MIT OpenCourseWare http ocw mit edu 2 61 Internal Combustion Engines Spring 2008 For information about citing these materials or our Terms of Use visit http ocw mit edu terms 2 61 Internal Combustion Engine Laboratory Session Engine Disassembly 2 07 08 Thursday 1 00 3 00 PM Please report to Vikram Mittal and Thane Dewitte in the Sloan Automotive Lab Everybody should wear safety glasses The purpose of this session is to get some hands on experience on the mechanical aspect of the engine You should learn the mechanical construction of the engine how the different components are arranged and get a feel for the size and weight of the components It is important to know the numbers Do weigh and measure the components There are two engines Both are Ford 4 cyliner 16 valve engines for the compact size vehicles The more modern one has a plastic intake manifold to reduce cost and NVH Noise Vibration and Harshness The class will be divided into two groups each group is responsible to disassemble one engine However the whole class should participate in the initial looking at each of the whole engine and the final study of all the parts for both engines Before disassembly take a look at the engines as a whole note the arrangement of the different components the gas exchange circuit intake exhaust EGR Exhaust Gas Recirculation and PCV Positive Crankcase Ventilation system the coolant circuit the fuel flow circuit Understand the function of these components When the engine is opened look at the valve train arrangement the lubrication circuit the EGR route the coolant passage and the piston crank balance weight arrangement Record the following on the next page The measurements may be shared by the group but the comments and calculations should be done by each individual Measure the intake runner length and the size of the manifold these values do not have to be precise Calculate the organ pipe frequency wave length 4 runner length of the former and the ratio of the latter to the displacement volume Measure the Bore the stroke and the connecting rod lengths Measure the mass and dimensions of the piston see figure Why are the values of B1 B2 B3 and Bs different Estimate the inertia force required to move the piston at 6000 rpm Estimate the temperature at which the top land diameter B1 would be touching the liner which is kept by the coolant to be at 100o C Measure the valve diameters and the lifts The latter may be obtained from the cam measurements Why are the valve diameters different Measure the valve masses Estimate the spring force required to operate at 1000 and 6000 rpm B1 2 g1 g2 g3 h1 d1 h2 d2 h3 d3 Bs 2 hs w1 B2 2 B3 2 w2 t1 Top ring t2 Second ring Engine just fill in this form for the engine that you are working on Intake runner length organ pipe frequency lowest Manifold volume Ratio of above to displacement Bore Stroke 2a Connecting Rod Length A Displacement VD Piston mass Piston diameter at first land B1 Inertia force required to move piston at 6000 rpm Piston diameter at second land B2 Piston diameter at third land B3 Piston diameter at skirt Bs Top land height h1 Second land height h2 Third land height h3 Skirt height hs Top ring groove gap g1 Second ring groove gap g2 Control ring groove gap g3 Top ring groove depth d1 Second ring groove depth d2 Control ring groove depth d3 Top ring width w1 Top ring thickness t1 Second ring width w2 Second ring thickness t2 Temperature at which interferes with liner top land Intake valve mass Intake valve diameter Intake valve Lift Spring force estimate for 1000 rpm Spring force estimate for 6000 rpm Exhaust valve mass Exhaust valve diameter Exhaust valve lift Spring force estimate for 1000 rpm Spring force estimate for 6000 rpm Measurements units required Comments