PROTON ENGINE 4G15

1. Copy Right © Akademi Saga/EON Berhad

2. Stroke Cycle
Operation
CLASSIFICATION OF ENGINE
Combustion Cooling Valve
Mechanism
Cylinder
Arrangement
• Four Stroke Cycle
Engine
• Two Stroke Cycle
Engine
• Spark Ignition
Engine ….Petrol
• Compression
Ignition….Diesel
• Water Cooled
• Air Cooled
• OverHead Valve
• OverHead Cams
Classification Of Engine
• In-Line
• V Type
• Horizontally
Opposed Type
• Horizontally
Mounted Type

3. COMBUSTION
REQUIREMENTS
There is three condition are
required to run the
engine smoothly :
Proper Compression
Proper Air/Fuel Mixture
Proper Sparking

4. CYLINDER BLOCK
Block Manufacturing Design
• The main structure of engine.
• All other engine parts attached to cylinder block
Copy Right © Akademi Saga/EON Berhad

5. CRANKSHAFT ASSEMBLY
Copy Right © Akademi Saga/EON Berhad
Crankshaft Design
• Two type manufactured
a. Forged Steel
b. Cast Iron

6. Copy Right © Akademi Saga/EON Berhad
Bearing Design
BEARING ASSEMBLY

7. BEARING ASSEMBLY
Copy Right © Akademi Saga/EON Berhad
Thrust Bearing
To absorb axial or thrust motion

8. BEARING ASSEMBLY
Copy Right © Akademi Saga/EON Berhad
Bearing Clearance
• Bearing clearance determine how much oil will flow past and out
• To small or much clearance will effect engine condition and performance

9. PISTON ASSEMBLY
Piston And Rod Assembly
• Piston and rod are used to transmit
the power from combustion to the
crankshaft
Copy Right © Akademi Saga/EON Berhad

10. Copy Right © Akademi Saga/EON Berhad
Piston Parts
PISTON ASSEMBLY
• Most piston made from hollow aluminum alloy.
• It’s design to operate under severe temperature

11. Copy Right © Akademi Saga/EON Berhad
Connecting Rod
PISTON ASSEMBLY
• Purposely to change energy motion
• As a lubrication system component

12. CYLINDER HEAD
Cylinder Head Design and Manufacturing
• It is used for sealing
• Head design example Valve port, combustion chamber
coolant passage and material will effect system operation
Copy Right © Akademi Saga/EON Berhad

13. CYLINDER HEAD
Gasoline Combustion Chamber
• Placed Air/Fuel mixing and explode
• Type of combustion chamber and head shape will change
engine performance.
• Turbulence cause better combustion
• Quench area will get better turbulence efficiency and for cooling system
• Type of combustion chamber are commonly used
a. Hemispherical type
b. Wedge Shaped Type
c. Pent roof type
Copy Right © Akademi Saga/EON Berhad

14. Copy Right © Akademi Saga/EON Berhad
Valve Parts
VALVE ASSEMBLY
• It is made of very strong metal with nickel, chromium and other material

15. Copy Right © Akademi Saga/EON Berhad
Valve Seat
VALVE ASSEMBLY
• Valve seat help the valve seal to cylinder block or head

16. Copy Right © Akademi Saga/EON Berhad
Valve Spring
VALVE ASSEMBLY
• Valve keeper or log was used to keep the valve spring and retainer in place

17. LUBRICATING SYSTEM OPERATION
Lubricating system was most importance thing on engine operation
The system composed of several parts include :
a. Oil Pan
b. Oil Pump
c. Main Oil Gallery
d. Oil Filter
e. Pressure Regulator
f. Oil Cooler
g. Oil Sensor
Copy Right © Akademi Saga/EON Berhad

18. LUBRICATING SYSTEM OPERATION
Copy Right © Akademi Saga/EON Berhad
Oil Flow System
• Oil flow from oil pan, through the pump and into the main gallery

19. LUBRICATING SYSTEM OPERATION
Copy Right © Akademi Saga/EON Berhad
Oil Flow System
• Oil from main gallery is sent through passages into the crankshaft.

20. LUBRICATING SYSTEM OPERATION
Copy Right © Akademi Saga/EON Berhad
Oil Pump System
• Oil pump was direct drive by crankshaft, belt or change
• Three type commonly used are :
a. Gear Type
b. Eccentric Type
c. Trochoid Type

21. LUBRICATING SYSTEM OPERATION
Oil Pressure Regulating Valve
• Purposely to maintain, increase and reduce oil pressure to main oil gallery
Copy Right © Akademi Saga/EON Berhad

22. COOLING SYSTEM OPERATION
Purpose Of Cooling System
• To maintain operating temperature.
• To remove Excess heat
• To bring working temperature.
Copy Right © Akademi Saga/EON Berhad

23. COOLING SYSTEM OPERATION
Copy Right © Akademi Saga/EON Berhad
Liquid Cooled Engine
Coolant is pumped from water pump, through the block and head, thermostats into radiator.

24. FOUR STROKE CYCLE
FOUR CYCLE ENGINE
•4 Stroke engine can also called a
4 cycle engine.
•These four stroke are titled :
1. Intake
2. compression
3. power
4. exhaust
Copy Right © Akademi Saga/EON Berhad

25. FOUR STROKE CYCLE
INTAKE STROKE
Copy Right © Akademi Saga/EON Berhad
•As the piston is
cranked
downward
called the intake
stroke,air and
fuel are drawn
into cylinder.
•Because the
piston moves
down a vacuum
is created.

26. FOUR STROKE CYCLE
COMPRESSION STROKE
Copy Right © Akademi Saga/EON Berhad
•The higher the
compression ratio
the greater the
mixing of air and
fuel.
•The compression
stroke takes the air
fuel mixture and
compresses it
according to the
compression ratio
of engine.

27. FOUR STROKE CYCLE
POWER STROKE
Copy Right © Akademi Saga/EON Berhad
•Both the intake and
exhaust valve
remain closed.
•The piston is
coming up on the
compression
stroke,spark will
occur very near
TDC.
•At this point air,fuel
and ignition are
present,than air and
fuel to explode.

28. FOUR STROKE CYCLE
EXHAUST STROKE
Copy Right © Akademi Saga/EON Berhad
•The exhaust
stroke starts
when the piston
starts moving
upward again.
•At the
beginning of the
exhaust stroke
,the exhaust
valve opens.

29. ENGINE SPECIFICATION specification
Bore x Stroke
Under square Engine
- Length of the stroke greater than
the diameter of the bore
- Purposely long-stroke design
provided greater torque in the low
speed range
Over square Engine
- Diameter of bore is longer than
the length of the stroke
- Also called short stroke engine
- Purposely can increase torque at
high speed
Copy Right © Akademi Saga/EON Berhad

30. ENGINE SPECIFICATION
Compression ratio
•During engine operation the
air and fuel mixture must be
compressed
•This compression helps
squeeze and mix the air and
fuel molecules for better
combustion
Copy Right © Akademi Saga/EON Berhad

31. ENGINE SPECIFICATION
HOW TO MEASURE TOTAL
DISPLACEMENT
TOTAL DISPLACEMENT
33..1144
44 FF//mm :: p == xx DD² xx LL xx 44
Copy Right © Akademi Saga/EON Berhad
[B
ore
]Stroke
0.7854 x Bore²(cm) x Stroke(cm) x No.Cyl.
Example : 0.7854 x 7.6 x 7.6 x 8.73 x 4
=1584 cc

32. ENGINE SPECIFICATION
HOW TO MEASURE COMPRESSION RATIO
Copy Right © Akademi Saga/EON Berhad
Specification
Clearance Volume (CV) + Swept Volume (SV)
Clearance Volume (CV)
SV
CV
Compression Ratio

33. TIMING
DIAGRAMS
Copy Right © Akademi Saga/EON Berhad

34. Engine Specification
Specification OPP NPP(MAGMA) 12 VALVE
ENGINE MODEL 4G13 4G15 4G13 4G15 4G13 4G15
Combustion chamber type Hemi-spherical
Hemi-spherical
Compact type Compact
Copy Right © Akademi Saga/EON Berhad
type
Pentroof
type
Pentroof
type
Compression ratio 9.8 9.5 9.7 9.4 9.5 9.2
Valve Arrangement OHV OHV OHV OHV OHV OHV
Total Displacement 1298 1468 1298 1468 1298 1468
Bore X stroke mm 71 x 82 75.5 x 82 71 x82 75.5 x 82 71 x 82 75.5 x 82
Valve
inta
Open
19 19 19 19 15 15
timing
ke
ed
Close
d
57 57 57 57 53 53
exh
aust
Open
ed
57 57 57 57 57 57
Close
d
19 19 19 57 15 15

35. GENERAL INFORMATION
TECHNICAL FEATURES
•The engines for the ISWARA 1.3 & 1.5 model of a SOHC type develop
based on MITSHUBISHI “CYCLONE” series
•It employ three valve per cylinder
•The combustion chamber is a pentroof type which improves
combustion process
Copy Right © Akademi Saga/EON Berhad ENGINES 4G1 SERIES

36. Copy Right © Akademi Saga/EON Berhad
THE CYLINDER HEAD
•The cylinder head is made of aluminum alloy
•2 intake ports at each chamber
•Roller type rocker arm for smooth operation and reduces frictional resistance

37. Copy Right © Akademi Saga/EON Berhad
LUBRICATION SYSTEM
•Is a forced feed full flow filtration type
•Oil pump is of “trochoid rotor”
•The inner rotor of the pump is driven by the crankshaft

38. Copy Right © Akademi Saga/EON Berhad
COOLING SYSTEM
•The system utilieses a pressured and corrugated fin type radiator
•Fan is electrically driven and operates automatically according to
coolant temperature.

39. Copy Right © Akademi Saga/EON Berhad
INDUCTIONSYSTEM
•Air cleaner is an “Axial Flow” and it has a special features.
•Large filteration area and reduction in flow resistance
•Decreasing the percentage of pollutants in the exhaust gases

40. Copy Right © Akademi Saga/EON Berhad
EXHAUST SYSTEM
•The exhaust manifold is made of cast iron and designed with dual outlet
to reduce the exhaust interface.

41. Plastic region tightening method
XX
EEllaassttiicc rreeggiioonn PPllaassttiicc rreeggiioonn
FFaaiilluurree SSmmaallll vvaarriiaattiioonn
LLaarrggee vvaarriiaattiioonn
YYiieellddiinngg
PPooiinntt
VVaarriiaattiioonn iinn
ttiigghhtteenniinngg aannggllee
PPllaassttiicc rreeggiioonn ttiigghhtteenniinngg
mmeetthhoodd
CCaalliibbrraatteedd wwrreenncchh
TTiigghhtteenniinngg mmeetthhoodd
TToorrqquuee vvaarriiaattiioonn AAnnggllee ooff bboolltt rroottaattiioonn
Tightening torque
Axial
tension
Cylinder
head
Copy Right © Akademi Saga/EON Berhad

42. Tightening procedure
11
33
4
Copy Right © Akademi Saga/EON Berhad
55
22
77..4 KKggmm
22..00 KKggmm
9900°°
9900°°
AAxxiiaall tteennssiioonn
PPllaassttiicc rreeggiioonn

43. Tighten the bolts by the following
procedure (4G9)
STEP OPERATION REMARKS
1 Tighten to 74 Nm Carry out in the order shown in the
illustration
2 Fully loosen Carry out in the reverse order of that
shown in the illustration
3 Tighten to 20 Nm Carry out in the order shown in the
illustration
4 Tighten ¼ of a turn ( 90° ) Carry out in the order shown in the
illustration
5 Tighten ¼ of a turn ( 90° ) Carry out in the order shown in the
illustration
Copy Right © Akademi Saga/EON Berhad

44. Type of compression ring
PPiissttoonn
CCyylliinnddeerr
OOiill
Copy Right © Akademi Saga/EON Berhad
CCoommbbuussttiioonn ggaass
PPiissttoonn
Plane type
CCyylliinnddeerr
Tapered face type
CCoommbbuussttiioonn ggaass
PPiissttoonn
CCyylliinnddeerr
OOiill
Inner bevel type

45. Type of piston pin
SEMI-FLOATING TYPE FULL-FLOATING TYPE
Copy Right © Akademi Saga/EON Berhad

46. Piston pin installation
Push Rod
Guide C
Base
Frt
Mark
C D
3 mm
Guide B
Guide A
A B
C D
LL == (( AA –– CC )) –– (( BB –– DD ))
22
Copy Right © Akademi Saga/EON Berhad

47. Lubrication system 4G15
Lubrication System
• Used full flow pressure feed
system
• Oil Capacity up to 3.8 L
• Engine oil is feed up by oil pump
drive by crank shaft and oil
pump gear
• Oil pump used trochoid gear type
and relief valve incorporated
in the front case.
Copy Right © Akademi Saga/EON Berhad

48. Valve clearance
adjustment
Position the No.
1 cylinder at top
dead center on
the compression
stroke
Standard value : on
cold engine
Intake : 0.09 mm
(0.004 in)
Exhaust : 0.20 mm
(0.008 in)
Copy Right © Akademi Saga/EON Berhad

49. Oil Pump Relief Valve
RReelliieeff vvaallvvee
 RReelliieeff vvaallvvee ppuurrppoossee ttoo aaddoopptteedd ffoorr
rreedduuccttiioonn ooff aaeerraattiioonn
Copy Right © Akademi Saga/EON Berhad

50. Crankshaft Pulley
Rubber
Hub
Pulley
Fin
The crankshaft pulley consists
of a cast-iron pulley and hub
connected by a rubber
section. It also functions as a
torsional damper that
minimizes twisting vibration of
the crankshaft.
Copy Right © Akademi Saga/EON Berhad

59. Copy Right © Akademi Saga/EON Berhad

60. VVEERRNNIIEERR CCAALLIIPPEERR
Copy Right © Akademi Saga/EON Berhad

61. HHOOWW TTOO RREEAADD SSCCAALLEE
Formula for reading length L (mm) L = L1 + X
X = No. of graduations x 0.05
Copy Right © Akademi Saga/EON Berhad
AA
BB

62. MMEEAASSUURRIINNGG PPRROOCCEEDDUURREE
Regular scale jaw
Inside diameter Depth
Copy Right © Akademi Saga/EON Berhad
Venire scale jaw
Object to be measured
Wrong way
Correct way
Outside diameter
Regular scale jaw
Object to be
measured
Depth stick

63. MMEEAASSUURRIINNGG PPRROOCCEEDDUURREE
PPooiinntt ttoo nnoottee wwhheenn uussiinngg mmiiccrroommeetteerr ::
aa)) CClleeaann tthhee mmiiccrroommeetteerr aanndd tthhee ssuurrffaaccee ttoo bbee mmeeaassuurreedd
bb)) CChheecckk tthhee zzeerroo ppoossiittiioonn ((tthhrroouugghh uussee ooff aa ssttaannddaarrdd ggaauuggee
Copy Right © Akademi Saga/EON Berhad

64. MMEEAASSUURRIINNGG PPRROOCCEEDDUURREE
Copy Right © Akademi Saga/EON Berhad

65. Copy Right © Akademi Saga/EON Berhad