Center) Chamber

Stroke Cylinder
Displacement

BDC
(Bottom Dead Center)

Cylinder Piston
Trade Theory Engine

Compression Ratio

Ratio

TDC
1
Volume of
combustion chamber Vc 1
2
3 8:1
4
Stroke S Volume of cylinder
5 displacement Vh 8
6
7
8
BDC

Formula of compression ratio 

Vc + Vh
=
Vc
Trade Theory Engine

Compression Ratio

Boyle-Mariotte’s law Gay-Lussac’s Law

The physicians Boyle and Mariotte found out
already in the 17. century that with constant
pressure the volume and pressure in a cylinder
have a reciprokal relation.
Example : If the volume of a cylinder compressed
until 8:1, the pressure will be 8 times
bigger.
Law : The product from pressure and volume
is constant
The French physiciant Gay-Lussac found out
that temperature is doubling the pressure in
a cylinder.
Example : If a gas will be warm-up to 273 K, the
volume of the gas is doubled.
If the expansion will be not allowed,
the pressure will be doubled too.
Law : Warmed-up gas of 1 K (1 C) at
constant pressure the expansion will
be the 273th part of volume.

Comparison of different compression ratio

Compression ratio 7:1 8:1
Compression pressure at end ~ 10 bar ~ 16 bar
Highest compression pressure ~ 30 bar ~ 42 bar
Pressure at opening exhaust valve ~ 4 bar ~ 3 bar
Compression temperature at end 400 C 500 C
Trade Theory Engine

Four Stroke Engine

Sparkplug
Camshaft
Exhaust Channel
Exhaust Valve
TDC
Intake Channel Cylinder
Intake Valve Stroke
Piston Rings
BDC
Piston Pin
Piston
Connecting Rod
Crankshaft
Crank Case
Trade Theory Engine

Four Stroke Engine

TDC TDC TDC TDC

BDC BDC BDC BDC

Stroke 1 Induction Stroke 2 Compression Stroke 3 Combustion Stroke 4 Exhaust

180 ° 180 ° 180 ° 180 °
Trade Theory Engine

Four Stroke Otto Engine


Action Data
TDC
- Piston is at top dead centre (TDC) - Inlet valve open 2-20° before TDC
- Iinlet valve is open - Iinlet valve close 40-60° after BDC
- Exhaust valve is close - Measurment of
- The piston moves from TDC valve timing with
to BDC and produce vacuum test valve clearance 0,4 mm
- Fuel air mixture is sucked - Exhaust gas residue
BDC
into the cylinder pressure 0,1-0,6 bar
- Temperature 400-600 °C
- Air required 15 kg
Filling dependet upon air pressure, - Air ratio 0,7-1,3
temperature, speed, throttle control - Negative gauge
position, compression ratio, engine pressure in the
condition, suction pipe and valve suction pipe 0,1-0,3 bar
opening time. - In the air funnel 0,4-0,7 bar
- Suction temperature 50-100 °C
- Filling efficiency 0,7-0,9

Stroke 1 : Induction
180 °
Trade Theory Engine

Four Stroke Otto Engine


Action Data
- Piston is at bottom centre (BDC) - Compression 7-10:1
TDC
- Iinlet valve is closing - Burning pressure 12-18 bar
- Exhaust valve is close - Working pressure 6-12 bar
- The piston moves from BDC - Compression
to TDC and compressed the temperature 400-600 °C
fuel air mixture to the compression
BDC chamber.

The fuel and air particles come closer - Increase in

together. Pressure and temperature compression from 5 to 8:1
increase in the cylinder.. - Increases power ca. 20%
- Reduces fuel
consumption by ca. 18%

- Inrease in
compression from 6 to 7:1
- Increases power 6%
- Reduces fuel
Stroke 2 : Compression consumption by 5%
180 °
Trade Theory Engine

Four Stroke Otto Engine


Action Data
- Piston is at top dead centre (TDC) - Maximum pressure 40-60 bar
TDC
- Iinlet valve is close - Maximum temperature 2000-2500 °C
- Exhaust valve is close - Mean working pressure 6-10 bar
- Combustion chanber is filled with
hot compressed fuel air mixture - Basic setting of ignition
- Some degree before top dead time point 10 ° before TDC
BDC centre an electric ignition spark until 5 ° after TDC
strikes on the electrode of the
spark plug - Adjustment by negative
- The spark ignite the fuel air mixture gauge pressure upto 20 ° KW
- The flame spreads out and the - Interia up to 45 ° KW
mixture burn fast.
- The gases become hot - Flame speed 10 to 25 m/sec
- Pressure increases in the cylinder - Combustion time 0,001 s
and the piston is pushed from TDC or 30-40 °KW
to the the bottom dead centre (BDC) - Pressure increase 1 at/ °KW
- Useful work 24 %

Stroke 3 : Combustion
180 °
Trade Theory Engine

Four Stroke Otto Engine


Action Data
- Piston is at bottom dead centre (BDC) - Exhaust gas temperature
TDC
- Iinlet valve is close at full load 700-1000 °C
- Exhaust valve is opening at Idle 300-500 °C
- The cylinder is filled with hot exhaust - Exhauste gas pressure
gas under positive gauge pressure at beginning 4,7 bar
- The piston is moved to the top dead at end 01,-0,6 bar
BDC centre, thereby the exhaust gases are
pushed out towards exhaust valve port. - Exhaust valve open 35-60° before BDC
- During the beginning of exhaust, the - Exhaust valve closing 5-30° after TDC
gases get puffed out due to the positive - Valve overlap 10-50 ° KW
gauge pressure prevailing in the piston
chamber at high speed. The fluctuating - Loss through cooling 33 %
conditions of flow and stress cause Loss through radiation 7%
vibrations Loss through exhaust gases 36 %

Stroke 4 : Exhaust
180 °
Trade Theory Engine

Piston

Piston head

Compression ring
Compression ring 2
Oil ring

Piston pin bore

Shaft

Shirt
Trade Theory Engine

Piston description

Piston head
Fire land

Ring zone
Oil return slot

Steel band

Piston pin
Piston Shaft

Piston pin bore

Piston skirt
Trade Theory Engine

Steel banded Piston

Single metal piston

Recoil piston

Shank expansion to be
Influenced by cast ribbing
of low thermal expansion;
Bimetal effect or shrinking
effect.

a) Steel ring circular strip

piston, DUOFLEX,
DEBELACK and
Perematic piston
b) Nelson-Bohnalite (invar-
steel), AUTOTHERMIC,
punched strip and formed
strip piston

Steel band
Trade Theory Engine

Piston Description

Piston pin offset

Piston clearance
in mm Piston diameter
in mm

84,00

Sp 0,04 KS
L6

Installing Manufacturer
direction code
Trade Theory Engine

Basic Form of a Piston

Exaggeration

Cold condition Hot condition

conical/ballig/ (± 80 °C)
ovall round/cylindrical
Trade Theory Engine

Running clearance of steel banded piston

Head clearance Head clearance

Steel banded piston (cold) (warm)

Ring land reduced

Shaft running
clearance line Shaft skirt line
(cold) (warm)

Piston clearance Piston clearance

(cold) (warm)
Trade Theory Engine

Piston-head shape
1 Flat haed
2 Pockets for valves
3 Asymmetric banked head
4 Unilateral banked,
1 2 3 4 unilateral recessed head
5 Compression camber
partly in piston head
6 Compression chamber
in piston head
7 Piston head for Diesel engine
with swirl chamber
5 6 7 8 8 Piston head for Diesel engine
with pre-chamber
9 Piston head for Diesel engine
with direct injection
10 Compression chamber in
piston head for Diesel engine
with M-Principle
(M= Mittelkugel-Brennraum)
9 10
Trade Theory Engine

Piston Description

Different piston heads

Hump
Flat

Pan Pan
Trade Theory Engine

Piston Description
Different piston heads

Spherical shaped combustion chamber Pan asymetric

Spherical shaped combustion chamber

Pan asymetric
Trade Theory Engine

Piston with flat head

Trade Theory Engine

Piston with pockets for valves

Trade Theory Engine

Piston Pin Offset

Major Minor
thrust face thrust face

Piston Pin Offset

1 .... 2
100 mm of Piston  = 0,5 – 1,5 mm
100
 Trade Theory Engine

Piston Pin Offset

Piston gauging

TDC

10 °
20 °
30 °

Crank angle

BTD

Major thrust face Minor thrust face

 Trade Theory Engine

Piston Speed
1 s
1 0 00 3
Acceleration Deecceleration 2 4

1 5

0 6
0 1 2 3 4 5 6 n = 5000 U/1min
60 12
1U= s = 1000 s
5000
1 1 s
U=
12 1000

1 s
Each
1000

Irregular motion Regular motion

Trade Theory Engine

Piston Speed

TDC BD
C
Trade Theory Engine

Piston way

90  180  270  360 

Piston head 0

Piston displacement
mm

Gudgeon
60

360  0
30

Crank displacement
+
270 
0
90  180  270 
-
30
180 
Trade Theory Engine

Piston Rings

Compression Rings Oil Control Rings

Plain Compression Ring TK 10 Oil Scraper Ring TK 30

Taper Face Ring TK 11 Taper Face Oil Scraper Rring TK 31

Minute Ring with Inner Face TK 11a Oil Ring TK 46

Keystone Ring, single TK 13 Spring-loaded Oil Ring TK 49

Keystone Ring TK 14 Triple Steel Ring Set TK 24

Trade Theory Engine

Piston rings for Diesel and petrol engines

Reinforcement
Diesel Engine Petrol Engine

TK 14 TK 10

TK 11 TK 11

TK 31 TK
30
TK 49
TK 49
TK 24
Trade Theory Engine

Damaged Piston

Piston jamming due lack of

lubrication or overheating

Hole in piston due to uncontrolled

ignition
Trade Theory Engine

Installing Piston Rings and Piston

Piston rings must be installed with

a piston-ring pliers

Pistonmust be installed with

a piston-ring scruff band
 Trade Theory Engine

Piston Ring Gap

Cylinder Block

Cylinder Bore

Piston Ring

Piston Ring Gap

0,2-0,3 mm
 Trade Theory Engine

Piston Ring Placement

Cylinder Block

Piston

Piston Ring

1 Piston Ring Joint

Top Ring 2
Piston Ring Joint
Middle Ring

90° 90°

3 Piston Ring Joint

Oil Ring

Minor thrust face

 Trade Theory Engine

Piston Rings
Sealing due to pressure
from combustion process Pumping Piston Ring
Normal axial play
0,025 – 0,04 mm Too much axial play
O 

Normal condition Cylinder Wall or Piston Rings are worn-out

Trade Theory Engine

Wear of Cylinder Bore

Normal Wear Unnormal Wear due to lack of Lubrication

TDC

BDC

The normal cylinder wear is 0,01 mm per 10.000 km

Trade Theory Engine

Different Types of Cylinder

Cylinder head

Cylinder head 0,1 mm

gasket

The exess hight is necessary

Cylinder liner
To press the cylinder liner
properly
Cylinder block

Cooling water
channel

Drain hole
Trade Theory Engine

Different Types of Cylinder

Cylinder with Liner
Cylinder for Air Cooling Engine

Grey Cast Iron

Aluminum
Cooling Water Channel Cylinder Block
Trade Theory Engine

Different Types of Cylinder

Dry Cylinder Liner

Wet Cylinder Liner

Cylinder Block

Cooling Water Channel

Cylinder Liner

Seal Ring

Drain Hole
Trade Theory Engine

Accessories for Pistons

Piston Pin
Piston Pin Retainer

Circlip

Retaining Ring
(Wire)

Shrink fit,
no retaining
ring
 Trade Theory Engine

Firing Order
1

1 Cylinder
1 Combastion Exhaust Induction Compression
Ignition interval 720 ° 0° 180° 360° 540° 720°

1 Combastion Exhaust Induction Compression

2 Cylinder
2 Induction Compression Combastion Exhaust
2
Ignition interval 360 ° 0° 180° 360° 540° 720°

1 2
1 Combastion Exhaust Induction Compression
2 Cylinder 2 Induction Compression Combastion Exhaust
0° 180° 360° 540° 720°
Ignition interval 360 °

1
3 Cylinder
1
1 Combastion Exhaust Induction Compression
Firing Order :
2 Exhaust Induction Compression Combastion
1-3-2
3 Compression Combastion Exhaust Induction
2 3
2 3 0° 60° 120° 180° 240° 300° 360° 420° 480° 540° 600° 660° 720°
Ignition interval 240°
Trade Theory Engine

Firing Order

4 Cylinder
1 ... 4 Combastion Induction Compression
1 Exhaust
1 4 Exhaust Induction Compression Combastion
2
3 Compression Combastion Exhaust Induction
4 Induction Compression Combastion Exhaust
2 3 0° 180° 360° 540° 720°

Ignition interval 180 ° Firing Order :

1-3-4-2
1-2-4-3

4 Cylinder
1 Combastion Exhaust Induction Compression
1 4
2 4 2 Exhaust Induction Compression Combastion
3 Compression Combastion Exhaust Induction
4 Induction Compression Combastion Exhaust
1 3
3 2 0° 180° 360° 540° 720°

Ignition interval 180 ° Firing Order :

1-4-3-2
Trade Theory Engine

Firing Order
5 Cylinder

1 Combastion Exhaust Induction Compression

1 4 5 1
2 Compress. Combastion
Exhaust Induction
5 4 3 Exhaust Induction Compression Combast.
4 Induction Compression Combastion Exhaust
5 Induction Compression Combastion Exhaust
2 3 3
2
0° 144° 288° 432° 576° 720°
Ignition interval 144°
Firing Order : 1-2-4-5- 72° 216° 360° 504° 648 °
3

6 Cylinder
1 6 1 Combastion Exhaust Induction Compression
2 Exhaust Induction Compression Combastion
3 Compression Combastion Exhaust Induction
4 Exhaust Induction Compression Combast.
2 3 4 5 5 Compress. Combastion Exhaust Induction
1,6 Induction Compression Combastion
6 Exhaust
Ignition interval 120°
0° 120° 240° 360° 480° 600° 720°
Firing Order :
1-5-3-6-2-4 60° 180° 300° 420° 540° 660°
1-2-4-6-5-3 2,5 3,4
1-5-4-6-2-3
Trade Theory Engine

Firing Order

8 Cylinder V

1,5 4,8
1,2,3,4 5,6,7,8 1 Combastion Exhaust Induction Compression
2 Compression Combastion Exhaust Induction
3 Exhaust Induction Compression Combastion
4 Induction Compression Combastion Exhaust
2,6 3,7 5 Exhau. Induction Compression Combastion
6 Comb. Exhaust Induction Compression
Ignition interval 90° Induct. Compression
7 Combastion Exhaust
8 Compr. Combastion Exhaust Induction
Firing Order :
0° 360° 540° 720°
1-5-4-8-6-3-7-2 180°
1-8-3-6-4-5-2-7
1-5-4-8-7-2-6-3 90° 270° 450° 630°
Trade Theory Engine

Ratio of Camshaft Drive

Camshaft gear Camshaft gear

Tensioner blade
Idler gear

Ratio = 1 : 2
Chain tensioner Drive chain

Tensioner blade

Crankshaft gear
 Trade Theory Engine

Camshaft drive

Gear drive Chain drive Belt drive Vertical-shaft drive

Camshaft Camshaft Thooted belt Camshaft Camshaft

gear Camshaft gear gear
Camshaft

Camshaft

Drive gear
Camshaft Drive Crankshaft Chain Drive Crankshaft Tensioner Crankshaft Crankshaft
gear gear gear Drive gear Vertical drive shaft
Trade Theory Engine

Arrangement of camshaft and valves

SV OHV OHC
(Side valves) (Overhead valves) (Overhead camshaft)

Camshaft Oscillating
Rocker arm lever
Push rod

Tappet Tappet

Camshaft Camshaft
Trade Theory Engine

Valve Arrangement

Exhaust Valve Compression Chamber

Intake Valve Sparkplug

Conventional Arrangement

3-Valve Arrangement 4-Valve Arrangement 5-Valve Arrangement

 Trade Theory Engine

Valve
Valve Stem Seal
Base Plate

Valve Spring
Cotter

Valve Spring
Retainer

Valve

Valve Rotating
Mechanism
45 °
Valve Guide

Valve Spring
 Trade Theory Engine

Valve
Intake Valve Exhaust Valve
Temperature of Valve :
Temperature of Valve :
Until 800 °C
Until 500 °C
Performance :
Performance :
Until 3000 times
Untill 3000 times
per minute open
per minute open
and closing
and closing
(50 times per second !!)
(50 times per second !!)
Valve Stem Hollow Stem
Sodium :
- Cold it is powder
Sodium Filling
and at 97 °C it is
60 %
fluid
- It reduce the valve
Welding Seam temperature by
ca. 100 °C
Armored Material
Valve Cone
45 ° 45 °
Valve seat

Valve Head
Trade Theory Engine

Valve rotating mechanism

Retracted postion Operating position

Valve spring
Diaphragm
Support spring in
normal Diaphragm
position spring in
Housing Spring action

Housing
(stretched Ball
position)

Ball in end Ball track Ball in

position action
Trade Theory Engine

Valve Seat

Cylinder Head
75 °
45 ° Valve Seat Ring

15 °

Correction Angle 15°

Valve Seat 45°

Correction Angle 75°

Trade Theory Engine

Valve Spring

Normal Spring Progressive Spring

Trade Theory Engine

Valve Train

OHV-
SV-Engine
Engine

S = Side OH = Overhead
V = Valve V = Valve
Trade Theory Engine

Valve Train

OHC-Engine DOHC-Engine

OHC = Overhead Camshaft DOHC = Double Overhead Camshaft

Trade Theory Engine

Valve mechanism

Rockerarm Oscillating lever Bucket tappet Roller oscillating lever

Trade Theory Engine

Arrangement of camshaft and valves

OHC DOHC CIH

(Overhead camshaft) (Double overhead camshaft) (Camshaft in head)

Rocker arm Camshaft Camshaft

Rocker arm
Tappet

Camshaft
Trade Theory Engine

Valve clearance

Manual adjustment

Oscillating
Adjusting screw lever Adjusting Bucket Adjusting
Rocker arm with counter nut tappet shim
screw

X
X X

X = Valve clearance
Trade Theory Engine

Valve clearance

Hydraulic valve tapet

Oscillating lever

Ball support
Housing
Seal
Resoir
Housing Piston

Resoir Oil chamber

Working chamber
Ball valve
Ball valve
Working chamber Return spring
Return spring
Cylinder housing
Trade Theory Engine

Camshaft

Journal bearing Drive flange

Flat cam

Cam

Acute cam
Valve lifting curve

Valve stroke

Asymetric cam

0 90 180
Trade Theory Engine

Camshaft

Valve lifting curve

Intake valve Intake valve

Valve stroke advancing late adjusting
in mm TDC

10

6
Exhaust Intake
valve valve
4

Valve Valve
2 overlapping overlapping
„advance“ „late“
0
Intake valve Intake valve
open advancing open late
Crankshaft angle in degree
Trade Theory Engine

Valve control diagram

Valve timing for four-stroke engiine

OT = Top dead center

UT = Bottom dead center

Eö = Intake valve open

Es = Intake valve closed

Aö = Exhaust valve open

As = Exhaust valve closed
 Trade Theory Engine

Crankshaft

Four cylinder crankshaft

Main bearing journal Bearing seat for pulley

Crankshaft
Connecting rod journal Material : - Nitride steel
- Heat-treated
alloyed steel
Flange for
- Sheroidal
flywheel
graphite
cast iron

Crank web
Lubrication port
Balance hole
Counter weight
Axial-thrust journal
 Trade Theory Engine

Crankshaft
Side-wall grinded Radius ± 0,5 mm Counter weight Balance hole

Lubrication
hole

Flange for fly wheel

Axial-thrust journal Main bearing journal Main bearing journal

Connecting-rod journal Connecting-rod journal
Trade Theory Engine

Connecting Rod

Connecting Rod Eye

Small End Bush

Connecting Rod Shank

Connecting Rod Bearing

Bearing Shell Locking strip

Connecting Rod Bolt
(reduced-shaft bolt)

Connecting Rod Bearing Cap

Trade Theory Engine

Connecting Rod

Small end bush

Connecting-rod eye

Reduced-sahft bolt Lubrication port

Connecting-rod
big end

Connecting-rod Connecting-rod shank

bearing cap

Connecting-rod bearing

Retaining nose
Trade Theory Engine

Connecting Rod

Face of fraction

Face of fraction

Traditional manufactured Modern manufactured

connecting rod connecting rod
Cutted and grinded Grinded and fractioned
 Trade Theory Engine

Sliding Bearing
Crankshaft Bearing

Upper Bearing Shell

Types of Sliding Bearings
Supporting Seat made of Steel1. Single substance bearing
a) Solid bearing box made of lead
Lead Bronze bronze, light metal or plastic
b) Bore covered by withe metal

2. Double-substance bearing
Withe Metal a) Supporting seat made of steel,
tin bronze or gun metal
Lower Bearing Shell b) Filling with sliding material :
Withe metal, lead bronze or
aluminium alloy
Layer Thickness
3. Three-substance bearing
Withe metal : 0,025 – 0,5 mm
Laed bronze : 0,300 – 1,5 mm a) Supporting seat made of steel
Main Crankshaft Bearing b) Lead bronze filling
c) Withe metal cladding (electrolysis)
Dimension of seats
are ready for assembly Bearing Clearance
Interchangeable bearing Depent upon bearing metal and
clearance H6/S6 and bearing diameter
1 normal step accurate Radial : 0,03 – 0,06 mm
4 Repair steps each of Axial : 0,10 – 0,30 mm
+0,25 mm
Locking strip Oil inlet hole Oil groove Collar
Trade Theory Engine

Crankshaft Bearing

Three-component axial-thrust bearing

Steel backing
Lubrication groove
Supporting layer 0,2 – 0,3 mm thick
Nickel layer 0,001 mm thick
Retaining nose
Sliding layer 0,012-0,020 mm thick
Lubrication port

Thrust collar

Lubrication pocket
Trade Theory Engine

Cylinder Head

Loosen cylinder head bolts

3 5 10 8 2 According to engine manfacturers

the struction for loosing cylinder
head bolts have to follow :

Procedure
- Loosen cylinder head bolts only when
engine is cold
- Loosing bolts from outside to the center
of cylinder head
1 7 9 6 4
Trade Theory Engine

Cylinder Head
Tighten cylinder head bolts

10 4 2 6 8
According to engine manfacturers
the struction for tighten cylinder
head bolts have to follow :

- Tighten cylinder head bolts

only when the engine is cold
7 5 1 3 9 - Tighten bolts from center to outside
- Tighten cylinder head bolts only
with calibrated torque wrench

10 6 2 3 7
Procedure
1. Thighten all bolts with torque wrench
with 90 Nm
2. Let rest the bolts for 10 minutes
3. Tighten all bolts 60angle

9 5 1 4 8
Trade Theory Engine

Cylinder Head Gasket

Hole for Hole for

Oil return hole
cylinder head cylinder head
bolt bolt and pressured Cylinder head gaskets
lubrication oil for modern engines
are developed to a
high tech product.
Elestomere
sealing
- It is not necessary
element
anymore to tighten the
Coated surface cylinder head bolts at
the first after sales
Reinforcement service.
for compression - In some engines a IC
chamber ship is integrated as
Holes for Additional partial anti-knock sensor.
coolant sealing element
Supporting
circulation sheet metal layer
Trade Theory Engine

Cylinder Head Gasket

Reinforcement
for sealing coolant
Beading ledge
If the bolts of a
cylinderhead are loosing
the cylinder head gasket
must be replaced.
Metal inlay
Reinforcement
for compression chamber
Trade Theory Engine

Tighten cylinder head

Torque wrench
Adjustable

Scale Adjusting lever Torque wrench

For loosing and tighten
cylinder head bolts every
engine manufacturer
recommend a special
procedure.
Square-head drive
1/4, 1/2, 3/8, 3/4 or 1 “
Socket
Trade Theory Engine

Tighten cylinder head

Torque wrench with angle scale

Adjustable

Flexible arm Engine manufacturer give

Magnet
Instruction for tighten the
Degree scale cylinder head bolts
Adjusting lever
Example :
1. Thighten all bolts
with torque wrench
90 Nm
2. Let rest the bolts
for 10 minutes
Socket 3. Tighten all bolts 60
 Trade Theory Engine

Two-stroke Engine

First stroke Second stroke

Overflow /Exhaust Compression Combastion Exhaust

above
TDC
piston

BDC Exhaust
Intake

Overflow
duct
below
piston

Overflow Pre-suction Pre-compression Pre-compression/

Overflow
Trade Theory Engine

Rotary Piston Engine

Felix Wankel
1902 - 1988 History
The Inventor of the rotary piston principle
and functioal engine was the German Engineer
Felix Wankel. He was born on19.08.1914 in
Lahr nearby Heidelberg and died on 09.10.1988
in Heidelberg.
The first rotary piston engine started to run
on 01.02.1957. A lot of major vehicle-, engine-
and compressor manufacturers got the license
to produce and develop engines with this priciple.
After that the four-stroke rotary engines were
built-in in vehicles aircrafts and boats. Test were
made as petrol, Diesel and gas engine with
fuel injection, direct injection, single and double
sparkplug. The only manufacturer who produce
still the rotary engine is MAZDA.
The disadvantage of a rotary engine is :
- High fuel consumtion
- High output of emission
- Costly production
- Short life of piston rings
Refer to web-page : www.der-wankelmotor.de
Trade Theory Engine

Rotary Piston Engine

B Rotor housing A
Internal-geared
piston Suction
Center of
eccentric shaft
Compression
Eccentric shaft

Combastion
Coolant
Gear ratio 3 : 2 Exhaust

C D
Intake port

Eccentric
journal
Exhaust port

Gear is fixed Apex-seal

on housing Corner seal
Side seal
Trade Theory Engine

Rotary Piston Engine

Piston & Cylinder

Combustion chamber Intake port

Eccentric
bearing seat

Spark plug
Apex-seal

Intrnal gearing Coolant channel

Exhaust port
Trade Theory Engine

Rotary Piston Engine

Piston Ring

Rotary piston

Seal carrier

Apex-seal

Corner seal
Trade Theory Engine

Rotary Piston Engine

Eccentric shaft
Crankshaft