ENGINE COMPONENTS

INTAKE MANIFOLD. In automotive engineering, an inlet manifold or intake manifold (in American English) is
the part of an engine that supplies the fuel/air mixture to the cylinders.

STARTER MOTOR. The function of the starter motor is to start up the combustion engine. An
electric motor forms the basis of the starter motor. When the starter switch is turned on, the starter relay turns
on the electric motor. This motor drives the starter gear ring via the pinion gear.

EXHAUST MANIFOLDS. Exhaust manifolds are generally simple cast iron or stainless steel units which collect
engine exhaust gas from multiple cylinders and deliver it to the exhaust pipe.

MANIFOLD GASKET. The intake manifold gasket is mounted between the intake manifold and the cylinder
head. It is usually made of plastic or rubber. The function of the intake manifold gasket is to avoid leakage of
fuel from the intake manifold, while also preventing additional air from entering the engine.

CARBURETOR. The carburetor has several functions: 1) it combines gasoline and air creating a highly
combustible mixture, 2) it regulates the ratio of air and fuel, and 3) it controls the engine's speed.

CYLINDER HEAD COVER. The present invention relates to a cylinder head cover, in particular for
covering the cylinder head of an internal combustion engine, having a plurality of functional parts such
as an oil separator mounted thereon.

CRANKSHAFT. The function of the crankshaft is to translate the linear reciprocating motion of a pistons
into the rotational motion required by the automobile. This is accomplished by connecting the pistons to the
crank throws, which are offset from the central axis of the crankshaft to create a rotation about that axis.

VALVE SPRING RETAINER. A valve retainer and keepers lock the valve spring on the valve.
The retainer is a specially shaped washer that fits over the top of the valve spring. The keepers, or
locks, fit into the valve stem grooves, holding the retainer and spring in place.

VALVE LOCK. Valve locks and retainers hold the retainer in place by using the force of the valve spring to hold
the retainer and lock in place, not by the tang locking into the groove on the valve stem.

CRANKSHAFT PULLEY. A crankshaft pulley powers components on the crankshaft. Crankshafts are
responsible for driving the car wheels. Crankshaft pulleys transmit mechanical power and torque, or the force
of motion, through the pulley system to additional car elements, such as the power steering pump and alternator.

FUEL WATER SEPARATOR. A fuel water separator is a device that works to ensure clean fuel is delivered to
the engine. Fuel separators provide effective protection for engines used in automotive, industrial, and marine
applications. The separator removes water and solid contaminants from the fuel before it reaches the fuel
pump.

TURBO CHARGER. A turbocharger, colloquially known as a turbo, is a turbine-driven forced induction

device that increases an internal combustion engine's efficiency and power output by forcing extra compressed
air into the combustion chamber.

VACUUM ADVANCER.The distributor's centrifugal timing advance mechanism makes the spark occur
sooner as engine speed increases. Many of these engines will also use a vacuum advance that advances
timing during light loads and deceleration, independent of the centrifugal advance.

DISTRIBUTOR ASSEMBLY.A distributor is an enclosed rotating shaft used in spark-ignition

internal combustion engines that have mechanically-timed ignition.
The distributor's main function is to route secondary, or high voltage, current from the ignition
coil to the spark plugs in the correct firing order, and for the correct amount of time.
 DISTRIBUTOR CAPS. Distributor caps and rotors are responsible for passing the voltage from the ignition coils
to the engine's cylinders in order to ignite the fuel-air mixture inside and power the engine. The coil connects
directly to the rotor, and the rotor spins inside the distributor cap.

ROTOR. The rotor is a moving component of an electromagnetic system in the electric motor, electric
generator, or alternator. Its rotation is due to the interaction between the windings and magnetic fields which
produces a torque around the rotor's axis.

DRAIN PLUG. A drain plug is a plug which is taken out to allow a fluid to be drained from a tank such as
an engine oil pan or sump.

Remove the oil drain plug and allow oil to drain out.
Remove the drain plug under the engine with the wrench, and let the oil flow into the pan.
The engine should be run for a few seconds to drive residual water out of the exhaust system, after which the drain plug needs to
be removed from any water-lift-type muffler.

PISTON. In an engine, its purpose is to transfer force from expanding gas in the cylinder to the crankshaft via
a piston rod and/or connecting rod. In a pump, the function is reversed and force is transferred from the
crankshaft to the piston for the purpose of compressing or ejecting the fluid in the cylinder.

HOT PLUG. A small electric heating element in an internal-

combustion engine that facilitates starting by preheating the air in acylinder and is used especially in diesel engines.

EXHAUST VALVE. An exhaust valve is a physical component located in a cylinder head. Its purpose is to open and
close which will allow exhaust gas, or the results of a burned combustion, to escape the combustion chamber so that
fresh air can be brought in to repeat the combustion cycle.

INTAKE VALVE. A valve in the cylinder head of an internal-combustion engine that opens at the proper moment
in the cycle to allow the fuel-air mixture to be drawn into the cylinder.

FLYWHEEL. A flywheel is a mechanical device specifically designed to efficiently store rotational

energy. Flywheels resist changes in rotational speed by their moment of inertia. The amount of energy
stored in a flywheel is proportional to the square of its rotational speed. The way to change a flywheel's
stored energy is by increasing or decreasing its rotational speed by applying a torque aligned with its
axis of symmetry. Since flywheels act as mechanical energy storage devices, they are the kinetic-
energy-storage analogue to electrical capacitors, for example, which are a type of accumulator.

OIL STRAINER. The function of an Oil Strainer is to remove system debris from the
refrigerant oil. Their purpose is to protect compressors and oil level regulators from
damage.

MAIN JOURNAL BEARING. It's a journal bearing, which means it uses the dynamics of oil or another fluid in a
narrow gap to support that load without the rigid components coming into physical contact under normal operating
conditions. It's a main journal bearing, which means that it supports the largest and/or most significant loads in the
system it's a part of.

VALVE LIFTERS. A hydraulic tappet, also known as a hydraulic valve lifter or hydraulic lash adjuster, is a device
for maintaining zero valve clearance in an internal combustion engine. Conventional solid valve lifters require
regular adjusting to maintain a small clearance between the valve and its rocker or cam follower.
 WATER PUMP. Water pumps are simple devices. They force coolant through the engine block, hoses and radiator to
remove the heat the engine produces. It is most commonly driven off the crankshaft pulley or in some cases
the pump is gear-driven off the crankshaft.

CAMSHAFT SPROCKET. The cam sprocket is attached to one end of the camshaft in a combustion
engine. This sprocket, along with the timing belt and the crankshaft sprocket, is responsible for
maintaining the timing between the crankshaft and the camshaft. It is similar to a pulley or gear, though
unlike a pulley, it has ridges along the outside, and unlike a gear, it does not come into direct contact with
another sprocket.

SPARK PLUG. The spark plug has two primary functions: To ignite the air/fuel mixture. Electrical energy is
transmitted through the spark plug, jumping the gap in the plugs firing end if the voltage supplied to the plug is high
enough. This electrical spark ignites the gasoline/air mixture in the combustion chamber.

OIL RING. An oil ring is the piston ring located in the ring groove closest to the crankcase. The oil ring is used to
wipe excess oil from the cylinder wall during piston movement. Excess oil is returned through ring openings to the
oil reservoir in the engine block. Two-stroke cycle engines do not require oil rings because lubrication is supplied by
mixing oil in the gasoline, and an oil reservoir is not required.

The thermostat is like a valve that opens and closes as a function of its temperature. The thermostat isolates the
engine from the radiator until it has reached a certain minimum temperature. Without a thermostat, the engine
would always lose heat to the radiator and take longer to warm up.

DIPSTICK. A dipstick is one of several measurement devices. Some dipsticks are dipped into a liquid to perform a
chemical test or to provide a measure of quantity of the liquid.

ROCKER ARM ASSEMBLY.A rocker arm assembly for an internal combustion engine is provided which is
lightweight and inexpensive to manufacture, which securely mounts and supports a pair of rocker arms and
associated structures on the cylinder head of an internal combustion engine, and which provides and
maintains a supply of lubricant to the rocker arm bearing structures, valves and push rods.

ALTERNATOR. Alternators are used in modern automobiles to charge the battery and to power the electrical
system when its engine is running. Until the 1960s, automobiles used DC dynamo generators with
commutators. With the availability of affordable silicon diode rectifiers, alternators were used instead.

DIESEL FUEL INJECTOR. The fuel injector, an electrically operated gate, delivers fuel into the engine via its
nozzle. The Engine Control Unit (ECU) dictates when the injector should inject fuel into the engine cylinder. It is
advisable to clean the injectors every 25,000 to 30,000 miles to ensure that they do not get clogged.

CLUTCH LINING. The clutch lining (center) is composed of a high friction material and fits between the
pressure plate(left) and the flywheel(right). When the clutch is released, powerful springs in the pressure plate
force the clutch lining against the flywheel ensuring a slip free connection between the engine and transmission.

FRICTION PLATE. A friction clutch plate is used in vehicles to allow the transmission input shaft and engine
to run at the same speed when rotating. When the clutch is engaged, the friction plate is sandwiched
between the engine flywheel and a steel pressure plate that is bolted to the flywheel.

PRESSURE PLATES. The functional purpose of pressure plates. Clutches, within their function as the link
between the engine and the gearbox, transfer the torque moment generated by the engine to the gearbox. The
pressure plate, which is bolted onto the flywheel, presses the clutch plate against the friction plate.
 STARTER MOTOR. The function of the starter motor is to start up the combustion engine. An
electric motor forms the basis of the starter motor. When the starter switch is turned on, the starter relay
turns on the electric motor. This motor drives the starter gear ring via the pinion gear.

IGNITION SYSTEM WIRING DIAGRAM

The purpose of the ignition system is to create a spark that will ignite the fuel-air mixture in the cylinder of an
engine. It must do this at exactly the right instant and do it at the rate of up to several thousand times per minute for
each cylinder in the engine. If the timing of that spark is off by a small fraction of a second, the engine will run poorly
or not run at all.

The ignition system sends an extremely high voltage to the spark plug in each cylinder when the piston is at the top of
its compression stroke. The tip of each spark plug contains a gap that the voltage must jump across in order to reach
ground. That is where the spark occurs.

The voltage that is available to the spark plug is somewhere between 20,000 volts and 50,000 volts or better. The job
of the ignition system is to produce that high voltage from a 12-volt source and get it to each cylinder in a specific
order, at exactly the right time.

The ignition system has two tasks to perform. First, it must create a voltage high enough (20,000+) to arc across the
gap of a spark plug, thus creating a spark strong enough to ignite the air/fuel mixture for combustion. Second, it must
control the timing of that the spark so it occurs at the exact right time and send it to the correct cylinder.
The ignition system is divided into two sections, the primary circuit and the secondary circuit. The low voltage
primary circuit operates at battery voltage (12 to 14.5 volts) and is responsible for generating the signal to fire the
spark plug at the exact right time and sending that signal to the ignition coil. The ignition coil is the component that
converts the 12-volt signal into the high 20,000+ volt charge. Once the voltage is stepped up, it goes to
the secondary circuit which then directs the charge to the correct spark plug at the right time

COOLING SYSTEM

A typical 4-cylinder vehicle cruising along the highway at around 50 miles per hour, will produce 4000 controlled
explosions per minute inside the engine as the spark plugs ignite the fuel in each cylinder to propel the vehicle down the road.
Obviously, these explosions produce an enormous amount of heat and, if not controlled, will destroy an engine in a matter of
minutes. Controlling these high temperatures is the job of the cooling system.

The modern cooling system has not changed much from the cooling systems in the model T back in the '20s. Oh sure, it has
become infinitely more reliable and efficient at doing its job, but the basic cooling system still consists of liquid coolant being
circulated through the engine, then out to the radiator to be cooled by the air stream coming through the front grill of the vehicle.

Today's cooling system must maintain the engine at a constant temperature whether the outside air temperature is 110 degrees
Fahrenheit or 10 below zero. If the engine temperature is too low, fuel economy will suffer and emissions will rise. If the
temperature is allowed to get too hot for too long, the engine will self-destruct.

Circulation

The coolant follows a path that takes it from the water pump, through passages inside the engine block where it collects
the heat produced by the cylinders. It then flows up to the cylinder head (or heads in a V type engine) where it collects more heat
from the combustion chambers. It then flows out past the thermostat (if the thermostat is opened to allow the fluid to pass), through
the upper radiator hose and into the radiator. The coolant flows through the thin flattened tubes that make up the core of the
radiator and is cooled by the air flow through the radiator. From there, it flows out of the radiator, through the lower radiator hose
and back to the water pump. By this time, the coolant is cooled off and ready to collect more heat from the engine.

The capacity of the system is engineered for the type and size of the engine and the work load that it is expected to
undergo. Obviously, the cooling system for a larger, more powerful V8 engine in a heavy vehicle will need considerably more
capacity then a compact car with a small 4-cylinder engine. On a large vehicle, the radiator is larger with many more tubes for the
coolant to flow through. The radiator is also wider and taller to capture more air flow entering the vehicle from the grill in front.
PARTS:

Coolant is a mixture of distilled water and alcohol. Also referred to as antifreeze, its primary function is to absorb the
extreme heat generated by a running engine. Coolant is introduced to the engine block and its components through a
reservoir affixed to the radiator.

RADIATOR. A radiator is a type of heat exchanger. It is designed to transfer heat from the hot coolant that
flows through it to the air blown through it by the fan. Most modern cars use aluminum radiators.
These radiators are made by brazing thin aluminum fins to flattened aluminum tubes.

UPPER/LOWER RADIATOR HOSE. The radiator hose is an essential part of your cooling system that manages the
flow of coolant from your water pump to the heater. Your radiator hose is a rubber device that removes excess heat
from the coolant before it goes back to your engine to repeat the cycle again. There are two types of radiator hoses,
upper and lower. These parts aren’t interchangeable and come in different length and shapes.

WATER PUMP. The purpose of a car water pump is to push coolant through the car's engine block, radiator and hoses
to get the engine heat away from the system. Most frequently, the water pump drives off the crankshaft pulley or the
crankshaft itself.

THERMOSTAT. The thermostat is like a valve that opens and closes as a function of its temperature.
The t hermostat isolates the engine from the radiator until it has reached a certain minimum temperature. Without
a the rmostat, the engine would always lose heat to the radiator and take longer to warm up.

THERMOSTAT HOUSING. Engine coolant is constantly flowing, it flows through ports located in the block and head;
it travels through these two components, through the thermostat housing and into the radiator where the coolant is
cooled. As the name implies, this engine component houses the thermostat which regulates the coolant flow.

BYPASS HOSE. A fifth hose, called the bypass hose, is used to circulate the coolant through the engine, bypassing
the radiator, when the thermostat is closed. Some engines do not use a rubber hose. Instead, they might use a metal
tube or have a built-in passage in the front housing.

RADIATOR CAP. As the engine’s coolant heats, it expands, increasing pressure inside the closed coolant system.
The radiator cap controls this expansion and provides a constant pressure on the system. The caps pressure rating
varies by engine application anywhere from 13 – 16 psi. High performance caps range from 19 – 32 psi. Water boils
at 212° F, increasing the pressure in a closed system increases the boiling point. This allows manufacturers to
manufacture engines with higher operating temperatures.

EXPANSION TANK. As the coolant heats up it expands. The expansion (overflow) tank is designed to capture this
expanded fluid and hold it for when the coolant cools down again after you shut off the engine. The excess that
flowed into the tank then gets sucked back into the radiator.

OVERFLOW HOSE. Passageway of the coolant through the overflow tank.

HEATER CORE. A heater core is a radiator-like device used in heating the cabin of a vehicle. Hot coolant from
the vehicle's engine is passed through a winding tube of the core, a heat exchanger between coolant and cabin
air.

HEATER CORE CONTROL VALVE. The heater control valve is a cooling and hvac system component that is
commonly found on many road going cars and trucks. The heater control valve is typically mounted near the
firewall, and acts as the valve that allows coolant to flow from the engine to the heater core, which is located
inside of the vehicle.

ENGINE FAN. A fan clutch is a thermostatic engine cooling fan that can freewheel at low temperatures when cooling
is not needed, allowing the engine to warm up faster, relieving unnecessary load on the engine. As temperatures
increase, the clutch engages so that the fan is driven by engine power and moves air to cool the engine.
 COOLANT TEMPERATURE SENSOR. A coolant temperature sensor (CTS) (also known as an ECT sensor or ECTS
(engine coolant temperature sensor) is used to measure the temperature of thecoolant/antifreeze mix in the cooling
system, giving an indication of how much heat the engine is giving off.

TOOLS AND DEFINITIONS

BOX WRENCH. A double-ended tool with one end being like an open-end wrench or open-ended spanner, and
the other end being like a box-end wrench or ring spanner. Both ends generally fit the same size of bolt.

SOCKET WRENCH. A socket wrench is a type of wrench or spanner that has a socket attached at one
end, usually used to turn a fastener. The most prevalent form is the ratcheting socket wrench, often informally
called a ratchet.

SHALLOW SOCKET WRENCH. Shallow sockets are the type most commonly found in socket wrench sets. In many
circumstances, people will need no more than a shallow set of sockets. The can fit into tighter spaces and are
particularly useful for carrying out jobs on car or motorcycle engines where space is more limited. The majority of DIY
enthusiasts will never need anything more than a shallow socket wrench set.

DEEP SOCKET WRENCH. A deep socket will generally be around 1-inch long. This will allow you to use a socket
wrench in inaccessible places, especially if you have an extension on the driver.

RATCHET HANDLE. A ratchet wrench is so named because it uses a ratcheting motion to tighten and loosen
fastening hardware. This tool is used when building or repairing many types of objects, including automobile
repair and building construction.

SPEED HANDLE. Speed handles have previously been used for ease of rotation of a socket being used to
loosen or tighten bolts or nuts. There are many situations where the use of such a speed handle is
advantageous.

TORQUE WRENCH. A torque wrench is a tool used to apply a specific torque to a fastener such as a nut or bolt.
A torque wrench is used where the tightness of screws and bolts is crucial. It allows the operator to set
the torque applied to the fastener so it can be matched to the specifications for a particular application.

PLIERS. Pliers are a hand tool used to hold objects firmly, possibly developed from tongs used to handle hot
metal in Bronze Age Europe. They are also useful for bending and compressing a wide range of materials.

SCREWDRIVERS. Screwdriver, tool, usually hand-operated, for turning screws with slotted heads. For screws
with one straight diametral slot cut across the head, standard screwdrivers with flat blade tips and in a variety of
sizes are used.

BALL PEEN HAMMER. A ball-peen hammer, also known as a machinist's hammer, is a type of peening hammer
used in metalworking. It has two heads, one flat and the other, called the peen, rounded. It is distinguished from
a cross-peen hammer, diagonal-peen hammer, point-peen hammer, or chisel-peen hammer by having a
hemispherical peen.

SPECIAL SERVICING TOOL

 COMPRESSION TESTER. A compression test reveals the condition of your engine's valves, its valve seats, and
piston rings and whether these parts are wearing evenly. Healthy engines should have compression over 100 psi
per cylinder, with no more than 10 percent variation between the highest and lowest readings.

IGNITION TIMING LIGHT. The timing light is connected to the ignition circuit and used to illuminate the timing
marks on the engine's crankshaft pulley or flywheel, with the engine running. The apparent position of the marks,
frozen by the stroboscopic effect, indicates the current timing of the spark in relation to piston position.

TACHOMETER. A tachometer (revolution-counter, tach, rev-counter, RPM gauge) is an

instrument measuring the rotation speed of a shaft or disk, as in a motor or other machine. The device
usually displays the revolutions per minute (RPM) on a calibrated analogue dial, but digital displays are
increasingly common.

MEASURING TOOLS

FEELER GAUGE. A feeler gauge is a tool used to measure gap widths. Feeler gauges are mostly used in
engineering to measure the clearance between two parts.

MICROMETER. A micrometer, sometimes known as a micrometer screw gauge, is a device incorporating a

calibrated screw widely used for accurate measurement of components in mechanical engineering and
machining as well as most mechanical trades, along with other metrological instruments such as dial, vernier,
and digital calipers.

VERNIER CALIPER. The Vernier caliper is an extremely precise measuring instrument; the reading error is
1/20 mm = 0.05 mm. Close the jaws lightly on the object to be measured. If you are measuring something
with a round cross section, make sure that the axis of the object is perpendicular to the caliper.

DIAL GAUGE. A gauge consisting of a circular graduated dial and a pointer actuated by a member that contacts
with the part being calibrated.

RULER. A ruler, sometimes called a rule or line gauge, is a device used in geometry and technical drawing,
as well as the engineering and construction industries, to measure or draw straight lines.
 Output
in
Automotive Servicing NC 1

Submitted by:
Elmer B. Octavo

Submitted to:
Mr. Angelo Llacuna