Engine 4G15

Copy Right © Akademi Saga/EON Berhad

Classification Of Engine

Stroke Cycle Operation

Combustion Cooling ValveMechanism

CylinderArrangement

• Four Stroke Cycle Engine

• Two Stroke Cycle Engine

• Spark Ignition Engine ….Petrol

• Compression Ignition….Diesel

• Water Cooled

• Air Cooled

• OverHead Valve

• OverHead Cams

CLASSIFICATION OF ENGINE

Classification Of Engine

• Four Stroke Cycle Engine

• Two Stroke Cycle Engine

• Spark Ignition Engine ….Petrol

• Compression Ignition….Diesel

• Water Cooled

• Air Cooled

• OverHead Valve

• OverHead Cams

• In-Line

• V Type

• Horizontally Opposed Type

• Horizontally Mounted Type

COMBUSTION REQUIREMENTS

There is three condition are required to run the engine smoothly :

Proper Compression

Proper Air/Fuel Mixture

Proper Sparking


Block Manufacturing Design

• The main structure of engine.• All other engine parts attached to cylinder block

CYLINDER BLOCK


Crankshaft Design

• Two type manufactured

a. Forged Steelb. Cast Iron

CRANKSHAFT ASSEMBLY


Bearing Design

BEARING ASSEMBLY


Thrust Bearing

To absorb axial or thrust motion

BEARING ASSEMBLY


Bearing Clearance

• Bearing clearance determine how much oil will flow past and out• To small or much clearance will effect engine condition and performance

BEARING ASSEMBLY


Piston And Rod Assembly

PISTON ASSEMBLY

• Piston and rod are used to transmit the power from combustion to the crankshaft


Piston Parts

PISTON ASSEMBLY

• Most piston made from hollow aluminum alloy.• It’s design to operate under severe temperature


Connecting Rod

PISTON ASSEMBLY

• Purposely to change energy motion• As a lubrication system component


Cylinder Head Design and Manufacturing

CYLINDER HEAD

• It is used for sealing• Head design example Valve port, combustion chamber coolant passage and material will effect system operation


Gasoline Combustion Chamber

CYLINDER HEAD

• Placed Air/Fuel mixing and explode

• Type of combustion chamber and head shape will change engine performance.

• Turbulence cause better combustion

• Quench area will get better turbulence efficiency and for cooling system

• Type of combustion chamber are commonly used

a. Hemispherical type

b. Wedge Shaped Type

c. Pent roof type


Valve Parts

VALVE ASSEMBLY

• It is made of very strong metal with nickel, chromium and other material


Valve Seat

VALVE ASSEMBLY

• Valve seat help the valve seal to cylinder block or head


Valve Spring

VALVE ASSEMBLY

• Valve keeper or log was used to keep the valve spring and retainer in place


Lubricating system was most importance thing on engine operation

The system composed of several parts include :

a. Oil Pan

b. Oil Pump

c. Main Oil Gallery

d. Oil Filter

e. Pressure Regulator

f. Oil Cooler

g. Oil Sensor

LUBRICATING SYSTEM OPERATION


Oil Flow System


• Oil flow from oil pan, through the pump and into the main gallery


Oil Flow System


• Oil from main gallery is sent through passages into the crankshaft.


Oil Pump System


• Oil pump was direct drive by crankshaft, belt or change• Three type commonly used are :

a. Gear Typeb. Eccentric Typec. Trochoid Type


Oil Pressure Regulating Valve


• Purposely to maintain, increase and reduce oil pressure to main oil gallery


Purpose Of Cooling System

COOLING SYSTEM OPERATION

• To maintain operating temperature.

• To remove Excess heat

• To bring working temperature.


Liquid Cooled Engine

COOLING SYSTEM OPERATION

Coolant is pumped from water pump, through the block and head, thermostats into radiator.

FOUR STROKE CYCLE


FOUR CYCLE ENGINE

•4 Stroke engine can also called a 4 cycle engine.

•These four stroke are titled : 1. Intake 2. compression 3. power 4. exhaust

FOUR STROKE CYCLE


INTAKE STROKE

•As the piston is cranked downward called the intake stroke,air and fuel are drawn into cylinder.

•Because the piston moves down a vacuum is created.

FOUR STROKE CYCLE


COMPRESSION STROKE

•The compression stroke takes the air fuel mixture and compresses it according to the compression ratio of engine.

•The higher the compression ratio the greater the mixing of air and fuel.

FOUR STROKE CYCLE


POWER STROKE

•Both the intake and exhaust valve remain closed.•The piston is coming up on the compression stroke,spark will occur very near TDC.•At this point air,fuel and ignition are present,than air and fuel to explode.

FOUR STROKE CYCLE


EXHAUST STROKE

•The exhaust stroke starts when the piston starts moving upward again.•At the beginning of the exhaust stroke ,the exhaust valve opens.


ENGINE SPECIFICATIONspecification

Bore x Stroke

Under square Engine

- Length of the stroke greater than the diameter of the bore

- Purposely long-stroke design provided greater torque in the low speed range

Over square Engine

- Diameter of bore is longer than the length of the stroke

- Also called short stroke engine

- Purposely can increase torque at high speed


ENGINE SPECIFICATION

Compression ratio

•During engine operation the air and fuel mixture must be compressed

•This compression helps squeeze and mix the air and fuel molecules for better combustion



HOW TO MEASURE TOTAL DISPLACEMENT

TOTAL DISPLACEMENT [

Bore

] Stroke

0.7854 x Bore²(cm) x Stroke(cm) x No.Cyl.

Example : 0.7854 x 7.6 x 7.6 x 8.73 x 4

=1584 cc

3.143.14 44

==F/m :F/m : ππ x Dx D² x L x 4² x L x 4



Specification

Clearance Volume (CV) + Swept Volume (SV) Clearance Volume (CV)

SV

CV

Compression Ratio

HOW TO MEASURE COMPRESSION RATIO

TIMING DIAGRAMS


Engine Specification


Specification OPP NPP(MAGMA) 12 VALVE

ENGINE MODEL 4G13 4G15 4G13 4G15 4G13 4G15Combustion chamber type Hemi-

sphericalHemi-

sphericalCompact type Compact

typePentroof

typePentroof

type

Compression ratio 9.8 9.5 9.7 9.4 9.5 9.2

Valve Arrangement OHV OHV OHV OHV OHV OHV

Total Displacement 1298 1468 1298 1468 1298 1468

Bore X stroke mm 71 x 82 75.5 x 82 71 x82 75.5 x 82 71 x 82 75.5 x 82

Valve timing

intake

Opened

19 19 19 19 15 15

Closed

57 57 57 57 53 53

exhaust

Opened

57 57 57 57 57 57

Closed

19 19 19 57 15 15

GENERAL INFORMATION

Copy Right © Akademi Saga/EON BerhadENGINES 4G1 SERIES

TECHNICAL FEATURES

•The engines for the ISWARA 1.3 & 1.5 model of a SOHC type develop based on MITSHUBISHI “CYCLONE” series

•It employ three valve per cylinder

•The combustion chamber is a pentroof type which improves combustion process


THE CYLINDER HEAD

•The cylinder head is made of aluminum alloy•2 intake ports at each chamber

•Roller type rocker arm for smooth operation and reduces frictional resistance


LUBRICATION SYSTEM

•Is a forced feed full flow filtration type

•Oil pump is of “trochoid rotor”

•The inner rotor of the pump is driven by the crankshaft


COOLING SYSTEM

•The system utilieses a pressured and corrugated fin type radiator

•Fan is electrically driven and operates automatically according to coolant temperature.


INDUCTIONSYSTEM

•Air cleaner is an “Axial Flow” and it has a special features.

•Large filteration area and reduction in flow resistance

•Decreasing the percentage of pollutants in the exhaust gases


EXHAUST SYSTEM

•The exhaust manifold is made of cast iron and designed with dual outlet to reduce the exhaust interface.

Plastic region tightening method

XX

Elastic regionElastic region Plastic regionPlastic region

FailureFailureSmall variationSmall variation

Large variationLarge variation

YieldingYieldingPoint Point

Variation in Variation in tightening angletightening angle

Torque variationTorque variation Angle of bolt rotationAngle of bolt rotation

Pla

stic

reg

ion

tight

enin

g P

last

ic r

egio

n tig

hten

ing

met

hod

met

hod

Cal

ibra

ted

wre

nch

Cal

ibra

ted

wre

nch

Tig

hten

ing

met

hod

Tig

hten

ing

met

hod Axial

tensionCylinder head

Tightening torque


Tightening procedure


11

33

44

55

22

7.4 Kgm7.4 Kgm

2.0 Kgm2.0 Kgm

9090°°

9090°°Axi

al t

ensi

on

Axi

al t

ensi

on Plastic regionPlastic region

Tighten the bolts by the following procedure (4G9)

STEP OPERATION REMARKS

1 Tighten to 74 Nm Carry out in the order shown in the illustration

2 Fully loosen Carry out in the reverse order of that shown in the illustration

3 Tighten to 20 Nm Carry out in the order shown in the illustration

4 Tighten ¼ of a turn ( 90° ) Carry out in the order shown in the illustration

5 Tighten ¼ of a turn ( 90° ) Carry out in the order shown in the illustration


Type of compression ring


Plane type

Combustion gasCombustion gas

PistonPiston

Cyl

ind

erC

ylin

der

Tapered face type

PistonPiston

Cyl

ind

erC

ylin

der

OilOil

Inner bevel type

Combustion gasCombustion gas

PistonPiston

Cyl

ind

erC

ylin

der

OilOil

Type of piston pin

SEMI-FLOATING TYPE FULL-FLOATING TYPE


Piston pin installation

Guide C

Push Rod

Base

FrtMark

C D

Guide AGuide B

3 mm

BA

C D

L = L = ( A – C ) – ( B – D )( A – C ) – ( B – D ) 22


Lubrication system 4G15

Lubrication System

• Used full flow pressure feed system• Oil Capacity up to 3.8 L• Engine oil is feed up by oil pump drive by crank shaft and oil pump gear• Oil pump used trochoid gear type and relief valve incorporated in the front case.


Valve clearance adjustment

Position the No. 1 cylinder at top dead center on the compression stroke

Standard value : on cold engineIntake : 0.09 mm (0.004 in)Exhaust : 0.20 mm (0.008 in)


Oil Pump Relief Valve


Relief valveRelief valve

Relief valve purpose to adopted for Relief valve purpose to adopted for reduction of aerationreduction of aeration

Crankshaft Pulley

Rubber

Hub

Pulley

Fin


The crankshaft pulley consists of a cast-iron pulley and hub connected by a rubber section. It also functions as a torsional damper that minimizes twisting vibration of the crankshaft.

VERNIER CALIPERVERNIER CALIPER


HOW TO READ SCALEHOW TO READ SCALE


Formula for reading length L (mm) L = L1 + XX = No. of graduations x 0.05

AA

BB


MEASURING PROCEDUREMEASURING PROCEDURE

Outside diameter Inside diameter Depth

Correct way

Wrong way

Venire scale jaw

Outside diameter

Object to be measured

Regular scale jaw

Regular scale jaw

Object to be measured

Depth stick



Point to note when using micrometer :Point to note when using micrometer :a)a) Clean the micrometer and the surface to be measuredClean the micrometer and the surface to be measuredb)b) Check the zero position (through use of a standard gaugeCheck the zero position (through use of a standard gauge

Engine 4G15

Automotive

Transcript of Engine 4G15