Sách Technical Service Training Global Fundamentals Curriculum Training – TF1010009S Engine Operation

Introduction 1
Preface 1
Global fundamentals training overview 1
Contents 2
Lesson 1 – Internal combustion engine 5
General 5
Objectives 5
At a glance 6
Purpose and function . 6
Theory . 7
Gasoline internal combustion engine 7
Operation 8
Creating mechanical motion . 8
The four-stroke cycle 9
Bore, stroke and displacement 10
Stroke 10
Displacement . 11
Intake stroke 12
Compression stroke . 12
Compression ratio . 13
Power stroke 14
Exhaust stroke . 14
Summary 15
Lesson 2 – Engine block assembly 16
General . 16
Objectives 16
At a glance 17
Engine block assembly 17
Components 18
Major components . 18
Engine block liners 19
Crankcase 21
Crankshaft . 21
Main bearing journals . 22
Vibration damper . 23
Connecting rods 26
Cylinder wall lubrication 28
Pistons . 29
Piston rings 31
Lesson 3 – Valve train 34
General . 34
Objectives 34
At a glance 35
Valve train types overview 35
Overhead camshaft (OHC) configuration . 38
Single overhead cam (SOHC) . 39
Double overhead cam (DOHC) . 39
Camshaft drives . 39
Components 40
Pushrod type (OHV) cylinder head . 40
Cylinder head gasket . 41
Head bolts 41
Valves 42
Valve seats . 43
Valve stem . 44
Valve guide 45
Valve clearance 46
Valve springs . 47
Spring tension 48
Working height 48
Camshaft . 49
Lift . 49
Duration . 50
Overlap 51
Overhead valve drive . 52
Pushrods 53
Rocker arms 53
Valve lifters . 54
Solid lifter . 54
Hydraulic lifters and buckets 55
Roller versus flat lifters . 56
Overhead camshaft (OHC) cam followers 57
Bucket-type solid lifters 57
Overhead camshaft (OHC) hydraulic lash adjusters . 58
Rocker arm-mounted hydraulic lash adjuster . 59
Overhead cam drive 60
Belt and chain drive . 61
Belt and gear drive 62
Theory . 63
Variable cam timing 63
Lesson 4 – Lubrication system 64
General . 64
Objectives 64
At a glance 65
Description 65
Theory . 66
Motor oil 66
Operation 68
Oil circulation . 70
Pressure lubrication . 71
Stresses on the oil 72
Oil changes 73
Components 73
Oil pan components . 73
Oil strainer . 73
Oil pump 74
Oil pump types 75
Oil filter . 77
Oil seals . 80
Dipstick . 80
Oil pressure warning indicator 80
Lesson 5 – Intake air system . 81
General . 81
Objectives 81
At a glance 82
Air intake system . 82
Components 84
Inlet runners 84
Variable Induction Systems . 84
Intake manifold runner control (IMRC) system . 85
Intake manifold tuning (IMT) valve . 86
Forced induction 87
Theory . 88
Turbocharging . 88
Lesson 6 – Exhaust system 91
General . 91
Objectives 19
At a glance 92
Description and Purpose . 92
Components 94
Mufflers . 94
Catalytic converter 94
Lesson 7 – Cooling system . 95
General . 95
Objectives 95
At a glance 96
Description 96
Operation . 98
Components 99
Coolant pump 99
Thermostat . 100
Cooling fan 102
Cooling fan drives . 102
Coolant overflow reservoir and degas bottle . 104
Degas bottle . 105
Radiator . 108
Lesson 8 – Diesel engine 111
General . 111
Objectives 111
At a glance 112
Description 112
Operation . 112
Components 113
Cylinder block . 113
Wet liners 114
Crankshaft . 114
Connecting rods 115
Pistons and rings . 115
Cylinder head 115
Open combustion chamber design 116
Pre-combustion chamber design . 117
Valves and seats . 118
At a glance 119
Fuel delivery system . 119
Lubrication system 121
Cooling system 122
Fuel injection . 124
Lesson 9 – Diagnostic process . 125
General . 125
Objectives 125
Overview . 126
Symptom-to-system-to-component-to-cause diagnostic process . 126
Workshop literature . 127
List of abbreviations 128

Engine Operation S