Unit –I Internal Combustion Engine (16 Marks)

ME5I (PER) Prepared By: Harun Sir

1.IC ENGINE TERMINOLOGY

1. Bore: The nominal inside diameter of the engine cylinder is called bore.
2. Top Dead Centre (TDC): The extreme position of the piston at the top of the cylinder of the
vertical engine is called top dead centre (TDC), Incase of horizontal engines. It is known as inner
dead centre (IDC).
3. Bottom Dead Centre (BDC): The extreme position of the piston at the bottom of the cylinder
of the vertical engine called bottom dead centre (BDC). In case of horizontal engines, it is known
as outer dead center (ODC).
4. Stroke: The distance travelled by the piston from TDC to BDC is called stroke. In other
words, the maximum distance travelled by the piston in the cylinder in one direction is known as
stroke. It is equal to twice the radius of the crank.
5. Clearance Volume (Vc): The volume contained in the cylinder above the top of the piston,
when the piston is at top dead centre is called the clearance volume.
6. Swept Volume (Vs): The volume swept by the piston during one stroke is called the swept
volume or piston displacement.
Swept volume is the volume covered by the piston while moving from TDC to BDC.
Swept volume = Vs = A x L = π/4 x D L
where A = Cross sectional area of the piston in Sq.m,
L = Stroke in m, and
D = Cylinder bore i.e., inner diameter of the cylinder in m.
7. Compression Ratio (rc):
Compression ratio is a ratio of the volume when the piston is at bottom dead centre to the volume
when the piston is at top dead centre.
Mathematically,
Compression ratio =MinimumCylinderVolume /MaximumCylinderVolume

= (SweptVolume + ClearenceVolume)/ ClearenceVolume

The compression ratio varies from 5 : 1 to 10 : I for petrol engines and from 12:1
to 22 : I for diesel engines.

Ph. No. 9987580155

 Unit –I Internal Combustion Engine (16 Marks)
ME5I (PER) Prepared By: Harun Sir

2. TWO STROKE ENGINES

TWO STROKE PETROL ENGINE (SI)

1. First Stroke (Upward Stroke of the Piston)
(a) Compression and Inductance:
1. During the upward movement of the piston from BDC to TDC, both the transfer and
exhaust ports are covered by the piston.
2. The petrol air mixture which is already transferred into the engine cylinder is compressed
by the moving piston. Thus, the pressure and temperature of the charge increases at the
end of compression.
3. The compression process is continued until the piston reaches TDC.
4. At the same time, the inlet port is uncovered by the moving piston and the fresh petrol air
mixture enters the crankcase through the inlet port.
(b) Ignition and Inductance:
1. After the piston almost reaches the TDC, the compressed petrol air mixture is ignited by
means of an electric spark produced by a spark plug.
2. The admission of fresh charge into the crankcase continues till the piston reaches the
TDC.
2. Second Stroke (Downward Stroke of the Piston)
(c) Expansion and Crankcase Compression:
1. The ignited gases expand and force the piston to move down, thus useful work is
obtained.
2. When the piston moves down, the petrol air mixture is partially compressed in the
crankcase. Thus compression is known as crankcase compression.
(d) Exhaust and Transfer:
1. Almost at the end of expansion, the exhaust port is uncovered and the combustion
products escape to the atmosphere.
2. Immediately, the transfer port is also uncovered and the partially compressed air fuel
mixture from the crankcase enters the cylinder through transfer port.
3. The crown of the piston is made of a deflected shape, so the fresh air – petrol mixture
entering the cylinder is deflected upward in the cylinder.
4. Thus the escape of fresh charge along with the exhaust gases is reduced.

Ph. No. 9987580155

 Unit –I Internal Combustion Engine (16 Marks)
ME5I (PER) Prepared By: Harun Sir

5. The cycle of operations are then repeated.

2.1TWO STROKE DIESEL ENGINE
For every one revolution of Crankshaft there is One Power Stroke
1. First Stroke (Upward Stroke of the Piston)
(a) Compression and Inductance:
 During the upward movement of the piston from BDC to TDC, both the transfer and
exhaust ports are covered by the piston.
 The air which is already transferred into the engine cylinder is compressed by the moving
piston. This increases the pressure and temperature of the air.
 The compression process is continued until the piston reaches TDC.
 At the same time, the inlet port is uncovered by the moving piston and the fresh air enters
the crankcase through the inlet port.

(b) Injection and Inductance:

 After the piston almost reaches the TDC, the fuel (diesel) is injected through the fuel
injector in the cylinder.
 The combustion of fresh fuel injected into the cylinder takes place due to the high
temperature already developed in the cylinder during compression of the air.
 The admission of fresh air into the crankcase continues till the piston reaches the TDC
2. Second Stroke (Downward Stroke of the Piston)
(c) Expansion and Crankcase Compression:
 The burnt gases expand and forces the piston to move down, thus useful work is
obtained.
 When the piston moves down, the air is partially compressed in the crankcase. This
compression is known as crankcase compression.
(d) Exhaust and Transfer:
 Nearly at the end of expansion, the exhaust port is uncovered and the combustion
products escape to the atmosphere.
 Immediately the transfer port is also uncovered and the partially compressed air from the
crankcase enters the cylinder through the transfer port.
 The cycle of the operations are then repeated.

3. FOUR STROKE PETROL ENGINE (SI)

Q. Discuss in brief process of combustion in SI engines with a sketch. (6M)
Ans. Petrol engine is also known as Spark Ignition (SI) engine. Invented by Nicolaus A. Otto
in 1876 that is why petrol engine is also known as Otto engine.
1. Suction or intake stroke,
2. Compression stroke,
3. Expansion or power stroke, and
4. Exhaust stroke.

Ph. No. 9987580155

 Unit –I Internal Combustion Engine (16 Marks)
ME5I (PER) Prepared By: Harun Sir

1. Suction Stroke:
a) During this stroke, the piston moves from Top Dead Centre (TDC) to Bottom Dead
Centre (BDC) creating a vaccum inside the cylinder.
b) During this stroke, the inlet valve is kept opened and the exhaust valve is kept closed
c) The vacuum created inside the cylinder draws the air petrol mixture (which
d) is also known as charge) into the cylinder through the inlet valve.
e) It is performed till the piston reaches BDC.
2. Compression Stroke:
a) During this stroke, both the inlet and exhaust valves are closed
b) The air petrol mixture is compressed as the piston moves upwards from BDC to TDC.
c) As a result of this compression, pressure and temperature of the air fuel mixture or charge
is increased.
d) Just before the piston reaches the TDC, the air petrol mixture (charge) is ignited by a
spark plug; suddenly burning of the air fuel mixture takes place almost instantaneously.
e) It increases the pressure and temperature inside the cylinder. Volume remains constant
during combustion. These two strokes (i.e., suction and compression stroke) complete
one revolution of the crankshaft.
3. Expansion or Power Stroke or Working Stroke:
a) During this stroke, both the inlet and exhaust valves remain closed.
b) The high pressure of the products of combustion (due to expansion of charge) pushes tile
piston from TDC to BDC. It is also called as working stroke as work is done by the
expansion of hot gases.
c) The force above the piston is transmitted to the crankshaft through the connecting rod and
crank mechanism.
d) Excess energy due to the combustion is stored in the flywheel which helps for the
operation of three idle strokes.

Ph. No. 9987580155

 Unit –I Internal Combustion Engine (16 Marks)
ME5I (PER) Prepared By: Harun Sir

4. Exhaust Stroke:
a) At the end of the expansion stroke, the exhaust valve opens and the pressure inside falls
suddenly.
b) Thus during this stroke, the inlet valve is closed and the exhaust valve is kept opened.
c) The upward movement of the piston from BDC to TDC, pushes out the products of
combustion from the engine cylinder through the exhaust valve into the atmosphere.
d) The cycle of operation is then repeated.
e) These two strokes (i.e., expansion and exhaust strokes) complete one revolution of the
crankshaft.

3.1. FOUR STROKE DIESEL ENGINE (CI)

Diesel engine is also known as compression ignition (CI) Engine. It is invented by Rudolf
Diesel (1892)
1. Suction or intake stroke,
2. Compression stroke,
3. Expansion or power stroke, and
4. Exhaust stroke.

1. Suction Stroke:
a) During suction stroke, the inlet valve opens and the exhaust valve closes.
b) The piston moves from TDC to BDC.
c) This piston movement reduces the pressure inside the cylinder below the atmospheric
pressure.
d) Due to the pressure difference, the fresh air is sucked into the cylinder through the inlet
valve.
2. Compression Stroke:
a) During this stroke, both the inlet and exhaust valves are closed.
b) The air in the cylinder is compressed as the piston moves upwards from BDC to TDC.

Ph. No. 9987580155

 Unit –I Internal Combustion Engine (16 Marks)
ME5I (PER) Prepared By: Harun Sir

c) As a result of this compression, pressure and temperature of the air is increased.

d) Just before the piston reaches the TDC, the diesel is injected into the cylinder in the form
of a fine spray.
e) The fuel gets vaporized and self-ignited due to the heat of compressed air.
f) The fuel burns instantaneously at constant pressure.
3. Expansion or Power Stroke:
a) During this stroke, both inlet and exhaust valves are closed.
b) The combustion of fresh fuel injected into the cylinder is due to the high pressure and
temperature developed during compression stroke.
c) The fuel is continuously injected for 20% of the expansion stroke.
d) The high pressure of the combustion products due to expansion of charge pushes piston
from TDC to BDC.
e) It is also called as working stroke as work is done by the expansion of hot gases.
4. Exhaust Stroke:
a) During this stroke, inlet valve is closed and the exhaust valve is opened
b) The piston moves from BDC to TDC.
c) The burnt waste gases are sent out through exhaust valve and the cycle is repeated
4. Difference between 2 Stroke and 4 Stroke Engines
Four stroke engine Two stroke engine
It has one power stroke for every two It has one power stroke for each revolution of the
revolutions of the crankshaft. crankshaft.
Engine is heavy Engine is light
Heavy flywheel is required Lighter flywheel is required
Engine design is complicated due to Engine design is simple due to absence of valve
valve mechanism. mechanism.
More cost. Less cost
Less mechanical efficiency due to more More mechanical efficiency due to less friction
friction on many parts. on a few parts.
Engine runs cooler. Engine runs hotter.
Engine is water cooled. Engine is air cooled.
Engine consists of inlet and exhaust
valve. Engine consists of inlet and exhaust ports.
More thermal efficiency. Less thermal efficiency.
It consumes less lubricating oil. It consumes more lubricating oil.
Used in cars, buses, trucks etc. Used in mopeds, scooters, motorcycles etc.

5.Difference between SI and CI Engine

Parameter SI Engine CI Engine
It is and engine in which heat of
It is an engine in which the spark is used compressed air is used to burn the
Definition to burn the fuel. fuel.
Fuel used Petrol is used as fuel. Diesel is used as fuel.

Ph. No. 9987580155

 Unit –I Internal Combustion Engine (16 Marks)
ME5I (PER) Prepared By: Harun Sir

Operating cycle It operates on Otto cycle. It operates on Diesel cycle.

Compression
ratio Low compression ratio. High compression ratio.
Thermal
efficiency High thermal efficiency. Less thermal efficiency.
Engine Speed High speed engines. Low speed engines.
Pressure Low pressure is generated after High pressure is generated
generated combustion. after combustion.
Constant
parameter during
cycle Constant volume cycle. Constant pressure cycle.
Intake Air + fuel. Only air.
Weight of engine Si engine has less weight. CI engine are heavier.
Noise production It produces less noise. It produces more noise.
Fuel supply Carburetor Injector
It is used in light commercial vehicles like It is used in heavy duty vehicles likes
Application motorcycle, cars etc. bus, trucks, ships etc.

6. Valve Timing Diagram for 4-Stroke Engine (petrol and diesel)

1. In suction stroke of 4-stroke engine the inlet valve opens 10-20 degree advance to TDC
for the proper intake of air-fuel (petrol) or air (diesel) ,which also provides cleaning of
remaining combustion residuals in the combustion chamber.
2. When the piston reaches BDC the compression stroke starts and again the piston starts
moving towards TDC ,The inlet valve closes 25-30 degree past the BDC during the
compression stroke, which provide complete seizure of the combustion chamber for the
compression of air-fuel(petrol engine)and air(diesel engine).
3. During the compression stroke as the piston moves towards TDC, combustion of fuel
takes place 20-35 degree before TDC which provides the proper combustion of fuel and
proper propagation of flame.

Ph. No. 9987580155

 Unit –I Internal Combustion Engine (16 Marks)
ME5I (PER) Prepared By: Harun Sir

4. The expansion strokes starts due to the combustion of fuel which in turn releases the
pressure inside the combustion chamber and provide rotation to the crank shaft
5. The piston moves from TDC to BDC during expansion stroke which continuous 30-50
degree before BDC.
6. The exhaust valve opens 30-50 degree before BDC which in turn starts the exhaust stroke
and the exhaust of the combustion residual takes place with movement of the piston from
BDC toTDC which continues till the 10-20 degree after the piston reaches TDC.

Ph. No. 9987580155

 Unit –I Internal Combustion Engine (16 Marks)
ME5I (PER) Prepared By: Harun Sir

7.Actual Indicator Diagram

Q. Draw actual indicator diagram for 4 stroke petrol engine. (4M)

8. Variable Valve Timing with intelligence [VVT-i]

 VVT-i, or Variable Valve Timing with intelligence, is an automobile variable valve
timing technology developed by Toyota.
 The Toyota VVT-i system replaces the Toyota VVT offered starting in 1991 on the 5-
valve per cylinder 4A-GE engine.
 Advantage of VVT-I
a) The VVT system is a 2-stage hydraulically controlled cam phasing system.
b) Adjustments in the overlap time between the exhaust valve closing and intake valve
opening result in improved engine efficiency.
c) More efficiently by continuously adjusting the timing of the intake and exhaust valves
d) Helps to improve power
e) Fuel efficiency
f) Reduce exhaust emissions.

9. Differences between Superchargers (vs) Turbochargers

Q. State any two any advantage of Turbo Charging

Q. State four objectives of supercharging.

Ph. No. 9987580155

 Unit –I Internal Combustion Engine (16 Marks)
ME5I (PER) Prepared By: Harun Sir

10.Multi Point Fuel Injection system (M.P.F.I)

Q. Explain with a neat sketch working of a MPFI
1. MPFI includes a fuel pressure regulator, fuel injectors, cylinders, pressure spring and a
control diaphragm.
2. It uses multiple individual injectors to insert fuel in each cylinder through intake port
situated upstream of cylinder’s intake value.
3. The fuel pressure regulator, connected to the fuel rail by means of an inlet and outlet,
directs the flow of the fuel. While the control diaphragm and pressure spring controls the
outlet valve opening and the amount of fuel that can return.

Ph. No. 9987580155

 Unit –I Internal Combustion Engine (16 Marks)
ME5I (PER) Prepared By: Harun Sir

4. The pressure in the intake manifold significantly changes with the engine speed and load.

Advantages of multi point fuel injection (MPFI) system

a) It increases fuel efficiency of the engine.
b) With MPFI system vehicle have less emissions.
c) Better atomization of fuel.
d) It encourages better utilization and distribution of fuel with in an engine.
e) Smooth operation of engine
Q. List diagnostic tools used in fault finding of MPFI engines. (2M)
1. Engine Code Readers
2. Compression Testers
3. Spark Plug Testers
4. Mechanic’s Stethoscope
5. Scan Tool
6. Battery Tester
7. Power Probe III
11. Fuel Injection Pump
Q. Draw inline fuel injection pump. Name different components. (4M)

Working
1. The pump camshaft is connected to the engine crankshaft, so that when the engine
cranks automatically the pump camshaft rotates.
2. This rotation will move the plunger, so that the plunger is pressed upwards and as a result
the fuel that is already in the fuel barrel is pressed with high pressure and enters the
injector.

Ph. No. 9987580155

 Unit –I Internal Combustion Engine (16 Marks)
ME5I (PER) Prepared By: Harun Sir

12. CRDI fuel injection system

Common-rail direct fuel injection is a direct fuel injection system for diesel engines. On diesel
engines, it features a high-pressure fuel rail feeding solenoid valves, as opposed to a low-
pressure fuel pump feeding unit injectors.

Working Process of CRDI

a) In the process of CRDI a pump is used to pressurize the fuel.
b) After the compression of fuel in the high pressure pump, the fuel is supplied to the
common fuel rail.
c) Then the fuel will be distributed to the different injectors.
d) Injectors will finally inject the fuel in the engine cylinders.

Ph. No. 9987580155

 Unit –I Internal Combustion Engine (16 Marks)
ME5I (PER) Prepared By: Harun Sir

Advantage of CRDI System

a) The engine with CRDI produces more power and torque then conventional direct
injection system
b) It has the ability to increase the power and torque of engine by 25%.
c) It increases the power and efficiency and reduces the emission.
d) It decrease the noise and vibration and provides improved pick up.
e) It increase the fuel efficiency and decrease the fuel consumption i.e. mileage of the
engine would be increased.

Disadvantage of Common Rail Direct Injection System

a) Its cost of vehicles with this technology is high.
b) This technology cannot be implemented in all type of engines.
c) The cost of maintenance is also high because its spare parts are expensive.
13.Piezoelectric Injector
Q.State the purpose of Piezo-electric injector.
a) These injectors open and close much faster than conventional injectors.
b) That makes for more precise control of the injection interval, which determines how
much fuel is sprayed into the engine.
c) Piezo units also provide feedback by producing minute fluctuations in the electricity used
to activate them.
d) Such precise fuel metering makes for improved combustion, which leads to better fuel
economy and reduced emissions.

14.Exhaust Gas Recirculation (EGR) system

Q.Explain the term ‘Exhaust Gas Recirculation’ with a neat sketch.

a) Within modern internal combustion engines, Exhaust Gas Recirculation (EGR) is a

method to control Nitrogen Oxides (NOx) emissions, produced as a by-product during
the combustion process.
b) Air from the environment, mostly a combination of Oxygen and Nitrogen, combines with
fuel and ignites inside the combustion chamber, temperatures increase and produce NOx
emissions.
c) The EGR system works by returning a small portion of exhaust gas to the engine's
combustion chambers through the intake manifold, lowering combustion temperatures
and therefore reducing the amount of NOx emitted.
d) The EGR valve is the main component of the EGR system and it's normally closed. It
connects the exhaust manifold to the intake manifold and is controlled by either a vacuum
or a built-in electric step motor.

Ph. No. 9987580155

 Unit –I Internal Combustion Engine (16 Marks)
ME5I (PER) Prepared By: Harun Sir

e) The function of the EGR valve is to control the flow of exhaust gas being recirculated
depending on the engine load.

15.Sensors Used In I.C. Engine.

Sensor Main Function

Calculates the density and the volume of the air taken in

The Mass Air Flow Sensor by the engine

The Engine Speed Sensor Monitors the spinning speed of the crankshaft

Measures the amount of unburden oxygen presented in the

Oxygen Sensor exhaust pipe

Manifold Absolute Pressure

Measures the manifold pressure inside and outside
Sensor

Spark Knock Sensor Ensures that the fuel is burned correctly

Ensures the right amount of fuel is injected to keep the

Fuel Temperature Sensor motion smoothly

Manages the car speed and ensures the speed is

Voltage Sensor controllable

Ph. No. 9987580155

 Unit –I Internal Combustion Engine (16 Marks)
ME5I (PER) Prepared By: Harun Sir

16.Viscous Coupling Fan

1. A fan clutch is a thermostatic engine cooling fan that can freewheel at low temperatures
when cooling is not needed, allowing the engine to warm up faster, relieving unnecessary
load on the engine.
2. As temperatures increase, the clutch engages so that the fan is driven by engine power
and moves air to cool the engine.

Function
1. When the engine is cool or even at normal operating temperature, the fan clutch partially
disengages the engine's mechanically driven radiator cooling fan, generally located at the
front of the water pump and driven by a belt and pulley connected to the
engine's crankshaft.
2. This saves power, since the engine does not have to fully drive the fan.

17. Diagnostic Tool For Two Wheeler

1. MS5650 and the MS5950 Motorcycle Scan Tools
2. Both units come preloaded with the software to diagnose over 50 of the most popular
manufactures.
3. The MS6050 allows the user to activate just the software needed, reducing the overall
cost of the unit without sacrificing performance.
4. The MS6050 Kit includes one free activation token, allowing the user to activate software
for the manufacturer of their choosing.
5. The MS6050M includes a master token to activate all of the manufacturers
6. The scanner covers the following functions: Ignition, Injection, ABS, Immobilizer/Anti-
Theft, Service Resets, Dashboard, Body Computer, Radio/Entertainment System and
RDC/Tire Pressure Monitoring.
7. The Diagnostic Scanner allows the technician to perform factory service procedures such
as re-setting the service light, encoding keys, unlocking and configuring the
immobilizer/alarm, making injection adjustments (CO Trimmer), adjusting the throttle
valve position sensor (TPS), re-setting auto adaptive parameters, and making idle
adjustments. The tool displays ECU data, reads stored faults (history) or live data (RPM,
battery voltage, throttle angle).

18. Method To Reduce Pollution In Diesel Engine

 Diesel Particulate Filters (DPFs) remove 99.9% of particles coming from the engine,
including ultrafine particles. Ceramic wall flow filters remove nearly all carbon particulates,
including fine particles less than 100 nanometres (nm) in diameter. Since the Euro 5b exhaust
emissions legislation was introduced in 2011, DPFs are effectively mandatory.

Ph. No. 9987580155

 Unit –I Internal Combustion Engine (16 Marks)
ME5I (PER) Prepared By: Harun Sir

 DeNOx exhaust aftertreatment systems such as Selective Catalytic Reduction (SCR) and
NOx traps further reduce and control tailpipe NOx emissions of diesel cars. In the SCR system,
ammonia is used to convert over 70% (up to 95%) of NO and NO 2 into nitrogen over a special
catalyst system.

 Oxidation catalysts remain a key technology for diesel engines and convert carbon monoxide
(CO) and hydrocarbons (HC) into CO 2 and water.

Q. List changes made by automobile manufactures in achieving BS VI norms in diesel

engines.
Q.What are the changes in BS6 engine?
1. Reduction in HC emission by 45%
2. Reduction in NOX emission by 70%
3. Reduction in PM emission by 80%
4. Use of Lean NOX traps
5. Use selective catalytic reduction (SCR)
6. Use of Diesel particulate filter
7. Five times reduction in Sulpher %
8. OBD for all diesel vehicles
9. Real Driving Emission introduced in vehicles
10. Fumigation
11. Catalytic converter monitoring
12. Misfire detection

Ph. No. 9987580155