Engine Design Classification

1. Cylinder arrangement: Refers to the position of the

cylinders in relation to the crankshaft
 There are four basic cylinder arrangements:
 inline
 V-type
 slant
 Opposed/horizontal
2. Number of Cylinders
Most car and truck engines have either 4, 6, or 8
cylinders
Some may have 3, 5, 10, 12, or 16 cylinders
Engine power and smoothness are enhanced by using
more cylinders
Engine Design Classification Cont.
3. Cooling System Type
There are two types of cooling systems:
i) Liquid cooling system
surrounds the cylinder with coolant
coolant carries combustion heat out of
the cylinder head and engine block
ii) Air cooling system
 circulates air over cooling fins on the
cylinders
 air removes heat from the cylinders
Engine Design Classification Cont.
4. Fuel Type
Engines are classified by the type of fuel used
Gasoline engines burn gasoline
Diesel engines burn diesel fuel
Liquefied petroleum gas (LPG), alcohol (10% alcohol, 90%
gasoline), and CNG Engine can also be used to power an
engine
Engine Design Classification Cont.
5. Ignition Type
Two basic methods are used to
ignite the fuel in an engine
combustion chamber:
i. Spark Ignition (SI Engine), Uses
an electric arc at the spark plug to
ignite the fuel (petrol.)
ii.Compression Ignition (CI Engine)
(compressed air) Relies on high
pressure and temperature to ignite
fuel; commonly uses diesel.
Engine Design Classification Cont.
6. Camshaft Location
There are two basic locations for the engine
camshaft:
i. Camshaft located in the block (cam-in-block
engine). Also called an overhead valve (OHV)
engine
• Uses push rods to transfer motion to the
rocker arms and valves.
ii.Camshaft located in the cylinder head, (Cam
in cylinder head). Also called an overhead
cam (OHC) engine
Engine Design Classification Cont.
OHC engines may use one or two camshafts:
Single overhead cam (SOHC) engine
 uses only one camshaft per cylinder head
Double overhead cam (DOHC) engine
 uses two camshafts per cylinder head
 one cam operates the intake valves, while
the other cam operates the exhaust valves
Valve Timing Diagrams
 A valve timing diagram is a graphical representation of
the opening and closing of the inlet and exhaust valve
of the engine,
 The opening and closing of the valves of the engine
depend upon the movement of piston from TDC to
BDC,
 This relation between piston and valves is controlled by
setting a graphical representation which is known as
valve timing diagram
Valve Timing Diagrams Cont.
Valve overlap is when both the intake and exhaust valves are open at
the same time.
Engine designers aim to close the exhaust valve just as the fresh charge
from the inlet valve reaches it, to prevent either loss of fresh charge or
un-scavenged exhaust gas
The number of degrees of the crankshaft rotation by which the valves
(inlet and exhaust valve) open or close before top dead centre or
bottom dead centre is reached is known as valve lead
The number of degrees of the crankshaft rotation by which the valves
(inlet and exhaust valve) open or close after top dead centre or bottom
dead centre is known as valve lag
Tappet clearance
 The valve timing of a diesel engine also depends on tappet
clearance of the inlet and exhaust valves.
 If tappet clearance is less, then valve will open early and close
late.
 If tappet clearance is more, then valve will open late and close
early.
 Tappet clearance is measured by an instrument called feeler
gauge
Example
 Draw the actual valve timing diagram for four-stroke diesel engine when.
 The inlet valve opens 25° before the top dead centre. Fresh air is sucked into the engine
cylinder till the inlet valve closes.
 The inlet valve closes 35° after the bottom dead centre position. The air is compressed
till the fuel is injected, the air fuel mixture burns.
 The exhaust valve opens 40° before the B.D.C. position. The exhaust gases are forced
out of the engine cylinder till the exhaust valve closes.
 The exhaust valve closes 15° after the T.D.C. position.
Draw the valve timing diagram of this engine and calculate;
a. Valve overlap in degree
b. Inlet valve lead in degree
c. Inlet valve lag in degree
d. Exhaust valve lead in degree
e. Exhaust valve lag in degree
Given
Inlet valve opens 25° before The
Top Dead Centre (IVO – BTDC)
Inlet valve closes 35° after the
Bottom Dead Centre (IVC – ABDC)
Exhaust valve opens 40° before
Bottom Dead Centre (EVO - BBDC
Exhaust valve closes 15° after the
Top Dead Centre (EVC – ATDC)
Diagram of valve timing diagram
shown in Figure below
Valve overlap = 40° TDC
Inlet valve lead = 25°
Inlet valve lag = 35°
Exhaust valve lead = 40°
Exhaust valve lag = 15°
Cooling system
A feature of the internal combustion
engine is that it crates a large amount of
heat as the fuel burns, the temperature in
the cylinders can be as high as 1500-
2000c.
To prevent the engine from over heating. It
is important not to overcool the engine, a
cold engine can consumes too much fuel.
Heat Transfer
The principle of operation is based on the three means of heat transfer:
conduction, convection and radiation. Cooling of the engine takes place in this
sequence.
Conduction: Heat flows from a hot substance to a cold substance. The hot
internal parts of the cylinder pass the heat from one metal particle to the next
through the walls to the comparatively cool outer surface. Coolant in contact
with the metal surface receives the heat and carries it away.
Convection: This is based on the principle that as the temperature of water rises
from 4°C, it gets lighter, i.e. its density decreases as the temperature increases.
Coolant in the water jacket becomes heated, and since it becomes lighter it rises
to the top of the jacket and flows through the header hose to the radiator.
Radiation: Heat travels through air in a wave form similar to light. cold air is
continuously supplied to the radiator through vehicle motion or using a fan, and
thus heated air is also carried away.
Cooling system
Engine Cooling System
The main functions of cooling system are
 To regulate the engine operating
temperature
 To increase the efficiency of engine
 To provide heat for other devices as the
manifold Heater and the automatic
choke
Cooling System
Types of Cooling System
Engine cooling system are
classified as either
Air-cooled
Liquid cooled
Liquid Cooling Engine
Air-cooling Engine
Air-cooled Engine
 This system is being used on both two and four stroke cycle’s
engines
 It is commonly used on motorcycle, airplane and other
applications
 Air cooled engines have cooling fins or ribs on have outer
surface of the engine which are cast into both the cylinder
block and cylinder head
 The purpose of fins is to increase the surface area of the
hottest parts of the engine and to help the flow of heat into the
passing air.
 The air –cooled engine is completely enclosed by a cover or
cowling. This is to allow an engine driven fan to circulate air
so that the engine is cooled evenly.
Air cooling system components
Air Cooling Engine
Air Cooling Engine
Advantages of air –cooled
 The system is free from leakage problems and
requires no maintenance
 The engine warms up to its normal running
temperature very quickly
 The engine can operate at a higher temperature
than a water-cooled engine
 The air-cooled engine should generally be
lighter than the equivalent water-cooled engine
Disadvantages air – cooled
 The engine is more liable to overheating under
normal combustion than a water-cooled engine
 Mechanical engine noises tend to be amplified
by the fins
 It is more difficult to arrange a satisfactory car
heating system
 The cylinders usually have proper formation of
the fins. This makes the engine more costly to
manufacture.
Water cooling system
Liquid Cooling System
The liquid used to carry heat away from the cylinders
and heads is almost invariably water, to which may be
added certain chemicals.
Common types of liquid cooling system are thermo-
syphon, Pump circulation systems and Sealed cooling
systems.
Modern vehicles rely on Pump circulation systems and
Sealed cooling systems.
Liquid-Cooled System - Thermo Syphon System
This was the earliest type of cooling system. It
is a natural circulating type which relied on
convection currents to circulate the coolant as
there was no pump.
In the thermo-syphon system when the coolant
in the water jacket becomes heated and since
it become lighter it will rise to the top of the
jacket and flows through the header hose to
the radiator.
Thermo-Syphon Components
Liquid-Cooled System – Thermo-Syphon System
The hot water in jackets with be
replace by colder water fed in from
the lower tank of the radiator when
the flow is combined with the
upward flow in the jacket a natural
circulation of the coolant is achieved
which called convection.
Thermo-Syphon System
Pump Circulation Cooling System
The main features of this cooling system
are the fitting of an engine driven water
pump to circulate the coolant and the
provision of the both a thermostat and a
pressure filler cap.
Pump Circulation Cooling System
Pump Circulation Cooling System
Radiator
The purpose of the radiator is to proved a means of reducing
the temperature of the engine cooling (water)
Construction
The basic construction of a radiator consists of upper or
header tank, lower (bottom) tank and radiator core which
attached to the upper and lower tanks. The core allows the hot
coolant to be cooled by surrounding air.
The two types of radiator cores are the
Tube and fins type
Cellular or film type
The flow of the coolant through a radiator can be from either
top to bottom (vertical flow) or side to side (cross flow)
Radiator Construction
Vertical Flow And Side To Side (Cross Flow) Radiator
Radiator
Cross Flow Radiator
Radiator Tubes and Fins
Radiator Cap
The cap allows access to the
cooling system for filling and
testing.
The cap has two valves: a pressure
relief valve set at around 15 PSI
and a vacuum valve which is
needed when the engine cools
down.
Raises boiling point of fluid
Able to take on more heat
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Radiator or Filler Pressure Cap
This used to maintain the pressure of the coolant at required setting
pressure
Radiator cap
Radiator or Filler Pressure Cap
Coolant Recovery Tank
 Keeps the coolant level full in the
system at all times.
 Works in conjunction with the
radiator cap.
 When the engine heats up the
coolant expands and flows to the
recovery tank.
 When the engine coolant the
coolant contracts and creates a
vacuum and draws the fluid back
into the radiator.
 Reduces air in system
 Reduces rust
 Less need to open radiator
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The Thermostat
This is a device used to control the
flow of coolant to the radiator until
the engine reaches its operating
temperature
There are two types in common use
The bellow types
The wax element thermostat
Thermostat
Controls coolant temperature.
Uses a temperature sensor and a valve.

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Thermostat
Thermostat
Water pump
 The water pump is the heart of the cooling
system.
 Most engines use a centrifugal water pump
that provides a large volume capacity and is
nonpositive in displacement.
 This type of pump has an impeller with
blades that force the coolant outward as the
impeller rotates.
Water Pump Construction
Water pump
The shaft on which the impeller is
mounted is usually driven by a fan belt
and revolves in a bushing or in ball
bearings inside the housing.
For different cooling systems, pumps
vary considerably in construction of
seals, bearings, mounting and drive.
Water pump
Water Pump
 Non-positive displacement
pump which circulates
coolant around cooling
system.
 Simple impeller design.
 Usually driven by drive
belt from crankshaft.

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Cooling Fans
The purpose of a cooling fan is to force or draw
additional quantities of air through the radiator
core
Three of the most popular types of cooling fan
are
Direct drive fans
Electrically driven fans
Viscous coupling fans
Radiator Fan (Electric Fan)
Fan belt
 The belt provides a simple means of
driving the alternator and water
pump.
 The two most common types of fan
belt fitted to the vehicle are the vee
belt and the ribbed vee belt.
Temperature Gauge
A temperature gauge is one of the most
important sensor gauges on any vehicle with
an internal-combustion engine that uses a
radiator and cooling jackets.
Temperature directly affects combustion and
moving internal parts.
 Without a temperature gauge, the engine would be
subject to overheat and damage the engine
Temperature Gauge
A temperature gauge is an
electrically operated measuring
device to give visual indication of
the engine operating temperature
Also known as A coolant
temperature sensor (CTS) or engine
coolant temperature sensor (ECT)
Temperature Sensor And Gauge
Coolant Temperature Sensor (CTS)
Reports to computer
Gauges
Location
Block
Head
Radiator tank

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Advantage and Disadvantage
Advantage of water-cooling system
The water and jacket deaden mechanical noise
Temperature throughout the engine are more uniform
Cylinders can be placed close together and engine made
compact and engine made compact

Disadvantage of water-cooling system

There is a constant risk of leakage of the coolant
A certain amount of maintenance is need
The engine heavier than an equivalent air-cooled engine.
Engine Coolant
A coolant (also called an antifreeze) is a special fluid
that runs through engine to keep it within its correct
operating temperature range.
It is made from either ethylene glycol or propylene,
water, some protection additives and is usually green,
blue or even pink in color.
Engine Coolant
Cooling System Inspection
Check coolant level. Check belt tension.
Check belt condition.
Check coolant condition.
Check hose condition.
Leak check system. Blow out radiator fins.
Check radiator cap. Check thermostat.
Check water pump Check radiator fan.

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