COURSE

DE

ENGINES
DIESEL
SHIPPING 1

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DIESEL ENGINES Page 1

 Welcome to the distance courses of the ALDEY INSTITUTE, under the supervision of
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DIESEL ENGINES Page 2

 PROGRAM

VIDEOS TEXTS
VW 1600. diesel engine description 1600 Operation of the diesel engine
Visual inspection of the engine condition Classification of diesel engines
Basic analysis of exhaust smoke Lubrication: oils, characteristics, and classification
Verification of oil level and pressure in the Specification of the engines
motor Products, parts, and operations
Heater verification Thermostat
Battery load test Supplementary controls
Compression test Analysis of engine oil samples
Determination of failures Oil consumption test
Disassembly of the engine

Engine disassembly, continuation Feeding system, fuel, parameters of

Inspection and measurement of cylinders diesel in the combustion performance, cover of
Engine adjustment fuel tank, use of the fuel of
Water seal inspection reservoir, supply and return piping, pump of
Crankshaft metal assembly air purging, rotary pump and linear, pump of
Crankshaft assembly, inspection with transfer or food, components of the
plastigage injector injection pump functioning and
controls, types.

Assembly of piston-connecting rod set Injection pumps

inspection and measurement of the components Mechanical systems
-Inspection of the oil pump, of the Rotary pump
water pump, of the thermostat Composition
-Inspection of the cylinder head, measurements, analysis High pressure generation
of failures, measurement of springs, verification of Flow regulation
the sealing of the valve, seats of Injection synchronization
valves, cylinder head gasket, assembly of the Feed valve
joint, torque sequence
Tuning of a 6 diesel engine
cylinders in line
Regulation of the point of a diesel engine 4
cylinders with rotary pump
Injector testing and cleaning

Service and maintenance of diesel engine of Linear pump

bus/truck Components.
Oil change, oil pressure test, Linear pump lubrication
valve regulation, disassembly of the Linear pump operation
{"inyector":"injector","limpieza del inyector":"injector cleaning","test del":"test of"} Combined linear pump regulator
injector, injector assembly, verifications,
disassembly and assembly of linear pump, purging
air filter change, air filter inspection
of the belts, checking the oil level
and refrigerant, thermostat verification, test
of air leaks, bearing inspection
of the compressor, water pump and alternator

DIESEL ENGINES Page 3

Operation and service of linear pump Rotary and linear injection pumps - commissioning to
large 6-cylinder inline engine point
Description of 6-cylinder engine for buses
with turbocharger
Description of large diesel engine 6
scania cylinders

-Turbocharger. description, analysis of Two-stroke diesel engines

internal components, damage observation, Superchargers and turbochargers.
analysis of possible failures, balancing Operation and maintenance
dynamic of turbochargers Intercooler
Observation of Scania engine with systems
turbo ecological
Observation of medium displacement engine of
VW truck
Presentation of alarm device and
control for diesel engines

International truck with a large diesel engine Electricity, units of measurement, conductors,
potencia. descripción thermistors, semiconductors
Mercedes OM352 bus engine with 140 hp. Preheating system
observation and description --heaters
Detroit diesel engine series 60 - observation and Starter motors
descripción -Sistema de carga
Detroit diesel engine 210 hp with injection Battery
electronic description irregularities.
Front truck brand International, series -
9800. description and observation Codes and tables of fuses, conductors, terminals,
symbols
-
Failures in diesel engines and maintenance Special motors
Motor overheating and leaks in Heat exchanger
lubrication system Alternative starting systems
Cleaning of the cooling system fixed and moving parts of engines and their repair
Temperature failures in the system of -Block, floating shirts
cooling - Pistons
Basic maintenance and adaptation of Aros
diesel engines Change of rings and oil consumption
Inspection and cleaning of the injector, tests, Distribution system
ultrasonic cleaning Valve turn systems
Maintenance, water level control, Connecting Rods
change diesel filter, air filter, system of
refrigeration, other considerations

Pneumatic system for diesel vehicles Applied electronics to diesel engines

trucks and buses Microcomputers
-Compressor. operation and maintenance VW Polo diesel, fuel injection, circuit
Air piping, tank purging electrical, tests, instruments
Batteries for large engines Electronic components, sensors
Starter motor for large engine, Diagnosis of failures in assisted diesel engines
descripción, diagnóstico, mantenimiento, electronically
assembly

DIESEL ENGINES Page 4

Alternator, disassembly, inspection, and assembly

Bus/truck brakes and axles

Operation of the braking system
tire
Disassembly and service of axles and system
pneumatic brakes

Bus/truck gearbox
Disassembly, inspection

Diesel injection control system

Detroit Series 80 electronic motor
-Description of components (computer,
sensors, actuators, injector pump, brake
motor, etc.)
Description of regulation procedure
of valves and fuel injectors
Procedure for diagnosis
computerized with diagnostic light and
special scanner
Motor International DT 466E
Description of electronic control system
(computer, sensors, actuators) and method
for computerized diagnosis

DIESEL ENGINES Page 5

 DIESEL ENGINES

FUNCTIONING Injector
A B

Diesel engines are basically divided into three.

groups:

Small motors: these motors work

from 1800 to 4500 rpm, being the most engines
fast. They are generally used in vehicles of
ride or vans.

Medium engines: these engines work

from 600 to 1600 rpm. They are slow and are used in their
large majority in lightweight marine engines,
locomotives and for heavy trucks.

Large engines: they are stationary engines

that generally work continuously.
They reach a maximum of 500 rpm.

Diesel engines are also classified by number Admission

of engine times. But now diesel engines can
to be classified by the number of cylinders (inline, boxer,
in 'V', etc.) A B
Let's see what the four strokes of an engine are.
Diesel and what are the differences in relation to gasoline engines
gasoline.

1st. Time - “Admission”: In this stage the

piston moves from TDC (top dead center)
superior) to the PMI (lower breakeven) and the
The intake valve opens. It is very important.
It is important to highlight that in this stage, the Diesel engine draws in.

only air, unlike gasoline engines,

that aspire a mixture of "air + fuel".

Second. Time - "Compression": In this stage the

piston moves from PMI to PMS and the valves
the intake and exhaust are closed. In the engines
Diesel, only the air is compressed.

Compression

DIESEL ENGINES Page 6

 In gasoline engines, at this stage, the fuel is compressed
air + fuel mixture, limiting the level of A E
compression, because when the mixture is very compressed,
they can enter in compression ignition. If the engine
compress only air, then it can reach levels of
higher compression.

3rd. Time- "Expansion": The piston moves

from PMS to PMI and the valves remain closed.
At the end of the compression, injection occurs
diesel at high temperature and initiates the
combustion. In Diesel engines it is not necessary
the ignition spark plug, as combustion begins
necessarily by compression ignition.

In gasoline engines, the spark from the ...

spark plugs, because the compression level is good
low and the fuel has other characteristics.

Time - "Escape": The piston moves from

PMI for the PMS and the relief valve opens for Combustion - Expansion
that the combustion gases can escape from the
cylinder, exactly as occurs in the engines
gasoline.
A E
In summary we have:

GASOLINA DIESEL
1st. Time Air mixture + Air
admission flammable.
2nd time air mix + Air
Combustion Compression.
3rd. Time Spark ignition Introduction of
expansion flammable.
Turned on by
compression of the
mix
4th time Gas emissions Gas emissions
escape of the escape. of the escape.

In gasoline engines, the throttle opening is

the one that controls the efficiency of the engine through
the amount of air + fuel mixture admitted,
Escape

DIESEL ENGINES Page 7

together with the control of the spark and the
start of combustion.
In diesel engines, the control is
performed only by the amount of
combustible and at the moment when it is
injected since the combustion starts at
through compression ignition.
For this we can say that the engines
Diesel do not need a throttle butterfly.
Diesel engines generate more noise.
due to its combustion form (ignition
for understanding) and, also, they need
stronger and heavier components for
resist combustion efforts,
returning to the heavier engine.
If the engine components are more
heavy, obviously, we will not achieve
reach higher revolutions.
If we have a piston at rest and
we need to change this direction, that is,
make it rise, logically the larger the piston, the greater the difficulty encountered.
This is the principle of inertia, which states that every body tends to continue in the
movement in which it is found, and the heavier it is, the greater the inertia will be
this body (the greater its difficulty in changing movement).
VALVE DIAGRAM
Theoretically, engines operate
exactly as described above, that is,
the valves open and close at TDC and
PMI.
However, this way much would be lost.
energy, because due to inertia the fluid
never manages to fill the cylinder well, and
it's never possible to expel all the gas from
escape.
How do these phenomena occur in the
interior of the cylinder?. Admission: yes
we placed a syringe in a glass of water and
we pull the plunger slowly, we'll see
that the fluid enters the syringe
accompanying the movement of the piston.
However, if we pull the plunger
quickly, we will see that the water does not
exactly accompanies the movement of the
plunger.

DIESEL ENGINES Page 8

 In the escape time, if we open the
valve in the PMI and we close exactly
in the PMS, all exhaust gas must be
expelled during this time.

Thus, the piston will have all this gas PMS

slowing its movement until expulsion
of gases. This phenomenon is called
Loss of pumping.

In order to gain energy and,

consequently, increase performance
of the engines, the diagram of was altered
the valves that vary from engine to engine,
looking for the best possible performance. PMI

If we keep the intake valve

open after the piston has reached the
PMI, and it is rising
until the compression energy equals
to the admission energy, and only in that
the moment we close the valves we will have
let in the maximum amount of air possible.

If we look closely at the diagrams,

we will see that in the larger part, there is a
period during which the intake valves and
the exits are open simultaneously.
This period is called crossing of
valves.

This crossing aims to improve the

washing of the cylinder, that is, the evacuation of
the exhaust gases through the air and
also increase the filling vortex of the
cylinder at high revolutions. We know
that exhaust gases at elevated
Revolutions help with air intake.

It is important to note that, in

Diesel engines, the valve overlap does not
they are related to the emission of pollutants from the exhaust, because during the crossing
only air comes out with gases from combustion (there is no fuel). In the
gasoline engines, the crossover allows unburned fuel to pass to the exhaust.

DIESEL ENGINES Page 9

 DESCRIPTION

In a diesel engine, the air inside the cylinders is compressed until it is very
hot, then, diesel fuel is injected. In a gasoline engine the
fuel is aspirated, mixed with air, compressed and then ignited by a spark
electric. In a diesel engine, the fuel is ignited by the heat of compression.
air. That is why the temperature of the air compression in the combustion chambers of a
diesel engines must be approximately 500ºC or higher. Consequently, diesel engines
they generally have a higher compression ratio. (15:1 to 22:1) than the engines
gasoline (6:1 to 12:1). At the same time, diesel engines are built to be more durable.
that gasoline engines for this same reason.

ADVANTAGES OF DIESEL ENGINE

a. The diesel engine has great thermal efficiency. This means that it consumes less
they are combustible and are more economical than gasoline engines of equal power.

b. Diesel engines are more durable and do not require electric ignition. This
means fewer problems than gasoline engines.

c. The torque of a diesel engine remains virtually unchanged over a wide range.
of speed. This means that diesel engines are more flexible and easier to operate.
that gasoline engines (this makes diesel engines suitable for vehicles
large).

DISADVANTAGES

a. The maximum combustion pressure of a diesel engine is nearly twice that of a gasoline engine.
gasoline. This causes a diesel engine to generate more noise and vibrations.

b. As the maximum combustion pressure is high, diesel engines must be made

with high-resistance materials and must have a very strong structure. This means
that diesel engines have a higher load per horsepower than gasoline engines
gasoline. This also implies higher manufacturing costs.

c. Diesel engines require a very precise injection system. Being more

expensive and require more careful maintenance and services than the engines at
gasoline.

d. Diesel engines have a high compression ratio and require great force to
to uproot them. Consequently, they require equipment such as starters and large batteries.
capacity.

DIESEL ENGINES Page 10

DIESEL ENGINE POWER
In a Diesel engine, the fuel is injected into the air which is heated to high
temperature due to having been strongly compressed. This causes the fuel to
light it up and let it burn.
To achieve high compression pressure even at low engine speeds, a large
the amount of air that should be sucked in by the cylinders, so that it is generally not used
a butterfly valve to restrict the flow of admitted air. Therefore, in a diesel engine,
The engine power is controlled by the amount of fuel injected.
DIESEL ENGINE
Comparison of the methods
usados para regular la potencia en un
gasoline engine and in a diesel engine.
Gasoline engine: Controlled by the
amount of the air-fuel mixture
supplied to the cylinders using the
acceleration butterfly.
Diesel engine: Controlled by the
amount of fuel injected.

THE POWER OF THE ENGINE A

GASOLINE
The power of a gasoline engine
it is controlled by the opening and closing
from the acceleration butterfly,
thus controlling the amount of the mixture
air-fuel that enters the
cylinders.
GASOLINE ENGINE
In a gasoline engine, the points
what require special attention are: the
air-fuel ratio of said
mix, the amount of mix that
enter, if there is an appropriate one
comprehension, if there is an adequate one
spark and if the ignition distribution
it is correct. However, in an engine
diesel, the sufficient compression is the
point of greatest importance. While
that this is also important in a
gasoline engine, in a diesel engine, compression affects not only the power of the engine
but it also affects the combustion of the injected fuel because this combustion
it completely depends on the heat generated by the compression of air.

DIESEL ENGINES Page 11

 (kg/cm)2 (ºC) COMBUSTION

The cause of the air in the cylinder

causes the increase in temperature.
The graph shows the theoretical relationship
between the compression ratio,
presión de compresión, y la
temperature, assuming that there is no
air leaks between the piston and the
Temperature cylinder without heat loss. For
of the air example, when the relationship of
compression is 16, the graph shows
that the pressure and the temperature
they can lift up to 50kg/cm2 (711
psi, 4,903 kPa) and 560ºC, (122ºF)
respectively.
In the diesel engine, the amount of
Compression pressure air that enters the cylinder
greatly affects the point of
self-ignition, which, in turn,
Compression relationship determine the output power. Therefore
thus, an efficient one is essential
admission.

COMBUSTIBILITY OF DIESEL

The diesel engine uses gasoil, a light oil. The fuel is injected into the chamber.
of combustion, where it spontaneously ignites due to the high temperature of the air.
The lowest temperature at which the fuel ignites spontaneously in
the absence of any external spark is called the ignition temperature
fuel autogenous.

The highest temperature of compressed air is the most susceptible to ignition.

spontaneous combustion.

In the diesel engine, using a high compression ratio and a fuel with a
lower ignition point improves fuel ignition performance.

The measure of diesel fuel's ability to ignite quickly is the

cetane number.
For high-speed diesel engines used in trucks and cars, it is required
generally a cetane number greater than 40 or 45.

DIESEL ENGINES Page 12

CETANE NUMBER

The procedure for obtaining the cetane number is almost identical to that for the number
of octane: The cetane number is the percentage of cetane in the standard fuel that gives
the same ignition performance as the fuel being tested. The
Standard fuels used are mixtures of cetane and another fuel generally.
alfa-metilnaftaleno o heptametilnonano, el cual tiene un mayor retardo de encendido. Los
the cetane values of these components are:

Cetane 100
Alpha-methyl naphthalene 0
Heptamethylnonane 15

The cetane number for the fuel that contains alpha-methylnaphthalene, for example,
it is obtained from the following formula:

Number Volume of cetane

cetane = ———————————————— X 100
Volume of cetane +
Methyl naphthalene volume

DIFFERENCES
NAFTA DIESEL
Progress in the opening of the Improvement of the filling wave Same.
intake valve
Delay in the closure of the Fill Wave Improvement The same.
intake valve.
Progress in the opening of the Reduce loss from Same.
relief valve. pumping
Delay in the closure of the Reduce loss of Same.
escape valve pumping
Valve overlap Improve the filling wave Improve the filling wave.
air outlet + fuel Air outlet + gases of
exhaust gases escape.

DIESEL ENGINES Page 13

COMBUSTION IN DIESEL ENGINES
Diesel engines operate with compression ignition of the fuel. That is, the
fuel that is injected during the compression stage, it takes time to ignite
combustion and spread quickly as the fuel is introduced. This
the time it takes for the fuel to ignite is called "Ignition Delay".
The shorter the delay, the better and smoother the combustion, improving performance.
of the engine.
This ignition delay exists due to the way combustion occurs in engines.
diesel. Let's see the essential requirements for proper functioning:
The amount of fuel injected as a function of engine speed and load.
The exact moment of the fuel injection.
High injection pressure depending on the following factors:
Fuel atomization, facilitating homogenization.
Sufficient injection pressure for this fuel to enter the mass
of compressed air.
Diffusion as uniformly as possible of the fuel particles and in
all directions (turbulence) to come into contact with the greatest
possible part of air.

Note that these factors have a direct influence on the ignition delay.
The basic differences in combustion between diesel and gasoline engines are
next:
Gasoline engines admit and compress the ready mixture, depending only
from a spark to initiate combustion, which is gradual and allows the engine to operate from
a softer and quieter way, without clashes, since there is enough time to
homogenize the entire mixture.
In figure 1 we see how
combustion occurs.
On the contrary, the engines
diesel is barely admitted and compressed
air and, when they inject the
combustible, there is almost no time
to atomize the mixture. From this
way, the fuel has to
penetrate into the air mass,
heat up, vaporize and enter
combustion spontaneously.
When it starts to burn
flammable, it spreads almost
instantly, generating the noise
of the diesel engine.

DIESEL ENGINES Page 14

 We also emphasize that, in Diesel engines, due to these characteristics of
fuel inflammation, we always work with excess air, since the time of
The atomization of the mixture is extremely small. The greater the amount of air
the more present, the easier and faster atomization will be. The air/fuel ratio, in
in this case, it varies from 20/1 to 50/1 for efficient combustion to occur, becoming the
more economical diesel engine.
Both combustion in gasoline and diesel engines has to be controlled.
When combustion occurs outside the specified parameters (uncontrolled)
We say that there is a detonation. However, the phenomenon of detonation is different.
in Diesel and Gasoline engines, because as we have already seen, combustion is also different.

To avoid confusion, let's first look at how detonation occurs in engines.

gasoline. These engines must always start combustion from the spark produced.
by the spark plug. However, several factors can cause spontaneous combustion before the
The spark plug produces the spark. If this happens, when the spark plug produces the spark, we will have two
flame sources: one produced by spontaneous combustion and the other by the spark plug. Both
they will collide producing a loud metallic noise.

FACTORS THAT INFLUENCE DETONATION IN

GASOLINE ENGINES

The factors that influence detonation are:

high intake air temperature.
poor blend.
lack of turbulence.
high compression level.
unspecified combustible.

Another important feature to understand detonation in gasoline engines is

to understand the influence of the fuel 'octane rating' on these engines. The 'octane rating'
expresses, exactly, the fuel's resistance to ignition by compression. Work
High-octane fuel allows for a higher compression level.

DIESEL ENGINES Page 15

To extinguish the detonation, the spark plug timing is delayed and the amount of is increased.
injected fuel, thus, we cool the combustion chamber. The detonation in these
engines are produced at the end of combustion, at which point the collision occurs between
the flame fronts.

DETONATION IN DIESEL ENGINES

Diesel engines, as we have seen, initiate compression through ignition by

compression, and the fuel, obviously, must have different characteristics. For
To understand how this detonation occurs, we must comprehend what 'cetane number' is.
cetane number expresses exactly the ease of the fuel (diesel) to ignite
for compression. For example, when we inject the diesel at the end of the compression and
we want it to ignite quickly, we say that the higher the cetane rating of diesel, the more
The ignition by compression will be faster, the delay will be smaller, and the engine will function better.
The smaller the delay in ignition, the better the fuel combustion will be, because
it will be regular and gradual. However, if the ignition delay is very large, it will be
too strong, generating the detonation in the diesel engines.

The factors that can trigger this detonation are:

Low cetane index fuel.

Compression loss (gaskets, valves, rings, etc)
Low fuel pressure.
Poor fuel atomization
Low temperature in the combustion chamber.

Note that the detonation in diesel engines begins along with the combustion and when
this will extend will produce the phenomenon of detonation.

DIESEL ENGINES Page 16

 FACTORS THAT INTENSIFY THE PROBABILITY OF DETONATION

DIESEL ENGINES GASOLINE ENGINES

Low compression High compression
With naturally aspirated engine With turbo engine
With low load With high load
With an increase in revolutions With low turnover
+ RPM RPM
With a decrease in With an increase in
liquid temperature liquid temperature
of cooling and cooling and increase
decrease of the de la temperatura
cylinder head temperature from the cylinder head.

With closed chain With an open chain

of hydrocarbon of hydrocarbon
(aromatic, naphthene) (paraffin, etc)

Unlike what happens in gasoline engines, in diesel engines, how much

the greater the amount of fuel injected, the higher the temperature generated in the
interior of the combustion chamber.

DIESEL ENGINES Page 17

 CLASSIFICATION OF DIESEL ENGINES

The combustion chamber of diesel engines is the individual component most

important for determining the performance of the diesel engine.
The configuration of several combustion chambers has been developed with intention
to improve the performance of the diesel engine, by making the fuel injected into the
camera to be pulverized, vaporized, and mixed uniformly with the air is used
intake ports specially formed in the cylinder heads to generate a
turbulence in the air inside the cylinder, or adding an auxiliary combustion chamber
that the gas expansion explodes in the initial state of ignition to improve the
efficiency of combustion.
The most common combustion chambers are:

Camera of Type
combustion Injection
Direct. Straight.
Camera of
Combustion
Diesel Type Camera of
Cameras Pre Combustion
Assistants of
Combustion Type of Camera
Turbulence.

DIRECT INJECTION
The injection nozzles spray the fuel directly into the chamber.
combustion principle between the cylinder head and the piston. The chambers provided in the
the top part of the piston is molded into various special shapes designed to
improve combustion efficiency.

DIESEL ENGINES Page 18

DIRECT INJECTION CHAMBERS

Advantages
A small area of the surface of the direct injection chamber minimizes the
heat loss, causing the temperature of the compressed air to rise and improve
the ignition. That is why pre-heating is unnecessary to start in
normal ambient temperatures. The high efficiency heat also produces high
power improving fuel economy.
The cylinder head has a simple structure, which makes it less prone to
deformations due to heat.
3. To lose less heat, the compression ratio can be reduced.
Disadvantages
The injection pump must be highly durable to produce the injection of
high pressure required to effectively atomize the fuel forcing it to
through the holes of the multiple types of injection nozzles.
2. The maximum possible speed of the engine is low, given that the turbulence of the
the fuel mixture is less pronounced than that of the auxiliary chamber type
combustion.
3. The high combustion pressure generates more noise and increases the risk of
knocking.
The engine is highly sensitive to the quality of the fuel, therefore it is required
generally one of good quality.
PRE-COMBUSTION CHAMBER

The fuel is pulverized by the

injection nozzle in the pre chamber
combustion, having a partial combustion
in this place, and the remaining fuel (not
burned) is downloaded through a small
passage between the pre-combustion chamber and the
main chamber, where it is vaporized for
complete the combustion in the main stroke.

DIESEL ENGINES Page 19

 Set of
mouthpiece holder
Camera of
precombustion
preheater

Pump of
diesel injection

Advantages

Various fuels and relatively inferior fuels can be used.

they can be used without producing smoke.
Easy to maintain fuel injection pressure because it is
relatively low, and the engine is comparatively insensitive to changes in
synchronization in injection.
3. Due to the use of 'acceleration' type injectors, the sound of the diesel is reduced.

Disadvantages

High construction cost due to the complex design of the cylinder.

A large start is required and glow plugs must be used.
Relatively high fuel consumption.

DIESEL ENGINES Page 20