gasoline engine.ppt

7/26/2019 Gasoline Engine.ppt

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Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

General Description General Description

(1/1)

Basic principle of four-stroke engine


2/75


Three Elements of Gasoline Engines Good Air-fuel Mixture

(1/2)

1.Good air-fuel mixture for

automobiles

Air

Fuel

15

Theoreticalair-fuel ratio

1510 20

Air-fuel ratioRicher Leaner

1


3/75



(1/2)

2.Air-fuel ratio

Air

Fuel

15


1510 20


1


4/75



(2/2)

3.Air fuel ratio and driving

conditions

Air

Fuel

15


1510 20


1


5/75


Three Elements of Gasoline Engines Good Compression

(1/1)

1.Necessity of compressing the air-fuel mixture

Compression

ratio

Volume of combustion chamber (A) + Volume of cylinder (B)

Volume of combustion chamber (A)=


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Three Elements of Gasoline Engines Good Spark

(1/1)

1 2

Spark plug

Air-fuelmixture


7/75



(1/1)

1 2

Spark plug

Air-fuelmixture

1.Conditions for a good spark


8/75



(1/1)

1 2

Spark plug

Air-fuelmixture


9/75


Engine Proper Description

(1/1)


10/75



(1/1)

Cylinder head

Cylinder head gasket


11/75



(1/1)

Cylinder block


12/75



(1/1)

Crankshaft

Bearing cap


13/75



(1/1)

Connecting rod

Bearing cap


14/75



(1/1)

Crankshaft

bearingThrust

washer

Connecting

rod bearing


15/75



(1/1)

PistonPiston pin

Piston

rings


16/75



(1/1)

(1) Exhaust camshaft (2) Intake camshaft

(3)(4)

(5)

(6)

(7)(8)

(9) Valve

(10) Timing chain

(11) Chain tensioner slipper

(13) Timing chain tensioner(14) Crankshaft timing sprocket

(12)Chainvibrationdamper


17/75


Engine Proper Cylinder Head

(1/1)

Cylinder head Spark plug

Intake port

Water jacket

Exhaust port

Cylinder head gasket

Combustion

chamber

Oil hole


18/75


Engine Proper Plastic Region Bolt

(1/1)

Elastic region Plastic region

SmallerLarger

Bolttension

Yield

point

Fracture

point

Bolts rotational anglePlastic region bolt

Cylinder head

Bolts rotational angle

Bolt

tension


19/75


Engine Proper Cylinder Block

(1/3)

Cylinder block

Cylinder liner

Combustion stroke Compression stroke

Ridge

Cylinder wear

Thrust force


20/75



(2/3)

1.Cylinder bore sizeLocation of cylinder bore STD size codes

(5VZ-FE engine)

Front

Bore size code

1

2

3

Small

Large

Cylinder bore size


21/75



(3/3)

2.Crankshaft main journal

bore size Location of main journal bore STD size codes(1NZ-FE engine)

Bore size code

0

1

6

Small

Large

Crankshaft main

journal bore size


22/75


Engine Proper Crankshaft

(1/3)REFERENCE:

Crankshaft Offset

Crankshaft

Crank pin

Crank journal Balance weight

Oil hole


23/75



(2/3)

Example

Bearing cap

Bearing cap unit with ladder-frame construction


24/75



(3/3)

1.Main journal and crank

pin sizeLocation of main journal and crank pin STD size codes

Main journal STDsize codes(1NZ-FE engine)

Main journal STD

size codes

(2JZ-GE engine)

Crank pin STD

size codes

(2JZ-GE engine)

Main journal or crank

pin size codes

1

2

3

Small

Large

Main journal or

crank pin size


25/75


Engine Proper Crankshaft Bearing

(1/1)

1.Bearing size/

2.Undersize bearingUpper halt-bearing

Oil holeOil groove

Thrust washer

Bearing size code

Oil grooveLower half-bearing

Locking lip

Bearing size code Bearing size

1

2

Thin

Thick


26/75


Engine Proper Connecting Rod

(1/1)

1.Big end bore size

Connecting rod

Oil jet

Big end bore

size codeFront mark

Big end bore

Big bore size

code

1

2

3

Large

Small

Big end bore size

Bearing cap


27/75


Engine Proper Connecting Rod Bearing

(1/1)

1.Bearing Size/

2.Undersize Bearing

Oil hole

Bearing size code

Bearing size code Bearing size

1

2

Thin

Thick

Di i T h i i G li E i G li E i


28/75


Engine Proper Bearing Selection

(1/2)

Oil clearance

Bearing Oil film

Oil clearance

Di i T h i i G li E i G li E i


29/75


Engine Proper Bearing Selection

(2/2)

1.Bearing selection method

No.2

No.1No.3No.5

No.1 No.2 No.3 No.4

No.5

Cylinder block main journal

bore size code (A)

Crankshaft main journalsize code (B)

Example

Use bearing size code

A = 4, B = 3, A + B = 7

0 - 2 3 - 5 6 - 8 9 - 11

7

1 2 3 4

Bearing size cord

No.4

Di i T h i i >> G li E i >> G li E i


30/75


Engine Proper Piston

(1/4)

1.Description

B

A

Oval Circle

SmallPiston pin boss

Piston

skirt

Large

Truncated cone

Cold

True cylinder

Hot



31/75



(2/4)

2.Thrust force

Combustion pressure Compression pressure

Major thrust force

(Combustion stroke)

Minor thrust force

(Compression stroke)



32/75



(3/4)

3.Piston slap (Side knocking)/

4.Operation of offset pistonsPiston slap

Offset piston

Center of piston pin Center of piston

Piston

Offset



33/75



(3/4)

3.Piston slap (Side knocking)/

4.Operation of offset pistons



34/75



(4/4)

5.Piston size

Piston size code

Piston size code and front mark

(5VZ-FE engine)

Front mark

REFERENCE:

Striations on the Piston Skirt



35/75



(4/4)

Piston size code


(5VZ-FE engine)

Front mark



36/75



(4/4)

Piston size code


(5VZ-FE engine)

Front mark



37/75


Engine Proper Piston Ring

(1/4)

1.Description

Compression ring No.1

Compression ring No.2

Oil ring side rail (upper)

Oil ring expander

Oil ring side rail (lower)

Oil rings



38/75



(2/4)

2.Marks of ring

Size

Manufacturer

No.1 code mark

No.2 code mark

No.1 compression ring end gap

and oil ring expander end gap Oil ring side rail (lower) end gap

No.2 compression ring end gapOil ring side rail (upper) end gap



39/75

Diagnosis Technician Gasoline Engine Gasoline Engine


(3/4)

3.Ring end gap

1NZ-FE engine:

110mm (4.33 in.)

Ring end gap



40/75

Diagnosis Technician Gasoline Engine Gasoline Engine


(4/4)

4.Ring pumping effect and

ring flutter

Cylinder

Engine oil

Piston

Piston ring



41/75

g g g

Engine Proper Valve Mechanism

(1/1)

1.Valve opening and closing system



42/75

g g g

Engine Proper Valve and Related Parts

(1/4)

2.Valve

Valve stem

Oil seal

Valve face

Camshaft

Valve guide

bushing

Valve head

44.5

or 45.5

Exhaust

valve

Intake

valve

Exhaust valve

Combustion chamber

Intake valve



43/75

g g g


(2/4)

3.Valve spring

Uneven pitch spring

(symmetrical)

Uneven pitch spring

(asymmetrical)

Double spring

Inner Outer

Top

a

b

c

d

e

a=ce



44/75

g g g


(3/4)

4.Valve seat

Valve contact face

60

45

30



45/75


(4/4)

5.Valve guide bushing and

oil sealOil seal

Valve quide bushing

Valve stem

Engine oil



46/75

Engine Proper Valve Timing

(1/2)

Valve timing diagram(2NZ-FE engine without VVT-i, leaded gasoline type)

Compression stroke

Exhaust stroke

Intake stroke

Combustion

(power) stroke

Ex.In.Ex.In.

Ex.In. Ex.In.

TDCValve overlap

Intake valve

opens

Intake

valve

closes

Exhaust

valve closesExhaustvalveopens

BDC

43

2 2

34



47/75

Engine Proper Valve Timing

(2/2)

Valve overlap



48/75

Engine Proper Valve Clearance

(1/1)



49/75

Engine Proper Adjustment of Valve Clearance

(1/2)

1. Type requiring

replacement of the

valve lifter when

adjusting valveclearance/

2. Type requiring

replacement of

shim when

adjusting valve

clearance

1

2-(2)

2-(1)

2-(3)

Valve lifter

Valve lifter

Adjusting shim

Valve lifter

Adjusting shim

Adjusting shim

Rocker arm



50/75

Engine Proper Adjustment of Valve Clearance

(2/2)

3.Type requiring

adjustment of the

adjusting screw

when adjustingvalve clearance

Adjusting screw Rocker arm

Valve lifer



51/75

Engine Proper Scissors Gear Mechanism

(Sub-gear Mechanism)

(1/1)

Backlash

Sub gear

Driven gearSub gear

Driven gear

Drive gear

Drive gear

Sub gear

Scissors spring

Driven gear

Drive gear



52/75

Engine Proper Balance Shaft

(1/1)

va, vb: Crankshaft rotational speed

Va, Vb: Piston movable speed

La, Lb: Piston movable distanceva = vb

Va Gasoline Engine >> Gasoline Engine


53/75

Engine Proper Timing Chain Auto-tensioner

(1/1)

Chain damper

Timing chain

auto-tensioner

Chain slipper

Chain

Engine

oil

Plunger

Spring

Check ball

CamSpring

Chain auto-tensioner (1NZ-FE engine)



54/75

Engine Proper Timing Belt Auto-tensioner

(1/1)

Piston rod

Timing belt auto-tensioner (2JZ-GE engine)

Timing belt

Idler pulley

Spring

Check ball

SpringTiming belt auto-tensioner



55/75

Lubrication System Description

(1/2)

Camshaft timing oil control valve

Main oil gallery

Oil return hole

Oil pressure switch

Oil filter

Oil strainer

Oil pump



56/75

Lubrication System Description

(2/2)

Main oil gallery

Oil filter

Oil cooler

Oil pump

Oil strainer

Crankshaft

journal

Connecting

rod

Oil jet

Piston

Oil jet

Timing

chain

Chain

tensioner

Cylinder head

Camshaft timing

oil control

valve filter

Intake

camshaft

journal

Exhaust

camshaft

journal

Camshaft timing

oil control valve

VVT-i

controller

Oil pan

Oil flow circuit for 1NZ-FE engine

The oil cooler, outlined with a dotted line, basically is not used on the 1NZ-FE engine.

Here is listed to understand the position of the oil cooler in the f low.



57/75

Lubrication System Oil Pump

(1/1)

Drive roter

Driven roter

Relief valve



58/75

Lubrication System Oil Filter

(1/1)

Check valve

Element

Relief valve

Oil flow (in)

Oil flow (out)

Oil flow if the relief valve open



59/75

Lubrication System Oil Pressure Warning Lamp

(1/1)

1.When the oil pressure is low

[19.6 4.9 kPa (0.2 0.05

kgf/cm2) or lower]/

2.When the oil pressure is high[19.6 4.9 kPa (0.2 0.05

kgf/cm2) or higher]

Oil pressure warning lamp

Low engine oil level warning lamp

Oil pressure switch

Oil pressure

(Normal)

ECU

Warning lamp

Oil temp. switch

Oil level sensorOil pan

Oil level(Normal)

Warning lamp

Oil



60/75

Lubrication System Oil Pressure Warning Lamp

(1/1)

1.When the oil pressure is low

[19.6 4.9 kPa (0.2 0.05

kgf/cm2) or lower]/

2.When the oil pressure is high[19.6 4.9 kPa (0.2 0.05

kgf/cm2) or higher]

Oil pressure warning lamp

Low engine oil level warning lamp

Warning lamp

Oil pressure switch

Oil pressure

(Low)

ECU

Warning lamp

Oil temp. switch

Oil level sensorOil pan

Oil level(Low)

Oil



61/75

Lubrication System Oil Cooler

(1/1)

Water bypass hose

Oil cooler

Oil filter

Engine coolant

Oil cooler

Oil filter

From Oil pump

to Main oil gallery

Relief valve


L b i ti S t


62/75

Lubrication System Oil Consumption

(1/1)The gap between the cylinder and the piston

The gap between the valve guide bushing and valve stem

Loss due to oil contained in blow-by gas

PCVvalve


C li S t


63/75

Cooling System Description

(1/1)

1.Cooling system

to Radiator

from Heater core

from Radiator

Bypass passage Cylinder head

Water pump

Thermostat

Cylinder blockThrottle body

Radiator

Heater core

to Heater coreto Throttle body


C li S t


64/75

Cooling System Flow of Engine Coolant

(1/1)

1.Thermostat in water inlet

type (With bypass valve)


C li S t


65/75

Cooling System Thermostat

(1/1)

With bypass valve Without bypass valve

Main valve

Cylinder

Bypass valveWax

Main valve

Jiggle valve

Jiggle valve

WaxCylinder


Cooling System W P


66/75

Cooling System Water Pump

(1/1)

V-ribbed belt Bearing Mechanical seal

Cylinderblock

Swirl

chamber

Rotor

Water pump pully Water drain hole


Cooling System El t i M t d i C li F


67/75

Cooling System Electric Motor-driven Cooling Fan

(1/2)

1.Outline

Cooling fan

Fan motor

Water temperature switch


Cooling System El t i M t d i C li F


68/75

Cooling System Electric Motor-driven Cooling Fan

(2/2)

2.Operation

Fan relayIgnition switch

Coolant

temp. switch

Coolant temperature


Cooling System T t t ll d Fl id C li


69/75

Cooling System Temperature-controlled Fluid Coupling

(1/2)

1.Overview

Pulley

Fluid coupling

Cooling fan

Air hot Air warm Air cold

Bimetal spring

Bimetal plate

Front operating chamber

Rear operating chamber

Silicone oil


Cooling System Temperature controlled Fluid Coupling


70/75

Cooling System Temperature-controlled Fluid Coupling

(2/2)

2.OperationWithout coupling

Fan

speed

Air hot

Air warm

Air cold

0

Air Temperature (HOT) during low speed driving

Air temperature (HOT) during high speed driving

Air temperature (WARM) during high speed driving

Air temperature (COLD) during high speed driving

Fluid coupling shaft speed


Cooling System Electronically Controlled Hydraulic


71/75

Cooling System y y

Cooling Fan System

(1/1)

Condenser

Radiator

Cooling fan

Hydraulic

motor

Solenoidvalve

Hydraulic

pump

Reservoir

Oil cooler

Water pump. sensor signal,

Air conditioner signal,

Engine speed signal

ECU


Inspection Compression Pressure


72/75

Inspection Compression Pressure

(1/1)

1.Check compression pressure



73/75


Engine Proper Crankshaft Offset


74/75

Engine Proper Crankshaft Offset

(1/1)

Combustion pressure Combustion pressure

Piston

Connecting rod

Crankshaft center

Offset

Offset crankshaft Center crankshaft


Engine Proper Striations on the Piston Skirt


75/75

Engine Proper Striations on the Piston Skirt

(1/1)

Resin coating

Striation finish

gasoline engine.ppt

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