Aim: To study the constructional detail of I.C.Engine.

Introduction:
The main parts of automobile engine are
1) Cylinder block & crank case.
2) Cylinder head
3) Sump & oil pan
4) Manifold
5) Gasket
6) Cylinder
7) Piston
8) Piston ring
9) Connecting rod
10) Crank shaft
11) Main levering
12) Crankshaft pin
13) Valve and valve actuating mechanism
14) Muffler
1) Cylinder blocks & crank case
In houses the engine cylinder which leavers bearing and guide for the piston reciprocating
in them around the cylinder.
Circulation of coolant, lubrication provided through drilled holes called as oil galleries.
The function of crankcase is to provide support for the main ground and bearing of
crankshaft. The construction of crankshaft has to such to provide reaction for the heavy forces set
up due to gas.
Fig. shows bottom view of cylinder block and crankcase showing main bearing housing to
support crankshaft.
At the top there is cylinder head attached to it, besides other parts like liming gear h2o pump
ignition diffuse, flywheel, pump etc. also attached to it.
The function of cam shaft is to change opening and closing of inlet and exhaust valve for
each cylinder crankshaft may be mounted to the cylinder block or head. It is always placed
parallel block or head
When in cylinder block it is mounted on to the one side of the cylinder either lowdown just
above the crankshaft or slightly below the cylinder head.

The cylinder block it is mounted on to the one side of the cylinder for good lubrication and
proper ring setting.
2) Cylinder head:
It is attached to the surface of cylinder block deck by means of study fixed to cylinder
block the gasket is used to provide a tight leak air at the interference of the head and blocks.
In forms a combustion chamber above each cylinder it also contains have guide valve seats
and cooling ports like water jacket and threaded holes for spark plug or injector.
Types of cylinder head
a) Loop flow type
b) Offset across flow type.
c) Unlined cross flow type
Material: C.I. and aluminum alloy
3) Oil pan:
Oil pan or sump from the bottom half of the crankcase. It is attached to the crankcase
through set screw and with a gasket to make the joint leak proof.
Function:
a) To start the oil for engine lubrication system.
b) To collect return oil carrying from bearing or walls of crankcase.
Construction:
The sump has a shallow downward slope at one end which merges deep narrow reservoir at
often end. Inside the sump bottle, usually provide to reduce oil surfing during turning to
automatic to drain out dirty oil is provided.
4) Manifolds:
These are separate sets of pipes attached to the cylinder head which carry the air fuel mixture
and exhaust gases. These cases are called manifold.
Construction:
In the air fuel mixture comes from the carburetor to the cylinder. The shape and size of the
inlet manifold such that it should prohibit the formation of fuel droplet without restriction the air

flow. The exhaust manifold is set of pipes carrying exhaust system. The exhaust manifold is
designed to minimize restriction to the flow of exhaust gases.
5) Gaskets:
These are used to provide a light fitting joint between two surfaces.
E.g. the join between cylinder head and block between crankcase and oil pan.
Requirements :
Confirming provision of operator.
Resistance impermeability.
Resistance to chemical attachment.
Resistance to operating condition
Material: asbestos, rubber etc.
6) Piston:
To transmit the forces at expansion to crankshaft.
To form a seal so that high pressure gases from combustion chamber should not escape into the
crankcase.
To serve at a guide and bearing for small end of connecting rod.
Characteristics:
It should be silent in operation both during work and normal running
Long life
Shortest possible length is resulting into small engine.
Construction
The top of the piston is caused as head or crown, generally low cost, low performance engine
have that head.
In some causes when piston is closer to the wall head is provided valve piston is used
sometime piston is designed to form a desired shape of combustion chamber along with cylinder
head.
Towards the top of the piston a few groves on cut to house the piston ring.

The lands support the engine rings against. The gas pressure and guide to that they may flux
freely.
In radial direction, the supporting vens transmit the force of expansion directly from the crown to
piston pin thereby the deformation of ring grooves.

Aim: To study the ignition system I.C. engine.

Introduction:
Ignition is nearly a prerequisite of combustion is considered from standard point of view. The
beginning of combustion process it indicates of combustion. The ignition process must add
necessary energy for starting and sub standing burning of fuel till combustion takes place on
ignite process can be considered at ignition of burning is as small spherical called min. volume.
Basic requirement of spark ignition system
1) The system must have source of electrical energy
2) The system must supply sufficient electric current to create high energy of spark to ignite
mixture.
3) The system produces a spark voltage great by small margin by then spark plug breakdown
voltage at all speed.
4) Duration of spark must be long enough with mixture has a high change of occurring.
5) They must distribute this high voltage to each of spark plug of exact time in every cycle.
Basic ignition system
1) Battery ignition system
2) Magnetic ignition system
3) Electric ignition system
1) Battery ignition system
The ignition will consist of two coils one primary and other secondary. The primary winding is
connected to spark plug through distributer. A typical ignition coil has to 100-200 no. of turns in
primary winding and 2000 no. of turns in secondary windings.
The primary coil has ignition switch, primary winding distributor frame and the secondary
winding has secondary spark plug, distributer, distributor cap etc.

Sr.no.

primary circuit

secondary circuit

ignition switch

secondary winding in ign.

resistance unit

coil to distributor rotor

primaries winding in ign. Coil

distributor rotor

distributor contact point capacitor

distributor cap

low voltage. Wiring

high voltage. Cable in ign. Coil

A ballet resistor is provided in series with primary winding for regular primary current for
starting torque. This resistor is by speed so that more current can flow in primary circuit.
A cam rotating at crankshaft contact bracket and cases the brake pt. to open and close when
ignition switches to is on contact breaker pt. are closed and current passes with battery through
primary winding and build up a magnetic field.
In order to obtain highest voltage in secondary circuit a quick collapse in magnetic field is
essential.
It is also necessary to prevent ordering and can sequent pt. these are achieving by providing a
condenser across the backer.
Due to rapidly collapsing magnetic field high voltage is induced in the primary circuit. A highest
voltage is at the order of 11 kW.
This voltage is highest than breakdown voltage. A spark occurs in spark plug to spark plug gap
causing ignition of combustive.
2) Magnetic ignition system
Magnetic is a special type of electric generator. It is mounted on engine and replaces all
components expect spark plug.
Fig. shows the schematic diagram of a high tension magnet incorporate in itself winding to
generator as well as a stop up voltage. Thus does not require a separate to boot up voltage.
Magnet can be either rotating armature type of rotating magnetic type. In first type armature
consisting of primary and secondary winding condenser all rotate between poles of speed
winding.
The operation of magnetic ignition system is exactly same as that of battery ignition system. In
that bracket point are opened and closed with the help of cam.

Comparison
Battery ignition system

magnetic ignition system

1) When battery is discharged it

1) no battery is needed here there is

Is impossible to start engine

no problem of battery discharge

2) Current in primary circuit

Is obtained from battery

2) the required current is obtained

magneto ignition system.

Starting system
The starting system is the part of electrical system in automobile. It consists of battery starting
system solenoid system.
When key is inserted ignition switch and turned to start position. A small amount of current
passes through a neutral battery cable to starter relay to flow through battery cable to start motor.
The starter motor then cranks when engine so that the piston moving downward cylinder.
That draws air fuel mixture into cylinder creating spark by ignition system mix. Is high enough
and all this happens of the right time the engine will start?
Starting motor:
I.C. engine are not self-starting ,they need to rotate for few cycle by external device known as
starting or cranking the engine meant to crankshaft by applying torque on it so that piston to get
reciprocating motion. The motor is mounted on engine to operate on large at low voltage. The
motor used in passenger car draws about 60 amps. When turning as no load and about 600 amp
when cranking for few seconds only. The mechanical construction of motor is very similar to
generator but their function is different.
Driver used for starting
1) Inertia drive
a) Bendix drive
d) Follow through drive.
2) Over running clutch.

Aim: study of carburetor.

Objective: to study the constructional details and working of solex carburetor.
Theory:
The carburetor is a drive which mixes air fuel mixture and supplies the correct amount to the
engine according to requirement. It is a device which atomizes the fuel and mixes it with air
varying proportions to meet the changing operating condition of automotive engine.
It is the most important part of injection system some imp carburetor being used in the
automobile are.
1) Zenith carburetor
2) Solex carburetor
Solex carburetor:
The solex carburetor is famous to each of starting good performance and reliability.
It is made on of solex carburetor.
Fig. shows a schematic arrangement of solex carburetor. The unique feature of this solex
carburetor are described, circuit of solex carburetor.
a) carburetor :
the solex carburetor conventional floats in a float chamber, for normal running fuel is provided
by main jet passes to the air entering fuel is automatically insured by air entering through a being
by corrosion jet.
The emulsion of fuel and air is spraying through the orifice or nozzle drilled horizontally in
vertical standard pipe in the middle of the chock tube or venture.
b) Cold
The starter valve is in the form of float with hole of different size. These holes are connected to
the petrol jet and starter air jet side of the passage open into a hole just below the throttle valve.
c) Idling and slow running
Further lower part of the wall of the emulsion system a hole leads to pilot jet. At the idling the
throttling is almost to closed and hence engine section is applied at the petrol jet.

The slow adjustment skew allows speed of engine to be varied.

d) Acceleration:
To avoid float spot curing acceleration a diaphragm type acceleration pump is provided. The
delivery ports of extra fuel needed for through the pump jet.

Aim: to study the fuel injection system of diesel engine.

Introduction:
The fuel injection is a vital composing the working of C.I. engine. The injection system has to
perform imp duty of ignition and controlling the combustion process. In a duel injection system
amount of fuel delivered in the air system going to engine controlled by pump which forces the
fuel injected into combustion chamber towards end of compression stroke. It is atomized into
heat transfer from the pump reaches a valve higher than its self-ignition temperature.
Functional requirement of ignition system:
For a purpose running and good performance from engine the following requirement must be
made by the ignition system.
1) Accurate metering of fuel injected per cycle mete errors may be caused drastic variation from
the desired output.
2) Timing of the ignition of fuel carefully in the periodic cycle, so that max. Power is obtained
ensuring fuel economy and clean burning.
3) Proper control a rate of injection so that the desired heat release pattern is achieving desired
combustion.
4) Proper atomization of fuel into every fine droplet.
5) Proper spray pattern to ensure rapid mixing of fuel and air.
6) Uniform distribution of fuel droplets throughout the combustion process.
7) To supply equal quantity of meter of fuel into oil cylinder in case of multi cylinder system
engine.
8) No long during beginning and end of injection.
Classification of injection system:
The function of fuel injection system is to inject required qty. of fuel into engine cylinder at the
correct time and predicted rate.
There are two types of fuel injection system
1) Solid fuel injection
2) Air injection system.

1) Solid injection system:

In this system the liquid fuel is injected into combustion on chamber without the compressed air,
hence its a seld injection system.
Every solid fuel injection system
1) Pressuring unit (pumps)
2) Atomizing unit (injector)
The different types of solid injection system vary in the manner that the operation and control
are thus basic two units.
1) Individual pump and injection system
When fuel injector pump when inject definite quantity of fuel individual cylinder in turn
according through firing order through injector fitted on turn. The injection pump is gear driven
from engine camshaft so that it drives at half the engine speed. Any excess fuel supply from
nozzle is returned to fuel tank such a fuel system is used in swornuda engine and is shown in fig.
2) Common rail fuel injection system
This type of fuel injection system is used in diesel engine commonly known as timely diesel. In
this a single injection pump with injector are operated by rocker man and pump similar to the
engine valve. A linkage connects to the rods of all injector.
Disadvantages:
1) Required in high pressure multistage compressed the large no. of parts like compressor ,
interworked etc. make the system heavy and expensive.
2) A separate mechanical linkage is required to operate fuel valve.
3) Fuel valve required considerable sealing.
Bosch fuel injection system
It consist of barrel in which a plunger reciprocate when driven by a camshaft plunger has a
constant stroke between plunger and barrel there is very small clearance. The pump barrel has
two reading opposite holes .these is inlet and control part of the plunger at top.
Operation
When plunger is at bottom of its stroke the flow through pipe enters into barrel and fill the space
above the plunger and also groove and space below helix.

When plunger start above certain amt. of fuel given out of fuel chamber through the pipes until
the plunger reaches to position of chamber through closes a part on further upward movement of
the plunger.
So that injector in all the cylinder are equal and simultaneously controlled ,fuel lines are
necessary in the common rail injection system excess fuel from nozzle is required of common.
The disadvantages of common rail system are that in case of injection needle striking in an open
position and excess amt. of fuel injected on various cylinder. This system also required that the
nozzle for different cylinder must be accurately notched for ensuring good fuel injection between
various cylinders.
3) Air injection system:
The fuel is metered and pumped through the camshaft driven pump. The fuel valve is also
connected to a high pressure air lined with multistage compressor which supplies air at pressure
of about 50-70bar.
Advantages:
1) The main advantages of air injection system is high pump fuel can be obtained and due to
good mixing
2) Heavy and viscous fuel which cheaper can be injected.
3) The fuel pump required to develop the small pressure.
The frapped fuel is compressed and forced out through the delivery valve to the pipe leading to
injector which is immediately injected into the combustion chamber. The injection process
continuous till the end of the helix up covers the spill back via vertical loaded delivery valve of
injector closed suddenly.