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Dismantle and Assemble Four Stroke Single Cylinder Petrol Engine

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Dismantle and Assemble Four Stroke Single Cylinder Petrol Engine VBN651 – Dismantle & Assemble Engine 4 Stroke Single Cylinder (Petrol) Page 1. Student Learning Guide & Record DATE INSTRUCTOR’S TASK PAGE TASK TITLE COMPLETED SIGNATURE Assessment 1 13 Explain the term ‘configuration' Assessment 2 13 Identify engine configurations Assessment 3 14 Identify four stroke engine configurations Identify and explain the following major Assessment 4 20 engine components Assessment 5 26 Four stroke principle of operation Assessment 6 29 Explain four stroke principle of operation Assessment 7 33 Review questions – Lead, lag and overlap Assessment 8 34 Explain a valve timing diagram Assessment 9 34 Complete four stroke cycle chart Assessment 10 42 Review questions water cooled engines Assessment 11 45 Identify cooling system components Identify location and function of major Assessment 12 46 cooling system components Assessment 13 48 Identify major components Assessment 14 48 Describe safety precautions Review question engine lubricating Assessment 15 53 system Identify various seal types and state an Assessment 16 55 application for each Assessment 17 59 Review questions – Gaskets Assessment 18 59 Identify a range of gasket materials Identify sealant types and state an Assessment 19 60 application for each Assessment 20 64 Review questions Assessment 21 66 Review questions © Copyright LAPtek Pty. Ltd. 22015VIC – Certificate II in Automotive Studies (Pre-vocational) Page 2. VBN651 – Dismantle & Assemble Engine 4 Stroke Single Cylinder (Petrol) DATE INSTRUCTOR’S TASK PAGE TASK TITLE COMPLETED SIGNATURE Dismantle, inspect, measure and Assessment 22 68 assemble a four stroke petrol engine Research engine dismantle, inspect and Assessment 23 69 reassembly procedures Assessment 24 71 Engine specifications Dismantle, clean, inspect, measure and Assessment 25 77 reassemble a single cylinder petrol engine Assessment 26 77 Carry out reassembly inspection Assessment 27 77 Rectify any faults discovered Assessment 28 78 Write a condition report for the customer Assessment 29 78 Evaluation 22015VIC – Certificate II in Automotive Studies (Pre-vocational) © Copyright LAPtek Pty. Ltd. VBN651 – Dismantle & Assemble Engine 4 Stroke Single Cylinder (Petrol) Page 11. DISMANTLE AND ASSEMBLE FOUR STROKE SINGLE CYLINDER PETROL ENGINE INTRODUCTION The four stroke engine is in comparison to the two stroke engine more complex in construction and operation, as it has many more primary moving parts (crankshaft, connecting rod, piston, camshaft, inlet valve and exhaust valve.). There is a large variety of design and construction that may be incorporated in a four stroke engine, the engine may be small or large, operate on the four stroke principle of operation, be air or water cooled and be constructed, basically, of aluminium alloy, cast iron, or a combination of both. The engine may also be one that operates on petrol or diesel. You need to have a thorough understanding of how a four stroke engine works before you can competently dismantle and assemble it. Enjoy gaining the knowledge of how a four stroke engine works and look forward to the feeling you get from dismantling and assembling the engine as per manufacturer specifications. ENGINE CONFIGURATIONS Engine configurations are usually described by the number of cylinders, arrangement of the cylinders (inline, horizontal, vee), position of the camshaft and how many camshafts.. The alignment of the crankshaft is also sometimes mentioned and can be either horizontal or vertical shaft. The majority of four stroke engines have one to eight cylinders, although twelve and sixteen cylinders designs are not unknown. There are several different multi cylinder layouts. The three most common designs are: 1. Inline – In the inline layout, the cylinders are arranged inline with one another. Inline Engine Layout 2. Horizontal – Horizontal engine layout (also called flat or opposed) are arranged with the pistons set 180° apart. Horizontal Engine Layout 3. Vee – The name describes the cylinder arrangement well. The cylinders are set 90°, 60° or other variations of degrees apart. Vee Engine Layout © Copyright LAPtek Pty. Ltd. 22015VIC – Certificate II in Automotive Studies (Pre-vocational) Page 12. VBN651 – Dismantle & Assemble Engine 4 Stroke Single Cylinder (Petrol) Engine variations: valve layout Four stroke engines employ one of three basic valve and camshaft layouts; Side valve Overhead valve (OHV) and Overhead camshaft (OHC). Side valve The side valve layout is almost a thing of the past. One will find it on older machines and on lawn mowers. Side valve engines have a flat cylinder head that generally houses no moving parts. In a side valve layout, the valves run along the outside of the cylinder. The valves are actuated by a camshaft driven through meshed gears or chain off the crankshaft. The design is simple to manufacture, but does not produce high compression ratios or let the engine breathe easily. Side valve engine layout Overhead valve The overhead valve layout, though more advanced than the flat head design is found on a few motor cycle engines, on lawn mowers and on small industrial engines. This design allows the valve to be located in the head, above the pistons, so that they enter the combustion chamber from the top. Push rods activate rocker arms that open the valves. An OHV layout allows for more efficient delivery of the fuel and air into the combustion chamber, but has the disadvantage of considerable reciprocating mass in pushrods, rocker arms and sometimes lifters. Overhead valve engine layout Overhead camshaft The overhead camshaft is the most advanced of valve design layouts. It is found on most high performance engines. The valves and the camshaft are situated above the combustion chamber. With valves and camshaft in close proximity (no more pushrods and often no lifters) the camshaft operates the valves. This layout greatly reduces reciprocating mass and allows the engine to rev higher before valve bounce occurs. This layout can employ a single cam (SOHC) or dual cams (DOHC) With SOHC , one camshaft actuates both inlet and exhaust valves. With DOHC, inlet and exhaust valves are actuated by independent camshafts. OHC designs often have three, four or even five valves Overhead camshaft engine layout per cylinder 22015VIC – Certificate II in Automotive Studies (Pre-vocational) © Copyright LAPtek Pty. Ltd. VBN651 – Dismantle & Assemble Engine 4 Stroke Single Cylinder (Petrol) Page 13. ASSESSMENT 1: EXPLAIN THE TERM ‘CONFIGURATION' Explain in your own words what is meant by the term engine configuration. ................................................................................................................................................................ ................................................................................................................................................................ ................................................................................................................................................................ ASSESSMENT 2: IDENTIFY ENGINE CONFIGURATIONS As mentioned earlier, engine configurations are usually described by the number of cylinders, arrangement of the cylinders, position of the camshaft and how many camshafts. In the following diagram, identify the four stroke engine configuration. ENGINE CONFIGURATIONS ................................................. ................................................. ................................................. 150cc liquid-cooled, 4-stroke, SOHC single-cylinder, 4-valve fuel-injected engine © Copyright LAPtek Pty. Ltd. 22015VIC – Certificate II in Automotive Studies (Pre-vocational) Page 24. VBN651 – Dismantle & Assemble Engine 4 Stroke Single Cylinder (Petrol) FOUR STROKE PRINCIPLE OF OPERATION INTRODUCTION The majority of small engines operate on the four stroke cycle, and are known as four cycle engines. Another name for this cycle is "Otto cycle" after the name of the inventor. The "Otto cycle" is divided into four strokes, each of which, theoretically, lasts one hundred and eighty degrees of crankshaft rotation. During each stroke a definite operation is carried out in each cylinder as shown below. The four strokes are illustrated and are named as follows: 1. Induction 2, Compression 3. power 4. Exhaust Single cylinder OHC engine 1. INDUCTION STROKE On the intake stroke the piston and rod assembly is pulled down the cylinder by the crankshaft. During that time the inlet valve is held open by the camshaft and the exhaust valve is closed. Since The piston has moved down the cylinder, creating a low pressure area (vacuum) atmospheric pressure forces an air-fuel mixture past the open inlet valve and into the cylinder. The air and fuel is delivered to the engine via the fuel system at a ratio of approximately 14.75:1 Atmospheric pressure is approximately 101.35 kilo/ pascals (14.7 p.s.i.) at sea level. Pressure in the cylinder on the intake stroke is considerably less and this difference is the force that causes that air-fuel mixture to flow into the cylinder. (Liquid or gas will always flow, from high to low pressure area). When the piston reaches the bottom of its stroke, the inlet valve is closed by the action of its spring. This stroke is called the induction Induction stroke stroke. 22015VIC – Certificate II in Automotive Studies (Pre-vocational) © Copyright LAPtek Pty. Ltd. Page 30. VBN651 – Dismantle & Assemble Engine 4 Stroke Single Cylinder (Petrol) ADVANCE OF SPARK, VALVE LEAD, VALVE LAG AND VALVE OVERLAP In an actual engine valves
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