BANGLADESH UNIVERSITY OF ENGINEERING & TECHNOLOGY

Course No.: ME 402

Course Title: INTERNAL COMBUSTION ENGINES SESSIONAL

Experiment No.: 2
Name of the Experiement:
DISMANTLING AND ASSEMBLING OF A DIESEL ENGINE

Date of Performance Name: Aashique Alam Rezwan

21/03/2011 Student No.: 06 10 012
Date of Submission Section: “A” Group: A12
18/04/2011 Dept: Mechanical Engineering

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Experiment No.: 2
Name of the Experiment:
Dismantling and Assembling of a Diesel Engine

Objectives:
The objectives of this experiment are as follows
 Overview of a Diesel Engine
 Identifying and studying different components of a Diesel Engine
 Dismantling the Engine
 Assembling the Engine

Name Plate Data of the Engine

ICC Diesel Model KD60
CONT. Output: 5HP/2200RPM
Max. Output: 6HP/2400RPM
MFG. No.: 4347 JO

Engine Specifications:

Bore 75 mm

Stroke 76 mm

No of Cylinders 1

Camshaft Type In block

Injection Type Airless

Arrangement of Cylinders Horizontal

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Basic Components of a Diesel Engine
1. Fuel Supply System

Pump
Fuel Tank Filter Pipe Line
(Plunger)

Fuel over flow Fuel

Injector

Cylinder
Head

All diesel engines require a method to store and deliver fuel to the engine. Because diesel
engines rely on injectors which are precision components with extremely tight tolerances and
very small injection hole, the fuel delivered to the engine must be extremely clean and free of
contaminants. So, the fuel system not only delivers the fuel but also ensure its cleanliness.
This is usually accomplished through a series of in-line filters. Commonly, the fuel will be
filtered once outside the engine and then the fuel will pass through at least one more filter
internal to the engine, usually located in the fuel line at each fuel injector. In a diesel engine,
the fuel system is much more complex than the fuel system on a simple gasoline engine
because the fuel serves two purposes. One purpose is obviously to supply the fuel to run the
engine; the other is to act as a coolant to the injectors. To meet this second purpose, diesel
fuel is kept continuously flowing through the engine's fuel system at a flow rate much higher
than required to simply run the engine. The excess fuel is routed back to the fuel pump or the
fuel storage tank depending on the application.

Governor
Speed Control
Lever Fuel Filet

Crankshaft
Gear
Camshaft
Gear
Plunger
Pump

Fig.: Fuel System

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 Fig.: Fuel Line

Valve Decompression
Lever

Fuel Injector

Fig.: Cylinder Head & Cylinder Head Cover

Fuel Tank: The fuel tank is made of sheet metal, fiberglass, or plastic. It has two main
openings. Fuel is pumped in through one opening and out through the other.
Fuel Filter and Screens: Fuel systems use filters and screens to prevent dirt from entering
the fuel line and fuel pump. Most fuel systems have at least two filters. A filter screen or
strainer attaches to the pickup tube in the bottom of the fuel tank. An inline filter is between
the fuel tank and the fuel injectors.
Fuel Pump: The fuel pump sends fuel from the fuel tank to the fuel injectors. The pump has
a barrel and plunger assembly. An injection line or tube connects the barrel and plunger
assembly to an injection nozzle.
Low pressure fuel from the fuel supply pump flows through the inlet port into the space
above the plunger. The plunger has a roller that rides on a cam on the camshaft. This is like
the roller tappets used in some engine valve trains. When the cam love comes up under the
plunger, the lobe raises the plunger. This applies high pressure on the fuel trapped above the
plunger. The fuel is forced through the tube to the injection nozzle in the cylinder where the
piston is reaching TDC on the compression stroke. The fuel sprays out and ignites from the
heat of compression.

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2. Lubricating System:

Crankcase or
Oil Sump

Moving
Strainer
Bearing

Oil Pump
Gallery (Gear)

Lub Oil
Indicator
Filter

An internal combustion engine would not run for even a few minutes if the moving parts
were allowed to make metal-to-metal contact. The heat generated due to the tremendous
amounts of friction would melt the metals, leading to the destruction of the engine. To
prevent this, all moving parts ride on a thin film of oil that is pumped between all the moving
parts of the engine.
Once between the moving parts, the oil serves many purposes.
► The oil lubricates moving parts to reduce wear.
► As the oil moves through the engine, the oil picks up heat.
► Oil fills the clearances between bearings and rotating journals.
► The oil helps form a gas-tight seal between piston rings and cylinder walls.
► The oil acts as a cleaning agent.
The flow of oil to the moving parts is accomplished by the engine's internal lubricating
system.

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 Indicator
Gear Pump

Lubrication
Oil Filter
Dip Stick

Strainer

Timer Cover
Oil Pump: Oil is accumulated and stored in the engine's oil pan where one or more oil pumps
take suction and pump the oil through one or more oil filters. The gear-type pump has a pair
of meshing gears. As the gears unmesh, the spaces between the teeth fill with oil from the
pump inlet. The gears mesh and force the oil out through the pump outlet.
Oil Filters: The oil from the pump flows through the filter before reaching the engine
bearings. The filter has a pleated-paper filtering element. It allows the oil to pass through
while trapping particles of dirt and carbon.
The filter has a spring-loaded bypass valve. It opens to protect the engine from oil starvation,
if the filter becomes clogged. Then unfiltered oil bypasses the filter and goes directly to the
engine. However, the filter should be changed before this happens.
Oil Pressure Indicator: An oil-pressure indicator in the instrument panel warns the driver if
engine oil pressure is too low. There are four types of oil-pressure indicators.
1) Indicator Light
2) Electric Gauge
3) Electronic Gauge
4) Digital Gauge

3. Cooling System:

Water Inlet Water Jacket Radiator Air

The cooling system keeps the engine at its most efficient temperature at all speeds and
operating conditions. Burning fuel in the engine produces heat. Some of this heat must be
taken away before it damages engine parts. This is one of the three jobs performed by the
cooling system. It also helps bring the engine up to normal operating temperature as quickly

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as possible. In addition, the cooling system provides a source of heat for the passenger-
compartment heater and air conditioner.
Water Jacket: Water mixed with antifreeze flows through the water jackets, peaks up heat.
This cools the metal parts and heats the coolant.
Radiator: The radiator is a heat exchanger with two sets of passages. One set is for coolant
and the other for outside air. In the radiator, the coolant loses heat to the passing air.
Fan: A fan pulls or pushes outside air through the radiator. This improves engine cooling,
especially at idle and low speed.

4. Fuel Control System:

Speed Control
Governor
Lever

Valve Filter Tank

Fuel

Engine

In Diesel Engine, engine speed is controlled by controlling the fuel entering in the
combustion chamber. The control of a diesel engine is accomplished through several
components. The speed control lever controls the governor. The governor regulates the valve
which allows the fuel to enter into the injector. Together, these major components ensure that
the engine runs at the desired speed.
Governor: Moving the speed control lever (the accelerator pedal in case of automotive
system) changes the setting of the governor. It then automatically controls the amount of fuel
injected. A governor has flyweights that spin with the injection pump camshaft. The faster
they spin, the further out they move. This acts on the plunger and adjusts the fuel delivery.

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Figures of Some Other Parts of the Diesel Engine

Muffler
(Silencer)

Fig.: Intake & Exhaust Manifold

Fig.: Rear Cover Fig.: Pushrod & Rocker Arm

Fig.: Head Cover

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Answers of the Questions
i) No. of Cylinder rings, their types and functions.
Ans:
There are 4 rings in the cylinder, 3 of them are compression rings and single oil rings.
Functions:
1. Compression rings form sliding seal between the piston and the cylinder wall. These
seal compression and combustion pressures in the combustion chambers.
2. Oil rings scrape off most of the lubricating oil splashed on the cylinder wall and
return the oil to the crankcase.
Need for Three Compression Rings:
At the start of the power stroke combustion pressures may go as high as 1200 psi. A single
compression ring usually cannot hold this much pressure. Therefore three compression rings
are used.

Oil Ring
Compression
Rings

Guardian Pin

Big End
Bearing

Fig.: Piston & Connecting Rod

ii) No of bearings, their types and functions.
Ans:
There are 3 types of bearing in the engine cylinder. They are –
1. Connecting Rod Bearings (Big End Bearing)
2. Main Bearing (Journal Bearing) in the Crankshaft
3. Thrust Bearing in the Crankshaft
Functions:
Bearings are placed in the engine where there is rotary motion between engine parts. There
functions are –
a) They carry the loads imposed by high compression, high speed engines
b) They protect the more expensive part of the crankshaft or connecting rod from
being wear out

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 c) The bearing surfaces embed small particles that work their way onto the bearings
d) The bearing reduces the cost to repair by allowing the reuse of the more expensive
part

iii) No of valves and mention which one was bigger.

Ans:
There are two valves in the cylinder head. They are –
1. Intake Valve
2. Exhaust Valve
Among them the intake valve is larger than the exhaust valve. The reason is that when the
intake valve is open, the only force moving air-fuel mixture into the cylinder is atmospheric
pressure. Whereas, when the exhaust valve opens on the exhaust stroke, there is still high
pressure in the engine cylinder. A smaller exhaust valve provides enough space for the high-
pressure exhaust gases to get out of the cylinder.

iv) Location of cooling water pump.

Ans:
The cooling water provided for the engine is cooled by natural circulation of the heated water
through the radiator. This system is mounted overhead of the engine. The heated water is
lighter than the cold water and goes up to the radiator passage. In the radiator, the coolant
loses heat to the passing air. Then the coolant flows back through the water jackets to pick up
heat again. There is a mechanically driven fan mounted in front of the radiator to flow the air
to the radiator.

v) Fuel injection type and no of holes in each nozzle.

Ans:
The fuel injection system is Airless Injection, where only diesel is injected to the cylinder.
There are total 4 holes in the nozzle.

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Discussion:
The engine that we have studied is a Diesel Engine or Compression-Ignition Engine. In
compression ignition engines, air alone is inducted in to the cylinder. The fuel is injected
directly into the engine cylinder just before the combustion process is required to start. Load
control is achieved by varying the amount of fuel injected each cycle; the air flow at a given
engine speed is essentially unchanged.
The engine we have used for studying have a small power generation capacity of about 5HP
at 2200 RPM. The engine has a single piston to generate this amount of power. The airless
injection nozzle has 4 holes in it. The four holes are not same in size. This provides the even
fuel injection in the compressed chamber of the cylinder. The fuel is pumped to the fuel
injection system by a plunger type pump, which is operated by the cam eccentric. The pump
delivers the required amount of fuel in each power stroke. This amount is maintained by the
governor attached with the system. The governor is operated by a speed control lever. As we
required increasing the speed of the engine, more fuel is required for combustion. The
governor along with speed control lever controls the whole system. Before delivering the fuel
from the fuel tank, the fuel is filtered through a fuel filter. The filter element is usually made
of ceramic or paper. There is also a screen in the fuel tank which provides additional
filtration.
The lubrication is essential in any machines that have rotating parts. There are several
moving and rotating parts which are supported by bearings. These bearings require proper
lubrication for better performance. The lubrication system of the engine provides this activity
for the engine. Lubricating oil is pumped to the moving part using a gear type pump. As the
lubricating oil circulating through the moving parts, it also collects soot, dirt and other
particle. These particles must remove before the lubrication oil is being pumped again. There
is a lubricating oil filter mounted in line with the lubrication system. This filter provides
much of the filtration of the lubricating oil. Before entering the system, the lubricating oil is
first filter through a strainer in the oil sump.
The burning of air-fuel mixture in the engine cylinders may reach 2200°C or higher. This
means engine parts get hot. Higher temperature cause lubricating oil to break down and lose
its lubricating ability. Other engine parts are also damaged. To prevent overheating, the
cooling system removes the excess heat. This is about one-third of the heat produced in the
combustion chambers by the burning air-fuel mixture. For cooling the engine, the engine
studied use a natural circulation operated overhead cooling system.

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The rear cover of the engine provides ventilation of the engine. If some high pressure gas
from the combustion chamber escapes to the cylinder block, the high pressure accumulated in
the cylinder block may damage the connecting rod or the shaft. For proper ventilation of this
high pressure gas, there is an air ventilation pipe mounted on the rear cover.
The engine that we have studied is started manually. Manual starting of a diesel engine is
very risky. And care must be taken when someone is trying to start a diesel engine. The high
compression ratio used in the diesel engine makes the starting very harder. To release some
of the pressure, a decompression lever is used during the starting of the engine. This causes
some of the gas to flow through the exhaust valve and the high compression force required is
decrease somewhat.
The escaping of the exhaust gas through the exhaust valve creates a high noise. To reduce the
intensity of the noise, a muffler type silencer is used in the exhaust manifold. The muffler
used in this engine is a reaction type muffler. This damps out the noisy high pressure surges
resulting from the opening of the exhaust valves.
The study we performed in this experiment is very much necessary for a much wider
knowledge in diesel engine construction and operation. It helps me to clarify my theoretical
knowledge learned through the books. The complex mechanism of the combustion process
can’t be comprehended without the practical experience.

References:
1. Heywood, J. H., 1988, “Internal Combustion Engine Fundamentals”, pp 1~36
2. Pulkrabek, W. W., 2004, “Engineering Fundamentals of the Internal Combustion
Engine”, Second Edition, pp 19~24
3. Crouse, H. C., Anglin, D. L., 2010, “Automotive Mechanics”, Tenth Edition

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Assignment
Pintle Nozzle
In a diesel fuel injection system a multi-hole nozzle is used to evenly distribute the charge
(fuel) into the combustion chamber. The nozzle consists of a needle valve. This nozzle is
usually described as PINTLE NOZZLE. The valve of the pintle nozzle has an extension that
protrudes through the hole in the bottom of the nozzle body and produces a hollow cone
shaped spray. The included angle of the spray cone may be up to a maximum of 60 degrees,
depending on the type of combustion chamber in which it is used. A pintle nozzle generally
opens at a lower pressure than the pressure at which the hole nozzle opens because fuel flows
more readily from the large hole of the pintle nozzle. Although atomization of the fuel is not
so complete in the pintle nozzle as it is in the hole nozzle, penetration into the combustion
space is greater. Consequently, pintle type nozzles are used in engines having precombustion,
divided, air cell or energy-cell combustion chambers, where mixing of fuel and air is largely
dependent on combustion reaction or turbulence. In addition, the motion of the pintle tends to
inhibit the formation of carbon crust on the tip of the nozzle.

Fig.: Construction of a diesel-engine injection nozzle

(Chevrolet Division of General Motors Corporation)

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