a.

Low engine output power

Results of Engine performance deterioration b. high oil consumption
c. poor fuel economy

aluminum alloy is lighter and has better heat transmission making it easier to cool than cast iron

made of special steel because they are exposed to high pressures and temperatures
valve
closed by spring force and opened by the force from the camshaft

valve face has 44.5-45.5degrees to provide a good seal between the vave and valve seat
uneven pitch spring and double spring use to prevent valve surging when the engine is running at high speed

caused by valve spring movement irrelevant to cam operation

valve surging occurs when the engine is operated at above the allowable maximum speed
it causes interference and/or damage between the valve and piston

has wider pitch at the top and narrower pitch at the bottom
Asymmetrical type uneven pitch spring
installed with the wider pitch at the top

press-fitted into the cylinder head and maintain air-tightness for the combustion chamber when
Valve seat the valve head comes into close contact
transfer the heat from the valve to the cylinder head for cooling of the valve

generally shaped like a 450 cone to conform with the shape of the valve face and has 1.2 - 1.8mm
width
valve seat
Excessive valve seat contact will cause carbon intrusion but good cooling effect
narrow valve seat will result to improve airtightness but poor cooling effect

generally made of cast iron and is press-fitted in the cylinder head

valve guide bushing
it guides the valve so that the valve face makes proper contact with the valve seat

provided on the top of the valve guide bushing to prevent a large amount of engine oil from
valve stem oil seal
entering the combustion chamber
 unsmooth movement or sticking of the valve stem in the valve guide bushing
valve sticking occurs when the clearance between the valve stem and valve guide bushing is too small or not
lubricated well

will cause excessive engine oil leak to the combustion chamber resulting to excessive oil
damaged valve stem oil seal
consumption

used instead of valve spring retainers and allows the valve to rotate while moving up and down
valve rotators
the rotation of the valve prevents it from improper sealing with the valve seat due to the lead
compounds or carbon when leaded gasoline is burned
tightening of ordinary bolt wherein the axial tension of the tightened bolt increases in proportion to
elastic region
the bolt's rotational angle
tightening beyond the elastic region wherein only the bolt's rotational angle changes, while the
plastic region
axial tension of the bolt changes little.
plastic region bolt special bolts that must be tightened in the plastic region to obtain the specific bolt tension

has a true cylindrical shape and has a polished finish but wears out due to constant contact with
cylinder bore
piston and piston ring under high pressure and high temperature.

Cylinder wear it causes the following problems:

factors that causes cylinder wear
a. excessive piston side knock
b. excessive engine oil consumption
c. insufficient engine power due to reduced compression pressure
d. damage to top piston ring due to ridge developing in the cylinder bore
a. insufficient lubrication
b. improper maintenance of the engine oil or oil filter
c. dust being sucked in through the air intake system
d. air-fuel mixture being too rich
e. overheating

cylinder bore size stamped into the top of the cylinder block for each respective cylinder
Name:
Group ___ Reviewer Part I

a. Low engine output power

Results of Engine performance b. high oil consumption
deterioration
c. poor fuel economy

aluminum alloy is lighter and has better heat transmission making it easier to cool than cast iron

made of special steel because they are exposed to high pressures and temperatures
valve
closed by spring force and opened by the force from the camshaft

valve face has 44.5-45.5degrees to provide a good seal between the vave and valve seat
uneven pitch spring and double spring
use to prevent valve surging when the engine is running at high speed

caused by valve spring movement irrelevant to cam operation

valve surging occurs when the engine is operated at above the allowable maximum speed
it causes interference and/or damage between the valve and piston

Asymmetrical type uneven pitch has wider pitch at the top and narrower pitch at the bottom
spring installed with the wider pitch at the top

press-fitted into the cylinder head and maintain air-tightness for the combustion chamber when the valve
Valve seat head comes into close contact
transfer the heat from the valve to the cylinder head for cooling of the valve

generally shaped like a 450 cone to conform with the shape of the valve face and has 1.2 - 1.8mm width
valve seat
Excessive valve seat contact will cause carbon intrusion but good cooling effect
narrow valve seat will result to improve airtightness but poor cooling effect
 generally made of cast iron and is press-fitted in the cylinder head
valve guide bushing
it guides the valve so that the valve face makes proper contact with the valve seat

provided on the top of the valve guide bushing to prevent a large amount of engine oil from entering the
valve stem oil seal
combustion chamber

unsmooth movement or sticking of the valve stem in the valve guide bushing
valve sticking occurs when the clearance between the valve stem and valve guide bushing is too small or not lubricated
well

damaged valve stem oil seal will cause excessive engine oil leak to the combustion chamber resulting to excessive oil consumption

used instead of valve spring retainers and allows the valve to rotate while moving up and down
valve rotators the rotation of the valve prevents it from improper sealing with the valve seat due to the lead compounds
or carbon when leaded gasoline is burned

tightening of ordinary bolt wherein the axial tension of the tightened bolt increases in proportion to the
elastic region
bolt's rotational angle

tightening beyond the elastic region wherein only the bolt's rotational angle changes, while the axial
plastic region
tension of the bolt changes little.

plastic region bolt special bolts that must be tightened in the plastic region to obtain the specific bolt tension
Name:
Group ____ Reviewer Part II

it causes the following problems:

a. excessive piston side knock
Problem that appears when
b. excessive engine oil consumption
cylinder wear progresses
c. insufficient engine power due to reduced compression pressure
d. damage to top piston ring due to ridge developing in the cylinder bore
a. insufficient lubrication
b. improper maintenance of the engine oil or oil filter
factors that causes cylinder
c. dust being sucked in through the air intake system
wear
d. air-fuel mixture being too rich
e. overheating

it indicates the small variances in the cylinder bore diameter and stamped into the top of the
cylinder bore size
cylinder block for each respective cylinder

cylinder bore has a true cylindrical shape and has a polished finish

is subject to the hot, high pressure gasses produced during combustion and place where the
cylinder bore
piston and piston rings are constantly sliding into , and as a result become worn out overtime

bore size code are used when selecting bearing thickness in order to improve the accuracy of oil clearance

it forms the bottom portion of the combustion chamber and is subject to the same high
piston head temperature conditions as the rest of the cylinder but cannot be cooled directly by coolant or by
the outside air

is slightly oval in shape to compensate for the thermal expansion of the thick metal of the piston
piston
pin boss
force that pushes the piston skirt against the cylinder wall when the compression or combustion
Thrust force
pressure is applied to the piston

major thrust force generated during the combustion stroke and stronger than minor thrust force

minor thrust force generated during the compression stroke and weaker than major thrust force

is the noise made by the piston when its side surface slaps against the cylinder wall and is also
Piston slap
called side knocking
it is created whenthe piston is force to strike against the cylinder wall at the time of transition from
Piston slap
the minor thrust to the major thrust force
this is done by setting the center of the piston pin slightly away from its center line to reduce the
offset piston
piston slap

piston pins fitted into piston pin holes that match the diameter of the piston pin

piston size code is stamped in the piston head and as the number gets larger, the bore size also gets larger

applied to piston skirt to enhance anti-seizing properties and sometimes coated with resin to
striation finish
reduce friction

The crankshaft main journal bores are machined with the bearing caps mounted on the cylinder
TRUE
block
TRUE The crankshaft main journal bore size codes are stamped in the cylinder block
Name:
Group ___ Reviewer Part III

a. fit the piston ringsonto the piston with the marks facing up
b.No.1 compression ring can be fitted on any side if there is no mark
Precautions when fitting the
piston ring c.Make no mistake in the order in which the compression rings are fitted
d. Fit the rings in such a way that the ring end gaps are not lined up together.
if too large will cause the pressureized gases to leak
Ring-end gap
if too small will result to breaking of piston ring that will damage the cylinder wall
is the pumping of oil above the rings when the piston rings move up and down inside the piston ring grooves
ring pumping effect
while the engine is running
up and down or side to side vibration of the piston rings in the piston grooves that reduces the effectiveness
ring flutter
of the ring.
has sufficient strength and rigidity to receive the heavy load from the piston and connecting rod while rotating
crankshaft
at high speed
made of aluminum alloy or kelmet metal and has oil holes for lubrication of the crankshaft main journal and oil
crankshaft bearings
groove for lubrication of the connecting rod bearing
locking lip prevents the upper and lower half-bearings from turning
If there is no crankshaft main journal code, the standard bearing size code should be the same code as the
TRUE
main journal bore size code.
main journal bore size code is located in the cylinder block while the main journal size code is located in the
TRUE
crankshaft
is continuously subjected to compressive force, to bending and tensile forces and other loads from the high
connecting rod
pressure of combustion and inertial force of the piston
provided in the big end of the connecting rod in order to supply lubricating oil to cylinder, cool the piston and
oil jet
lubricate the piston pin.
before TDC, the position of the crankshaft pin journal oil hole and oil jet coincide, and oil is sprayed out
TRUE
through the oil jet
TRUE If the connecting rod is assembled in reverse way, the cylinder will receive insufficient lubrication
If the engine does not have crankshaft pin size code, the bearing size is selected with a size code which is
TRUE
the same as the connecting rod big end bore size code.
 TRUE The method used to select the bearing size diffes on the engine so always refer to the repair manual.
is the valve opening and valve closing timing expressed in terms of the crankshaft angle from the piston TDC
valve timing
or BDC
valve overlap final stage of the exhaust stroke wherein both the intake valve and exhaust valve are open
scissor gear mechanism is used to drive the camshaft in order to prevent gear noise due to backlash
balance shaft provided in recent in-line four-cylinder engines having large displacements to reduce engine vibration
uses a spring and oil damper to maintain proper timing belt tension at all times and supresses noice
timing belt auto-tensioner
generated by the timing belt
Firing order A sequence in which combustion takes place
Running mate a piston movement inside the cylinder at the same direction regardless of condition inside the cylinder
is the distance between the valve stem end and the rocker arem when the valve is closed and must be
Valve clearance
provided because each part of the engine expands when heated
causes incomplete valve closing, resulting in the leakage of compressed and burned gas which may cause
Insufficient valve clearance
the engine to run improperly
excessive valve clearance caused the generation of abnormal noise due to contact between the rocker arms and valves.
maintains zero valve clearance at all times in order to provide maintenance-free valve clearance adjustment
hydraulic valve lifters
and to reduce the valve noise
Name:
Group ____ Reviewer Part IV - Lubricating and Cooling System

a system that supplies engine oil to the rotating and sliding parts of the engine so engine can
lubrication system
operate smoothly
draws the oil from the oil pan through a strainer and a suction pipe and pumps the oil to each
oil pump
part of the engine
oil pressure regulator is fitted inside the oil pump body to maintain the oil pressure at a constant level regardless of
(relief valve ) the engine speed
oil filter filters the oil coming from the oil pump before it is being sent to each part of the engine
permits the oil to flow to each part of the engine without passing through the filter element so
by-pass valve
that insufficient lubrication is prevented when the element becomes clogged
prevents contaminants collected in the oil filter from flowing back to the oil pump and stores
check valve ( oil filter )
the oil in the oil filter when the engine is stopped,
oil pressure warning lamp / oil is provided to warn the driver if the lubrication system is abnormal by sensing improper oil
pressure gauge pressure
oil pressure switch mounted in the cylinder block and detects if there is any oil pressure in the gallery
is a switch that is closed when the oil pressure is low and open when the oil pressure is high
oil pressure switch
causing the oil warning lamp to turn on and off
prevents the oil temperature to rise above 1000C preventing the deterioration of lubricating
oil cooler
properties
allows part of the oil flowing from the oil pump to pass through the oil cooler, then returned to
air-cooled oil cooler
the oil pan.
when the engine speed is low the relief valve of air-cooled oil cooler is closed but when the
TRUE
engine speed is high the it opens allowing the oil to flow in the oil cooler
allows all of the oilf from the oil pump to pass through the oil cooler and after being cooled the
water cooled oil cooler
oil flows to the engine parts
prevents the damage to the oil cooler by by-passing the oil cooler when the pressure
relief valve of oil cooler
difference between its inletside and outlet side rises beyond 147kPa
a. oil loss via the piston rings
Routes of oil loss b. oil loss via the valve guide
c. oil loss due to blow by gass being mixed with oil

differentiated by the position where the thermostat is mounted, first type, the thermostat is
cooling system
mounted in the water inlet and second thermostat is mounted in the water outlet.
an engine equipped with a thermostat with by-pass valve should not be run while the
TRUE
thermostat is removed

contains a cylinder that is move by the thermal expansion of wax in the cylinder causing the
thermostat
main valve to open

the by-pass valve of thermostat operates together with the main valve, when the main valve
TRUE
opens, the bypass valve closes

bleeds the air when the coolant is replaced and is closed by the flow of coolant when the
jiggle valve
engine is running
driven by the drive belt, timing chain or timing belt and circulates the coolant through the
water pump
cooling and heater system.
provides better cooling efficiency and helps engine to warm up faster aside from lowering fuel
electric motor driven cooling fan
consumption and reducing noise.
the engine idling speed should always be adjsuted with the cooling fan stop because the
TRUE
operation of fan motor increases the engine load
temperature controlled fluid allows changes of speed in different stages based on the temperature of the air passing
coupling through the radiator.

When the air temperature is low, the fan speed is low to quicken the warm-up and reduce the
TRUE
noise
 When the air temperature is high, the fan speed is increased over 3 stages to attain a
TRUE
sufficient cooling performance.