engine basics & engine components

Technician Level-1 (Program 5)
Engine Basics & Engine Components
<Day #1
Program Session ResourcesUsed SuggestedDuration
 Introductionof Engine
Basics
 PPT
 White Board/Flipcharts
10 minutes
 Diesel Engine Basics
 PPT
 Animation
30 minutes
 Air Intake System
 PPT
 Animation
60 minutes
 Fuel System
 PPT
 Animation
30 minutes
 Emission Control
 PPT
 Animation
30 minutes
 Lubrication System
 PPT
 Animation
 Componentsandgauges
90 minutes
 Cooling System
 PPT
 Animation
 Componentsandgauges
180 minutes
 Exhaust System
 PPT
 Animation
60 minutes

<Day #2
Program Session ResourcesUsed SuggestedDuration
 Engine Metrology
 Diagramsand PPT
 Animations
 Gauges
 Engine components
 360 minutes
Introduction
Resourcesto be used
 PPT
 White Board/Flip charts
Objective
To make the student understand:
 Purpose, function and construction of an engine
 Components of Engine
Say
 What is the whirring noise you hear when you turn on the ignition key of your
car? It is the Engine. Engine is the heart of an automobile. It fuels raw power to
drive the vehicle.
Ask
 Have you ever seen any engine?
 How many types of Engines are available?

Do
 Run the PPT.
 Explain them the concept of Engine
 Take them to a demo-engine
 Give them an overview
Notesfor Facilitation
 Arrange the display materials required in the classroombefore the session
Diesel Engine
Resourcesto be used
 PPT
 Animation
Objective
To make the student understand
 The concept of a Diesel Engine
 It’s function and the various systems of a Diesel engine
Say
 Engine creates power, which is its sole function. But how does it do that. It
simply converts chemical energy into heat energy, which in turn is converted to
mechanical energy, thus sets our wheels rolling.
 Its simpler said than done. There are hundreds of components which are a part
of this engine, enabling the power packed performance.
 To get a better view let’s take a tour inside the engine.

Ask
 Name a vehicle which has got a Diesel Engine
 What is the difference between Diesel and Petrol
 What is the difference between a Diesel and a Petrol Engine
 Any other application where the Diesel Engine is used
Do
 Run the PPT
 Explain the various components of an engine
 The working procedure of an engine
 The function of the major components of an engine.
 Arrange the display materials like Diesel, petrol, cut section of an Engine
model etc prior to the commencement of the session
Air Intake System
Resourcesto be used
 PPT
 Animation
Objective
To make the students:
 Understand the importance of air-intake system
 The various components of air-intake system, its working and function

Say
 As we all know, we need to fuel our engine. How does it burn? Who helps in
burning? We also know for combustion 3 things are required- Fuel, Air & Heat.
 So for the induction of air in the engine we have an air intake system. There is n-
number of parameters required for a clean and pressurized air entry
 In this module we shall discuss each of the components that are part of the air-
intake system
Ask
 What do we breathe?
 How air is filtered in our respiratory system?
 What happens if we breathe in dirty air?
Do
 Run the PPT
 Brief them the entire systemi.e. how the air enters and finally how it reaches its
destination
 Then go for a component level description, as to what role each component play
 Show the location of each components of air-intake systemin the demo-engine
 Arrange the display materials like air filter, snorkel, air cooler, intake
manifold etc. prior to the session
Fuel System
Resourcesto be used
 PPT
 Animation

Objective
To make the studentsunderstand
 Importance of a fuel system
 The various types of fuel system
 Function of the fuel system
 Components of a fuel system
Say
 As you know we need food to keep doing our daily work, so does a vehicle. The
food for a vehicle is fuel
 It burns this fuel to do work i.e. gets the vehicle in motion
Ask
 Why do we take a vehicle to a Petrol Pump?
 What is the source of fuel?
 How do you measure the quality of fuel?
Do
 Run the PPT
 Explain them the animations
 Explain the combustion technology, function and working of a fuel system
 The advanced technologies like CDRi should be given first hand importance
 The different types of injectors and fuel pump should be elaborated upon.
 Arrange the display materials like injectors, FIP, fuel pump etc prior to the
session

Emission Control
Resourcesto be used
 PPT
 Animation
Objective
To make the studentunderstandemissionnorms,emissioncontrol systemsincorporatedin
the vehicle
Say
 As Government pitches for infrastructure growth, the vehicle sales keep
increasing, thus the emission from each vehicle attributes to pollution. Pollution
affects our environment
 So to take care of our environment, Government has regulated certain laws,
regarding the emission levels of a vehicle
 So to take care of emission level, we improve the technology of our engine and
change the quality of exhaust gas which is directed to the environment
Ask
 Have you heard of Global warming and Green house effect?
 Have you ever heard of BS or Euro norms?
 Why did the production of Maruti-800 stop?
Do
 Run the PPT
 Explain them the emission norms
 Explain why are we going for electronic engines, a deviation from mechanical
engines
 Mention the components which take care of emission control
 Take them to the vehicle and showcase the emission regulating components

 Arrange the materials if required
Lubrication System
Resourcesto be used
 PPT
 Animation
Objective
To make the studentunderstand
 The function, purpose and working of a Lubrication System
 The various components of a Lubrication System
Say
 Just hold your hands in front of you and rub them against each other. What
do you feel? It gets hot due to friction between the two surfaces.
 Similarly, there are so many parts of an engine like crankshaft, camshaft,
bearings, which move & rub against each other when an Engine works, so
lubrication in these areas is essential
Ask
 What are the various types of oil you have come across in your day to day life?
 Where are these oils used?
 Say we are unable to open a lock properly as the key is getting jammed. What do
we do? We put some oil in the keyway of the lock, and then try again. What
happens?

Do
 Run the PPT
 Explain them the lubrication system i.e. the path through which the lubricants
flow, from sump to cylinder head and back to sump
 Explain them the grade of lubricants we use, its property etc
 Arrange all the materials like oil filter, sump, strainer, some lubricants etc.
should be kept on the table prior to the session
Cooling Systems
Resourcesto be used
 PPT
 Animation
Objective
 The purpose, function and working of a cooling system
 The different components and its location in a cooling circuit
Say
 Why dowe take colddrinksinsummer?To cool ourselves.SimilarlyforanEngine itis
alwayssummer,since itisa heatproducingagent.Some partsget sohot that theymay
leadconsequential damage andfailureof the engine.
 So to preventsucha mishapwe have a coolingcircuitneatlychalked outinourEngine
 It isone of the most critical systemof anEngine
Ask
 How many of you have ceiling fan in your home?
 How many of you have visited a shopping complex?
 Why do we perspire?

Do
 Run the PPT
 Explain them the purpose of cooling system
 Display the cooling circuit of an Engine
 Take them to the vehicle and show them the cooling system
 Arrange all the materials like thermostat, radiator pressure cap, viscous fan,
coolant on the table, before the start of the session.
Exhaust System
Resourcesto be used
 PPT
 Animation
 White board/Flipcharts
Objective
 The purpose, working and function of an exhaust system
 The exhaust system components and their location
Say
 All living organisms have a mechanism to dispose of their waste (metabolism)
 The amount of combustion taking place in the engine results in the production
of a lot of gas which needs to be disposed off.
 For that we have an exhaust system
Ask
 How long can we hold our breath?
 Has anyone ever seen a chimney of a factory?

Do
 Run the PPT and explain them the animation
 Explain them the entire exhaust system
 Elaborate on the components involved and their working
 Arrange all the materials like silencer, exhaust manifold and the tail pipe on
the table before the commencement of the session
Engine Metrology
Resourcesto be used
 PPT
 White Board
 Engine Components
Objective
 The various components of the engine we measure
 The importance of gauges like vernier calliper, micrometer, pressure gauges
etc.
 The method of measuring the engine components
Say
 Accuracy is the essential tool of success
 Guys you have a pre-test and a post-test for every module. The pre-test gives an
idea to the trainer about knowledge level of the participants, the post-test gives
the idea as to how much further knowledge you took in
 Similarly in Engine various components are measured to check whether they
meet the desired specification
 So in this module we shall discuss the importance of various gauges and
instruments used, various components of the engine where the measurement is
taken and the unit of measurement

Ask
 What are your age, height and weight?
 How do you measure them?
 What is the percentage of marks you scored in your board exams?
Do
 Run the PPT
 Explain them the concept of tolerance and clearance
 Which are the components we measure
 Keep some engine components, gauges etc. prior to the session

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