Mazda Technical Service Training Piston Engine Fundamentals

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Mazda Technical Service Training Piston Engine Fundamentals

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LEVEL F

Piston Engine
Fundamentals
TC010-05-01S

Mazda Motor Corporation


Technical Service Training

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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

How to Use This Guide ......................................................................... 3


Section Objectives ......................................................................... 3
Text and Illustrations...................................................................... 3
Review Exercises .......................................................................... 4

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

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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

4 – VALVE TRAIN .............................................................................. 43


Objectives ........................................................................................... 43
Cylinder Head ..................................................................................... 44
Construction................................................................................. 44
Sealing......................................................................................... 45
Valves ................................................................................................. 46
Components ................................................................................ 46
Construction................................................................................. 47
Multi-Valve Design ....................................................................... 47
Valve Seats......................................................................................... 48
Valve Guides....................................................................................... 49

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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

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Piston Engine Fundamentals
CONTENTS TC010-05-01S

Pressure Lubrication ........................................................................... 76


Oil Pumps ........................................................................................... 77
Pressure Relief Valve .................................................................. 77
Rotor-Type Pump (Trochoid) ....................................................... 78
Gear Pump .................................................................................. 79
Oil Filter............................................................................................... 80
Bypass Valve ............................................................................... 80
Anti-Drainback Diaphragm........................................................... 81
Sealing Materials ................................................................................ 81
Review Exercise 7 .............................................................................. 82

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.

Audience and Purpose

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.

1
Piston Engine Fundamentals
1 – INTRODUCTION TC010-05-01S

Course Content and Objectives

In addition to this Introduction (Section 1), this guide includes five major sections and a
glossary. The objectives for each section follow.

2 – Basic Engine Operation


• Describe how engines generate and control power.
• Describe the four-stroke cycle.
• Define engine design characteristics, such as bore, stroke, and displacement.

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.

2
Piston Engine Fundamentals
1 – INTRODUCTION TC010-05-01S

HOW TO USE THIS GUIDE

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.

Text and Illustrations

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.

Each illustration includes numbered “callouts” that identify engine parts or


processes described in the text. The numbered items beside the
illustration identify the parts that are called out, as shown in the following
example from Section 2.

Piston
Crankshaft
Flywheel

To transmission

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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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Piston Engine Fundamentals


2 – BASIC OPERATION TC010-05-01S

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.

This section provides an overview of how the engine converts


energy from burning fuel into power that drives the vehicle’s
wheels.

OBJECTIVES

After completing this section, you will be able to describe how:

• The cylinders and pistons convert energy from burning fuel into power.

• The crankshaft converts up-and-down motion into rotational (turning) motion.

• The flywheel stores energy for a smooth transfer of power.

• The four-stroke cycle operates.

• Valves control intake and exhaust in a cylinder.

• Engines are classified by their design characteristics, including:

- Cylinder configuration

- Valve train type

- Bore, stroke, and displacement

- Compression ratio

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