[DIESEL ENGINE BASICS]

MP/CC/18/DEB/00 Sept’19
 Contents
1 The Diesel Engine ............................................................................................................................ 1
2 Principle of 4-stroke Diesel Engine ................................................................................................. 2
3 Valve Timing .................................................................................................................................... 3
4 Firing Order ..................................................................................................................................... 3
5 Working systems in a Diesel Engine ................................................................................................ 4
5.1 Air System ............................................................................................................................... 4
5.2 Cooling System ........................................................................................................................ 6
5.3 Lubricating System .................................................................................................................. 7
5.4 Fuel System ............................................................................................................................. 8
 DIESEL ENGINE BASIC

1 The Diesel Engine

Engine

The Diesel Engine converts the chemical energy of Diesel into mechanical energy.

During combustion the fuel burns and expands in the form of gas. While expanding it pushes the Piston
down. The linear movement of the Piston is transferred via Connecting Rod to Crankshaft. The
diagram explains that Piston and Connecting Rod movement is linear and the Crankshaft motion is
rotary.

The Piston movement is guided by the Cylinder. Top most position of the Piston is known as TDC (Top
Dead Centre) and the bottom most position of the Piston is known as BDC (Bottom Dead Centre).

1
 DIESEL ENGINE BASIC

2 Principle of 4-stroke Diesel Engine

Stroke 1: INTAKE / SUCTION

Air is sucked in to the cylinder due to the vacuum created by the down ward movement of the Piston
(T.D.C. to B.D.C) through the Inlet Valve.

Stroke 2: COMPRESSION

The Piston rises from B.D.C. to T.D.C, during Compression Stroke. At this point both the valves are
closed. Thus the Air which entered the Cylinder during Suction gets compressed to Pressures around
30 – 40 Kg / Cm2 and simultaneously the Temperature Rises to around 650 – 800 Degree Centigrade.

Stroke 3: EXPANSION / POWER

As the piston reaches T.D.C. during Compression Stroke the Injector sprays Diesel in to the Cylinder
(Combustion Chamber). The high temperature of the air ignites the fuel and combustion takes place,
which further boosts up the pressure and pushes the Piston Downwards. Since Power is generated
during this stroke this stroke is termed as Power Stroke.

Stroke 4: EXHAUST

The Exhaust valve Opens and Combustion Gas is discharged through the Exhaust Valve as the Piston
Moves from B.D.C to T.D.C. thus completing one whole cycle of four strokes.

Thus this is termed as “Four Stroke Engine”.

2
 DIESEL ENGINE BASIC

3 Valve Timing

Theoretically the Inlet Valve should open at T.D.C. and close at B.D.C. Similarly the exhaust valve
should open instantaneously at B.D.C. and should remain open till the piston reaches T.D.C., where it
must close. But in practice due to inertia the valves cannot open instantaneously and time has to be
allowed for the intake and exhaust processes to complete.

Hence Inlet Valve opens before T.D.C (Valve Lead) and close after B.D.C. (Valve Lag).

Similarly exhaust Valve Opens before B.D.C. and closes After T.D.C.

Hence both Inlet & Exhaust Valve are simultaneously open for certain period called Valve Overlap.

4 Firing Order

The firing order is the sequence of power delivery of each cylinder in a multi-cylinder reciprocating
engine. This is achieved by the sequence of fuel injection in a Diesel engine.

When designing an engine, choosing an appropriate firing order is critical to minimizing vibration,
improve engine balance and achieving smooth running. It heavily influences the Crankshaft design.

Firing order may different for different engine manufacturers.

Examples:

a) Firing order of a 4-Cylinder Inline engine:

b) Firing order of a 6-Cylinder Inline engine:

c) Firing order of a 6-Cylinder V-type engine:

3
 DIESEL ENGINE BASIC

5 Working systems in a Diesel Engine

5.1 Air System

The air system consists of Air Intake System and Exhaust System.

AIR INTAKE SYSTEM: Based on Method of air intake a Diesel Engine can be categorised as Naturally
Aspirated engine or Turbocharged Engine.

Air circuit in Naturally Aspirated engines

Air circuit in Turbocharged (with Intercooler) engines

4
 DIESEL ENGINE BASIC

Turbocharger:

A Turbocharger can significantly increase an engine’s power without increasing much of its weight.
That is why Turbochargers are so popular

Turbochargers are driven by exhaust gasses directed on ‘Turbine wheel’ and supplies compressed high
pressure air to cylinders to increase the engine power output.

Exhaust Outlet

Air Intake

Exhaust Intake

Air Outlet (compressed)

5
 DIESEL ENGINE BASIC

5.2 Cooling System

The cooling system keeps the engine running under optimum temperature. To ensure an even
temperature the Cylinder Head and Cylinder Block is cooled by Coolant. The coolant is circulated
through the cooling jackets provided in the Cylinder Head and the Cylinder Block.

The coolant is cooled in the Radiator. It is circulated from the Radiator to the Engine and back to the
Radiator by means of a Water Pump. The flow and temperature of the Coolant is regulated by valve
called Thermostat.

The Cooling Fan rotates by a Pulley & Belt arrangement which takes power from the Crankshaft. The
Fan draws cold air through the Radiator. The Radiator is connected to the Engine by an Inlet Hose and
an Outlet Hose. Hot Coolant passes through some thin pipes built inside the Radiator, where it gets
cooled.

The Thermostat remains closed until the engine reaches its operating temperature. When the
Thermostat is in closed condition, it does not allow the coolant to enter the radiator. As soon as engine
attains its operating temperature Thermostat opens and allows the Coolant to flow through the
Radiator.

6
 DIESEL ENGINE BASIC

5.3 Lubricating System

To prevent excessive friction and heat generation between any two surfaces in relative motion with
respect to each other, an oil or lubrication film is required in between two.

The Diesel engine consists of several moving parts made in metal, therefore friction, heat generation,
wear and tear is inevitable. Faulty lubrication system will result in engine seizure.

The functions of lubricant are:

• Lubricate moving parts to minimize Wear & power loss from friction.
• Remove heat from Engine Parts by acting as a cooling Agent.
• Absorbs shocks between Moving parts to reduce Engine Noise.
• Forms a good seal between Piston Rings and cylinder Walls.
• Acts as a Cleaning Agent.

Lube Oil Pump: The Engine Oil Pump draws Oil from the Oil Sump pressurises it and feeds it to the
Main Gallery from where the oil circulates to other parts of the Engine.

Oil Filter: The Oil Filter is used to clean the Lubricating Oil and prevent foreign particles from entering
in between the moving parts, which may damage them. Most Lube Oil Filters are equipped with a
Bypass Valve. This valve saves the engine from oil starvation in case the filter gets choked. The Bypass
Valve allows unfiltered lubricating oil to enter into the engine block when the filter is choked.

7
 DIESEL ENGINE BASIC

5.4 Fuel System

Basic objectives of any fuel system are to control the quantity of fuel to each cylinder and to ensure
that the fuel is delivered at correct time and in correct condition. The fuel system also governs the
engine speed.

Major building blocks of a diesel fuel system are as follows:

The Feed Pump sucks fuel from the Fuel Tank and delivers it to the Fuel Filter. After filtering the fuel
flows into the Fuel Injection Pump and is boosted to very high pressure. Controlled quantity of high
pressure fuel flows through the High Pressure Pipe to the Fuel Injector. The fuel is then atomized and
sprayed to the combustion chamber through nozzle orifices. Surplus fuel goes back to Fuel Tank
through Fuel Return Pipe.