MODULE: PERFORM ENGINE OVERHAUL

UNIT: SERVICE CYLINDER HEAD

ENGINE

An engine is a machine that converts heat energy (usually from fuel) into
mechanical energy to perform work, such as moving a vehicle or
operating machinery. Or Engine is the source power of the machine.

Terminology used in machine.

[Link]- Top dead center( piston move to the top)

2. BDC- Bottom dead center ( piston move to the bottom)

3. Stroke - Distance the piston move TDC to BDC or from BDC to TDC.

4. Cylinder -Where piston move ( reciprocates)

5. Cylinder bore - Diameter of the cylinder.

Two Types of Engines

a) Internal Combustion Engine (IC Engine)

In this type, fuel burns inside the engine cylinder.

The combustion produces high-pressure gases that move pistons to

generate [Link]: petrol engine, diesel engine (used in cars,
trucks, motorcycles).

b) External Combustion Engine (EC Engine)

In this type, fuel burns outside the engine.

The heat produced is used to generate steam or another working fluid

that drives the [Link]: steam engine.

Types of internal combustion engine

Internal combustion engines (IC engines) can be classified in several

ways. Here are the main types with explanations:

1. Based on Type of Fuel

a) Petrol Engine (Spark Ignition Engine – SI)

b) Diesel Engine (Compression Ignition Engine – CI)

2. Based on Working Cycle

a) Two-Stroke Engine

b) Four-Stroke Engine

3. Based on Number of Cylinders

a) Single-Cylinder Engine

b) Multi-Cylinder Engine

4. Based on Cooling System

a) Air-Cooled Engine

b) Water-Cooled Engine

5. V- type engine

Different between two stroke engine and four stroke engine

Two stroke engine Four stroke engine

Use port Use valve
Less power High power
Low cost High cost
One power stroke per one One power stroke of crankshaft per
revolution of crankshaft two revolution of crankshaft
Exhausted gas not fuel yield Exhausted gas fuel yield
Oil and fuel mixed together Oil and fuel separated
How engine works

Four stroke of the engine

1. Induction stroke

2. Compression stroke

3. Power stroke

4. Exhaust stroke

Event of each stroke of the engine

1. Induction stroke

• Inlet valve open

• Exhaust valve remain close

• Piston move from Tdc to Bdc

• Air fuel mixture enter to the cylinder.

2. Compression stroke
 • Inlet valve close

• Outlet valve remain close

• Piston move from BDC to TDC

• Mixture are compressed

3. Power stroke

• Both valve remain closed

• Piston move from TDC to BDC

• Fuel injected by nozzle or spark plug ignite the mixture

• Mixture are burned and expand pushing piston down wards.

• The useful of the engine are obtained.

4. Exhaust stroke

• Inlet valve remain closed

• Outlet valve open

• Piston move from BDC to TDC

• Exhausted gas yield from the cylinder.

Major parts of the engine

There are three major parts of the engine

• Cylinder head

• Cylinder block

• Crankcase

[Link] head

Cylinder head is the upper part of the engine,

Main Components of a Cylinder Head

➢ Combustion Chamber

Space where air-fuel mixture burns to produce power.

➢ Inlet (Intake) Valve

Allows air or air-fuel mixture to enter the cylinder.

➢ Exhaust Valve

Allows burnt gases to leave the cylinder.

➢ Valve Guides

Support and guide the movement of valves.

➢ Valve Seats

Provide a sealing surface for valves when closed.

➢ Spark Plug (Petrol Engine)

Ignites the air-fuel mixture.

➢ Fuel Injector (Diesel Engine)

Injects fuel into the combustion chamber.

➢ Camshaft (in OHC engines)

Controls opening and closing of valves.

➢ Rocker Arms (in some engines)

Transfer motion from camshaft to valves.

➢ Cooling Passages (Water Jackets)

Allow coolant to flow and remove heat.

➢ Oil Passages

Supply lubrication to moving parts.

➢ Head Gasket Surface

Sealing surface between cylinder head and engine block to prevent

leakage.

Function of Cylinder Head

• Seals the top of the cylinder

• Houses valves and spark plug/injector

• Forms the combustion chamber

• Helps in heat dissipation

• Controls airflow in and out of the engine

Cylinder head is made of cast iron or aluminium alloy

2. Cylinder block

The cylinder block (engine block) is the main body of an internal

combustion engine. It houses cylinders and many important engine
parts.

Main Components of a Cylinder Block

➢ Cylinders / Cylinder Bores

Hollow tubes where the piston moves up and down.

➢ Pistons

Move inside the cylinders to compress air-fuel mixture and transmit

power.

➢ Piston Rings

Seal the gap between piston and cylinder wall, prevent leakage, and
control oil.

➢ Connecting Rods
Connect pistons to the crankshaft and transmit motion.

➢ Water Jackets (Cooling Passages)

Passages for coolant flow to remove heat from the engine.

➢ Oil Passages (Oil Galleries)

Channels for lubricating oil to reach moving parts.

➢ Main Bearings

Support and allow smooth rotation of the crankshaft.

➢ Camshaft (in some engines)

Located inside the block in older or OHV engines.

➢ Timing Chain / Gear Housing

Encloses components that synchronize camshaft and crankshaft.

➢ Core Plugs (Freeze Plugs)

Seal openings in the block and protect against freezing damage.

Function of Cylinder Block

• Forms the main structure of the engine

• Houses cylinders and moving parts

• Supports crankshaft and camshaft

• Provides passages for cooling and lubrication

3. Crankcase

The crankcase is the lower part of an internal combustion engine that

encloses and supports the crankshaft. It is usually attached below the
cylinder block or forms part of it.

🧩 Main Parts of a Crankcase

➢ Crankshaft

Converts up-and-down motion of pistons into rotary motion.

➢ Crankshaft Housing

Space where the crankshaft rotates.

➢ Main Bearings

Support the crankshaft and allow smooth rotation.

➢ Oil Sump (Oil Pan)

Stores engine lubricating oil at the bottom of the crankcase.

 ➢ Oil Pump Mounting Area

Location where the oil pump is installed.

➢ Seals (Front & Rear Oil Seals)

Prevent oil leakage from the crankshaft ends.

➢ Breather / Ventilation System

Releases gases and pressure from inside the crankcase.

➢ Fly wheel

Is a heavy rotating disc attached to the engine’s crankshaft.

➢ Big end bearing

is a bearing located at the lower end of the connecting rod, where it

connects to the crankshaft.

➢ Dipstick

is a metal rod used to check the level of engine oil in the engine.

Functions of the Crankcase

• Stores lubricating oil (in the oil sump)

• Supports engine components like bearings and oil pump

• Prevents contamination and oil leakage

• Helps in cooling and ventilation

Major Engine Components

➢ Cylinder block ➢ Piston rings

➢ Cylinder head ➢ Connecting rod

➢ Piston ➢ Crankshaft
 ➢ Crankcase ➢ Fuel injector / carburetor

➢ Camshaft ➢ Spark plug (petrol engine)

➢ Valves (Inlet & Exhaust) ➢ Dipstick

➢ Timing chain/belt/gears ➢ Oil filter

➢ Big end & small end ➢ Air filter

bearings
➢ Water pump
➢ Gudgeon pin (piston pin)
➢ Fly wheel
➢ Oil pump

PISTON

A piston is a movable part fitted within the engine cylinder that receives
force from expanding gases (during combustion) and transmits that
force to the crankshaft through the connecting rod. Or

is a cylindrical mechanical component that moves up and down inside

the cylinder of an engine.

Functions of piston

➢ Used to convert heat energy into mechanical energy

➢ Used to press out exhausted gas

➢ Move up and down to accomplish engine stroke

➢ Receive combustion pressure and transmit force to crankshaft.

➢ Seals crank shaft from combustion chamber.

piston is made of cast iron or aluminium alloy

Piston parts are the following

 ➢ Piston Crown (Head)

The top surface of the piston. It faces the combustion chamber and
receives the force from burning gases.

➢ Piston Rings

Fitted into grooves around the piston.

➢ Ring Grooves

Grooves cut into the piston where the piston rings are fitted.

➢ Piston Skirt

The lower part of the piston. Guides the piston inside the cylinder and
reduces friction.

➢ Piston Pin (Gudgeon Pin / Wrist Pin)

Connects the piston to the connecting rod. Allows the piston to move
smoothly.

➢ Pin Boss

Thickened sections inside the piston where the piston pin is fitted.

➢ Oil Return Holes

Small holes that allow excess oil to flow back to the crankcase.
PISTON RING

Piston ring are split circular metal ring fitted into grooves on a piston. It
forms a seal between the piston and the cylinder wall to ensure efficient
engine operation.

Types of piston rings

1. Top compression ring.

2. Second compression ring

3. Oil ring

Functions of piston rings

➢ Compression ring are used to prevent compression burns gas

from leaking through gap between piston and cylinder wall.

➢ Transfer heat from the piston to the cylinder wall.

➢ Prevents oil from entering the combustion chamber (reduces

smoke).

Piston ring gap

Piston ring expands as piston become hot . Appropriate gap mus be left,
the ring end gap is from 0.2mm to 0.5mm

Too big ring gap

Lower engine compression pressure.

Too small gap

Can cause engine seizing due to thermal expansion and damage

cylinder wall

CONNECTING ROD

Connecting rod is a mechanical component in an internal combustion

engine that connects the piston to the crankshaft. It transmits the
reciprocating (up-and-down) motion of the piston into rotary motion at
the crankshaft.

Parts of a Connecting Rod

➢ Small End (Piston End)

The upper part connected to the piston using a piston pin (gudgeon pin).

➢ Big End (Crank End)

The lower part attached to the crankshaft. Usually split into two halves
for easy assembly.

➢ Rod Shaft (Shank)

The long middle section that connects the small end and big end.

➢ Bearing Inserts (Big End Bearings)

Fitted inside the big end to reduce friction between the rod and
crankshaft.

➢ Bolts and Nuts

Used to fasten the big end cap securely.

➢ Bush/Bearing (Small End Bush)

A soft metal lining in the small end to reduce wear.

Functions of a Connecting Rod

➢ Connecting piston to crankshaft

➢ Change reciprocating motion of piston into rotary motion of the

crankshaft.

➢ Transmit force from piston to crankshaft.

CRANKSHAFT

Crankshaft is a major component of an internal combustion engine that

converts the reciprocating (up-and-down) motion of the piston into
rotary (circular) motion to drive the vehicle or machine.

Main Parts of a Crankshaft

➢ Crankpins (Rod journals)

Where the connecting rods are attached.

➢ Main journals

Support the crankshaft and allow it to rotate inside the engine block.
 ➢ Counterweights

Balance the crankshaft and reduce vibration.

➢ Flywheel flange

Mounts the flywheel to the crankshaft.

➢ Crankshaft pulley (nose)

Drives belts for accessories like alternator and water pump.

➢ Oil passages

Allow lubrication of moving parts.

Functions of a Crankshaft

➢ Changes piston movement into rotational motion.

➢ Transfers engine power to the transmission system.

➢ Counterweights reduce vibrations for smooth operation.

➢ Supports engine timing

➢ Drive engine accessories

Crankshaft figure
CAMSHAFT

Camshaft is a rotating shaft in an internal combustion engine that has

specially shaped projections called camlobs.

These cams push against valves (through lifters, pushrods, or rocker

arms) to control their opening and closing at the correct time.

Functions of a Camshaft:

➢ Operates engine valves

➢ Operate mechanical fuel pump

➢ Operate oil pump

➢ Operate distributor.

Camshaft figure

Camshaft is driven by crankshaft by either

➢ Timing gear

➢ Timing chain

➢ Timing belt
Geometrical camshaft rotates one per two revolution of crankshaft

Gear ratio 2 : 1

Gear ratio = Driven

Driver

ENGINE VALVE

An engine valve is a mechanical component in an internal combustion

engine that controls the flow of air-fuel mixture into the cylinder and the
exit of exhaust gases out of the cylinder. It opens and closes at specific
times to ensure proper engine operation.

There are two main types of valve

➢ Inlet (intake) valve – allows air-fuel mixture into the cylinder

➢ Exhaust valve – allows burnt gases to leave the cylinder

Method for performing valve clearance (OHV)

➢ One to one valve adjustment

Each cylinder is adjusted one at a time.

The engine is rotated and each cylinder is brought to compression TDC

before adjustment.

➢ Valve overlap method (Exhaust–Intake method)

When one cylinder is at valve overlap (exhaust closing and intake

opening), the opposite cylinder can be adjusted.

Too small clearance gap(Valve does not fully close) can cause

➢ Loss of engine compression

➢ Valve not closing properly

 ➢ Early opening of valves

Too big valve clearance (loose clearance) can cause

➢ Loud tapping or knocking noise from engine

➢ Valve delay to open

➢ Lower engine power output

Figure of valve drive mechanism opening and closing of valve

VALVE TIMING

Valve timing is the process of controlling the exact opening and closing
of the engine’s inlet and exhaust valves in relation to the position of the
piston and the rotation of the crankshaft.

In simple term
 ➢ The inlet valve opens at the correct time to allow air-fuel mixture
enter the cylinder.

➢ The exhaust valve opens at the correct time to release burnt

gases.

➢ Both valves operate in proper sequence for efficient engine

performance.

Figure of valve timing

ENGINE TIMING

Engine timing arrangement for multi-cylinder engines is based on firing

order and even firing interval. In a 4-stroke engine, one complete cycle is
720° crankshaft rotation, so the firing interval is:

Firing order
Firing order is the specific sequence in which the cylinders of an internal
combustion engine ignite and produce power.

🔧 1. Four-cylinder engine

Firing interval: 720° ÷ 4 = 180°

Common firing order: 1 – 3 – 4 – 2

Each cylinder fires every 180° crankshaft rotation

🔧 2. Six-cylinder engine

Firing interval: 720° ÷ 6 = 120°

Common firing order:

1–5–3–6–2–4

Smooth power delivery with firing every 120°

🔧 3. Eight-cylinder engine

Firing interval: 720° ÷ 8 = 90°

Common firing order (V8):

1–8–4–3–6–5–7–2

Power stroke every 90° crank rotation

🔧 4. Twelve-cylinder engine

Firing interval: 720° ÷ 12 = 60°

Common firing order: varies by design,

1 – 12 – 5 – 8 – 3 – 10 – 6 – 7 – 2 – 11 – 4 – 9

Very smooth operation with firing every 60°

FIRING ORDER FOR V TYPE ENGINE

 ➢ V-6 engine

1–4–2–5–3–6

(may vary depending on design)

➢ V-8 engine

1–5–4–2–6–3–7–8

(common for many V8 engines)

➢ V-12 engine

1 – 7 – 5 – 11 – 3 – 9 – 6 – 12 – 2 – 8 – 4 – 10

PISTON PAIR

piston pair refers to two pistons in an engine that move together (reach
Top Dead Center or Bottom Dead Center at the same time). These
pistons are usually connected in such a way that their motion is
synchronized for proper engine balance and firing order.

Arrangement of Piston Pairs

1. Four-cylinder engine

Piston pairs:

(1 & 4) and (2 & 3)

2. Six-cylinder engine

Piston pairs:

(1 & 6), (2 & 5), (3 & 4)

3. Eight-cylinder engine

Piston pairs:

(1 & 8), (2 & 7), (3 & 6), (4 & 5)

4. Twelve-cylinder engine

Piston pairs:

(1 & 12), (2 & 11), (3 & 10), (4 & 9), (5 & 8), (6 & 7)

CYLINDER HEAD GASKET

Cylinder head gasket is a sealing material placed between the engine

cylinder head and the engine block to ensure a tight seal and prevent
leakage of gases, oil, and coolant.

Functions of Cylinder Head Gasket

➢ Prevents combustion gases from escaping the cylinders.

➢ Prevents oil leakage

➢ Prevent engine oil from mixing with coolant

➢ Prevents coolant leakage

The cylinder head tightening sequence is from center ( from small

number to outward large number)

Removing cylinder head opening sequence is from outward big number

to in ward small number.

FLY WHEEL

Flywheel is a heavy circular disc attached to the end of the crankshaft in

an engine. Its main purpose is to store and regulate rotational energy.

Function of fly wheel

➢ Contains one face for engagement with clutch

➢ Have gear ring for engagement with starter motor for cranking the
engine.

➢ Used to store energy for dead [Link] Induction stroke,

Compression stroke and Exhaust stroke.