Mazda Technical Service Training Piston Engine Fundamentals
Mazda Technical Service Training Piston Engine Fundamentals
Mazda Technical Service Training Piston Engine Fundamentals
LEVEL F
Piston Engine
Fundamentals
TC010-05-01S
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Piston Engine Fundamentals
CONTENTS TC010-05-01S
1 – INTRODUCTION ............................................................................ 1
Course Overview .................................................................................. 1
Audience and Purpose................................................................... 1
Course Content and Objectives ................................................. 2
2 – BASIC OPERATION....................................................................... 5
Objectives ............................................................................................. 5
How Power is Developed ...................................................................... 6
Harnessing Power.......................................................................... 6
Controlling Combustion.................................................................. 7
The Four-Stroke Cycle .......................................................................... 9
Intake Stroke................................................................................ 10
Compression Stroke .................................................................... 11
Power Stroke ............................................................................... 11
Exhaust Stroke ............................................................................ 11
Summary ..................................................................................... 12
Review Exercise 1 .............................................................................. 12
Basic Design Characteristics .............................................................. 13
Cylinder Configuration ................................................................. 14
Valve Train Type.......................................................................... 15
Bore, Stroke, and Displacement .................................................. 17
Compression Ratio ...................................................................... 18
Engine Components and Systems...................................................... 19
Review Exercise 2 .............................................................................. 19
page i
Piston Engine Fundamentals
CONTENTS TC010-05-01S
3 – SHORT BLOCK............................................................................ 21
Objectives ........................................................................................... 21
Overview ............................................................................................. 22
Cylinder Block ..................................................................................... 23
Construction................................................................................. 24
Crankcase.................................................................................... 24
Crankshaft Main Supports and Bearings ..................................... 24
Crankshaft........................................................................................... 25
Features....................................................................................... 26
Construction................................................................................. 27
Number of Journals...................................................................... 28
Vibration Damper ......................................................................... 28
Main Bearings ..................................................................................... 29
Lubrication ................................................................................... 30
Clearance .................................................................................... 31
Thrust Bearings ........................................................................... 32
Review Exercise 3 .............................................................................. 32
Connecting Rods ................................................................................ 34
Construction................................................................................. 35
Cylinder Wall Lubrication ............................................................. 35
Pistons ................................................................................................ 36
Construction.................................................................................
Clearance .................................................................................... 37
Piston Rings........................................................................................ 39
Compression Rings...................................................................... 40
Oil Rings ...................................................................................... 41
Review Exercise 4 .............................................................................. 42
page ii
Piston Engine Fundamentals
CONTENTS TC010-05-01S
Valve Springs...................................................................................... 50
Construction................................................................................. 51
Spring Tension............................................................................. 51
Working Height ............................................................................ 51
Overhead Valve Train ......................................................................... 52
Overhead Cam Valve Train................................................................. 53
Overhead Cam (OHC or SOHC).................................................. 53
Dual Overhead Cam (DOHC) ...................................................... 55
Camshaft Drives ................................................................................. 55
OHV Drive.................................................................................... 56
Chain Adjuster ............................................................................. 57
OHC Drive ................................................................................... 58
Timing Belt Auto Tensioner.......................................................... 59
Belt and Chain Drive .................................................................... 60
Gear-Driven Camshaft with Friction Gear .................................... 61
Camshaft Design ................................................................................ 62
Auxiliary Drives ............................................................................ 63
Lubrication ................................................................................... 63
Camshaft Measurements............................................................. 63
Review Exercise 5 .............................................................................. 64
Valve Adjustment ................................................................................ 65
Valve Clearance .......................................................................... 65
Hydraulic Lash Adjusters (HLA) .......................................................... 66
Description and Operation ........................................................... 66
Bucket-Type HLA......................................................................... 67
Rocker Arm-Mounted HLA........................................................... 68
Regular Oil Changes.................................................................... 68
Pushrods (OHV).................................................................................. 69
Rocker Arms ....................................................................................... 69
Review Exercise 6 .............................................................................. 70
5 – LUBRICATION SYSTEM.............................................................. 71
Objectives ........................................................................................... 71
System Components........................................................................... 72
Oil Pan ......................................................................................... 73
Oil Strainer (Pick-Up) ................................................................... 73
Oil Pump ...................................................................................... 73
Oil Filter ....................................................................................... 73
Oil Seals ...................................................................................... 74
Dipstick ........................................................................................ 74
Oil Pressure Indicator .................................................................. 74
How Oil Circulates .............................................................................. 75
page iii
Piston Engine Fundamentals
CONTENTS TC010-05-01S
6 – COOLING SYSTEM...................................................................... 83
Objectives ........................................................................................... 83
Components........................................................................................ 84
Coolant ........................................................................................ 84
Water Pump................................................................................. 85
Coolant Passages........................................................................ 85
Thermostat................................................................................... 85
Radiator Reservoir ....................................................................... 85
Fan............................................................................................... 85
Pressure Cap............................................................................... 85
Radiator ....................................................................................... 85
How Coolant Circulates....................................................................... 86
Water Pumps ...................................................................................... 87
Impeller-Type Pump..................................................................... 87
Centrifugal Operation................................................................... 88
Review Exercise 8 .............................................................................. 89
Radiators............................................................................................. 90
Downflow-Type ............................................................................ 90
Crossflow-Type ............................................................................ 91
Radiator Reservoir ....................................................................... 92
Pressure Cap ...................................................................................... 92
Thermostat.......................................................................................... 94
Fan Drives........................................................................................... 95
Viscous Drive Clutch.................................................................... 96
Review Exercise 9 .............................................................................. 97
7 – GLOSSARY.................................................................................. 99
page iv
Piston Engine Fundamentals
1 – INTRODUCTION TC010-05-01S
COURSE OVERVIEW
Welcome to the Mazda self-study guide Piston Engine Fundamentals. Before you begin,
please read the following information.
This guide is designed for entry-level automotive technicians. It introduces the basic
principles of engine operation, as well as descriptions of major engine components.
The guide assumes that you have little or no knowledge about engine operation. The
information covered in this guide is required for Mazda’s Engine Course.
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Piston Engine Fundamentals
1 – INTRODUCTION TC010-05-01S
In addition to this Introduction (Section 1), this guide includes five major sections and a
glossary. The objectives for each section follow.
3 – Short Block
• Identify the major parts of the short block.
4 – Valve Train
• Identify the major parts of the valve train.
5 – Lubrication System
• Identify the major parts of the lubrication system and describe how they lubricate engine
parts.
6 – Cooling System
• Identify the major parts of the cooling system and describe how they control engine
temperature.
7 – Glossary
• Define terms used throughout this guide.
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Piston Engine Fundamentals
1 – INTRODUCTION TC010-05-01S
To get the most benefit from this guide, complete the sections in order,
from 1 through 6. Allow enough time to complete each section, and don’t
try to complete the whole book in one sitting. You will retain more of
what you learn if you split up the reading and review exercises over
several days.
Section Objectives
Each section begins with a list of learning objectives. These objectives tell
you exactly what you will learn in the section. Read these objectives before
you begin a section. When you have completed the section, go back and
review the objectives to make sure you have learned the material.
Each section includes text and illustrations that explain important concepts
and terms. Read the text carefully and study the illustrations. You may also
want to take notes as you go along.
Piston
Crankshaft
Flywheel
To transmission
3
Piston Engine Fundamentals
1 – INTRODUCTION TC010-05-01S
Review Exercises
This guide includes nine sets of Review Exercises, which appear at various points
throughout the guide. These exercises are designed to check your understanding of the
material. Make sure you answer the questions in each Review Exercise. Then check your
answers with the answer key.
If you’re not sure about one or more of your answers, go back and read the material
again. Make sure you understand the previous material before you move on to new
material.
4
Mazda Technical Service Training Piston Engine Fundamentals
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In a car or truck, the engine provides rotating power to drive the wheels. This power is
transferred to the wheels through the transmission and driving axle. The source of this
rotating power is the energy released when fuel burns in the engine’s cylinders.
OBJECTIVES
• The cylinders and pistons convert energy from burning fuel into power.
- Cylinder configuration
- Compression ratio
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