INTERNAL

COMBUSTION
ENGINES

SECTION 1

AN INTRODUCTION TO
INTERNAL COMBUSTION
ENGINES

AN INTRODUCTION TO INTERNAL
COMBUSTION ENGINES
Introduction:Internal combustion engines are engines which burn fuel in a cylinder
to produce power.
In section 1, the principles of the internal combustion engine, its
general operation and parts are discussed.
The difference in combustion cycle of 2-cycle and 4-cycle engine, some of
more common cylinder arrangements is discussed.
In section 2, the details of construction of an IC engine, including the
camshaft, carburetor, natural gas admission system, safety devices and the
electrical system are discussed. Functions of these parts in the total engine,
the principle of a diesel engine, its operation and its difference from
traditional IC engine are also discussed.
In section 3, the details of the auxiliary systems, their operation,
including the cooling system, lubrication system, air cleaners, superchargers
and exhaust system are discussed.
In section 4, the operation and maintenance of engine is discussed.
How to read an instrument panel and interpret readings, typical engine startup and shut down procedure, some preventive maintenance procedures for
daily, weekly, and monthly checks are also discussed.

AN INTRODUCTION TO INTERNAL
COMBUSTION ENGINES
1.

An object needs a push to move it; this push is called force.

Work is done when a force.something to a distance.

Moves
2.

Anything which can do work has energy.

Water jetting out of the nozzles makes this lawn sprinkler..

Rotate / Turn
3.
The moving water has energy, and this energy is making the sprinkler
shaft
Rotate
4.
This rotation is mechanical energy.
This mechanical energy is available to do
Work
5.

Heat flows from a hotter object to a cooler object.

This flow is .
Heat

6.
This flow of heat is called thermal energy.
Thermal energy, like mechanical energy, can be used to do ..
Work
7.
Combustion occurs when fuel and oxygen combine chemically and
give off heat.
Burning gasoline gives off heat, which comes from chemical energy in the
..
Gasoline / Fuel
8.
A centrifugal pump can be driven by coupling its shaft to the shaft of
an IC engine.

The engine is producing and delivering to the pump.

Energy / Horsepower
9.
We want the pump to move more liquid.
The engine driving the pump must deliver (More / Less) HP to the pump.
More
10. We want the pump to move the liquid faster, so we increase the speed
of the pump.
The engine must produce .power.
More
11. Machines A and B are the same size. Machine As shaft turns at 300
rpm. Machine Bs shaft turns at 800 rpm.
The HP delivered by machine (A / B) is greater.
B
12. Machine A and B both operate at 1000 rpm; machine A is larger.
The HP delivered by machine (A / B) is greater.
A
13. HP depends on how much work is being done and on how it is
done.
Fast

14. Machines can be efficient or inefficient.

If a centrifugal pump transfers 90% of the HP from the engine to the liquid
being pumped, it is (More / Less) efficient than a pump which transfers only
50% of the HP to the liquid.
More
15. The mechanical efficiency of a machine depends on how much work
it can produce from the . supplied to it.
Energy / HP
The Internal Combustion Engine
16. The IC engine produces work by burning fuel.
The IC engine uses (Heat / Mechanical) energy to produce mechanical
energy
Heat
17.

The heat is produced by ..the fuel.

Burning

18. The engine uses this heat energy to rotate a shaft.

Heat energy is changed to (Mechanical / Electrical) energy.
Mechanical
19. Pumps and compressors are often driven by the power produced by
the IC engines.
The rotating shaft of the engine can be coupled to the ..or to the belt
drive of a pump or compressor.
Shaft
20. The rotating shaft of the engine makes the shaft of the compressor or
belt drive .
Rotate
21.

Combustion occurs when a mixture of fuel and oxygen is ignited.

The three elements needed for combustion are ., ..and a

source of ..
Fuel, Oxygen, Ignition

22. If anyone of these three elements is missing, combustion (Can /

Cannot) occur.
Cannot
23.

The most common source of oxygen is the

Air / Atmosphere

24.

A fuel-oxygen mixture contains carbon, hydrogen, and oxygen.

METHANE + OXYGEN = CARBON DIOXIDE + WATER

When a fuel-oxygen mixture is , the carbon, oxygen, hydrogen unite

chemically to form carbon dioxide gas and water.
Ignited / Burned
[

25.

The combustion produces .as well as gas and water.

Heat

26.

The temperature of the gas is (Increased / Decreased) by combustion.

Increased

27. The IC engine is a machine which harnesses the energy in the fuel to
produce work.
Chemical energy is changed to heat energy; then this heat energy is changed
to energy.
Mechanical
28.

Lets Review:

A rotating shaft has (Heat / Mechanical) energy.

Mechanical
An IC engine uses ..energy to produce mechanical energy.
Heat / Thermal
The engine produces this heat energy by ..an air fuel mixture.
Burning / Igniting
The HP a machine produces is the amount of .a machine does and
how.it does it.
Work, Fast

29.

The three elements needed for combustion are:

a.
..
b.
..
c.
..
Fuel, Air / Oxygen, Ignition

Principles of the IC engine

30.

This gas has been ignited in a closed container.

The hot gas expands and pushes out on the container walls with (Great /
Little) force.
Great
31. This outward push is called pressure; this pressure energy can do
mechanical work.

High pressure gas expands in this cylinder and pushes the piston (Upward /
Downward)
Downward
32.

This piston movement is (Mechanical / Chemical) energy.

Mechanical

33.

An IC engine basically consists of a piston housed in a .

Cylinder

34.

Expanding gas in the cylinder, forces the ..to move.

Piston

35.

The piston rotates a crankshaft, through the connecting rod.

The piston pushes down on the which turns the crankshaft.

Connecting rod
36. The crankshaft rotates and delivers energy to a pump or compressor.
The crankshaft gets its energy from the moving
Piston
37. The piston gets its energy from the expansion of the burned.
Gas
38.

The energy stored in the fuel is released by .. the fuel.

Burning

39. First, chemical energy becomes energy, then

heat energy produces high gas..,
high-pressure gas moves the ,
the piston turns the crankshaft, which delivers ..energy to a pump or
compressor.
Pressure, Piston, Mechanical
40.

Lets Review by naming the parts of this engine.

A.
B.
C.
D.
41.

Cylinder
Piston
Connecting Rod
Crankshaft

The combustion chambers for an engine are the cylinders.

The cylinders are actually holes bored through a metal casting called the
engine..
Block
42. Each cylinder houses a .., which is free to slide up and down in
the cylinder.
Piston
43. The piston fits closely to the cylinder walls.
Close clearance and a set of rings on the piston make a tight .between
the piston and the cylinder walls.
Seal / Fit
44.

The piston is attached to the connecting rod by a wrist pin.

The wrist pin (Allows / Does not allow) the connecting rod to pivot on the
piston.
Allows

45. Since the connecting rod is pivoted on the piston, it can move from
side to side.
But the piston itself can only move and .in line with the
cylinder.
Up, Down
46. The other end of the connecting rod fits on one of the cranks, which is
part of the..
Crankshaft
47.

When the piston is moved, the connecting rod..

Moves

48. The connecting rod fits on the crankshaft.

When the connecting rod moves, the crankshaft .
Moves / Rotates
49. The piston moves in a back-and-forth (reciprocating) motion. The
connecting rod transfers this reciprocating motion of the piston to the
crankshaft.

The crankshaft (Rotates / Moves back-and-forth).

Rotates
50. The reciprocating motion of the piston and the connecting rod is
changed to the..motion of the crankshaft.
Rotary
51. A multi-cylinder engine contains more than one crank.
All the cranks and connecting rods are mounted on a single ..
Crankshaft
52.

The cylinders are holes bored into the engine block.

The tops of the cylinders are covered with a cylinder .

Head
53. The cylinder head contains holes for the valves and the spark plugs.
The holes are bored in the cylinder ..
Head
54. Flow of gas into the cylinder and out of the cylinder is controlled by
the ..
Valves
55. The spark plug ..the air-fuel mixture which enters into the
cylinder through the valves.
Ignites
56. The lower part of the engine block and the oil pan make up the
, which surround the crankshaft and the cranks.
Crankcase

The Combustion Cycle

[

57.

The distance a piston moves in one direction is called a stroke.

A piston traveling from the head end of a cylinder to the crank end
completes one ..
Stroke

58. A combustion cycle begins with the piston at the head end of the
cylinder.

As the piston begins to move down toward the crank end, the (Intake /
Exhaust) valve opens.
Intake
59. The moving piston creates a low pressure area behind it.
When the pressure inside the cylinder is (Higher / Lower) than the pressure
outside, the fuel air mixture (charge) rushes into the cylinder.
Lower
60.
This downward stroke is called the intake stroke.
At intake, the piston is moving toward the (Head / Crank) end of the
cylinder.
Crank
61. During the intake stroke, the intake valve is and the exhaust
valve is ..
Open, Closed
62. The piston reaches the bottom of the cylinder.
The rotation of the .starts the piston moving back toward the head
end.
Crankshaft
63. Now, both valves are closed.
Since the charge cannot escape through either valve, the gas is compressed
and the pressure in the cylinder (Increase / Decrease)
Increase
64. This is the compression stroke.
When the piston reaches the head end again, the spark plug.the highpressure charge.
Ignites

65.

Burning causes the gases to get hot and .

Expand

66. The expanding gases push outward and force the back down to
the crank end.
Piston
67. This is the power stroke.
At the end of the power stroke the piston is at the bottom of the cylinder and
the cylinder is filled with expanded, burned ..
Charge
68. To start the cycle over again, these gases must be pushed out of the
cylinder.
The valve opens, and the piston pushes the gas out of the cylinder
into the exhaust system.
Exhaust
69. This is the exhaust stroke.
Now, the piston is in position to start a new cycle with of a fresh
charge.
Intake
70. Energy from combustion is applied to the piston only during the
stroke, when the fuel is being burned.
Power
71. During the other three strokes, the piston is moved by the ..of
the crankshaft.
Rotation
72. A heavy flywheel at the end of the crankshaft provides the momentum
needed to keep the crankshaft..between power strokes.
Turning / Rotating
73.

As the crankshaft turns, the flywheel stores and releases energy.

Thus, the flywheel produces a smooth and continuous of the

crankshaft.
Rotation / Motion
74.

Most engines have more than one piston turning the same crankshaft.

In this 4-cylinder engine, each piston is at (A different / The same) stroke at

the same time.
A different
75. In a multi cylinder engine, the crankshaft is built so that at least one
power stroke is always occurring.
This makes the job of flywheel much
Easier
76. The power stroke of a (Single / Multi-) cylinder engine is staggered to
provide a smooth, more efficient power engine.
Multi[

Cylinder Arrangement
77.

Cylinder arrangements are different in different engines.

In the (V-arrangement / In-line arrangement) the cylinders are upright and in

a single row.
In-line arrangement

78. In the V-arrangement, the cylinders are arranged in.banks

which are at an angle to each other.
Two
79. A V-8 engine has 8 cylinders.
Large industrial engines may produce more power by havingthan
eight cylinders or by having ..cylinders.
More, Larger
80.

An engine used to drive a compressor may be in one internal unit.

This IC engine is driving a (Rotary / Reciprocating) compressor.

Reciprocating
81. The engine piston drives the compressor piston.
They share the same
Crankshaft
82. When the piston of the engine moves either way, the piston of the
. moves with it.
Compressor
83. This angle machine is a single-unit engine and compressor.
[

Energy is transmitted from the pistons of the engine to the compressor

pistons through (A shared crankshaft / Two separate crankshafts).
A shared crankshaft

84. The energy of the moving pistons may also be adapted to drive
machines which require rotary motion instead of back-and-forth motion.
Then the crankshaft of the engine can be coupled to drive.of the
driven machine.
Shaft
85.

Lets Review

The combustion cycle of an IC engine consists of four events:

Intake, compression, ....., and
Power, Exhaust
86.

Look at this drawing.

This engine uses.piston stroke for each single event in the

combustion cycle.
One
87.

This engine is called a (2-cycle / 4-cycle) engine.

4-cycle

2-Cycle Engine
88. A2-cycle engine completes the four combustion events in only two
strokes.

In this small, single cylinder 2-cycle engine, the piston acts in place of
valves, by covering and uncovering .in the cylinder wall.
Ports
89.

A 2-cycle engine is (Like / Different from) a 4-cycle engine.

Different from

90. The crankshaft of this engine rotates in an air tight crankcase.

An intake valve lets the air-fuel charge into the from the intake
manifold.
Crankcase
91. The charge is then forced into the cylinder under .from the
crankcase.
Pressure
92. During each upward stroke, the piston draws a new charge into the
crankcase through the manifold.
During each downward stroke, the piston forces this charge into the cylinder
through the manifold.
Intake, Inlet
93. When the charge is ignited on the power stroke, both the inlet port and
the exhaust port are covered.
As the expanding gases force the piston downward toward the bottom of its
stroke, both ports are.
Uncovered
94. The exhaust port is uncovered first, and the expanding exhaust gases
rush out of the exhaust port.

As the piston moves on downward, it uncovers the intake port and the
compressed charge in the crankcase.the cylinder.
Enters
95. When the piston reaches the top, both ports are covered and the
charge is ..again.
Ignited
96. In most industrial 2-cycle engines the charge is forced into the
cylinder under pressure from a separate source.
This intake pressure is maintained high enough to overcome the high
pressure present in the cylinder when valve is uncovered.
Exhaust
97. The piston of a 4-cycle engine produces power every 4 revolutions of
the crankshaft.

Each piston of a 2-cycle engine produces

revolutions of the crankshaft.
One / Single

power

with

every

98. In small 2-cycle engines the intake port and the exhaust are both open
during part of the exhaust and intake cycle, so fresh fuel may be swept out of
the cylinder with the.
Exhaust
99. Since most large multi-cylinder 2-cycle engines have valves which
control fuel injection until the intake port is closed, no..is lost with
the exhaust in a large 2-cycle engine.
Fuel
100. Because it requires more fuel, the small 2-cycle engine may be (More /
Less) efficient than the 4-cycle engine.
But most large 2-cycle engines have about the same fuel consumption and
as compared to 4-cycle engines.
Less / Efficiency
101. The 2-cycle engine gives twice as many power strokes as the 4-cycle
engine.
Thus the power output of a 2-cycle engine is about (Twice / Half) that of a
4-cycle engine of the same size.
Twice

Review And Summary

102. Look at these two engines.

This is a (2-cycle / 4-cycle) engine.

4-cycle

This is a (2-cycle / 4-cycle) engine.

2-cycle
103. Name the lettered parts of this IC engine.

A. Head
B. Piston
C. Connecting rod
D. Cylinder
E. Crankshaft
F. Crankcase
a. The piston gets its energy from the high-pressure
Gas
b. The piston and the connecting rod move up and down.
The crankshaft .
Rotates
c. A pump can use this mechanical energy of the rotation of the
crankshaft if its..is coupled to the crankshaft.
Shaft