Piston Engine

LEVEL F
Piston Engine
Fundamentals
TC010-05-01S
Mazda Motor Corporation

Technical Service Training
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
page i
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
page ii
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
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
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
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
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
3
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
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
5
HOW POWER IS DEVELOPED
Figure 1 shows how the energy from burning fuel is converted into rotating
power. In an engine, a piston is closely fitted into a hollow cylinder. The
cylinder has free space at the top, where a mixture of air and fuel is
inserted.
FIGURE 1.
Power is
developed by
burning fuel in a
cylinder.
Burning
mixture of air
and fuel
Piston
Cylinder
Crankshaft
The air-fuel mixture is ignited, and the burning gases from the mixture
expand, creating very high pressure. This pressure pushes down on the
piston, causing it to move down in the cylinder.
The process shown in Figure 1 is how the engine produces power.

Everything else on the engine is designed to control this process, harness
the power, and transmit it to the wheels.
Harnessing Power
To harness this power, the up-and-down movement of the piston is

changed into a turning (rotary) motion by connecting the piston to a
crankshaft, as shown in Figure 1.
6
The engine’s cylinders are arranged to fire one after the other. In this way,
some pistons are always supplying power to the crankshaft while other
pistons are moving up into their cylinders. To keep the crankshaft rotating
smoothly, it is connected to a flywheel, which is a heavy round plate that
turns with the crankshaft. See Figure 2.
FIGURE 2. The
flywheel Keeps the
crankshaft
turning smoothly.
Piston
Crankshaft
Flywheel
To transmission
Because of its weight, the flywheel tends to keep turning smoothly even
though power is applied in spurts by the pistons. The end of the crankshaft
is also connected to the vehicle’s transmission to continue the power flow
through the drive train to the wheels.
Controlling Combustion
The process of burning the air-fuel mixture in the cylinder is called

combustion. The combustion process in an engine requires four steps:
1. Admit the proper mixture of air and fuel into the cylinder.
2. Squeeze (compress) the mixture so it will burn better and deliver

more power.
7
3. Burn the air-fuel mixture.
4. Remove the burned gases from the cylinder so intake, compression,

and combustion can be repeated.
As Figure 3 shows, each cylinder has several parts that help control the
combustion process:
• An intake valve lets the air-fuel mixture into the cylinder.
• A spark plug ignites the air-fuel mixture.
• An exhaust valve lets the burned gases out of the cylinder.

FIGURE 3.
Valves and a
spark plug help
control
combustion in
the cylinder.
Intake valve
Spark plug
Exhaust
valve
8
THE FOUR-STROKE CYCLE
Most automotive engines use a four-stroke cycle to complete the

combustion process. A stroke is the movement of the piston from its
highest point in the cylinder to its lowest point, or from its lowest point to
the highest point.
The piston’s highest point in the cylinder is called top dead center, or TDC.
The lowest point is called bottom dead center, or BDC. As Figure 4 shows,
a full stroke of the piston takes one half-turn of the crankshaft, or 180
degrees.
FIGURE 4. A stroke
is the distance a
piston travels from
top dead center to
bottom dead center,
or from bottom dead
center to top dead
center.
Top dead center

(TDC)
One stroke
Bottom dead
center (BDC)
The four-stroke cycle requires four up-and-down movements of the piston

to complete the cycle. Figure 5 shows the stages of the four-stroke cycle,
including the:
1. Intake stroke
2. Compression stroke
3. Power (combustion) stroke
4. Exhaust stroke
9
FIGURE 5. The
four-stroke cycle
includes intake,
compression,
power, and
exhaust strokes.
Intake valve
Exhaust valve
Intake port
Exhaust port
Intake Stroke Compression Power Stroke Exhaust Stroke

Stroke
Intake Stroke
The four-stroke cycle begins with the intake stroke. The rotating crankshaft
pulls the piston down from TDC. The exhaust valve is closed, and the
intake valve is open.
As the piston moves down in the cylinder, it creates a partial vacuum,

which draws the air-fuel mixture through the intake valve into the cylinder.
The closed exhaust valve prevents the mixture from escaping through the
exhaust port.
When the piston is at BDC, the intake stroke is completed. However, the
intake valve may be held open slightly longer to let the air-fuel mixture fill
the cylinder more completely.
10
Compression Stroke
As the piston passes BDC and starts up again, the compression stroke begins. The intake
valve closes, and the exhaust valve stays closed. With both valves closed, the air-fuel
mixture is trapped in the cylinder. As the piston pushes up into the cylinder, it squeezes, or
compresses, the air-fuel mixture into a very small volume between the piston and cylinder
head.
Compression of the air-fuel mixture is very important for developing power. The greater the
compression, the more pressure the mixture will create when it burns. Compression also
“pre-heats” the mixture to help it burn better. Because compression is so important, the
valves and piston rings must seal the cylinder perfectly, or power will be reduced.
Power Stroke
Just before the piston reaches TDC, a spark from the spark plug ignites the air-fuel mixture,
and the power stroke begins. The burning gases expand rapidly, creating very high pressure
on top of the piston. Both valves remain tightly closed, so all the force is directed down onto
the piston, which is pushed down in the cylinder and turns the crankshaft. The greatest push
on the piston occurs in the first half of the power stroke.
By the time the piston approaches BDC, most of the pressure in the cylinder is used up. At
this point, the exhaust valve begins to open, relieving any remaining pressure so the piston
can move back up into the cylinder during the final stroke.
Exhaust Stroke
During the exhaust stroke, the exhaust valve remains open, and the rotating crankshaft
pushes the piston back up the cylinder. The motion of the piston pushes the burned gases
out through the exhaust valve.
As the piston passes TDC, the four-stroke cycle begins again with the intake stroke. The
exhaust valve stays open momentarily at the beginning of the intake stroke, allowing the
momentum of the gases to empty the cylinder completely.
11
Summary
We have illustrated the four-stroke cycle in only one cylinder. Remember, though, that these
four strokes are continuously repeated in all the cylinders.
The four strokes of the cycle — intake, compression, power, and exhaust — require two full
rotations of the crankshaft. However, the piston receives direct combustion pressure only
during one stroke, or about one quarter of the cycle.
When you realize that no power is being generated during 3/4 of the four-stroke cycle, you
can begin to see why the flywheel is so important. The flywheel “stores” the energy that is
generated, and uses that stored energy to keep the pistons moving smoothly when they are
not receiving combustion pressure.
REVIEW EXERCISE 1
Fill in the words that correctly complete these sentences. Check your answers with the
answer key on page 15.
1. In an engine, power is generated when an air-fuel mixture is ignited in the free space
at the top of the ____________________.
2. To convert the up-and-down motion of the piston into rotary motion, the piston is
attached to a connecting rod, which is connected to the _______________________.
3. The heavy plate connected to the crankshaft that stores the energy generated during
combustion is called the _______________________.
12
Refer to the illustration below to complete the following two items.
4. This illustration shows the _____________________ stroke of the four-stroke cycle.

5. Item “ ” in the illustration is the ________________________.
BASIC DESIGN CHARACTERISTICS
There are many variations in basic engine design, and automotive technology has its own
vocabulary for describing these designs. Engines are often described by the various
arrangements and measurements of their components, including:
• Cylinder configuration
• Valve train type
• Size of the engine’s bore, stroke, and displacement
• Compression ratio
13
Cylinder Configuration
Automotive engines typically have four, six, or eight cylinders, which are
arranged either in a line or in a “V” shape. Figure 6 shows the typical
arrangement of a
4-cylinder in-line engine. As the illustration shows, the cylinders are all in
one straight row. Most 4-cylinder engines are built with the cylinders in-line.
FIGURE 6. A
four-cylinder
in-line engine
has four
cylinders
arranged in a
single row.
Cylinders
Figure 7 shows another typical cylinder arrangement, the V-6 engine. The
V-6 has two banks of three cylinders arranged in a “V” pattern. Even though
the cylinders are in two banks, they are still connected to a common
crankshaft.
FIGURE 7. A V-6
engine has two
banks of three
cylinders
arranged in a
“ V” pattern
Cylinders
The V-8 engine is a variation of this design. The V-8 includes two banks of
four cylinders each, arranged in a “V” pattern.
14
Valve Train Type Answers to

Review Exercise
Mazda engines have the valves mounted above the cylinders in the
1. cylinder
cylinder head. The valves are operated by a camshaft, which controls the
opening and closing of the valves. An overhead valve, or OHV design, has 2. crankshaft
the camshaft installed below the valves, in the engine block. If the
camshaft is mounted above the cylinders, the design is called overhead 3 flywheel
cam, or OHC.
4. power
In some engines, a single camshaft is used to operate both the intake and 5. spark plug
exhaust valves. In many engines, though, a dual overhead camshaft
(DOHC) design is used. The DOHC design uses one camshaft to operate
the intake valves, and the other camshaft to operate the exhaust valves.
This arrangement eliminates extra weight, allowing the engine to operate
at higher RPMs. Figure 8 shows a DOHC design in a 4-cylinder in-line
engine.
FIGURE 8 The dual
overhead camshaft
(DOHC) design uses
separate camshafts
for the intake and
exhaust valves. Two
camshafts are used
on this 4-cylinder
in-line engine
Intake camshaft
Intake valve
Exhaust camshaft
Exhaust valve
15
A V-6 or V-8 DOHC engine will have two sets of camshafts, one set for
each bank of cylinders. Figure 9 shows the two sets of camshafts on a V-6
engine.
FIGURE 9. A V-6
or V-8 DOHC
engine has two
sets of
camshafts, one
for each bank of
cylinders. A total
of four
camshafts are
used on this V-6
engine.
Exhaust
camshaft,
right bank
Intake
camshaft,
right bank
Intake
camshaft,
left bank
Exhaust
camshaft,
left bank
16
Bore, Stroke, and Displacement
Bore, stroke, and displacement are measurements of the cylinders and

pistons in an engine. These three measurements are shown in Figure 10.
FIGURE 10. Bore

and stroke
determine the
displacement of
a cylinder.
Bore (mm)
TDC
BDC
Stroke (mm)
Displacement
(cc or L)
Bore is the diameter of a cylinder, usually expressed in millimeters (mm).

Stroke is the length of piston travel between TDC and BDC, usually
expressed in millimeters.
The displacement of a cylinder is the volume of the cylinder between the

TDC and BDC positions of the piston. The displacement of an engine is the
total displacement of all the cylinders in the engine. Displacement is
normally measured in cubic centimeters (cc) or liters (L).
Generally speaking, engine displacement is a rough indicator of power

output. For example, a 2000 cc (2.0 L) engine is usually more powerful
than a 1500 cc (1.5 L) engine. Displacement can be increased by opening
the bore to a larger diameter, or by increasing the length of the stroke.
17
Compression Ratio
The compression ratio measures how much the air-fuel mixture is

squeezed during the compression stroke. The compression ratio is the
ratio of the cylinder volume at BDC to the volume at TDC. For example,
Figure 11 shows a compression ratio of 8 to 1, where the volume at BDC
is eight times larger than the volume when the piston is at TDC.
FIGURE 11. The

compression
ratio compares
the cylinder
volume at BDC
to the volume at
TDC.
BDC
Volume
before
compression
TDC
Volume after
compression
Generally, a higher compression ratio means greater power output. For

example, a compression ratio of 8 to 1 will probably produce more power
than a ratio of 7 to 1. However, higher compression engines may require
premium fuel. Most engines have compression ratios of 9.5 to 1 or less so
they can take advantage of regular unleaded fuel.
18
ENGINE COMPONENTS AND SYSTEMS
In this section, you have learned how the four-stroke cycle produces power in an engine.
The rest of this guide covers the following components and systems, which are important
to the engine’s overall operation:
• Short block — A term used in the automotive repair business to describe the cylinder
block, crankshaft, bearings, connecting rods, and pistons as a unit.
• Valve train — Opens and closes the intake and exhaust valves so that events are
properly timed in the four-stroke cycle.
• Lubrication system — Lubricates all moving parts to reduce heat and wear.
• Cooling system — Maintains ideal operating temperatures in the engine.
Each of these components and systems is described in detail in the following sections of
this guide.
REVIEW EXERCISE 2
1. A V-6 engine usually has six cylinders arranged in _____________________ banks of

________________________ cylinders each.
2. An engine that uses separate intake and exhaust camshafts mounted above the
cylinders is called a ________________________ design.
3. The diameter of a cylinder is called its __________________________.
4. The _______________________ of an engine measures how much the air-fuel

mixture is squeezed before it is ignited.
5. The ______________________ of an engine is the total volume of all the cylinders

between the TDC and BDC positions.
19
Answers to
Review
Exercise 2
1. 2 banks; 3
cylinders
2. DOHC
3. bore
4. compression
ratio
5. displacement
20
3 – SHORT BLOCK TC010-05-01S
The short block includes the cylinder block, crankshaft, bearings, connecting rods, and
pistons. (A partial engine, or long block, is a short block plus cylinder head(s) and cover(s),
timing belt and covers, and oil pan.) A low mileage engine with excessive oil consumption or
lower end knocking is usually replaced with a short block. This section describes how each
part of the short block works.
OBJECTIVES
After completing this section, you will be able to:
• Identify the important parts of the cylinder block and describe their functions.
• Identify the important parts of the crankshaft and describe their functions.
• Describe how main bearings secure and lubricate the crankshaft.
• Describe how the piston is attached to the crankshaft.
• Identify important parts of the piston and describe their functions.
• Describe how pistons are constructed to overcome the problems of heat expansion.
• Identify the piston rings and describe their functions.
21
OVERVIEW
FIGURE 12. A
short block is a
The major parts of the short block are shown in Figure 12.
cylinder block
fitted with a
complete crank-
shaft assembly.
Cylinder
block
Piston
Connecting
rod
Crankshaft
The engine’s cylinders are bored in the cylinder block, which is a large
casting made of iron or aluminum. The combustion chambers are the
spaces where the air-fuel mixture is compressed and burned. Usually, the
combustion chambers are formed in the cylinder head, although some
engines have chambers in the tops of the pistons.
The pistons are fitted closely inside the cylinders, where they form the
“floor” of the combustion chambers. The pistons are linked to the
crankshaft by connecting rods and bearings. The crankshaft is mounted in
bearings in the cylinder block.
22
CYLINDER BLOCK
Figure 13 shows a typical cylinder block for a 4-cylinder in-line engine.
FIGURE 13. The

cylinder block is
the engine’ s
main supporting
part.
Cylinder
bores
Cylinder head
Front mounting
surface
Crankshaft
Opening
The cylinder block is the main supporting member of the engine. Almost
every other engine component is either connected to or supported by the
cylinder block. The pistons, connecting rods, and crankshaft work inside the
cylinder block.
The cylinder block contains the cylinders, internal passages for coolant and
oil, and mounting surfaces for attaching engine accessories, such as the oil
filter and water pump. The cylinder head is mounted on top of the cylinder
block, and the oil pan is mounted on the bottom.
23
Construction
Cylinder blocks are usually made of cast iron or aluminum alloy. Cast iron cylinder liners
are cast into aluminum alloy blocks. These materials can easily be machined for the
cylinder bores and other mating surfaces. Coolant and oil passages are cast into the block
when it is manufactured. The block is heavy and rigid, so it can withstand the vibration
and heat stress of engine operation.
The cylinder bores are carefully machined and angled correctly to match the crankshaft.
The block material is designed to handle the wear that occurs in the cylinders as the
pistons move up and down.
Crankcase
The crankcase contains and supports the crankshaft and main bearings. The bottom of
the cylinder block forms the upper part of the crankcase. The oil pan attached to the
bottom of the cylinder block forms the bottom part of the crankcase.
Crankshaft Main Supports and Bearings
The crankcase includes several support surfaces for the crankshaft. The number of
supports varies, depending on the length of the crankshaft. For example, a four-cylinder
engine will usually have five of these support surfaces.
The crankshaft mounts on insert bearings that are installed on the support surfaces and
attached with bearing caps. The supports have oil passages that lubricate the crankshaft
as it spins against the bearings. These passages align with oil holes in the bearings. The
cylinder block also includes a groove for the rear main oil seal, which keeps the oil from
leaking out at the rear of the crankshaft and engine.
In automotive technical vocabulary, the term main refers to bearings, seals, and other
mounting hardware for the crankshaft itself. Main distinguishes these mounting parts from
other mounting parts that connect to the crankshaft, such as connecting rod bearings.
24
CRANKSHAFT
The crankshaft is the component that changes the up-and-down motion of

the pistons into rotational motion that drives the wheels of the vehicle. The
crankshaft attaches to the cylinder block supports with main bearing caps,
as shown in Figure 14. When the bearing caps are bolted on, they hold
the crankshaft in place. When the block is machined, main bearing
surfaces are aligned and bored on the crankshaft’s center line (line-bored),
so bearing caps must never be interchanged.
FIGURE 14. Main

bearing caps are
used to attach
the crankshaft to
the cylinder
block.
Cylinder
block
Crankshaft
Main bearing
Thrust
bearing
Main bearing
cap
Main bearing
cap mounting
bolt
25
Features
Figure 15 shows the important features of a crankshaft. The dashed line

represents the center of the shaft.
FIGURE 15. Main

bearing journals
are used to
mount the
crankshaft.
Connecting rod
journals connect
the pistons to
the crankshaft.
Front end
Oil passage
Connecting
rod journal
(crankpin)
Flywheel end
Main bearing A journal is a smooth, round bearing surface. A main bearing journal is a
Journal surface that mounts on the supports in the crankcase, with an insert
bearing between the journal and the support. The main bearing journals
actually support the crankshaft in the crankcase. In Figure 15, the main
bearing journals are all in a line defined by the center line of the shaft.
The other journals — called connecting rod journals or crankpins — are

offset from the center line of the crankshaft. These journals are used to
attach the connecting rods from the pistons.
The connecting rod journals are positioned on the crankshaft so that the
pistons can be at different points in the combustion cycle as the crankshaft
turns. This spaces out the power strokes from the cylinders as they fire in
turn. The result is a smooth flow of power, rather than a jerky, pulsing
motion.
26
Construction
Because the crankshaft must handle the tremendous forces of the pistons’
power strokes, it is usually made of heavy, high-strength cast iron or
forged steel for high performance or heavy-duty applications. Some
crankshafts have counterweights cast opposite the crankpins, as shown
in Figure 16. The counterweights help balance the crankshaft and prevent
vibration during high-speed rotation.
FIGURE 16.
Counterweights
on the crankshaft
improve balance
and prevent
vibrations.
Crankshaft
counter-
weights
Main bearing
journals
The main bearing journals on a crankshaft are highly polished and are
manufactured to exact roundness so they will rotate properly in the
bearing inserts. Oil passages drilled into the main journals receive oil flow
from the supports in the cylinder block.
Slanted oil passages are drilled from the main journals to the crankpin
journals to lubricate the connecting rod bearings. In addition, one of the
main journals — usually in the middle — is machined with a thrust surface.
This surface rides against a special thrust bearing that controls
front-to-rear movement of the crankshaft.
27
Number of Journals
The crankshaft shown in Figure 16 has five main bearing journals and four crankpin
journals. This is a common design for a 4-cylinder engine. One piston is connected to each
crankpin journal with a connecting rod.
You might expect V-6 and V-8 engines to use longer crankshafts, with more crankpin
journals to connect the additional pistons. However, most V-6 and V-8 engines actually
have shorter crankshafts because they connect two pistons to each crankpin journal.
For example, a V-6 engine might use a crankshaft with three crankpin journals and four
main bearing journals. When the cylinder banks are arranged at 90 degrees from each
other, two pistons on the same crankpin journal will always be a half-stroke apart in the
cycle.
Vibration Damper
Even though the crankshaft is very strong, it must have a certain amount of “give” that
allows it to flex slightly. The downward thrust against the crankpin during the power stroke
actually twists the crankpin slightly. This force is immediately relieved, and the crankpin
returns to its original shape.
At a normal hot idle, this twisting and untwisting may repeat five times every second. When
the vehicle is accelerating under load, the cycle may occur 25 or 30 times per second. The
result of this constant twisting and untwisting is torsional vibration, or flexing of the
crankshaft.
To control torsional vibration, a vibration damper (or harmonic balancer) is usually mounted
on the front end of the crankshaft, often as part of the crankshaft pulley. Figure 17 shows a
typical torsional damper.
28
FIGURE 17. The

torsional damper
controls twisting
of the crankshaft.
Torsional
damper
(crankshaft
pulley)
Rubber
Timing belt
pulley
Crankshaft
MAIN BEARINGS
The crankshaft main bearings are split circular sleeves that wrap around
the crankshaft main journals. The upper half of the bearing has one or
more oil holes to allow lubricant to coat the inside surface of the bearing,
as shown in Figure 18. The upper bearing fits into a main support on the
bottom of the cylinder block. The lower half of the bearing fits into the
bearing cap.
FIGURE 18.
Crankshaft main
bearings wrap
around the main
journals.
Upper main
bearing
Oil hole
Lower main
bearing
29
The wear surfaces of the bearings are made of softer material than the
crankshaft. The softer material reduces friction, and it tends to mold itself
around any uneven areas on the main journal. In addition, if wear does
occur, it will affect the bearing, which is cheaper to replace than the
crankshaft.
Lubrication
In most engines, the upper and lower bearings are not interchangeable
because the upper bearings have an oil hole. Pressurized oil is forced
through the hole, allowing lubricant to flow around the bearing as the
journal turns.
To prevent the bearing from seizing on the crankshaft journal, the inside
diameter of the bearing is slightly larger than the journal diameter, usually
by a few thousandths of an inch. The gap between the bearing and the
journal allows oil to circulate freely between the two surfaces, as shown in
Figure 19.
FIGURE 19.
Bearing
clearance allows
oil to circulate
between the
bearing and
journal
surfaces.
Oil passage
Upper main
bearing
Oil film
Lower main
bearing
Crankshaft
main journal
Bearing
clearance
30
Clearance
The gap between the bearings and the main journal is called the bearing clearance.
Clearance is one of the most critical measurements in the engine.
The oil that lubricates the bearings does not actually stay in a continuous film. As the
crankshaft turns, the oil works its way to the outer edges of the bearings, where it is thrown
off into the crankcase. New oil constantly feeds in through the oil hole to replace the oil
thrown off.
The constant flow of oil over the bearings helps cool them and flushes away grit and dirt
from the bearing surface. If the clearance is too small, not enough oil will be allowed in to
lubricate the bearings. The resulting friction will wear out the bearings quickly. On the other
hand, if the clearance is too large, too much oil will flow through the bearings. Oil pressure
will drop and the crankshaft journal may start to pound against the bearing rather than spin
inside it.
The oil pump in an engine has a limited capacity, and if all the oil is being pumped through
a few bearings close to the pump, then other engine parts will be robbed of lubrication. For
example, bearings further away from the oil pump will not get an adequate supply of oil, so
they will wear out quickly. (The major early symptom for loose or failing bearings is low oil
pressure.)
To prevent damage to the bearings — and possibly to the crankshaft — the bearing
clearances must be set precisely whenever the bearings or crankshaft are repaired.
31
Thrust Bearings
In addition to rotating, the crankshaft also tends to move back and forth.
This movement is called end play. To limit end play, one of the main
journals on the crankshaft is machined to accept a thrust bearing. This
bearing keeps the crankshaft from moving back and forth. The upper and
lower thrust bearings have oil grooves that allow oil to flow around the
journal, as shown in Figure 20.
FIGURE 20. The

thrust bearing
controls the
front- to-rear
movement of
the crankshaft.
Upper thrust
bearing
Oil grooves
Lower thrust
bearing
REVIEW EXERCISE 3
Fill in the words that correctly complete these sentences. Check your
answers with the answer key on page 35.
1. The ___________________ is the main supporting member of the

engine.
2. The crankshaft is attached to the cylinder block with U-shaped parts

called ___________________ .
3. The term main refers to parts used to mount the

___________________ .
4. The bearing that controls crankshaft end play is called the

_____________________ .
32
5. The gap between the main bearings and the main journals is called
_____________________ .
6. The _____________________ half of the crankshaft main bearing has oil holes and fits
into the ___________________ .
Match the numbered items on the crankshaft drawing to the definitions below.
7. _______ A. main journal
8. _______ B. oil passages
9. _______ C. crankpin
10. Which of these symptoms would you expect to find in an engine that has worn main
bearings? More than one answer may be correct.
A. low oil pressure
B. leaking gasoline
C. hard starting
D. low rattle noise from engine
33
CONNECTING RODS
The connecting rod transfers the movement of the piston to the crankpin
on the crankshaft. Figure 21 shows the connecting rod and its related
parts.
FIGURE 21. The

connecting rod is
attached to the
piston with a
piston pin.
Piston pin
Bushing
Connecting
rod
Connecting
rod bearing
cap
Upper
connecting
rod bearing
Lower
connecting
rod bearing
Oil holes
Bearing cap
nut
Bearing cap
bolt
A steel piston pin (commonly called the wrist pin) connects the piston to
the rod. The pin slips through the piston and through the bushing (a
circular, sleeve-type bearing) in the connecting rod. The pin must be free
to turn either in the piston or the connecting rod so the rod can rock back
and forth as the crankshaft turns. In some engines, the pin turns freely in
both the piston and the connecting rod. Some pins have retainers at both
ends to keep the pins from sliding out.
The large end of the connecting rod is connected to the crankshaft with a
connecting rod bearing cap. This cap is very similar to the main bearing
caps, and the clearances are equally important.
34
Construction Answers to
Review
Exercise 3
Connecting rods must be very strong and rigid to handle the force of the
piston on the power stroke. Connecting rods are usually made of 1. cylinder
high-strength steel, with an “I” construction for extra rigidity. The rods are block
kept as light as possible, and weight variation among the rods is carefully
controlled so the engine will be balanced. 2. main bearing
caps
Like the main bearings, the connecting rod bearing surfaces are 3. crankshaft
line-bored. They must be reinstalled in the same positions from which
4. thrust
they were removed. If they are not, it can cause premature and
bearing
uneven wear. Usually, both the rod and cap are stamped to ensure
proper reassembly. 5. bearing
clearance
6. upper;
cylinder
Cylinder Wall Lubrication block’s main
support
As shown in Figure 22, an oil jet in the connecting rod lubricates the 7. B
cylinder walls and cools the piston. The crankshaft oil passages deliver oil 8. C
to the connecting rod journals. When the bearing holes match up with the 9. A
oil hole in the connecting rod journal, pressurized oil is squirted through 10. A and D
the oil jet.
FIGURE 22. The

oil jet on the
connecting rod
squirts oil onto
the cylinder wall.
Connecting
rod
Oil holes
Upper
connecting
rod bearing
Lower
connecting
rod bearing
Oil jet
35
PISTONS
The piston forms the bottom of the combustion chamber in the cylinder. It
transfers the power created by the burning air-fuel mixture to the
crankshaft. Figure 23 shows a typical piston.
FIGURE 23. The

piston forms the
bottom of the
combustion
chamber.
Head
Piston pin
bore
Piston ring
grooves
Thrust
surface
“ Front”
mark
Center of
piston
Center of
piston pin The top surface of the piston is called the head, or crown. The upper part
bore of the piston contains several grooves where the piston rings fit. The
Offset lower part of the piston, under the rings, is called the skirt. Thrust
Skirt surfaces on the skirt guide the piston in the cylinder bore and prevent the
piston from rocking back and forth in the cylinder. Most pistons have a
mark on one side that identifies the side of the piston that faces the front
of the engine.
The piston pin bore is drilled through the piston. The piston pin is
inserted through this bore to attach the piston to the connecting rod. In
some piston designs, the pin bore is offset slightly from the center of the
piston. The offset — usually no more than a few thousandths of an inch
or 0.5-2 millimeters — helps keep the piston from “slapping” against the
cylinder walls during the power stroke.
36
Construction
Pistons are usually made of aluminum alloys, which are lighter than cast
iron or iron-steel alloys. While lighter weight is an advantage, aluminum
alloys also tend to expand more with heat. To overcome this problem,
some pistons have a steel strut cast into the bottom of the piston head.
This strut helps control expansion.
Clearance
Although the piston fits closely in the cylinder bore, it does not seal the
combustion chamber. The compression seal is made by the piston rings
installed in grooves near the top of the piston. To allow room for the piston
rings and lubricating oil, a clearance of a few thousandths of an inch must
be maintained between the outside edge of the piston and the cylinder
wall.
This clearance lets lubricating oil into the upper part of the cylinder. The
clearance also prevents the engine from seizing if one of the pistons
expands too much from overheating.
To maintain a consistent clearance from the top to the bottom of the

cylinder, the piston usually has a slightly tapered shape, as shown in
Figure 24. The top diameter of the piston is slightly smaller than the
bottom diameter when the piston is cold. When the engine operates, the
top of the piston gets much hotter than the bottom, and the expansion at
the top evens up the diameter.
FIGURE 24. The

upper part of the
piston gets very
hot, and its
smaller diameter
expands to
maintain
consistent clear-
ance from top to
bottom.
Top
diameter
(smaller)
Bottom
Diameter
(larger)
37
Another technique used to make the piston fit better in the cylinder and
control heat expansion is called cam grinding. Cam-ground pistons are
slightly oval shaped, as shown in Figure 25.
FIGURE 25. The

oval shape of a
cam-ground
piston allows
different parts of
the piston to
expand at
different rates.
When the piston
heats up, it
becomes round.
Piston pin
bore
Large
diameter.
Small Surfaces of the piston expand at different rates because they are made of
Diameter different materials. For example, the area around the piston pin bore is
made of denser material to maintain strength. Therefore, this area
expands more when it is heated. The oval shape of the piston allows for
this expansion. As the piston heats up and expands, its shape becomes a
perfect circle.
If the piston clearance becomes too large, the piston can rock in the
cylinder, striking the cylinder wall loud enough to be heard. This condition
is called piston slap. Piston slap usually occurs in older, high mileage
engines with worn cylinders.
38
PISTON RINGS
The piston rings seal the combustion chamber, forming a closed, sealed
space where the air-fuel mixture is ignited. In addition to sealing the
combustion chamber, the piston rings also:
• Scrape oil from the cylinder walls so it doesn’t get into the upper
cylinder and burn.
• Carry heat from the piston to the cylinder walls.
Figure 26 shows the rings on a typical piston. The top two rings are
called compression rings. They are made of cast iron with chrome plating,
and come in various shapes. The bottom oil ring is made of two separate
scuff rings and an expander.
FIGURE 26. A
typical piston
has two
compression
rings on top and
an oil ring on the
bottom.
Top
compression
ring
Second
compression
ring
Scuff rings
on oil ring
Expander on
oil ring
39
FIGURE 27. Compression Rings

Compression
rings scrape the
Compression rings seal, scrape, and cool the cylinder, as shown in Figure
cylinder wall
and seal the 27. Compression rings are designed to twist slightly when they are not
combustion under pressure. The top edge of the ring will be twisted away from the
chamber. cylinder wall, while the bottom edge presses against the wall. So while the
piston is moving down during the intake stroke (View A), the lower edge of
Compression the compression rings scrape off any oil that was missed by the oil ring.
rings scrape
cylinder wall
Compression
rings skim
over oil film
View A Intake or View B Compression and

power stroke exhaust strokes
On the compression and exhaust strokes (View B), the twist lets the
compression rings skim over the oil film so the oil is not pushed into the
combustion chamber.
During the power stroke (View A), the combustion pressure on the rings
forces them to untwist, so both the top and bottom edges of the rings
contact the cylinder wall. This creates a tighter seal for the combustion
chamber. The untwisted rings also create a path for heat to flow from the
piston to the cylinder wall.
40
Oil Rings
Oil rings help lubricate the cylinder walls and control the flow of oil. Oil is
constantly sprayed or splashed onto the walls of the cylinders, where it
keeps the metal parts from wearing against each other. Oil also helps cool
the cylinder, and it washes carbon and dirt particles from the cylinder
walls.
So much oil is on the walls of the cylinders that it won’t all fit into the small
clearance next to the piston when the compression rings scrape the walls.
To provide a place for the extra oil to go, the oil ring is usually segmented
— made of three pieces — as shown in Figure 28.
FIGURE 28. Oil
rings are
usually made of
three pieces, or
segments.
Oil rings
Expander
ring
As the oil is scraped, it flows behind the expander ring to holes in the ring
groove. These holes direct the oil to the open space inside the piston skirt,
where it eventually drains back into the crankcase.
The expander ring is a steel ring installed between the two oil rings. These
oil rings are made of more flexible material than compression rings. The
expander ring holds the oil rings tightly against the cylinder wall, improving
their ability to scrape the oil.
41
REVIEW EXERCISE 4
1. The part that attaches the piston to its connecting rod is called the
___________________ .
2. When the pin bore is not drilled directly in the center of the piston, it is called an
___________________ pin bore.
3. Cam-ground pistons have a slightly ___________________ shape.
4. The piston rings that scrape the cylinder walls and seal the combustion chamber are
called ___________________ rings.
5. The expander ring is usually part of the ___________________ ring on a piston.
6. Which of these symptoms would you expect to find in an engine that has worn or
damaged piston rings? More than one answer may be correct.
A. excessive oil consumption
B. blue smoke in exhaust
C. leaking coolant
D. high idle
42
4 – VALVE TRAIN TC010-05-01S
Engines have passages that let the air-fuel mixture into the cylinders and let exhaust gases
out after the mixture has burned. These passages, called valve ports, must be sealed very
tightly during parts of the four-stroke cycle.
The valves must open and close the ports at precise times.
The engine parts that open and close the valves are called the valve train. This section
describes how the valve train operates.
OBJECTIVES
• Identify the important parts of the cylinder head and gasket and describe their
functions.
• Identify important parts of valves and describe how they operate.
• Describe the advantages of multi-valve engines.
• Describe how the valve seals against the valve seat.
• Describe how valve guides hold the valve in the cylinder head.
• Identify important parts of the valve spring and retainer assembly.
• Describe the differences among OHV, SOHC, and DOHC valve trains.
• Identify the four types of Mazda camshaft drives.
• Describe how camshafts are designed.
• Describe the differences between manual valve adjustment and automatic valve
adjustment.
• Describe how pushrods and rocker arms transfer motion to the valves.
43
Answers to CYLINDER HEAD

Review
Exercise 4
The cylinder head bolted on top of the cylinder block, forms the roof of the
1. piston pin combustion chamber. The cylinder head:
2. offset • Seals the tops of the cylinders.
3. oval • Holds the spark plugs.

4. compression
• Provides seats, guides, and ports for the intake and exhaust valves.
5. oil
• Holds the valve train.
6. A and B
• Provides mountings for the intake and exhaust manifolds.
Construction
Like the cylinder block, the cylinder head is made of cast iron or aluminum
alloy. The intake and exhaust manifolds are mounted to the cylinder head,
against the valve ports, shown in the side of the head in Figure 29. Most
V-6 or V-8 engines have two cylinder heads, one for each bank of
cylinders. (This drawing shows the right cylinder head on a typical V-6
engine.) The top part of the cylinder head is manufactured so that the
valve rocker arms and/or other parts of the valve train can be mounted on
it.
FIGURE 29. The
cylinder head
contains the Front
valve train
components and
spark plugs.
Right cylinder
head for V-6
engine
Intake port
Valve
Spark plug
Exhaust port
44
The cylinder head includes spark plug mounting holes, valve ports and
seats, and coolant and oil passages.
Sealing
The cylinder head gasket, shown in Figure 30, seals the combustion
chambers. The gasket is usually made of steel coated with a softer sealing
material.
FIGURE 30. The

cylinder head
gasket seals the
combustion
chambers and
coolant
passages.
Left cylinder
Head gasket
for V-6
engine
Cylinder
opening
Identifying
Because this seal is so important to engine operation, the head gasket mark for left
cylinder head
must be replaced whenever the cylinder head is removed and replaced. In
addition, the sequence and procedure for tightening the cylinder
head bolts is critical to good sealing.
45
VALVES
As shown in Figure 31, a valve has a round head with a tapered face that
seals against a seat in the cylinder head. Because of its stem-and-head
construction, the valve is sometimes called a mushroom valve.
FIGURE 31.
Valves seal
against a seat in
the cylinder
head.
Keeper
groove
Stem
Face
Margin
Head
Components
The head of the valve is the larger end that seals the valve port. The
surface of the head that seals the port is called the face, and it is tapered
at an angle. The valve seat in the cylinder head is ground to match the
angle of the valve face to provide a tight seal.
The valve margin is the thickness of the valve head. On some valves, the
margin can be ground to form a new face finish so the valve can be
reused after wearing. The margin also lets the valve transfer some of the
heat created in the combustion chamber.
46
The valve stem is the long, narrow part above the head. The stem has a groove at the end
for keepers. The valve spring pulls the head of the valve up to close the port. The spring is
held in place by an upper spring seat and the keepers. The stem fits inside the valve guide,
which holds the valve in the cylinder head.
Construction
Valves are made of special high-strength steel that resists heat. Heat resistance is not quite
so important to intake valves because they get a cool “bath” every time a fresh air-fuel
mixture enters the cylinder. However, exhaust valves receive heat blasts of up to 4000
degrees Fahrenheit every time they open.
As protection from these extreme temperatures, exhaust valves have two ways of
transferring the heat from the exhaust gases. First, when the valve is seated, some of the
heat is transferred from the valve head to the seat. The seat transfers the heat to the
cylinder head, which has coolant passages to control temperature. Second, the valve stem
transfers heat to the valve guide, which is located in the cylinder head.
The width of the valve face and margin are critical. The face must be perfectly uniform and
wide enough to seal tightly and transfer heat. The margin must be large enough for the
valve head to absorb and hold the heat until it can be transferred.
Multi-Valve Design
Mazda engines use three or four valves per cylinder because multiple valves are more
precise and efficient. A three-valve design typically uses two valves for intake and one
valve for exhaust. A four-valve design uses two valves each for intake and exhaust.
47
VALVE SEATS
The valve seat is made of very hard metal so it can stand up to constant
hammering as the valve opens and closes. When the engine is running at
high speed, the valves may open and close up to 25 times per second.
In addition, the intense heat in the combustion chamber and the

chemical properties of the exhaust gases can cause corrosion. So the
valve seat must also be resistant to heat and corrosion.
If the cylinder head metal meets these requirements, the valve seat may
be machined directly into the head. If the cylinder head metal is not
strong enough to withstand the hammering, corrosion, and heat, the
valve seat may be a hardened steel insert that is pressed into the
cylinder head.
The valve seat includes several machined surfaces, as shown in Figure 32.
The sealing surface is cut to nearly the same angle as the valve face. To
make a tighter seal and prevent build-up of carbon deposits, two other
surfaces are machined: a wide-angle upper clearance and a narrow-angle
lower clearance.
FIGURE 32. Each
valve seat has
several
machined
surfaces to make
a tight seal.
Upper
clearance
Valve seat
Lower
clearance
When the upper and lower clearances are correct, and the valve seat has
the proper width, the valve face will close tightly against the seat. The
machining of these surfaces must be very accurate. If valve seat inserts
are used, the surfaces are machined after the insert has been pressed
into the valve port. The seat must also be installed properly so that
efficient heat transfer can take place.
48
VALVE GUIDES
Some valve guides are machined directly into the cylinder head casting.
Other guides are soft alloy inserts that are pressed into the head, as
shown in Figure 33. In some cases, the valve guide is reamed (drilled out)
for a close fit to the valve stem after the guide has been installed.
The valve guide fits very closely around the valve stem, with just enough
room for lubricant and free movement of the stem. When the guide wears
out, it can sometimes be reamed out so that a valve with an oversized
stem can be installed. Insert-type guides are replaceable.
FIGURE 33. Valve

guides hold the
valve stem so the
valve fits
squarely on its
seat.
Cylinder
head
Valve stem
Valve guide
Valve seal
49
VALVE SPRINGS
Springs are used to close the valves firmly against their seats. A typical
valve spring assembly is shown in Figure 34.
FIGURE 34.
Springs are used
to close the
valves
Valve
Keepers
Upper spring
seat
Spring
Lower spring
seat
Valve seal
Valve guide
The valve is installed in the cylinder head, with the spring and upper
spring seat over the stem. Then the spring is squeezed, and the keepers
are fitted into the groove in the valve stem. The keepers form a collar
around the valve stem, and hold the spring in place. On some engines,
the keepers allow the exhaust valve to rotate in the valve guide, resulting
in equal heat distribution, more even wear, and ‘self-cleaning’ of the
valve-to-seat surface.
50
Most overhead valves also use an oil seal to prevent oil from being drawn through the valve
guide and into the combustion chamber. The seal may be a cup type that fits over the end
of the valve guide, or it may be installed directly on the valve stem.
Construction
Valve springs are made of high quality steel to exact specifications for spring force and
squareness. The ends are ground flat, and squareness is checked carefully so the spring
will not tilt the valve.
Spring Tension
The valve spring requires very high tension to close the valve completely. As the engine
speed increases, higher force is needed. If the spring is weak, the valve will tend to float, or
fail to seat at high speed. This condition causes lost power and burned valves.
On the other hand, the spring tension must be limited because of wear to the cam lobe,
lifters, and other valve train parts. Since spring tension can be lost over time, used springs
are checked on testers to make sure the tension is correct at the normal working height of
the spring.
Working Height
Working height is the length of the installed spring between the retainer and the spring pad
on the cylinder head when the valve is fully closed. When valve faces and/or seats are
refinished, the working height increases slightly, resulting in less spring tension. To make
up for this loss, the technician installs one or two shims under the spring to compress it to
the correct height.
51
OVERHEAD VALVE TRAIN
An overhead valve (OHV) train design means that the valves are
mounted in the cylinder head at the top of the combustion chamber.
OHV engines have the camshaft installed below the valves, in the
cylinder block. Figure 35 shows the major parts of the overhead valve
train.
FIGURE 35. In an
OHV design,
lifters and push
rods transfer the
action of the
camshaft to the
rocker arms.
Rocker arm
Valve
Pushrod
Lifter
Cam
Camshaft
As the camshaft turns, the cam lobe moves against the lifter (sometimes
called a tappet or cam follower). The lifter pushes up on the pushrod,
which contacts the rocker arm. The valve end of the rocker arm pushes
down on the valve and opens it. As the cam lobe moves past the lifter, the
valve spring pushes against the rocker arm, and the pushrod moves down,
allowing the valve to close.
52
OVERHEAD CAM VALVE TRAIN
The overhead cam (OHC) design provides more direct control over valves
than the OHV design. This advantage may explain why overhead cams are
the most commonly used design. The overhead cam design includes
engines with a single overhead cam (OHC or SOHC), as well as engines
with dual overhead cams (DOHC).
Overhead Cam (OHC or SOHC)
In an overhead cam engine, the camshaft is installed in the cylinder head

above the valves. The camshaft, shown in Figure 36, is a solid or hollow
cast iron shaft with several cams on it. Each cam has an off-center bulge
on one side called a cam lobe. On most Mazda OHC engines, the
camshaft runs directly on the cylinder head journal surface without insert
bearings.
FIGURE 36. The

camshaft rides
directly on the
cylinder head
journal surface.
Cam lobes
Camshaft
journal
Cams
53
To make sure that the valves open and close at the right time in the
four-stroke cycle, the camshaft is driven by the crankshaft. The camshaft
turns at one half the speed of the crankshaft because it takes two
revolutions of the crankshaft to complete one cycle. So the camshaft
completes a full cycle in one revolution.
As the camshaft turns, a lobe on one of the cams contacts a rocker arm
which presses on the valve stem end and opens the valve, as shown in
Figure 37. As the lobe turns past the rocker arm, it releases the valve,
allowing the spring to close it. The single overhead camshaft includes
two or more cam lobes for each cylinder — one lobe for each valve — so
that the intake and exhaust valves can open and close at different times.
FIGURE 37. As
the camshaft
turns, the lobe
contacts the
rocker arms,
opening and
closing the
valves.
Rocker arms
Camshaft
Valves
Cam lobes
On V-6 and V-8 engines with an SOHC, two separate camshafts are used,
one for each bank of cylinders. Even though two camshafts are used, this
is still an SOHC design because one camshaft operates all the valves for
the cylinder bank.
54
Dual Overhead Cam (DOHC)
The dual overhead cam (DOHC) design is also very common in

light-weight, multi-valve engines that operate at high speeds. Dual
camshafts reduce the weight of the valve train parts, which means the
engine can generate more power without an increase in displacement and
weight.
FIGURE 38. Dual
camshafts
reduce the
weight of the
valve train and
improve intake
and exhaust
efficiency.
Camshafts
Exhaust
valves
Intake valves
V-6 and V-8 engines with dual camshafts actually have four separate
camshafts, two for each bank of cylinders.
In addition, the OHC design also allows four valves per cylinder — two
intake valves and two exhaust valves, as shown in Figure 38. This
arrangement improves the intake and exhaust efficiency of the engine.
CAMSHAFT DRIVES
This section covers four types of camshaft drives:
• OHV Drive
• OHC Drive
• Belt and Chain Drive
• Gear-driven Camshaft with Friction Gear
55
OHV Drive
In an OHV engine, where the camshaft is mounted below the valves in the
block, a crankshaft gear is used to drive a timing chain, which drives the
camshaft gear. Figure 39 shows a typical drive for an OHV engine.
FIGURE 39. OHV

drives typically
use a timing
chain to drive the
camshaft.
Camshaft
Camshaft
gear
Timing chain
Crankshaft
gear
56
Chain Adjuster
Timing chain tension changes with engine temperature and wear. A chain
adjuster mounted on the cylinder block uses both engine oil pressure and
spring tension to automatically maintain timing chain tension.
When the engine is started, oil pressure builds in the adjuster. As shown in
Figure 40, oil pressure and spring tension push the chain adjuster sleeve
outward if the chain is loose. The ratchet pawl skips to the next tooth,
pushing the chain lever against the chain, taking out excess slack. When
the engine is stopped, the oil pressure drops, but the ratchet pawl prevents
the adjuster sleeve from being pushed back into the chain adjuster.
FIGURE 40. The
chain adjuster
uses oil
pressure and
spring tension to
automatically
maintain timing
chain tension.
Ratchet
spring
Ratchet pawl
Chain aduster
sleeve
Drain
Plunger
spring
Chain lever
Timing chain
57
OHC Drive
To drive the camshaft(s), a pulley on the end of the crankshaft drives a

timing belt or timing chain that turns the camshaft(s).
Figure 41 shows how this works on an OHC engine (in this case, an
engine with dual overhead cams). The timing belt is driven by the
crankshaft pulley. The camshaft pulleys connected to this belt then turn
each camshaft.
FIGURE 41. A
pulley and a belt
or chain transfers
rotation from the
crankshaft to the
camshaft.
Camshaft
pulleys
Tensioner
pulley
Timing belt
Timing belt
pulley
Idler pulley
As Figure 41 shows, the timing belt pulley has half as many teeth as the
camshaft pulleys. This means that the camshafts turn once for every two
turns of the crankshaft. OHC drives also include a tensioner pulley and
tensioner spring or hydraulic auto tensioner, which maintain timing belt
tension and valve timing.
58
Timing Belt Auto Tensioner
OHC drives use a timing belt auto tensioner, which works similar to the
chain adjuster, except that the auto tensioner uses a rod and piston
instead of a ratchet. As shown in Figure 42, when the engine is cold, there
is little tension on the belt. The auto tensioner rod pushes the tensioner
pulley up, taking the slack out of the belt.
When the engine is warm, expansion causes increased belt tension, which
pushes the rod into the tensioner.
FIGURE 42. The

maintenance-
free timing belt
auto tensioner
automatically
adjusts the belt
tension
according to
engine
temperature.
Tensioner
pulley
Auto
tensioner
59
Belt and Chain Drive
Another type of DOHC drive is the combination belt and chain drive. In
this design, shown in Figure 43, a timing belt drives the intake camshaft,
and a timing chain drives the exhaust camshaft. The major advantage of
this design is that it allows the valves to be placed at a more vertical
angle. This angle produces enhanced combustion efficiency, better fuel
economy, and lower emissions.
FIGURE 43. The

combination
DOHC drive uses
a timing belt for
the intake
camshaft and a
timing chain for
the exhaust
camshaft.
Camshaft
pulley
Camshaft
chain
Chain
adjuster
Intake
camshaft
Exhaust
camshaft
Timing belt
pulley
Timing belt
Tensioner
pulley
60
Gear-Driven Camshaft with Friction Gear
Mazda also uses another type of cam drive that features a gear-driven
camshaft with a friction gear. In this design, shown in Figure 44, the timing
belt drives one camshaft on each head. The other camshaft is driven by
helical gears. The helical gears turn the driven-side camshaft
counter-clockwise. This design creates a more compact valve train, which
allows a lower hood line on the vehicle.
FIGURE 44 The
drive camshaft is
driven by the
timing belt. The
driven camshaft is
driven by helical
and friction gears.
Driven
camshaft
Drive
camshaft
Helical gears
Timing belt
Friction gear
The arrangement of the cam lobes on the two cams causes a clicking
noise as the cams turn. To eliminate this noise, the driven gear is
equipped with a friction gear.
The friction gear has one more tooth than the helical gear. The friction gear
causes a slight bind between the drive and the driven cam gears,
eliminating any clicking noise resulting from backlash/freeplay between the
gears.
61
CAMSHAFT DESIGN
Figure 45 shows a typical pair of camshafts used in a DOHC engine,

with one shaft for the intake side and one for the exhaust side.
FIGURE 45.
Camshafts
typically have a
thrust flange to
control
front-to-back
movement, and a
groove to drive
the distributor.
Intake
camshaft
Distributor
drive groove
Exhaust
camshaft
Journals
Cast
Hexagons
Thrust
flanges
Camshafts have thrust flanges either on the front or rear. In the illustration,
the flanges are on the front. These flanges match up with thrust surfaces in
the cylinder head to control front-to-back movement of the camshaft. These
flanges work much like thrust bearings do on the crankshaft. Some
camshafts have a separate thrust plate that performs the same function as
the flange.
Mazda OHC engines do not have insert bearings. Instead, the camshaft
rides directly on the polished journal of the head, which serves as the
“bearing” surface.
62
These camshafts also have hexagons cast right into the shafts. The hexagons are used to
hold the camshaft and keep it from turning when the camshaft pulley is removed or
replaced. The exhaust camshaft includes a groove that drives the distributor. The distributor
shaft rotates, allowing the distributor to direct electrical current to the spark plugs as they
fire in turn.
Auxiliary Drives
Some camshafts also have extra lobes, gears, or grooves that drive the fuel pump or oil
pump.
Lubrication
Oil passages in the cylinder head distribute oil through holes in the bearing surface to
lubricate the journals. The cam lobes are lubricated by oil dripping back into the oil pan or
by tubes delivering oil directly to the cams.
Camshaft Measurements
Critical measurements include:
• Clearance between the camshaft journals and bearing surface
• Journal roundness
• Camshaft end play
If any of these measurements are outside factory specifications, the engine may run poorly.
63
REVIEW EXERCISE 5
1. The surface of the valve head that contacts the valve seat is called the
____________________.
2. The _____________ holds the valve stem so the valve fits squarely on its seat.
3. Exhaust valves are more likely to be damaged by _______________ than intake

valves.
4. The length of an installed valve spring between the retainer and the spring pad is
called the __________________ .
Match the numbered illustrations to the valve train descriptions below.
5. _______ A. Overhead valve train (OHV)
6. _______ B. Single overhead camshaft (SOHC)
7. _______ C. Dual overhead camshafts (DOHC)
8. In an indirect camshaft drive, the camshaft pulley is driven by a _______________ or

______________ connected to a pulley on the crankshaft.
9. Which of these symptoms would you expect to see in an engine that has worn valves?
More than one answer may be correct.
A. low oil pressure
B. poor engine performance
C. overheating
D. rough idle
64
VALVE ADJUSTMENT
When a valve closes, there must be a small amount of clearance between

the end of the valve stem and the rocker arm. This clearance is called by
various names such as valve lash, tappet clearance, or valve clearance.
Engines that have solid lifters require periodic valve adjustments to make
sure the clearance is correct. The proper valve clearance eliminates noise
and excess friction.
In some engines, the clearance is adjusted by using shims, which are small
metal disks that come in various thicknesses. Figure 46 shows a tappet
and adjustment shim. By changing the thickness of the shim, the technician
adjusts the valve clearance.
FIGURE 46. In
some engines, a
shim is used to
adjust the valve
clearance.
Adjustment
shim
Tappet
Valve Clearance
The purpose of valve clearance is to make sure that the valve can close
tightly against its seat during compression and combustion. With no
clearance, the valve can be held slightly off its seat, causing compression
pressure to leak past the valve. When the valve remains partially open,
the valve head does not transfer heat to the seat, and combustion gases
will gradually burn the valve away.
On the other hand, if there is too much clearance, the valve train parts can
hammer against each other, causing a ticking noise often called ticking
valves.
65
Answers to HYDRAULIC LASH ADJUSTERS (HLA)

Review
Exercise 5
On other engines, the valve clearance is adjusted automatically by
1. face hydraulic lash adjusters (HLAs). HLAs eliminate the need for manual valve
2. valve guide adjustments.
3. heat
4. working
height Description and Operation
5. C (DOHC)
6. A (OHV) The HLA is mounted above the valve stem. A bucket-type HLA is
7. B (SOHC) positioned between the top of the valve stem and the camshaft, as shown
8. timing belt,
in Figure 47. In this design, the camshaft directly contacts the top of the
timing chain
9. B, D HLA. In some engines, a rocker arm-mounted HLA fits between the valve
stem and the rocker arm. (Rocker arm-mounted HLAs are described on
page 68.)
FIGURE 47.
Hydraulic lash
adjusters auto-
matically adjust
valve clearance.
Camshaft
Bucket-type
hydraulic
lash
adjusters
(HLAs)
66
Bucket-Type HLA
The bucket-type HLA, shown in Figure 48, has a bucket body that contains
two oil chambers. Movement of oil between these two chambers is
controlled by a check ball and spring.
FIGURE 48. A
bucket-type HLA
has two oil
chambers, a
check ball, and a
plunger.
Bucket
body
Body
Plunger
spring
Check ball
cage
Check ball
Check ball
spring
Plunger
As the oil moves from one chamber to the other, a spring-controlled

plunger moves up and down, and contacts the top of the valve stem.
67
Rocker Arm-Mounted HLA
Rocker arm-mounted HLAs operate much like bucket-type HLAs, except

that the top of the HLA contacts the rocker arm, rather than the camshaft.
Figure 49 shows how rocker arm-mounted HLAs are positioned in a DOHC
engine.
FIGURE 49.
Rocker arm-
mounted HLAs
are positioned
between the
valve stem and
the rocker arm.
Rocker
arms
HLAs
Camshafts
An HLA mounted on a rocker arm does not have a bucket body, but the
check ball, plunger, and body work the same way to maintain a valve
clearance of 0.
Regular Oil Changes
Because the plunger and body of the HLA fit so closely together, regular
oil changes according to the maintenance schedule are very important.
Even small particles of dirt can clog an HLA, resulting in a ticking noise.
Regular oil changes help prevent HLA noise.
68
PUSHRODS (OHV)
In an OHV engine, pushrods transfer the lifting motion from the camshaft
and lifters to the valves. Pushrods are made of stiff steel tubing, with cups
or balls on the ends to mate with the lifters and rocker arms.
The pushrods flex slightly in normal operation, and this flexing is taken into
account when the cam lift is designed. On some engines, pushrods come
in varying lengths to provide an initial clearance adjustment with hydraulic
lifters.
ROCKER ARMS
The rocker arm reverses the direction of lift from the pushrod or camshaft
to the valve. Mazda engines use shaft-pivoted rocker arms, as shown in
Figure 50. The rocker arm is made of aluminum, and a pivot is drilled out
so the rocker arm can run on a hollow rocker arm shaft.
FIGURE 50.
Rocker arms are
fitted to shafts.
Rocker arm
shaft
Shaft-pivote
d rocker arm
Valve
Pushrod
69
REVIEW EXERCISE 6
1. The space between the end of the valve stem and the rocker arm is called
_________________________________.
2. A(n) __________________ uses oil pressure and a plunger to eliminate the need for
manual valve adjustments.
3. In an OHV engine, the ______________________ transfers the lifting motion from the
camshaft and lifters to the valves.
4. A ___________________________ changes the direction of pushrod or camshaft

motion.
5. A ticking noise from the top of the engine at one half crankshaft speed may be caused
by:
A. excessive valve clearance

B. worn cylinders
C. a clogged HLA
D. carbon build-up
70
5 – LUBRICATION SYSTEM TC010-05-01S
The lubrication system provides a steady supply of pressurized oil to the moving parts of
the engine. Lubrication reduces friction and keeps parts from wearing against each other.
Oil also helps cool, clean, and reduce noise by constantly recirculating the engine oil
through an external filter. This section describes how the lubrication system works.
OBJECTIVES
• Identify important parts of the lubrication system and describe how they operate.
• Describe how oil flows through the lubrication system.
• Describe the differences between rotor-type and gear-type oil pumps.
• Describe how the oil filter traps dirt and debris in the oil.
• Describe the materials used in oil seals and gaskets.
71
SYSTEM COMPONENTS
Some important parts of the lubrication system are shown in Figure 51.
These parts are described in the following paragraphs.
FIGURE 51. The

lubrication
system provides
a steady supply
of pressurized
oil to moving
engine parts.
Oil pan
Oil strainer
Oil pump
Oil filter
72
Oil Pan Answers to

Review
Exercise 6
Bolted onto the engine under the crankcase, the oil pan is a holding area
— also called a reservoir or sump — for the engine oil. The oil pan transfers 1. valve
heat from the oil to the outside air, and it allows dirt picked up in the engine clearance
to settle out at the bottom. Many oil pans include a baffle to prevent oil from or lash
sloshing. 2. hydraulic
lash
adjuster
(HLA)
Oil Strainer (Pick-Up) 3. pushrod
4. rocker arm
The oil strainer or pick-up, is located in the bottom of the oil pan, where it is 5. A, C
completely covered by the engine oil. The oil pump draws oil through the
strainer. The oil strainer has a filter screen to keep large pieces of dirt and
debris out of the circulating oil.
Oil Pump
The oil pump provides the “push” that circulates the pressurized oil
throughout the engine.
Oil Filter
The oil filter traps smaller particles of metal, dirt, and debris carried by the oil
so they don’t recirculate through the engine. The filter keeps the oil clean to
reduce engine wear.
73
There are several other important parts of the lubrication system not shown in Figure 51.
These are described below.
Oil Seals
At various points in the engine, seals and gaskets are installed to prevent oil from leaking
out of the engine or into places in the engine where oil should not be present.
Dipstick
The engine oil dipstick is used to measure the level of oil in the oil pan. One end of the
dipstick dips into the top of the oil reservoir, and the other end has a handle so it can be
pulled out easily. The end that dips into the oil pan has a gauge on it that show whether oil
should be added to the engine.
It’s important to keep the oil level above the “ADD OIL” line at all times. The
crankcase should never be overfilled or allowed to drop too low. Too much oil may permit
the crankshaft to contact the oil and churn it until it turns to foam. The oil pump can’t pump
foam, and foam will not lubricate. Low oil levels can result in excessively high oil
temperatures, which may lead to bearing failure. An oil level that is too high or too low can
also increase oil consumption.
Consult the Workshop Manual or Owner’s Manual for the correct oil capacity and
recommended oil.
Oil Pressure Indicator
The instrument panel usually has some type of oil pressure indicator that warns the driver
when the lubrication system cannot maintain the oil pressure needed by the engine. This
indicator may be a gauge or a warning light.
74
HOW OIL CIRCULATES
Figure 52 shows how oil circulates through the lubrication system. The
numbers in this figure match the numbered steps in the description that
follows.
FIGURE 52. Oil

circulates from
the bottom of
the oil pan up
through the oil
filter, into the
cylinder block
and cylinder
head, through
the crankcase,
and back down
into the oil pan.
The oil in the oil pan is drawn up through the oil strainer by the oil
pump. The strainer filters out large particles.
Oil flows through the oil filter, which cleans the oil of smaller
particles of dirt and debris.
75
From the oil filter, the oil flows into the main oil passage — or gallery — in the
cylinder block.
From the main gallery, oil flows through smaller passages to the camshaft, pistons,
crankshaft, and other moving parts. Oil holes and jets direct the flow of oil to critical
parts, such as the bearings and pistons.
As the oil lubricates the surfaces of moving parts, it is constantly pushed off by new oil,
which cools the parts. The oil drips from the lubricated surfaces back into the oil pan.
In the oil pan, the oil cools before being drawn back through the oil strainer to repeat
the cycle.
PRESSURE LUBRICATION
Full pressure is used to pump oil through the main oil gallery, which is a hollow passage
cast into the cylinder block. Oil from the main gallery lubricates the crankshaft main
bearings, connecting rod bearings, camshaft, and hydraulic lash adjusters (if equipped).
In other parts of the engine, the volume is reduced as oil flows through smaller passages.
The reduced volume ensures that the main bearings get enough oil and that excess oil is
not introduced into the combustion chambers. The parts that are lubricated by reduced oil
pressure include pushrod ends (in OHV engines) and rocker arms.
76
OIL PUMPS
The oil pump pulls oil from the oil pan and pressurizes it so it will flow through the
lubrication system. The oil pump is usually mounted on the cylinder block or the front
engine cover. Most oil pumps are driven by the camshaft or crankshaft, using a gear and
chain.
Engine oil pumps are classified as positive displacement pumps. This means that all oil
entering the pump also comes out. Oil is not allowed to circulate inside
the pump.
Pressure Relief Valve
Oil pumps include a pressure relief valve, which limits the oil pressure that the pump can
develop. The faster an oil pump is driven, the more oil it pumps. So the capacity of the
pump will always be more than the engine needs.
If all the oil from the pump were forced into the oil passages, the oil would quickly heat up
and break down. To limit the oil pressure, the pressure relief valve opens at a preset
pressure and sends some of the oil from the pump’s outlet back into the inlet. In some
engines, the oil from the pressure relief valve is diverted back into the oil pan.
Excessive oil pressure damages seals and gaskets, causing oil leaks. Two main types of oil
pumps are typically used: rotor-type pumps and gear-type pumps.
77
Rotor-Type Pump (Trochoid)
A rotor-type, or trochoid, pump uses two rotors, one turning inside the other,
to pressurize the oil. The two rotors turn at slightly different speeds. The
rotors have smooth, rounded lobes. These types of rotors are called
trochoid gears. Figure 53 shows a typical rotor-type oil pump.
FIGURE 53. A
rotor-type, or
trochoid, oil
pump uses
rotors with
rounded lobes to
push oil through
the pump.
Inner rotor
Outer rotor
Outlet port
Pressure
relief valve
Inlet port
Engine oil
Pump body
In this design, the inner rotor is driven by the crankshaft. The inner rotor
turns the outer rotor. As the two rotors turn, pumping cavities are formed
between the lobes on the two rotors. Oil is drawn into these cavities at the
inlet port of the pump. The pumping cavities become smaller and larger as
the lobes on the two rotors mesh. This squeezing action pushes the oil
through the pump to the outlet port.
78
The simple design of the rotor-type pump makes it very reliable. In addition,
rotor-type pumps can withstand high-speed operation, and they produce a
smooth flow of oil, rather than a pulsing action.
The rotor-type pump used on Mazda engines has a small hole at the outlet
side to allow air to escape. If there is no oil in the pump because the
vehicle has not been driven for a long time, the air hole vents the air
quickly when the engine is started. This allows oil to flow almost
immediately to critical engine parts.
Gear Pump
In a gear-type oil pump, two gears are used to push the oil through the
pump. Figure 54 shows how a typical gear-type pump operates.
FIGURE 54. A
gear-type oil
pump uses a
drive gear and a
driven gear
turning in
opposite
directions.
Outlet port
Drive gear
Driven gear
Inlet port
The drive gear is driven by the camshaft or crankshaft. As the drive gear
turns, it meshes with the driven gear, which turns in the opposite direction.
As the gears turn within the pump body, they create a vacuum — an
area that has no gas or fluid in it — at the inlet port. Oil is drawn into this
vacuum. The oil moves between the gears and the pump body to the
outlet port.
79
OIL FILTER
The engine oil filter traps very small particles that may get through the oil
strainer. Mazda oil filters are the full-flow type. This means that all the oil
pumped by the oil pump passes through the oil filter. The filter contains a
paper element that screens out particles in the oil.
A typical oil filter is shown in Figure 55. Oil flows from the oil pump and
enters the oil filter through several holes. The oil first flows around the
outer part of the filter element. Then it passes through the filter material
into the center of the element. Finally, the oil flows out to the main gallery
through a tube in the center of the filter.
FIGURE 55. The

paper element in
the oil filter traps
particles and dirt
in the oil.
Paper
element
Flow to
main gallery
Flow from
oil pump
Spring
Bypass
valve
The filter screws onto the main oil gallery tube. A seal prevents oil from
leaking at the connection between the filter and the cylinder block.
Bypass Valve
As the element in the oil filter becomes dirty, the oil pump must work
harder to push oil through the filter. If the filter becomes fully clogged, the
engine could be starved of oil, and important parts such as the crankshaft
bearings could be damaged.
80
To prevent this type of damage, the filter also includes a spring-loaded bypass valve. This
valve “senses” the back-pressure from the filter as it becomes clogged. When the
back-pressure becomes great enough to overcome the spring on the bypass valve, the
valve opens, allowing some of the oil to bypass the filter and go directly to the oil gallery
tube.
Anti-Drainback Diaphragm
Mazda oil filters also contain an anti-drainback diaphragm, which keeps oil in the filter when
the engine is shut off. The diaphragm covers all the filter inlet holes when the oil pump
stops. When the engine is shut off, the pressure of the oil in the filter forces the diaphragm
down on the holes, sealing oil in the filter.
When the engine starts again, oil flows immediately from the filter. In this way, critical
engine parts receive lubrication right away. As the pressure from the oil pump grows, the
diaphragm is pushed away from the holes, allowing normal oil flow to begin again.
SEALING MATERIALS
At various locations in the engine, seals and gaskets keep the oil from leaking. The most
common material used for sealing the lubrication system is synthetic rubber. In critical
areas, it may be bonded to metal or fiber. Natural rubber is never used because engine oil
will break it down.
When seals or gaskets are replaced, the surfaces must be cleaned completely before
the new seal or gasket is installed. In addition, the bolts that secure the seal must be
tightened to the correct tightness, or torque, in the proper order.
When a properly installed seal or gasket begins to leak, the cause is usually excessive
internal pressure, worn bearings, a bent shaft, or a rough sealing surface.
81
REVIEW EXERCISE 7
1. The component in the bottom of the oil pan that filters out large particles is called the
______________________.
2. The largest oil passage in the cylinder block is called the

__________________________.
3. As oil is pushed off lubricated surfaces by new oil, it collects at the bottom of the engine
in the ______________________ .
4. An oil pump that uses two rotors, one turning inside the other, is called a
_____________________ -type pump.
5. The ________________________ contains a bypass valve and an anti-drainback

diaphragm.
6. Which of these symptoms would you expect in an engine that has a damaged oil
pump? More than one answer may be correct.
A. high idle
B. noisy engine
C. dirty oil filter
D. low oil pressure
82
6 – COOLING SYSTEM TC010-05-01S
Most engines are cooled by a steady flow of liquid coolant through the cylinder block and
heads. The cooling system is one of the automobile’s most important systems. It removes
excess heat produced during combustion and keeps the engine operating at its most
efficient temperature. If the cooling system fails, the engine can overheat and seize. An
operating temperature that is too cool results in poor gas mileage and incomplete
combustion. The hot coolant is also used to operate the heater for the passenger
compartment. This section describes how the cooling system works.
OBJECTIVES
• Identify important parts of the cooling system and describe how they work.
• Identify the important parts of a water pump and describe how they operate.
• Describe the differences between downflow and crossflow radiators.
• Describe how the radiator reservoir works.
• Identify the important parts of the pressure cap and describe how they work.
• Describe how the thermostat works.
• Describe the differences between mechanical and electric fan drives.
• Describe how a viscous drive clutch works.
83
COMPONENTS
The cooling system maintains an efficient operating temperature. About

one third of the heat created by combustion is removed by the cooling
system. Important parts of the cooling system are shown in Figure 56.
These parts are described in the following paragraphs.
Coolant
In early engines, water alone was used as coolant. Today, most engines
use an ethylene-glycol-based coolant mixed with water that lowers the
freezing point of water, raises the boiling point of water, adds water pump
lubrication, and prevents engine corrosion.
Because coolant is toxic, never dump it down a drain.

FIGURE 56. The
cooling system
circulates coolant
throughout the
engine.
Water pump
Coolant
passages
Thermostat
Radiator
reservoir
Fan
Pressure cap
Radiator
84
Water Pump
Answers to Review
Exercise 7
The water pump circulates coolant throughout the cooling system.
1. oil strainer
Coolant Passages 2. main gallery
3. oil pan
Coolant passages are cast into the cylinder block and cylinder head. 4. rotor or trochoid
These passages carry coolant around the cylinders and combustion
5. oil filter
chambers. The coolant picks up heat and carries it away from these
parts. 6. B & D
Thermostat
The thermostat regulates engine temperature by controlling the flow of
coolant until a certain preset temperature is met. This helps the engine
warm up quickly and maintain a more even temperature.
Radiator Reservoir
As coolant becomes hot, it expands. The coolant recovery system

stores the excess coolant released from the radiator. When the engine
cools, the coolant in the reservoir is drawn back into the cooling system.
This keeps the cooling system constantly full, increasing cooling system
efficiency.
Fan
The radiator fan pulls cool outside air over the radiator surface to pick
up heat from the coolant for faster heat transfer, especially during idling.
Models equipped with air conditioning usually have an additional fan for
increased cooling.
Pressure Cap
The pressure cap maintains pressure in the system which raises the
boiling temperature of the coolant, preventing the coolant from
evaporating or boiling off. This cap also allows excess pressure to
escape from the system.
Radiator
The radiator transfers heat from the coolant to the outside air. The
radiator core contains tubes and fins. Coolant flows through the tubes,
and the fins increase the radiator’s surface area exposed to the air. This
allows the air to carry away more heat, reducing the coolant
temperature.
85
HOW COOLANT CIRCULATES
Figure 57 shows how coolant circulates through the cooling system. The
numbers in this figure match the numbered steps in the description that
follows.
FIGURE 57. Coolant
flows from the
cylinder head
passage through
the radiator and
water pump to the
cylinder block.
To/from heater
86
When a cold engine is started, the water pump only circulates coolant through the
cylinder head and engine block coolant passages, quickly raising the engine
temperature.
When enough heat is created to open the thermostat, the water pump circulates
coolant throughout the engine and into the radiator.
The hot coolant flows from the upper tank of the radiator, to the lower radiator tank.
Cool air passing over the radiator fins removes heat from the coolant.
From the lower tank, coolant flows through the lower radiator hose to the water pump
inlet.
The water pump circulates the coolant through the pump outlet into the cylinder block
coolant passage.
Coolant flows from the cylinder block passage into the cylinder head coolant passage
to complete the circuit.
As Figure 57 also shows, some of the coolant may be diverted to the heating system, which
heats the passenger compartment of the vehicle.
WATER PUMPS
Most water pumps are impeller or non-positive displacement pumps. This means that all the
water that enters the pump does not necessarily have to come out of the pump. This design
is different from the oil pump (a positive displacement type), in which all the oil that enters
the pump is pumped out.
Impeller-Type Pump
Water pumps are usually designed as simple impeller-type pumps. Figure 58 shows the
parts of a typical impeller-type water pump.
87
FIGURE 58.
Water pumps are
simple impeller-
type pumps.
Pump pulley
Shaft and
bearing
assembly
Pump body
Water seal
Impeller
Pump inlet
The water pump has a pump body, which holds the impeller (also called
a vane or rotor). The impeller turns on a shaft that is connected to a
pulley driven by the crankshaft. The impeller shaft is supported by a
bearing. A water seal keeps coolant from leaking out of the pump. A worn
bearing or impeller shaft causes the seal to leak.
Centrifugal Operation
The impeller-type pump operates on centrifugal action, which is the

tendency of a rotating weight to be pushed outward. Coolant flows
through the pump inlet and enters the center of the impeller, as shown in
Figure 59. As the impeller rotates, it “slings” the coolant to the outside
edges of the impeller. The coolant is trapped by the pump body and
forced into the pump outlet.
FIGURE 59.
Centrifugal force
pushes coolant
from the center of
the impeller to the
outside edges of the
impeller.
Pump inlet
Impeller
Pump outlet
88
REVIEW EXERCISE 8
1. Coolant lowers the freezing point of water and ______________________ the boiling
point.
2. The _____________________ helps the engine warm up by restricting coolant flow

until a certain temperature is reached.
Use the water pump illustration below to complete the following two items.
3. Item in this illustration is the _______________________.
4. Item in this illustration is the _______________________.
5. Which of these symptoms would you expect to find in an engine that has a failing
water pump? More than one answer may be correct.
A. overheating
B. noisy tappets
C. hard starting
D. gasoline fumes
89
RADIATORS
Mazda uses both downflow and crossflow radiators.
Downflow-Type
Figure 60 shows a typical downflow-type radiator. As its name suggests,

the downflow radiator has an upper and lower tank. Tubes connect the
tanks. Coolant flows down from the upper tank through the core and into
the lower tank. Cooling takes place as the liquid passes through the
radiator core. If the vehicle has an automatic transmission, the radiator
may have a separate cooler at the bottom for the automatic transmission
fluid.
FIGURE 60. A
downflow-type
radiator has an
upper and lower
tank.
Coolant Flow
Coolant inlet
Upper tank
Lower tank
Coolant
outlet
Core
90
Crossflow-Type
The crossflow-type radiator is also commonly used. In this design

(shown in Figure 61), the tanks are on the side of the core, so the
coolant flows through tubes from one side to the other.
FIGURE 61. A
crossflow-type
radiator has side
tanks.
Right tank
Left tank
Coolant Flow
Coolant inlet
Coolant outlet
Core
Answers to
Review Exercise
8
1. lowers
2. thermostat
3. water seal
4. impeller
5. A — over-
heating
91
Radiator Reservoir
Coolant level is checked and coolant is added at the radiator reservoir. A

hose connects the reservoir to the radiator filler neck, as shown in Figure
62. As engine temperature rises, the expanding coolant flows from the
radiator into the reservoir. When the engine is stopped, the coolant
temperature drops and contracts. A partial vacuum develops in the
cooling system, drawing coolant from the reservoir backinto the cooling
system.
As shown in Figure 62, the reservoir has an overflow tube that allows
coolant to escape if the cooling system is overfilled or when the engine
overheats.
FIGURE 62. As
the coolant
expands, the
excess coolant
flows into the
reservoir. As it
contracts, it is
drawn back into
the radiator.
Radiator
reservoir hose To filler neck
Overflow tube
PRESSURE CAP
The pressure cap on the radiator maintains pressure in the cooling

system. The boiling point of a liquid rises with the amount of pressure it is
under. For example, water at sea level boils at about 212 degrees
Fahrenheit. Water in a typical pressurized cooling system boils at more
than 250 degrees Fahrenheit. So pressurizing the cooling system
effectively raises the operating temperature of the engine.
Figure 63 shows a typical radiator pressure cap, which fits on the filler
neck on the radiator. The cap includes a pressure valve (or blow-off
valve) and a vacuum valve. Both are spring-loaded to remain closed
when the system is within operating ranges.
92
FIGURE 63. The

pressure cap raises
the operating
temperature of the
engine.
Pressure cap
Radiator
reservoir hose
Pressure valve
Vacuum valve
Filler neck
To radiator reservoir
If the pressure in the cooling system exceeds the specified limit, the
pressure valve opens to avoid bursting the radiator or hoses. Steam
and coolant can then escape through the reservoir hose (attached to
the filler neck) into the radiator reservoir.
When the engine is shut off, steam in the system condenses back into
liquid, creating a vacuum in the system. In this case, the vacuum valve
on the pressure cap opens, allowing coolant from the reservoir back
into the radiator through the radiator reservoir hose. Without a vacuum
valve, the radiator tanks and hoses could collapse.
The pressure cap protects the cooling system from springing leaks due
to excess pressure or vacuum. For the cap to work correctly, the entire
cooling system must be air-tight.
Testers are used to check the cooling system for proper sealing. The
tester is attached to the radiator filler neck and pumped up to see if the
system will maintain pressure. The cap is also tested separately.
Removing the radiator cap while the engine is running, or when

the engine and radiator are hot is dangerous. Coolant and steam
may escape and cause serious injury. Turn off the engine and wait
until it is cool before removing the cap. Even then, be very careful.
93
THERMOSTAT
The thermostat restricts the flow of coolant through the system until the
engine reaches its operating temperature. This helps the engine warm up
quickly, which improves fuel economy and emissions. A quick warm-up also
keeps combustion chamber gases from blowing by the pistons and entering
the crankcase, contaminating the oil.
The thermostat contains a heat-sensitive wax pellet, as shown in Figure 64.

When the engine is cold, the wax remains solid, and the spring holds the
valve closed.
FIGURE 64. A
wax pellet Closed Open
expands and
contracts to
open and close
the thermostat
valve.
Valve
Coolant flow
Spring
Wax
When the coolant heats up, the wax turns to liquid and expands. The
expansion pushes the body of the valve down, which opens the flow of
coolant to the radiator.
94
To provide an outlet for air in the cooling system, many thermostats

include a jiggle pin, either in the thermostat itself or in the thermostat
housing. Figure 65 shows how a jiggle pin works.
FIGURE 65. The
Open Closed jiggle pin opens
when air is in
the cooling
system.
Jiggle pin
Thermostat
housing
When there is air in the cooling system, the weighted end of the jiggle
pin drops down, allowing the air to escape. When the engine is
operating, pressure from the water pump pushes the jiggle pin against
its seat. The closed jiggle pin prevents coolant from flowing to the
radiator until the thermostat opens.
FAN DRIVES
The cooling system fan draws air through the radiator core to cool the
engine coolant. Most fans have four or more blades to increase their
cooling capacity. A fan shroud may surround the fan to concentrate the
flow of air.
On some engines, an electric motor drives the fan. In this design, a

thermoswitch (engine coolant temperature sensor) monitors the coolant
temperature. When the coolant reaches a preset temperature, the
thermoswitch activates an electrical relay, which turns on the fan motor.
When the coolant temperature drops, the thermoswitch turns off the fan
motor.
On other engines, the coolant fan is driven by a pulley and belt. This
design is called a mechanical drive.
95
Viscous Drive Clutch
Most mechanical drive fans use a clutch drive, which allows the fan to
turn at lower speeds when the temperature is lower. If the fan were
constantly turned at the speed of the engine, the fan would become very
noisy at high speeds, and it would sap engine power.
One of the most common types of fan clutches is the viscous type. A
viscous drive is a fluid coupling. Viscous refers to the viscosity, or
thickness, of the fluid — usually a silicon oil — that is used to control the
clutch. A typical viscous drive clutch is shown in Figure 66.
FIGURE 66. A
viscous drive fan
clutch conserves
engine power by
match- ing fan
speed to air
temperature.
Clutch plate
Bi-metal
thermostat
The amount of coupling is controlled by a bi-metal thermostat, which is a
spring made of two types of metal. The spring expands at higher
temperatures and contracts at lower temperatures. The thermostat is
connected to a valve that controls the amount of fluid available to couple
the clutch.
The thermostat responds to the temperature of the air passing through

the radiator. If the air temperature is cold, the flow of fluid in the clutch is
restricted. Little or no coupling occurs, and the fan turns very slowly or
not at all. At higher temperatures, the fluid operating on the clutch
increases, causing a tighter coupling and faster fan speed.
96
REVIEW EXERCISE 9
1. A radiator that has side tanks, rather than top and bottom tanks, is called a
______________________ radiator.
2. A coolant fan that is driven by the engine is called a _______________________

drive.
Use the pressure cap illustration below to complete the following two items.
3. Item in this illustration is the ________________________.
4. Item in this illustration is the ________________________.
5. Which of these symptoms would you expect to find in an engine that has a faulty
thermostat? More than one answer may be correct.
A. leaking oil
B. fan not rotating
C. overheating
D. noisy engine
97
Answers to Review
Exercise 9
1. crossflow
2. mechanical
3. vacuum valve
4. radiator
reservoir
hose
5. C — overheating
98
7 – GLOSSARY TC010-05-01S
anti-drainback diaphragm — an oil filter camshaft flange — a raised surface on

component that keeps oil in the filter when the camshaft that matches a thrust surface
the engine is shut off. in the cylinder head to control front-to-back
movement of the camshaft.
BDC — See bottom dead center.
combustion — the process of controlled
bearing cap — a U-shaped component burning of an air-fuel mixture in the
used to attach the crankshaft, connecting cylinders.
rod, or camshaft to its support surface.
combustion chambers — the spaces in
bearing clearance — the gap between a the cylinder head where the air-fuel mixture
main bearing and a main journal. is compressed and burned.
belt and chain drive — a camshaft drive compression ratio — the ratio of the
in which a timing belt drives the intake cylinder volume at bottom dead center to
camshaft, and a timing chain drives the the volume at top dead center.
exhaust camshaft.
compression rings — the top two rings
blow-off valve — See pressure valve. mounted on the piston that seal, scrape,
and cool the cylinder.
bore —the diameter of a cylinder, usually
expressed in millimeters (mm). compression stroke — the part of the
four-stroke cycle in which the upward
bottom dead center — the position of a stroke of the piston compresses the air-
piston at its lowest point in the cylinder; fuel mixture into a very small volume at the
abbreviated as BDC. top of the cylinder.
bushing — a circular, sleeve-type bearing. connecting rod — attaches a piston to the

crankshaft; the connecting rod transfers the
bypass valve — an oil filter component movement of the piston to the connecting
that “senses” back-pressure from a clogged rod journal on the crankshaft.
filter and allows some oil to bypass the
filter. connecting rod bearing — a split circular
sleeve that wraps around a connecting rod
cam follower — See lifter. journal on the crankshaft.
cam lobe — an off-center bulge on a connecting rod journal — a smooth

camshaft that pushes against a lifter or round surface, offset from the center line of
rocker arm to control the opening and the crankshaft, that is used to attach the
closing of a valve. connecting rods from the pistons; also
called a crankpin.
cam-ground piston — a piston that is
slightly oval shaped to allow for heat coolant passage — a passage cast into
expansion. the cylinder block or cylinder head to carry
coolant around the cylinders.
camshaft — a solid or hollow cast iron
shaft with offset lobes, or cams, that control
the opening and closing of the valves.
99
cooling system — the engine components cylinder head gasket — seals the
that circulate coolant to maintain proper connection between the cylinder block and
operating temperatures in and around the cylinder head; the gasket is usually made
cylinders. of steel coated with a softer material.
counterweight — a weight cast into the dipstick — a fluid level gauge used to
crankshaft opposite a connecting rod measure the level of engine oil in the
journal; counterweights help balance the oil pan.
crankshaft and prevent vibration during
high-speed rotation. displacement —the volume of a cylinder
between the top dead center and bottom
crankcase — the chamber at the bottom of dead center positions of the piston; the
the cylinder block where the crankshaft displacement of an engine is the total
turns. displacement of all the cylinders in the
engine, usually expressed in cubic
crankpin — See connecting rod journal. centimeters (cc) or liters (L).
crankshaft — the shaft that changes the distributor — directs electrical current to
up-and-down motion of the pistons into the spark plugs as they fire in turn.
rotational motion.
distributor groove — a groove on the
crossflow-type radiator — a radiator with exhaust camshaft that drives the
side tanks that allow coolant to flow through distributor.
the core from side to side.
DOHC — See dual overhead cam.
cylinder — See cylinder bore.
downflow-type radiator — a radiator
cylinder block — the main supporting with upper and lower tanks that allow
member of the engine that contains the coolant to flow through the core from top
cylinders, pistons, connecting rods, to bottom.
and crankshaft.
dual overhead cam — an engine design
cylinder bore — a machined space in the in which the valves and two camshafts are
cylinder block where the pistons are mounted above the cylinders; one
housed. camshaft operates the intake valves and
the other operates the exhaust valves;
cylinder head — a structural member of abbreviated as DOHC.
the engine that is bolted to the top of the
cylinder block; the cylinder head seals the electric fan drive — a radiator fan drive
tops of the cylinders, and contains the valve that uses an electric motor to operate the
train components and spark plugs. fan only when a thermoswitch senses that
the coolant has reached a preset
temperature.
end play — movement of the crankshaft or

camshaft from front to rear.
100
exhaust stroke — the part of the four- head — See cylinder head, piston head, or
stroke cycle in which the piston moves up valve head.
into the cylinder, pushing burned gases out
through the exhaust valve. head gasket — See cylinder head gasket.
exhaust valve — lets burned gases out of hydraulic lash adjuster — a component
the cylinder. mounted above the valve that uses
hydraulic pressure to automatically adjust
face — See valve face. the valve clearance to 0; abbreviated as
HLA.
fan — pulls cool outside air over the
radiator surface to pick up heat from the impeller-type pump — a pump that uses
coolant. a vane or rotor and centrifugal action to
pressurize liquid; most water pumps are
filter element — the paper material in an impeller-type pumps.
oil filter that screens out dirt and debris.
in-line — an engine design with the
flex-blade fan — a radiator fan that cylinders arranged in a single row.
flattens out as its speed increases.
insert bearings — smooth surfaces fitted
float — See valve “float.” into the support surfaces on the bottom of
the cylinder block; the crankshaft main
flywheel — a heavy, round metal plate journals are supported by insert bearings.
attached to the crankshaft; the flywheel
keeps the crankshaft turning smoothly. intake stroke — the part of the four-
stroke cycle where the piston moves down
four-stroke cycle — in most piston in the cylinder, creating a partial vacuum
engines, the set of piston movements that that sucks the air-fuel mixture through the
produce power through combustion; intake valve into the cylinder.
includes the intake, compression, power,
and exhaust strokes. intake valve — lets the air-fuel mixture
into the cylinder.
full-flow oil filter — an oil filter that filters
all the oil pumped by the oil pump. jiggle pin — a thermostat component that
allows air in the cooling system to escape.
gear-driven camshaft with friction gear
— a camshaft drive in which a timing belt journal — a smooth round surface on a
drives one camshaft on each head; the shaft that allows the shaft to turn freely.
other camshaft on each head is driven by
helical gears and a friction gear. keeper — small, semi-circular metal parts
that fit in a groove at the end of the valve
gear-type pump — a pump that uses two stem to hold the valve spring in place.
gears, turning in opposite directions, to
pressurize liquid. lash — See valve clearance.
harmonic balancer — See vibration

damper.
101
lifter — the component in an overhead oil filter — traps small particles of metal,
valve engine that transfers the rotary dirt, and debris carried by the oil so they
motion of the camshaft into the don’t recirculate through the engine.
up-and-down motion of the pushrod.
oil pan — a pan bolted to the engine under
long block — See partial engine. the crankcase that serves as a holding
area for engine oil.
lubrication system — the engine
components that distribute oil to moving oil pick-up — See strainer.
parts to reduce heat and wear.
oil pressure indicator — a gauge or
main bearing — a split circular sleeve that warning light on the instrument panel that
wraps around a crankshaft main journal; the shows when the lubrication system cannot
upper bearing fits into a main support on supply all the oil needed by the engine.
the bottom of the cylinder block; the lower
bearing fits into a bearing cap. oil pump — provides the “push” to
circulate pressurized oil throughout the
main bearing journal — a smooth round engine.
surface on the crankshaft that supports the
crankshaft in the crankcase and allows it to oil ring — three pieces, or segments,
turn freely. mounted below the compression rings on
the piston that scrape oil from the cylinder
main gallery — the largest oil passage in wall and direct it into the open space inside
the cylinder block. the piston skirt; the oil ring typically
includes two scraper rings and an
margin — the extra material on a valve expander ring.
head behind the valve face that can be
ground to form a new face finish so the oil seals — installed at various points in
valve can be reused after wearing. the engine to prevent oil from leaking out of
the engine or into places where oil should
mechanical fan drive — a radiator fan not be present.
drive that uses a pulley and belt to drive
the fan. overflow tube — a cooling system
component that allows coolant to escape if
mushroom valve — See valve. the cooling system is overfilled or if the
engine is overheating.
non-positive displacement pump — a
pump that does not have to pump out all overhead cam — an engine design with
the liquid that enters it; most water pumps the camshaft and the valves mounted
are non-positive displacement types. above the cylinders; the camshaft directly
operates the valves; abbreviated as OHC.
offset piston — a piston with the piston
pin bore drilled slightly away from the overhead valve — an engine design with
center of the piston; offset pistons reduce the valves mounted above the cylinders;
piston slap. the camshaft, located in the engine block,
operates each valve through a pushrod
OHC — See overhead cam. and rocker arm; abbreviated as OHV.
OHV — See overhead valve.
102
partial engine — a short block plus pressure relief valve — an oil pump
cylinder head(s) and cover(s), timing belt component that allows oil to be diverted
and covers, and oil pan. from the pump when maximum oil pressure
has been reached.
piston “slap” — the sound made by a
piston as it hits the cylinder wall during the pressure valve — a spring-loaded valve in
power stroke. the radiator pressure cap that allows steam
and coolant to escape to the radiator
piston — forms the bottom of the reservoir when high pressure builds in the
combustion chamber and receives the cooling system.
energy created by combustion; pistons
move up and down in the cylinders. pushrod — a component in an overhead
valve engine that transfers motion from the
piston head — the top surface of a piston. lifter to the rocker arm, which opens and
closes the valve.
piston pin — a steel pin (also called a
wrist pin) that attaches the piston to the radiator — the part of the cooling system
connecting rod. that dissipates the heat the coolant has
absorbed from the engine.
piston pin bore — a cylindrical hole drilled
through the piston; the piston pin is inserted radiator reservoir — holds coolant that
through the piston pin bore. flows from the radiator when the engine is
very hot; when the engine cools, the
piston rings — rings mounted on the coolant in the reservoir is drawn back into
piston to seal the combustion chamber, the cooling system.
scrape oil from the cylinder walls, and
carry heat from the piston to the cylinder retainer — See valve retainer.
walls.
rocker arm — a valve train component
positive displacement pump — a pump that pushes down on the valve spring,
that pumps out all the liquid that enters it; allowing the valve to open; the rocker arm
liquid is not allowed to circulate inside a is moved by a pushrod or camshaft.
positive displacement pump; most oil
pumps are positive displacement types. rocker arm shaft — a hollow shaft used to
mount shaft-pivoted rocker arms.
power stroke — the part of the four-
stroke cycle where a spark from the spark rotor-type pump — a pump that uses two
plug ignites the air-fuel mixture, creating rotors, one turning inside the other, to
very high pressure on top of the piston, pressurize liquid; most oil pumps are rotor-
which is pushed down in the cylinder and type pumps, also called trochoid pumps.
turns the crankshaft.
seat — See valve seat.
pressure cap — screws onto the radiator
filler neck and maintains pressure in the short block — describes the cylinder
cooling system to raise the boiling block, crankshaft, bearings, connecting
temperature of the coolant. rods, and pistons as a unit.
103
skirt — the lower part of the piston, from timing chain — a chain connecting the
below the piston rings to the bottom of the crankshaft gear to the camshaft gear used
piston. to drive the camshaft.
spark plug — produces a spark to ignite top dead center — the position of a
the air-fuel mixture in the cylinder. piston at its highest point in the cylinder;
abbreviated as TDC.
spring seat — washer-like parts that hold
the valve spring in place. torque — turning or twisting effort.
strainer — a component in the oil pan that torsional vibration — the constant
draws oil from the pan for circulation twisting and untwisting of the crankshaft
throughout the engine; screens out large caused by the downward thrust of the
pieces of debris in the oil. pistons.
stroke — the length of piston travel trochoid pump — See rotor-type pump.
between top dead center and bottom dead
center, usually expressed in millimeters. V-6 — an engine design in which the
cylinders are grouped into two banks of
tappet — See lifter. three cylinders each, arranged in a “V”
pattern.
tappet clearance — See valve clearance.
V-8 — an engine design in which the
TDC — See top dead center. cylinders are grouped into two banks of
four cylinders each, arranged in a “V”
tensioner pulley — a pulley that maintains pattern.
timing belt tension and prevents the timing
belt from slipping. vacuum valve — a spring-loaded valve
in the radiator pressure cap that allows
thermostat — restricts the flow of coolant coolant to return to the radiator when the
until the engine reaches its operating engine cools.
temperature.
valve “float” — the failure of a valve to
thermoswitch — an electrical component seat at high speed, usually caused by a
that senses the coolant temperature and weak valve spring.
activates an electric motor for the radiator
fan. valve “ticking” — a noise created when
the valve train parts hammer against each
thrust bearing — a special bearing that other, usually because the valve clearance
matches up with a thrust surface on the is too large; an HLA noise caused by dirt or
crankshaft to control front-to-rear air trapped in the HLA.
movement of the crankshaft.
valve — seals against a seat in the cylinder
ticking — See valve “ticking.” head and opens and closes at precise
intervals to allow the air-fuel mixture into
timing belt — a belt connecting the the cylinder or exhaust gases out of the
crankshaft pulley to the camshaft pulley(s) cylinder.
used to drive the camshaft(s).
104
valve adjustment — the process of vibration damper — controls torsional

setting the valve clearance to proper vibration of the crankshaft; mounted on the
specifications; valves can be manually or front end of the crankshaft, often as part of the
hydraulically adjusted. pulley; also called a torsional damper or
harmonic balancer.
valve clearance — the small gap between
the end of the valve stem and the rocker viscous drive clutch — a type of radiator
arm; also called lash. fan clutch controlled by a thermostat and
fluid coupling; a viscous drive clutch allows
valve face — the tapered surface of the the fan to turn slow at low temperatures
valve head that seals against the valve and fast at high temperatures.
seat in the cylinder head.
water pump — provides the “push” to
valve guide — a hollow insert or passage circulate coolant throughout the cooling
in the cylinder head that holds the valve system.
stem.
working height — the length of an
valve head — the larger end of the valve installed valve spring between the retainer
that seals the valve port. and the spring pad on the cylinder head
when the valve is fully closed.
valve lash — See valve clearance.
wrist pin — See piston pin.
valve port — a passage controlled by a
valve that lets the air-fuel mixture into the
cylinders through the intake port; lets
exhaust gases out through the exhaust
port after the mixture has burned.
valve seal — seals the valve stem in the

valve guide, preventing oil from entering
the combustion chamber.
valve seat — the surface on the cylinder

head where the valve head closes to seal
the valve port.
valve spring — holds the valve closed

when the cam lobe is not pressing it open.
valve stem — the long, narrow part of the

valve above the valve head.
valve train — the engine components that

open and close the intake and exhaust
valves so that the four-stroke cycle is
timed properly.
105
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LEVEL F

Mazda Motor Corporation

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

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

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

Audience and Purpose

Course Content and Objectives

2 – Basic Engine Operation

HOW TO USE THIS GUIDE

Text and Illustrations

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

This section provides an overview of how the engine converts

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

• 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:

- Valve train type

- Bore, stroke, and displacement

HOW POWER IS DEVELOPED

The process shown in Figure 1 is how the engine produces power.

To harness this power, the up-and-down movement of the piston is

The process of burning the air-fuel mixture in the cylinder is called

2. Squeeze (compress) the mixture so it will burn better and deliver

3. Burn the air-fuel mixture.

4. Remove the burned gases from the cylinder so intake, compression,

• An intake valve lets the air-fuel mixture into the cylinder.

• A spark plug ignites the air-fuel mixture.

• An exhaust valve lets the burned gases out of the cylinder.

THE FOUR-STROKE CYCLE

Most automotive engines use a four-stroke cycle to complete the

Top dead center

The four-stroke cycle requires four up-and-down movements of the piston

3. Power (combustion) stroke

Intake Stroke Compression Power Stroke Exhaust Stroke

As the piston moves down in the cylinder, it creates a partial vacuum,

Refer to the illustration below to complete the following two items.

4. This illustration shows the _____________________ stroke of the four-stroke cycle.

BASIC DESIGN CHARACTERISTICS

• Valve train type

• Size of the engine’s bore, stroke, and displacement

Valve Train Type Answers to

Bore, Stroke, and Displacement

Bore, stroke, and displacement are measurements of the cylinders and

FIGURE 10. Bore

Bore is the diameter of a cylinder, usually expressed in millimeters (mm).

The displacement of a cylinder is the volume of the cylinder between the

Generally speaking, engine displacement is a rough indicator of power

The compression ratio measures how much the air-fuel mixture is

FIGURE 11. The

Generally, a higher compression ratio means greater power output. For

ENGINE COMPONENTS AND SYSTEMS

• Cooling system — Maintains ideal operating temperatures in the engine.

1. A V-6 engine usually has six cylinders arranged in _____________________ banks of

3. The diameter of a cylinder is called its __________________________.

4. The _______________________ of an engine measures how much the air-fuel

5. The ______________________ of an engine is the total volume of all the cylinders

After completing this section, you will be able to:

• Describe how main bearings secure and lubricate the crankshaft.