TTEC 3202
Grading Criteria
To achieve a C grade
To achieve a B grade
To achieve an A grade
C1
Identify the minor components of a Diesel and petrol engine.
B1
Complete the Venn diagram detailing the differences between SI (Spark ignition) and CI Compression ignition) engines
C2
Describe the 4 – stroke cycles for both petrol and diesel engines.
C3
Complete the grid identifying engine components and there functions.
C4
Describe the procedure involved with performing oil system maintenance.
A1
Describe the term heat exchanger and give its application within a vehicles lubrication system.
C5
Identify the components of a Lubrication system.
B2
Describe the operation of a rotary and gear type oil pump.
C6
Describe the operation of full-flow and by-pass system.
C7
Use a spreadsheet to create a graph, identifying heat loss from a spark ignition (SI) engine.
B3
Give a description for conduction, radiation, and convection.
C8
Describe the purpose of a vehicles cooling system.
B4
Describe the process for pressure testing a cooling system and testing for hand gasket failure.
A2
Use the library to re-ser how to test a pressure control radiator cap.
C9
Label the radiator and describe how heat is dissipated.
A3
Compile a detailed check list for the cooling system components, relate to a created trouble shooting chart.
C10
Describe the function and operation of a contact breaker spark ignition system.
A4
Create a diagnostic check sheet for spark plugs.
C11
Give examples of the input and output signals for an ECU, identify the meaning of the abbreviation used in relation to EFI.
C12
Identify the operation of a multi-point EFI (Electric Fuel Injection) system. Relate to its efficiency compared to carburetion especially when emission control is considered.
Learning Time
Directed (Supervised)
Hours
Self – directed
(Unsupervised hours)
Total hours
168
132
300
Aim: To develop students’ knowledge in engines and engineering design features.
C1: Identify the major internal engine components for this 3 cylinder petrol engine.
Camshaft sprockets
Bushed roller chain
Hydraulic chain tensioner
Oil pump sprocket
Oil pump
Timing case
Spring loaded chain tensioner
Oil pump sprocket
Sprocket drive of camshafts and oil pump
Piston
Crankshaft
Valve
C1: Name the engine components marked with a red line.
AUDI Engine
Using a variety of resources investigate and describe the four stroke cycle. Make sure that you reference your sources. Write the answer below make a new slide if you run out of room.
C2: Describe the four stroke engine cycle.
Answer:-
C2: What stroke is this cylinder currently on and what is happening?
Answer:-
C2: What stroke is the cylinder currently on and what is happening?
Answer:-
C2: What stroke is the cylinder currently on and what is happening?
Answer:-
C2: What stroke is the cylinder on and what is happening?
Answer:-
Example
V1 = 32 cc
V2 = 315 cc
CR = V1 + V2
V1
= 32 cc + 315 cc
32 cc
Compression Ratio = 10.8 : 1
Click on LINK for further information.
Data:
V1 = 85 cc
V2 = 115 cc
Find CR =
C2: Work out the compression ratio for the given engine data: (use the compression ratio formula given)
(CR)
Data:
Stroke = 12.5 cm
Bore = 7.5 cm
Number of cylinder = 4
Engine capacity = cubic centimeter (CC)
C2: Find an online calculator to solve problem (use the data provided).
Convert your answer to litres: Ltr
C2: Describe the diesel four stroke cycle (Compression ignition engine). Make a new slide for your answer use pictures and diagrams to help explain.
Cutaway showing injector and glow plug
Self combustion of fuel using compression
The four stroke cycle for the CI engine
Diesel fuel igniting under combustion
Component
Function
Spark Plug.
Ignites the fuel and air mixture in the
cylinder.
Inlet valve.
Opens at the correct time to allow the exhaust gasses out.
Piston.
Connects the piston to the connecting rod.
Flywheel.
Forms a gas tight seal in the cylinder.
C3: Fill in the missing text boxes.
Component
function
Oil control ring.
Crankshaft.
Physical link between crankshaft and cam.
Camshaft.
Sump.
Removes larger particles of carbon from the lubrication system.
Petrol fuel injector.
C3: Fill in the missing text boxes.
component
Function
Ignition coil
Circulates coolant around the engine.
Cylinder liner
Snaps the valve shut when opened by the cam shaft.
C3: Fill in the missing text boxes.
C4: The lubrication system and its components.
2. What kind of cloth should be used for wiping the dipstick?
3. How should old engine oil be disposed of?
4. Before refitting the sump drain plug. What should be examined and replaced if necessary?
5. When checking the oil level. Why is it essential that the vehicle is placed on level ground?
6. Oils are said to be graded. How is this grade defined. Make sure that you define viscosity
C4: Describe the procedure involved with oil system maintenance.
Insert a new slide to answer if needed.
The main function of a lubrication system is to form a film of oil between the working surfaces of the components to prevent damage by direct contact and to reduce friction to a minimum.
The oil's function is to act as a seal and protect against corrosion. It is a means of conducting heat away from the moving parts and to wash away any abrasive and corrosive deposits from the working surfaces.
C4: Engine lubrication.
Oil galleries
Oil filter
Pressure relief valve
Oil pump
sump
C5: Identify the components of a lubrication system by matching the names to the parts.
Splash feed
C5: Label these lubrication system components below.
They are usually a “spin-on” fitting with
an O-ring seal to prevent leakage.The outlet tube is at the centre.
The paper element traps small metal, rust, carbon or dirt particles.
This keeps impurities out of the engine to
prevent damage to working surfaces.
Several input feed holes are arranged directly into the filter element.
Click Link
There may be a separate housing that bolts to the cylinder block for mounting the oil filter.
The oil pressure switch/sender unit may be mounted on this housing
Some vehicles have oil cooling, and a cooler adapter or heat exchanger may be attached here.
The oil filter is fitted onto the bottom, allowing oil to flow through both the cooler and filter.
A heat shield may be used to keep engine heat away from the cooled oil.
When engine speed is low
When engine speed is high
C5: Why is the pressure relief valve required?
Make a new slide for your answer use diagrams and pictures to help with the explanation.
High pressure relieving back to sump
Normal operation pressure steady
C6: Describe the operation of the lubrication system used in vehicles today. Make reference to the pressure relief valve, filter, oil galleries and return.
Click on link to watch video on lubrication. The lubrication system
Write your explanation below, insert a new slide if needed.
Answer:-
Click this link to watch a video clip. Cooling System.
Air cooling requires a large volume of airflow around the engine.
The cylinder has cooling fins to improve radiation of heat. The large surface area of the fins, transfers heat to the surrounding air.
With water cooling, the coolant
circulates around a water jacket to
absorb the heat energy.
The coolant is a mixture of water and
antifreeze and anticorrosion additives.
Water cooling provides better control and stability of the engine temperature
Air or Water
The Cooling System
Combustion temperatures in the cylinders can reach 2500ºC (4500ºF).
If uncontrolled, these high temperatures can cause damage to the engine.
Coolant absorbs heat energy in the cylinder by conduction, radiating the excess heat to the air by use of the radiator.
Normal coolant operating temperatures are about 80-100ºC (180-210ºF).
The rate of airflow over the radiator may be increased by the use of a fan.
Heat Transfer
The internal combustion engine is a heat engine, the burning gas in the cylinder raises the temperature, which in turn raises the pressure and forces the piston down the cylinder.
When petrol and air mixture is burned in the cylinder it produces heat energy at a temperature of approximately 2,500° C
C7: Use a spreadsheet to create a pie - chart, identifying heat loss from a spark ignition engine from the data provided.
•25% of this heat energy (thermal efficiency) is converted into useful work.
•34% of heat is lost to the exhaust gas.
•32% cooling loss.
•3% pumping loss.
•6% friction loss.
Insert a new slide for your answer.
C8: Describe the purpose of a vehicle's cooling system (state reference used).
Insert a new slide for your answer, use diagrams and pictures to help explain.
A liquid cooling system consists of a water pump, radiator, thermostat, cooling fan, water jackets and rubber hoses.
The simple cooling system consists of water jackets in the cylinder head and the cylinder block. A radiator provides the main cooling and rubber pipes connect the radiator to the engine. A thermostat is used to control the engine temperature, a cooling fan to cool the water in the radiator when the vehicle is stationary and a water pump to circulate the water.
Water jackets
Cooling fan
By –pass hose
Thermostat
Water pump
C8: Label the cooling system diagram with the correct names.
C8: Describe the operation of a wax thermostat and state its function.
Insert a new slide for your answer
C9: Match the radiator parts with their correct names. ( First one is done for you)
Radiator Parts Assembly Diagram for 1998 Toyota Camry
Radiator assembly manual trans : 1
Upper bracket :
Lower support:
Reservoir assembly:
Reservoir cap:
Upper hose:
Lower hose:
Inlet pipe:
Thermostat:
Housing:
Water outlet:
Radiator cap:
Oil Cooler:
C9: Describe how the radiator loses heat to the atmosphere.
Insert a new slide include diagrams and pictures in your answer.
Antifreeze/Anti Corrosion Inhibitor
C10: Describe the function and operation of a spark ignition system.
Function:
Operation:
Answer:-
Answer:-
1. What two substances are mixed together to form electrolyte?
2. What is the purpose of an ignition coil?
3. What three elements are required to make an engine run effectively?
4. Battery cells are linked together in?
C10: The power supply for the ignition system. Answer the following questions.
The primary circuit consists of components and LT leads that operate on battery or alternator voltage.
Describe the circuit operation:
C10: The primary circuit (battery voltage).
Answer:-
The secondary circuit consists of components and HT leads that operate on high voltage.
Describe the circuit operation:
C10: The secondary circuit (High tension).
Answer:-
Secondary terminal
Terminal (-)
Casing
Laminated iron core
Terminal (+)
Primary windings
Secondary windings
insulator
Insulation paper
C10: Label the ignition coil components.
Describe how the ignition coil operates and what happens in the primary and secondary windings. Write your answer below if you need more space insert a new slide.
C10: Ignition coil operation.
Answer:-
Distributor cap
Rotor
Condenser
Contact breaker
Distributor body
Base plate
C10: Label the parts of a simple contact breaker point distributor ignition system.
The distributor cap is made from a polymer
called Bakelite . This is a superb material and
Is non conductive. Therefore electricity will not pass through this material.
Considering electrics, Define the term conduction? Write your answer below.
C10: Materials used as insulators in high voltage applications.
Answer:-
The distributor is mounted on the engine and is usually driven by the camshaft. It houses the breaker, the condenser (capacitor), the rotor arm and mechanisms to adjust ignition (spark) timing.
The condenser and the breaker sit on a base plate, inside the distributor body.The breaker is operated by a cam on the distributor shaft. Normally, the number of cam lobes equals the
number of engine cylinders.
The rotor arm fits onto the distributor shaft.The other end of the shaft is fitted with a gear that meshes with the camshaft.
The distributor cap fits onto the distributor
body and is secured by clamps or
screws. The fit must be splash proof.
C10: Operation of a simple distributor ignition system. These systems have been superseded with full engine management control since the 1980's.
To coil primary
Shaft
Cam
Contacts
Gap
C10: The distributor distributes the high voltage to the spark plugs. It also houses a mechanical switch called the contact breaker points.
Explain what is the purpose of the contact breaker points. In other words what do they do?
Answer:-
When the contacts initially open, the induced back EMF tries to jump the widening gap.
Connecting a condenser (capacitor) in parallel with the contacts prevents this problem.
At the moment the contacts open, the condenser provides an alternative path for the high voltage and it is charged up. After a fraction of a second it discharges, but by this time, the contacts are far enough apart to prevent 'spark-over'.
In practice, a very small spark does still occur and over time causes erosion of the contacts. Periodic readjustment of the contacts gap is always required.
An internal combustion engine requires three key ingredients to operate: air, fuel and spark. A spark plug is a critical engine component that provides the spark that ignites the air-fuel mixture that drives an engine.
A spark plug operates by directing electrical current to flow through a centre electrode, forming a spark across an electrode (or air) gap, completing the circuit to a ground electrode.
The centre electrode is surrounded by a ceramic insulator which is non-conductive preventing current leakage and ensuring electricity flows in the desired direction
C10: Name the 3 different types of spark plugs and the benefits of each.
Answer:-
Answer:-
Answer:-
The following spark plugs are marked as follows.
cmr6ft15 :
lmrc-11 :
What spark plugs are required for a Skyline GTR?
Use the following link Spark Plug Finder to answer the following.
C10: What do the following NGK spark plug numbers mean, use the web link to answer the following.
An engine management system (EMS) integrates both the ignition and fuel control into one ECU (electronic control unit). The system constantly monitors all aspects of combustion and adjust fuelling and spark accordingly to maintain peak combustion efficiency.
C11: Give examples of the input and output signals for an ECU
Input signals output signals
Engine ECU
Engine speed / crank sensor
C11: Identify the meaning of the following abbreviations used in relation to EFI.
Abbreviation
Meaning
MAP
PPM
TPS
PCV
EFI
CDI
EGR
ECM
HC
CO2
AAV
EOBD
Working on the EFI system can be extremely hazardous. Fuel is kept under pressure in the EFI system.
From a technician's perspective give the basic precautions which should be taken when working with fuel. Write your answer below.
C11: Fuel systems and layouts.
Answer:-
A fuel injector (may be 2)
is located in a throttle body assembly that sits on top of the inlet manifold.
Fuel is sprayed into the
inlet manifold from above
the throttle valve, mixing
with incoming air.
Fuel timing and quantity
is controlled by an ECU.
Layout of a single point fuel injection system
Fuel injection timing refers to when fuel is actually sprayed into the inlet manifold. There are 3 main types of multi point fuel injection timing:
Intermittent
Timed (Sequential)
Continuous
Define the three types of multi point fuel injection timing listed:
C11: Fuel injection timing.
Air mass meter
Electric fuel pump
Throttle position
sensors
Knock sensors
Rotary idle valve
C11: Identify the function of these components.
Electronic computer
Unit (ECU)
Oxygen sensor
Crank position
sensor
Petrol injector
C11: Identify the function of these components.
C12: Identify the operation of a multi-point EFI system. Name the parts on the EFI diagram below.
1. Fuel Tank.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
L-Jetronic Fuel System.
Advantages
Disadvantages
C12: State the advantages and disadvantages of EFI over using a carburettor.
What is meant by the following term's?
Open Loop:
Closed Loop:
C12: Open and closed loop.
C12: Describe how a catalytic converter operates.
Insert a new slide for the answer and include pictures and diagrams.
Unique
Unique
Similar
B1: Complete the Venn describing the differences between SI and CI engines
Crankshaft-Driven crescent oil pump.
B2: Use the library or internet to research the procedure to test an oil pump for wear.
(Reference your source)
Make a new slide for your answer, use pictures and diagrams to help answer the procedure.
Rotary Oil Pump
Gear Type Pump
B2: Describe the operation of a Rotary and Gear type oil pump.
Make a new slide for your answer, use pictures and diagrams to help answer.
Conduction
Radiation
Convection
B3: Describe the terms conduction radiation and convection in the table below.
B4: Describe the process for pressure testing a cooling system and testing for head gasket failure.
(Put your answer on a new slide)
Cooling system pressure tester
Cooling system pressure tester
The cooling system
Blown head gasket between two cylinders
Combustion tracks showing escaping gasses between two cylinders
Temperature of engine oil should not rise above 100° C
At 125° C the oil begins to lose its lubrication properties
A1: Select a car of your choice and describe how its heat exchanger system works.
Make a new slide, use pictures and diagrams to help explain your answer.
A2: Use the Library or internet to research how to test a pressure radiator cap (reference your source of information).
Make a new slide use diagrams and pictures to help your answer, reference all material used.
A3: Compile a detailed check list for the cooling system components; relate it to an already created trouble shooting chart.
Make a new slide for your check list.
Click on link Spark Plugs and use the information from the site to create a fault diagnosis chart for spark plugs. Use the internet for further information, build up your chart similar to the example below.
A4: Make a diagnostic check sheet for spark plugs to show common combustion faults.
Make a new slide for your diagnostic chart.