INTERNAL COMBUSTION ENGINES

LABORATORY MANUAL

DEPARTMENT OF MECHANICAL
ENGINEERING (KSK CAMPUS)
UNIVERSITY OF ENGINEERING & SCIENCE TECHNOLOGY LAHORE

Dr. Muhammad Mujtaba Abbas

Instructor

Mohsin Javed
Lab technician
Submitted by:
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Preface
In most of the engineering institutions, the laboratory course forms an integral form of the
basic course in Internal Combustion Engines at undergraduate level. The experiments to be
performed in a laboratory are ideally designed in such a way as to reinforce the understanding
of the basic principles as well as help the students to visualize the various phenomenon
encountered in different applications.
The objective of this manual is to familiarize the students with practical skills, measurement
techniques and interpretation of results. It is intended to make this manual self-contained in
all respects, so that it can be used as a laboratory manual. In all the experiments, the relevant
theory and general guidelines for the procedure to be followed have been given. Tabular
sheets for entering the observations have also been provided in each experiment while graph
sheets have been included wherever necessary.
It is suggested that the students should complete the computations, is the laboratory itself.
However the students are advised to refer to the relevant text before interpreting the results
and writing a permanent discussion. The questions provided at the end of each experiment
will reinforce the students understanding of the subject and also help them to prepare for
viva-voce exams.
General Instructions to Students

 The purpose of this laboratory is to reinforce and enhance your understanding of the
fundamentals of Internal Combustion Engines. The experiments here are designed to
demonstrate the applications of the basic Internal Combustion Engines principles and to
provide a more intuitive and physical understanding of the theory. The main objective is
to introduce a variety of classical experimental and diagnostic techniques, and the
principles behind these techniques. This laboratory exercise also provides practice in
making engineering judgments, estimates and assessing the reliability of your
measurements, skills which are very important in all engineering disciplines.

 Read the lab manual and any background material needed before you come to the lab.
You must be prepared for your experiments before coming to the lab.

 Actively participate in class and don’t hesitate to ask questions. Utilize the teaching
assistants. You should be well prepared before coming to the laboratory, unannounced
questions may be asked at any time during the lab.

 Carelessness in personal conduct or in handling equipment may result in serious injury to

the individual or the equipment. Do not run near moving machinery. Always be on the
alert for strange sounds. Guard against entangling clothes in moving parts of machinery.

 Students must follow the proper dress code inside the laboratory. To protect clothing
from dirt, wear a lab apron. Long hair should be tied back.

 Calculator, graph sheets and drawing accessories are mandatory.

 In performing the experiments, proceed carefully to minimize any water spills, especially
on the electric circuits and wire.

 Make your workplace clean before leaving the laboratory. Maintain silence, order and
discipline inside the lab.

 Cell phones are not allowed inside the laboratory.

 Any injury no matter how small must be reported to the instructor immediately.

 Wish you a nice experience in this lab

Instructions to complete the lab manual

 Read everything carefully.

 Use the given template. If you change the template and use any other format, a penalty
will be awarded.

 Don’t edit anything that is already included in the manual.

 You are expected to fill in the tables, attach plots and write conclusions.

 Additionally, you are expected to add discussion and images wherever asked.
Table of contents

Preface.......................................................................................................................................3
General Instructions to Students............................................................................................4
Instructions to complete the lab manual................................................................................5
Table of contents......................................................................................................................6
List of Experiments..................................................................................................................9
1. LAB SESSION 1.............................................................................................................10
1.1 Learning objective....................................................................................................10
1.2 Apparatus.................................................................................................................10
1.3 Components..............................................................................................................10
2. LAB SESSION 2.............................................................................................................11
2.1 Learning objective....................................................................................................11
2.2 Apparatus.................................................................................................................11
2.3 Components..............................................................................................................11
3. LAB SESSION 3.............................................................................................................12
3.1 Learning Objectives.................................................................................................12
3.2 Apparatus.................................................................................................................12
3.3 Components of a Cooling System............................................................................12
3.4 Procedure..................................................................................................................12
3.5 Observations and Calculations.................................................................................13
Table.................................................................................................................................13
Plots..................................................................................................................................13
3.6 Conclusions..............................................................................................................13
4. LAB SESSION 4.............................................................................................................14
4.1 Learning Objectives:................................................................................................14
4.2 Apparatus.................................................................................................................14
4.3 Components of the lubrication system.....................................................................14
4.4 Procedure..................................................................................................................14
4.5 Observations and Calculations.................................................................................14
 Table.................................................................................................................................15
Plots..................................................................................................................................15
4.6 Conclusions..............................................................................................................15
5. LAB SESSION 5.............................................................................................................16
5.1 Learning Objectives.................................................................................................16
5.2 Apparatus.................................................................................................................16
5.3 Components of the cooling system..........................................................................16
5.4 Procedure..................................................................................................................16
5.5 Observations and Calculations.................................................................................17
Table.................................................................................................................................17
Plots..................................................................................................................................17
5.6 Conclusions..............................................................................................................17
6. LAB SESSION 6.............................................................................................................18
6.1 Learning Objectives:................................................................................................18
6.2 Apparatus.................................................................................................................18
6.3 Components of the lubrication system.....................................................................18
6.4 Procedure..................................................................................................................18
6.5 Observations and Calculations.................................................................................18
Table.................................................................................................................................19
Plots..................................................................................................................................19
6.6 Conclusions..............................................................................................................19
7. Lab session 7...................................................................................................................20
7.1 Learning objective....................................................................................................20
7.2 Apparatus.................................................................................................................20
7.3 Procedure..................................................................................................................20
7.4 Observations.............................................................................................................20
Table.................................................................................................................................20
7.5 Conclusions..............................................................................................................20
8. Lab session 8...................................................................................................................21
8.1 Learning objective....................................................................................................21
8.2 Apparatus.................................................................................................................21
8.3 Procedure..................................................................................................................21
 8.4 Observations.............................................................................................................21
Table.................................................................................................................................21
8.5 Conclusions..............................................................................................................21
9. Lab session 9...................................................................................................................22
9.1 Learning objective....................................................................................................22
9.2 Apparatus.................................................................................................................22
9.3 Procedure..................................................................................................................22
9.4 Observations.............................................................................................................22
9.5 Conclusions..............................................................................................................22
10. Lab session 10.............................................................................................................23
10.1 Learning objective....................................................................................................23
10.2 Apparatus.................................................................................................................23
10.3 Procedure..................................................................................................................23
10.4 Observations.............................................................................................................23
Table.................................................................................................................................23
10.5 Conclusions..............................................................................................................23
11. Lab session 11.............................................................................................................24
11.1 Learning objective....................................................................................................24
11.2 Apparatus.................................................................................................................24
11.3 Procedure..................................................................................................................24
11.4 Observations.............................................................................................................24
List of Experiments

Experiment
Description
No.
1 Identification and recognition of different parts of four stroke diesel engine.

2 Identification and recognition of different parts EFI petrol engine.

3 To study the parts and working of the cooling system for Diesel Engines.
To study the parts and working principle of the diesel engine lubrication
4
system.
To study the parts and working of the cooling system in dual-fuel petrol
5
engine.
To study the parts and working principle of the lubrication system in Dual-fuel
6
petrol engine.
7 Investigate the power supply circuit on EFI engine system

8 To investigate the main relay circuit on the EFI engine system

To investigate the effect of faulty fuel injector circuits on the engine

9
acoustics

To investigate the effect of faulty circuit on idle speed control valve on the
10
engine

11 To disassemble and assemble a small single-cylinder used for grass cutter

 1. LAB SESSION 1
Identification and recognition of different parts of four stroke diesel engine.

1.1 Learning objective

After this lab session students will be able to:

1. To understand all the parts of diesel engine

2. To understand the working principle of diesel engine
3. To understand the operation of diesel engine
1.2 Apparatus
Cut out model of four stroke diesel engine

1.3 Components
1. Cylinder Block
 Function: The cylinder block forms the main structure of the engine, housing the
cylinders where the combustion process takes place.
 Working Principle: It provides a space for the piston to move and forms the base for
mounting other components like the crankshaft, camshaft, and cylinder head.
2. Piston
 Function: The piston is a cylindrical part that moves up and down inside the cylinder,
converting pressure from combustion into mechanical power.
 Working Principle: In a four-stroke engine, the piston moves through four distinct
strokes (intake, compression, power, and exhaust). The movement of the piston helps
compress the air and fuel mixture and transmits the resulting force to the crankshaft.
3. Crankshaft
 Function: The crankshaft converts the linear motion of the pistons into rotary motion,
which is used to drive the engine’s output (e.g., wheels or machinery).
 Working Principle: As the pistons move up and down, the crankshaft rotates, turning
the linear motion into rotary motion that powers the engine’s output.
4. Camshaft
 Function: The camshaft controls the opening and closing of the engine’s intake and
exhaust valves.
 Working Principle: It is connected to the crankshaft by a timing belt or chain and
rotates at half the speed of the crankshaft, opening and closing the valves at the
correct timing to allow for proper engine intake and exhaust cycles.
5. Cylinder Head
  Function: The cylinder head is located at the top of the engine’s cylinder block and
houses the valves, fuel injectors, and sometimes the spark plugs in petrol engines.
 Working Principle: It seals the top of the cylinder, ensuring the combustion chamber
is enclosed and maintaining the integrity of the pressure buildup during combustion.
6. Valves (Intake and Exhaust)
 Function: The intake valve allows air (and in some cases, air-fuel mixture) into the
combustion chamber, while the exhaust valve lets out the exhaust gases.
 Working Principle: The camshaft operates these valves, which open and close at
specific points in the engine’s cycle to regulate the flow of air and exhaust gases.
7. Fuel Injector
 Function: The fuel injector sprays diesel fuel directly into the combustion chamber at
high pressure.
 Working Principle: In diesel engines, fuel is injected directly into the combustion
chamber, where it is compressed and ignited by the high temperature generated by
compressing the air.
8. Glow Plug
 Function: Glow plugs are used to heat the air in the combustion chamber, aiding
ignition, especially during cold starts.
 Working Principle: Glow plugs warm up the combustion chamber by using
electrical resistance, making it easier to ignite the diesel fuel during the engine’s
starting process.
9. Connecting Rod
 Function: The connecting rod connects the piston to the crankshaft, transferring the
force generated by the piston to the crankshaft.
 Working Principle: The connecting rod moves the piston’s up-and-down motion into
rotational motion for the crankshaft.
10. Crankcase
 Function: The crankcase houses the crankshaft and other related components like the
pistons and connecting rods. It also contains the engine’s lubrication oil.
 Working Principle: The crankcase contains and protects the engine’s internal
components while providing space for lubrication to minimize friction between
moving parts.
11. Timing Gear
 Function: The timing gear system ensures that the crankshaft and camshaft are
synchronized to ensure proper valve timing.
  Working Principle: It connects the crankshaft to the camshaft (usually via a chain or
belt) to ensure that the intake and exhaust valves open and close at the correct times
during the engine’s cycle.
12. Oil Pump
 Function: The oil pump circulates engine oil to lubricate the engine’s moving parts
and maintain proper engine temperature.
 Working Principle: The oil pump takes oil from the oil pan and circulates it through
passages in the engine to reduce friction, clean the engine, and keep parts cool.
13. Exhaust Manifold
 Function: The exhaust manifold collects exhaust gases from multiple cylinders and
directs them into the exhaust system.
 Working Principle: It is usually made of cast iron or steel, and it channels exhaust
gases out of the engine to be expelled through the exhaust pipe.
14. Intake Manifold
 Function: The intake manifold distributes air (and air-fuel mixture in some cases)
evenly to the cylinders.
 Working Principle: It is connected to the intake valves and directs the flow of
air/fuel mixture into the combustion chamber during the intake stroke.
15. Turbocharger (if present)
 Function: The turbocharger uses exhaust gases to spin a turbine, which drives a
compressor that forces more air into the engine, increasing efficiency and power
output.
 Working Principle: The exhaust gases that leave the engine spin the turbine, which
in turn powers the compressor that pushes air into the intake manifold, enhancing
engine performance.
16. Water Pump
 Function: The water pump circulates coolant through the engine to maintain an
optimal operating temperature.
 Working Principle: The water pump draws coolant from the radiator and circulates it
through the engine block, where it absorbs heat, and then back into the radiator to
release the heat.
17. Radiator
 Function: The radiator cools the engine’s coolant by passing it through a series of
tubes and fins to release heat.
 Working Principle: The coolant passes through the radiator’s cooling fins, where air
moving through the radiator helps dissipate the heat, maintaining the engine’s proper
temperature.
 2. LAB SESSION 2
Identification and recognition of different parts EFi petrol engine.

2.1 Learning objective

After this lab session students will be able to:

1. To understand all the parts of EFI Petrol engine.

2. To understand the working principle of EFI Petrol engine.
3. To understand the operation of EFI Petrol engine.
2.2 Apparatus
EFI petrol engine model
2.3 Components
To complete the task of identifying and explaining the components of an EFI (Electronic Fuel
Injection) petrol engine, here's a breakdown of key components you might find, along with
brief explanations of their functions:
1. Fuel Injector
 Function: The fuel injector delivers fuel directly into the engine's combustion
chamber. It atomizes the fuel, ensuring that it mixes properly with air for efficient
combustion.
 Working Principle: EFI engines use electronic sensors to determine the exact
amount of fuel needed based on various factors like air-fuel ratio, engine temperature,
and load. The injector is electronically controlled to spray fuel precisely.
2. Electronic Control Unit (ECU)
 Function: The ECU acts as the brain of the EFI system. It receives input from sensors
and sends commands to components like fuel injectors and ignition systems to ensure
optimal engine performance.
 Working Principle: It processes information from various sensors (such as the
oxygen sensor, mass air flow sensor, etc.) and adjusts fuel injection timing, ignition
timing, and air-fuel ratio.
3. Throttle Body
 Function: The throttle body controls the amount of air entering the engine. It is
usually connected to the accelerator pedal.
 Working Principle: When the accelerator is pressed, it opens the throttle plate,
allowing more air into the engine. The ECU adjusts the fuel injection to maintain the
correct air-fuel ratio.
4. Mass Air Flow (MAF) Sensor
 Function: The MAF sensor measures the amount of air entering the engine, helping
the ECU calculate the appropriate amount of fuel.
  Working Principle: It uses a heated wire or film that cools as air passes over it. The
amount of cooling is used to determine the air mass entering the engine, and the ECU
uses this data for fuel adjustments.
5. Crankshaft Position Sensor
 Function: This sensor detects the position and speed of the crankshaft, which is
essential for determining the timing of fuel injection and ignition.
 Working Principle: It provides the ECU with data on the crankshaft's position and
rotational speed, which is vital for synchronizing the ignition system and fuel
injection.
6. Oxygen Sensor (O2 Sensor)
 Function: The oxygen sensor monitors the amount of oxygen in the exhaust gases,
allowing the ECU to adjust the fuel-air mixture for optimal combustion.
 Working Principle: It compares the oxygen content in the exhaust to the air outside,
helping the ECU fine-tune the air-fuel ratio to improve fuel efficiency and reduce
emissions.
7. Fuel Pump
 Function: The fuel pump sends fuel from the tank to the injectors under high
pressure.
 Working Principle: It is typically an electric pump that draws fuel from the tank and
pushes it through the fuel lines and filter to the fuel injectors at the required pressure.
8. Fuel Pressure Regulator
 Function: This component maintains a consistent fuel pressure in the fuel rail, which
ensures that injectors deliver the correct amount of fuel.
 Working Principle: It adjusts fuel pressure based on the engine’s needs, ensuring
optimal fuel flow to the injectors under varying engine speeds and loads.
9. Air Intake System
 Function: The air intake system channels air from the environment into the engine.
 Working Principle: It usually includes an air filter to remove dirt and contaminants,
and it often has a sensor to measure incoming air for the ECU to adjust fuel delivery
accordingly.
10. Ignition System
 Function: The ignition system is responsible for igniting the air-fuel mixture in the
engine's cylinders.
 Working Principle: The ECU controls the timing of the spark, ensuring that it occurs
at the optimal point for combustion efficiency. This system includes spark plugs,
ignition coils, and the distributor (in some designs).
11. Idle Control Valve
 Function: This component controls the engine's idle speed by regulating the amount
of air bypassing the throttle valve when the engine is idling.
 Working Principle: The ECU controls the idle valve to adjust air flow, helping the
engine maintain a steady idle speed regardless of changes in load or temperature.
12. Exhaust Gas Recirculation (EGR) Valve
 Function: The EGR valve reduces nitrogen oxide (NOx) emissions by recirculating a
portion of the exhaust gas back into the intake manifold.
 Working Principle: The valve opens and closes based on the engine load and
temperature, redirecting exhaust gases to lower the combustion temperature and
reduce NOx formation.
13. Timing Belt or Chain
 Function: The timing belt or chain synchronizes the rotation of the crankshaft and
camshaft, ensuring that the engine's intake and exhaust valves open and close at the
correct time.
 Working Principle: It transfers motion from the crankshaft to the camshaft,
controlling the timing of valve openings and closings to optimize engine performance
 3. LAB SESSION 3
To study the parts and working of the cooling system for Diesel Engines.
3.1 Learning Objectives
After completing this experiment, you will be able to:

1. Recognize the corresponding components of cooling system.

2. Understand the work principles of cooling system.
3. Understand the function of radiator.

3.2 Apparatus
Diesel Engine Test Bed
3.3 Components of a Cooling System
 Here is a list of components you might encounter in a Diesel engine cooling system:

 Radiator: The radiator helps in dissipating heat from the engine coolant. It uses fins and
tubes to transfer heat from the coolant to the surrounding air.

 Water Pump: The water pump circulates coolant through the engine and the radiator.

 Thermostat: This regulates the engine’s temperature by controlling the flow of coolant. It
ensures that the engine maintains an optimal operating temperature.

 Cooling Fan: The fan helps cool the radiator by pushing air through the radiator fins.

 Coolant Reservoir: Stores extra coolant and maintains the coolant level in the system.

 Hoses and Pipes: These connect different components of the cooling system, ensuring the
flow of coolant between the engine, radiator, and other parts.

3.4 Procedure
 The water level in the engine is checked prior to starting the experiment and necessary
deterrents are taken.
 After the water inspection the engine is started, if the engine does not start then
preheating using glow plug may be required which is done by turning the key counter
clockwise and holding for a few seconds.
 Now that the engine has started, we set a base engine speed (say 800 rpm), and proceed
with our experiment.
 We note the corresponding values of inlet and outlet water temperature, given to us by
sensors and dial connected to the engine apparatus, for given value of engine speed.
 Increase the engine speed with suitable increments and note corresponding values of inlet
and outlet water temperature

3.5 Observations and Calculations

Table

No. of Engine Time Water Engine Engine Ambient

Observations Speed (min) Temperature Water Inlet Water Outlet Temperature
(rpm) Gauge Temperature Temperature T6 (oC)
T3 (oC ) T4(oC)
1 800 5 50 60 75 22
2 1000 10 55 62 80 22
3 1200 15 58 65 85 22
4 1500 20 60 70 90 22
5 1800 25 62 72 95 22

Plots

3.6 Conclusions
 Based on the data collected, you should conclude the efficiency of the cooling system
at different engine speeds.
 Key observations could include:
o How the water temperatures change with an increase in engine speed.
o The effectiveness of the radiator in dissipating heat as engine speed increases.
o The role of the water pump and thermostat in maintaining the coolant flow and
engine temperature.

This experiment provides insights into the cooling system’s ability to regulate engine
temperature, ensuring the engine operates within its optimal temperature range.
 4. LAB SESSION 4

To study the parts and working principle of the diesel engine lubrication system.

4.1 Learning Objectives:

1. Inspect Engine Oil Level and condition.
2. Ensure that the lubrication system is working properly.
3. Relationship between engine speed, oil temperature and oil pressure.

4.2 Apparatus
Diesel Engine Test Bed

4.3 Components of the lubrication system

Here are common components found in a diesel engine lubrication system that you could
identify and explain:
1. Oil Pump: The oil pump circulates oil throughout the engine, ensuring all moving
parts are lubricated.
2. Oil Filter: The oil filter removes contaminants from the engine oil to prevent engine
damage and ensure smooth operation.
3. Oil Cooler: The oil cooler reduces the temperature of the engine oil to maintain its
optimal working condition.
4. Oil Pressure Relief Valve: This valve regulates the oil pressure in the system to
prevent excessive pressure buildup.
5. Oil Pressure Gauge/Sensor: The sensor measures the oil pressure and provides data
to ensure the system is functioning properly.
6. Oil Pressure Regulator: This component helps maintain stable oil pressure
regardless of engine conditions.
7. Lubrication Gallery: A network of channels that distribute oil to various engine
components, including the crankshaft and camshaft.
8. Sump (Oil Pan): The sump collects the used oil after it has circulated through the
engine, where it is then pumped back through the system.
4.4 Procedure

 The oil level in the engine is checked prior to starting the experiment and necessary
precautions are taken.
 After the oil inspection the engine is started, if the engine does not start then preheating
using glow plug may be required which is done by turning the key counter clockwise and
holding for a few seconds.
 Now that the engine has started, we set a base engine speed (say 800 rpm), and proceed
with our experiment.
 We note the corresponding values of oil pressure and oil temperature, given to us by
sensors and dial connected to the engine apparatus, for given value of engine speed.
 Increase the engine speed with suitable increments and note corresponding values of oil
temperature and pressure.


4.5 Observations and Calculations

Table

No of Engine speed Time Oil Pressure Oil

observations (rpm) (min) (Psi) Temperature
(oC)
1 800 0 45 60
2 1000 2 55 65
3 1200 4 55 70
4 1400 6 60 75
5 1600 8 65 80
Plots

4.6 Conclusions
Based on your experimental data, you can draw conclusions regarding the relationship
between engine speed, oil temperature, and oil pressure. You might observe trends such as:
 Oil pressure generally increases as the engine speed increases, as the oil pump
circulates oil more quickly.
 Oil temperature typically increases as engine speed increases due to more friction
and heat generation from engine components.
 5. LAB SESSION 5
To study the parts and working of the cooling system in dual-fuel petrol engine.
5.1 Learning Objectives
After completing this experiment, you will be able to:
4. Recognize the corresponding components of cooling system.
5. Understand the work principles of cooling system.
6. Understand the function of radiator.

5.2 Apparatus
Petrol Engine Test Bed
5.3 Components of the cooling system
1. Radiator
 Function: The radiator is the central component of the cooling system, responsible
for dissipating the heat from the coolant.
 Working Principle: Coolant flows through the radiator, where it is cooled by air
passing through the radiator fins. The coolant absorbs heat from the engine and
releases it to the surrounding air, preventing the engine from overheating.
2. Water Pump
 Function: The water pump circulates the coolant throughout the engine and radiator
to maintain a consistent temperature.
 Working Principle: The pump draws coolant from the radiator and pushes it through
the engine's cooling passages, absorbing heat. It then sends the heated coolant back to
the radiator to release the heat.
3. Thermostat
 Function: The thermostat regulates the flow of coolant based on the engine’s
temperature, ensuring it remains within a specific range.
 Working Principle: When the engine is cold, the thermostat stays closed, preventing
coolant from circulating. As the engine heats up, the thermostat opens, allowing
coolant to flow through the radiator and engine, maintaining the correct operating
temperature.
4. Coolant Reservoir (Expansion Tank)
 Function: The coolant reservoir holds excess coolant that expands and contracts with
temperature changes.
 Working Principle: When the engine is running and the coolant heats up, it expands
into the reservoir. As the engine cools down, the coolant returns to the system. This
 component helps prevent air from entering the cooling system and maintains optimal
coolant levels.
5. Radiator Fan
 Function: The radiator fan assists in cooling the radiator by pushing or pulling air
through the radiator fins when the vehicle is moving slowly or idling.
 Working Principle: When the engine temperature rises, the fan is activated to
increase airflow through the radiator, improving heat dissipation and preventing
overheating.
6. Coolant (Antifreeze)
 Function: The coolant is a mixture of water and antifreeze that circulates through the
engine to absorb and dissipate heat.
 Working Principle: Coolant has a high heat capacity, which allows it to absorb a
significant amount of heat from the engine. The antifreeze prevents the coolant from
freezing in cold temperatures and boiling in hot temperatures.
7. Cooling Hoses
 Function: These hoses transport the coolant between the various components of the
cooling system, such as the radiator, engine block, and thermostat.
 Working Principle: The hoses are made of rubber or other durable materials and are
designed to withstand high temperatures and pressure. They ensure a continuous flow
of coolant to and from the engine.
8. Engine Block
 Function: The engine block houses the cylinders and serves as the main structure for
the engine.
 Working Principle: The cooling passages within the engine block allow coolant to
circulate around the cylinders, absorbing the heat generated during combustion.
9. Cylinder Head
 Function: The cylinder head sits on top of the engine block and contains the valves,
fuel injectors, and sometimes the camshaft.
 Working Principle: The cooling passages in the cylinder head allow coolant to flow
around the combustion chamber and valve areas, helping to regulate the temperature
and prevent overheating.
10. EGR (Exhaust Gas Recirculation) Cooler (if present)
 Function: The EGR cooler reduces the temperature of exhaust gases before they are
recirculated into the engine.
 Working Principle: The exhaust gases are cooled by the engine’s coolant before
being reintroduced into the intake system, which helps reduce nitrogen oxide (NOx)
emissions and improve engine efficiency.
11. Temperature Sensors
 Function: Temperature sensors monitor the engine and coolant temperature.
 Working Principle: These sensors send temperature data to the engine control unit
(ECU), which can adjust the engine’s operation if necessary to prevent overheating or
underheating..

5.4 Procedure
 The water level in the engine is checked prior to starting the experiment and necessary
deterrents are taken.
 After the water inspection the engine is started, if the engine does not start then
preheating using glow plug may be required which is done by turning the key counter
clockwise and holding for a few seconds.
 Now that the engine has started, we set a base engine speed (say 800 rpm), and proceed
with our experiment.
 We note the corresponding values of inlet and outlet water temperature, given to us by
sensors and dial connected to the engine apparatus, for given value of engine speed.
 Increase the engine speed with suitable increments and note corresponding values of inlet
and outlet water temperature.Observations and Calculations

Table

No. of Engine Time Water Engine Engine Ambient

Observations Speed (min) Temperature Water Inlet Water Outlet Temperature
(rpm) Gauge Temperature Temperature T6 (oC)
T3 (oC ) T4(oC)
1 800 1 45 40 55 25
2 1200 2 50 42 58 26
3 1600 3 55 45 63 27
4 2000 4 60 48 68 28
5 2400 5 65 50 73 29
Plots

5.5 Conclusions
The experiment provided insights into the functionality of the cooling system in a dual-fuel
petrol engine. Key observations included:
1. The cooling system maintained stable engine temperatures by regulating water flow
through the radiator and engine block.
2. Increased engine speed led to higher outlet water temperatures, demonstrating the heat
dissipation requirement at elevated engine loads.
3. Ambient temperature played a role in influencing the efficiency of the cooling system.
This session emphasized the critical role of the cooling system in ensuring reliable engine
operation and preventing overheating during prolonged or high-speed operations.
 6. LAB SESSION 6
To study the parts and working principle of the lubrication system in Dual-fuel petrol engine.

6.1 Learning Objectives:

4. Inspect Engine Oil Level and condition.
5. Ensure that the lubrication system is working properly.
6. Relationship between engine speed, oil temperature and oil pressure.

6.2 Apparatus
Petrol Engine Test Bed

6.3 Components of the lubrication system

1. Oil Pump
 Function: The oil pump is responsible for circulating engine oil throughout the
lubrication system.
 Working Principle: The pump draws oil from the oil sump (pan) and forces it
through the engine’s components to lubricate parts such as the crankshaft, pistons, and
camshaft. The pump ensures a continuous flow of oil to maintain smooth engine
operation and reduce friction.
2. Oil Filter
 Function: The oil filter removes impurities and contaminants from the oil to ensure
that only clean oil circulates in the engine.
 Working Principle: The filter contains a filtering element that traps dirt, metal
particles, and other impurities from the oil. This helps maintain the engine’s
efficiency and prevents damage to the internal components.
3. Oil Sump (Oil Pan)
 Function: The oil sump is the reservoir that holds the engine oil when it is not being
circulated through the system.
 Working Principle: The sump collects used oil that has drained from the engine’s
components. The oil pump draws the oil from the sump and sends it back through the
system for circulation and re-lubrication of engine parts.
4. Oil Pressure Relief Valve
 Function: The oil pressure relief valve helps maintain consistent oil pressure by
redirecting excess oil back to the sump when the pressure is too high.
 Working Principle: If the oil pressure exceeds a preset limit, the valve opens to
allow excess oil to return to the sump, preventing damage to the engine due to
excessive pressure.
5. Oil Cooler (if present)
 Function: The oil cooler helps maintain the oil temperature within the ideal operating
range by dissipating excess heat from the oil.
 Working Principle: The oil cooler uses coolant (or air in some cases) to absorb heat
from the engine oil, ensuring that the oil does not overheat and maintains its
lubricating properties.
6. Oil Temperature Sensor
 Function: The oil temperature sensor monitors the temperature of the engine oil.
 Working Principle: This sensor provides real-time data on the oil temperature to the
engine control unit (ECU) or the dashboard display, alerting the driver if the oil is too
hot and may require action, such as cooling down or stopping the engine.
7. Oil Pressure Gauge
 Function: The oil pressure gauge measures the oil pressure within the lubrication
system.
 Working Principle: The gauge provides feedback on the pressure of the oil in the
system. Proper oil pressure is crucial for ensuring that the oil circulates effectively
and lubricates all the necessary parts. Low oil pressure may indicate issues such as
low oil level or a faulty pump.
8. Crankshaft Bearings
 Function: The crankshaft bearings support the crankshaft and help reduce friction
between it and the engine block.
 Working Principle: These bearings are constantly lubricated by engine oil,
preventing wear and tear on the crankshaft as it rotates within the engine block.
9. Piston Rings
 Function: Piston rings seal the combustion chamber and help control the flow of oil
in the engine.
 Working Principle: The piston rings are lubricated by oil to reduce friction and wear
between the piston and the cylinder wall. They also control oil consumption and
prevent excessive oil from entering the combustion chamber.
10. Camshaft Bearings
 Function: Camshaft bearings support the camshaft as it rotates and helps control the
engine’s valve timing.
 Working Principle: These bearings are lubricated by engine oil to reduce friction and
ensure smooth camshaft rotation, allowing proper operation of the intake and exhaust
valves.
11. Timing Chain or Belt (and Tensioner)
  Function: The timing chain or belt synchronizes the rotation of the crankshaft and
camshaft, ensuring proper valve timing.
 Working Principle: The chain or belt is lubricated with engine oil to reduce friction
and prevent wear, ensuring that it continues to function smoothly over time. The
tensioner ensures the appropriate tension on the chain or belt.
12. Valve Lifters and Push Rods
 Function: The valve lifters and push rods are components of the valve train system
that help operate the engine's intake and exhaust valves.
 Working Principle: These components rely on oil for lubrication to reduce friction
and wear as they move up and down to open and close the valves. Proper lubrication
ensures smooth valve operation.

6.4 Procedure

 The oil level in the engine is checked prior to starting the experiment and necessary
precautions are taken.
 After the oil inspection the engine is started, if the engine does not start then preheating
using glow plug may be required which is done by turning the key counter clockwise and
holding for a few seconds.
 Now that the engine has started, we set a base engine speed (say 800 rpm), and proceed
with our experiment.
 We note the corresponding values of oil pressure and oil temperature, given to us by
sensors and dial connected to the engine apparatus, for given value of engine speed.
 Increase the engine speed with suitable increments and note corresponding values of oil
temperature and pressure.
6.5 Observations and Calculations

Table

No of Engine speed Time Oil Pressure Oil

observations (rpm) (min) (Psi) Temperature
(oC)
1 800 1 25 40
2 1200 2 30 50
3 1600 3 35 60
4 2000 4 40 75
5 2400 5 45 85

Plots

6.6 Conclusions

The experiment provided insights into the functionality of the lubrication system in a dual-
fuel petrol engine. Key observations included:
1. The relationship between engine speed and oil pressure indicated that higher engine
speeds resulted in increased oil pressure.
2. Oil temperature rose with prolonged operation and increased engine speed,
emphasizing the need for effective cooling and lubrication.
3. Regular inspection of oil level and condition is critical for ensuring the engine
operates efficiently and avoids wear and tear.
This session emphasized the importance of the lubrication system in maintaining engine
reliability and performance.
 7. Lab session 7
Investigate the power supply circuit on EFI engine system

7.1 Learning objective

To get familiarized with and investigate how to troubleshoot the power supply circuit on an
EFI engine system

7.2 Apparatus
 EFI petrol engine test bed trainer
 Multimeter (for voltage and continuity measurements)
 Circuit diagram of the EFI system
 OBD-II scanner (for diagnostic fault codes)
 Tools for circuit repair (e.g., soldering kit, replacement wires, connectors)
 Safety gear (gloves, goggles, etc.)

7.3 Procedure
1. Preparation
o Adhere to safety protocols before beginning.
o Set up the EFI test bed trainer as per the manufacturer’s guidelines.
o Ensure all necessary tools and equipment are available.
2. Initial Testing
o Start the engine and check for any abnormal behavior or warning indicators.
o Measure voltage across key points in the power supply circuit to ensure proper
functionality.
3. Fault Simulation
o Introduce a fault in the power supply circuit (e.g., disconnected wire or
simulated short circuit).
o Observe the effects on engine performance and record the impact on various
systems.
4. Diagnostic Testing
o Use the OBD-II scanner to retrieve fault codes related to the power supply
circuit.
o Utilize the multimeter to pinpoint issues such as open circuits, voltage drops,
or short circuits.
5. Repair and Validation
o Fix the identified fault (e.g., replace damaged wires, reconnect loose
connections, or resolve short circuits).
o Re-test the circuit to verify normal operation and confirm the resolution of
issues.
7.4 Observations
Table
Normal Restored
Parameter Faulty Condition
Condition Condition

Voltage at Key Circuit

12 0 or fluctuating 12
Points (V)

Engine Start Behavior Normal No Start or Unstable Normal

P0562 (Low Voltage

Diagnostic Code (if any) None None
Detected)

7.5 Conclusions
The experiment provided insights into the troubleshooting and repair of the power supply
circuit in an EFI engine system. Key findings include:
 A stable power supply is crucial for the proper operation of EFI components such as
the ECU, injectors, and sensors.
 Faults in the power supply circuit can lead to engine starting issues, unstable
performance, or complete system failure.
 Systematic diagnostic tools like a multimeter and OBD-II scanner are essential for
identifying and resolving power supply issues.
 Restoring the circuit to normal conditions resolved all performance anomalies,
highlighting the importance of circuit integrity for EFI systems.
This session emphasized the significance of maintaining the power supply circuit to ensure
reliable engine performance.

8. Lab session 8
To investigate the main relay circuit on the EFI engine system
8.1 Learning objective
To get familiarized with and investigate the main relay circuit on an EFI engine system

8.2 Apparatus
 EFI petrol engine test bed trainer
 Multimeter (for electrical measurements)
 OBD-II scanner (for fault diagnosis)
 Relay testing tools (e.g., relay tester, jumper wires)
 Circuit diagram of the EFI system
 Tools for circuit repair (e.g., soldering kit, replacement wires)
 Safety gear (gloves, goggles, etc.

8.3 Procedure
1. Preparation
o Ensure safety protocols are followed.
o Familiarize yourself with the EFI test bed trainer and its components.
o Set up the test bed according to the manufacturer’s instructions.
2. Baseline Testing
o Start the engine and ensure all systems are operating under normal conditions.
o Use a multimeter to measure the voltage and continuity of the main relay
circuit.
3. Fault Simulation
o Induce a fault in the main relay circuit (e.g., disconnected wire or simulated
relay failure).
o Observe and document the impact on engine performance and system
behavior.
4. Diagnostics
o Use the OBD-II scanner to retrieve any fault codes associated with the main
relay.
o Measure the relay’s coil resistance and check for proper functionality.
5. Repair and Validation
o Rectify the simulated fault (e.g., reconnect wires or replace the faulty relay).
o Re-test the system to ensure the main relay circuit functions correctly.
8.4 Observations

Table
Normal Restored
Parameter Faulty Condition
Condition Condition

Voltage at Relay Terminal

12 0 12
(V)

Engine Start Behavior Normal No Start Normal

P0685 (Main Relay

Diagnostic Code (if any) None None
Malfunction)

8.5 Conclusions
This experiment highlighted the critical role of the main relay circuit in the EFI
engine system. Key findings include:
 A faulty main relay circuit prevents the engine from starting and interrupts fuel
injection and ignition processes.
 Diagnosing relay faults with a multimeter and OBD-II scanner was effective in
identifying issues.
 Restoring the main relay circuit resolved all anomalies, underscoring the importance
of regular maintenance and diagnostics for EFI systems.
The lab session provided practical insights into the functionality and troubleshooting of the
main relay in modern automotive systems.

9. Lab session 9
To investigate the effect of faulty fuel injector circuits on the engine acoustics
9.1 Learning objective
To investigate the effect of faulty fuel injector circuits on the vibrations and sound of an EFI
engine system

9.2 Apparatus
 EFI petrol engine test bed trainer
 Sound level meter (for measuring engine noise)
 Vibration analyzer
 Diagnostic tools (e.g., multimeter, OBD-II scanner)
 Fault simulation module (to induce injector circuit faults)
 Tools for circuit repair (e.g., soldering kit, replacement wires)
 Safety gear (gloves, goggles, etc.)

9.3 Procedure
1. Preparation
o Ensure all safety protocols are followed.
o Familiarize yourself with the EFI test bed trainer and diagnostic tools.
o Set up the engine test bed according to the manufacturer’s instructions.
2. Baseline Testing
o Start the engine and allow it to idle under normal conditions.
o Record baseline noise levels (in dB) and vibrations (using the vibration
analyzer).
3. Fault Induction
o Simulate a fault in the fuel injector circuit (e.g., disconnected injector or
altered resistance).
o Observe and document changes in engine acoustics and vibration patterns.
4. Diagnostics
o Use a multimeter to measure the electrical parameters of the injector circuit.
o Analyze fault codes using an OBD-II scanner to confirm the fault's nature.
5. Repair and Validation
o Rectify the simulated fault (e.g., reconnect wires or replace damaged
components).
o Test the engine again to verify that normal acoustics and vibrations are
restored.
9.4 Observations
Normal Restored
Parameter Faulty Injector Condition
Condition Condition

Noise Level (dB) 65 80 65

Vibration Amplitude
50 120 50
(μm)

Diagnostic Code (if P0201 (Injector Circuit

None None
any) Malfunction)

9.5 Conclusions
The experiment demonstrated that faulty fuel injector circuits cause notable changes in
engine acoustics and vibrations. Key findings include:
 Increased noise levels and higher vibration amplitudes during faulty conditions.
 Diagnostic tools effectively identified injector circuit malfunctions.
 Restoring the injector circuit resolved acoustic and vibration anomalies, emphasizing
the importance of maintaining injector circuit integrity for optimal engine
performance.
This investigation highlighted the interdependence of fuel injection and engine acoustics in
modern EFI systems.

10. Lab session 10

To investigate the effect of faulty circuit on idle speed control valve on the engine

10.1 Learning objective

To investigate the effect of circuit on the idle speed control valve on the on the working of an
EFI engine system
10.2 Apparatus
 EFI petrol engine test bed trainer
 Diagnostic tools (e.g., multimeter, OBD-II scanner)
 Fault simulation module (to induce faults in the circuit)
 Tools for circuit repair (e.g., soldering kit, replacement wires)
 Safety gear (gloves, goggles, etc.)

10.3 Procedure
1. Preparation
o Ensure all safety measures are in place.
o Familiarize yourself with the EFI test bed trainer and its components.
o Set up the engine test bed in accordance with the manufacturer’s guidelines.
2. Baseline Testing
o Start the engine and allow it to idle under normal conditions.
o Record baseline parameters, such as idle speed, fuel consumption, and
emission levels.
3. Fault Induction
o Simulate a fault in the idle speed control valve circuit (e.g., disconnected wire
or increased resistance).
o Observe and document changes in engine behavior and performance.
4. Diagnostics
o Use a multimeter to measure voltage and continuity in the circuit.
o Analyze fault codes using an OBD-II scanner to confirm the nature of the
fault.
5. Repair and Validation
o Rectify the simulated fault (e.g., reconnect wires or replace damaged
components).
o Test the engine again to verify that normal idle speed is restored.

10.4 Observations
Table
Normal Restored
Parameter Faulty Circuit Condition
Condition Condition

Idle Speed (RPM) 850 1100 850

Fuel Consumption
0.8 1.2 0.8
(L/h)

Emissions (CO in %) 0.02 0.05 0.02

Diagnostic Code (if P0505 (Idle Control

None None
any) Malfunction)

10.5 Conclusions
The investigation revealed that a faulty circuit in the idle speed control valve
significantly impacts the engine’s idle performance. Specifically:
 The engine exhibited higher idle speeds and increased fuel consumption under faulty
circuit conditions.
 Emission levels rose, indicating inefficient combustion.
 Restoring the circuit to its proper state resolved all abnormalities, demonstrating the
importance of a functional idle speed control system in maintaining EFI engine
efficiency.
This experiment emphasized the critical role of diagnostics and timely repairs in modern
engine management systems.
 11. Lab session 11
To disassemble and assemble a small single-cylinder used for grass cutter

11.1 Learning objective

To get familiarized with different components and repairing of a small single-cylinder engine

11.2 Apparatus
 Single-cylinder engine (used for a grass cutter)
 Basic hand tools (e.g., screwdrivers, wrenches, pliers, etc.)
 Cleaning materials (e.g., cloth, solvent)
 Lubricating oil
 Gaskets or replacement parts (if required)
 Safety gear (gloves, safety goggles, etc.)

11.3 Procedure
1. Preparation
o Ensure safety measures are in place.
o Gather all required tools and equipment.
o Place the single-cylinder engine on a stable workbench.
2. Disassembly
o Remove the spark plug and drain the engine oil.
o Dismantle the external components, such as the fuel tank and air filter.
o Remove the engine head and inspect the piston, valves, and cylinder bore.
o Separate the crankcase cover and take out the crankshaft and connecting rod
assembly.
3. Inspection
o Examine all parts for wear, damage, or corrosion.
o Replace defective or worn-out components if needed.
o Clean all components thoroughly.
4. Assembly
o Reassemble the crankshaft, connecting rod, and other internal components into
the crankcase.
o Reattach the engine head, ensuring proper alignment of the piston and
cylinder.
 o Secure external components, such as the air filter and fuel tank.
o Reinstall the spark plug and refill the engine with the appropriate oil.
5. Testing
o Start the engine to ensure proper operation.
o Check for any unusual noise, vibration, or leaks

11.4 Observations
 The engine consists of the following main components:
o Cylinder block
o Piston and connecting rod assembly
o Crankshaft
o Valves and camshaft
o Air filter and fuel tank
 The following issues were identified during disassembly:
o Observation 1: Slight wear on the piston rings
o Observation 2: Clogged air filter
o Observation 3: Minor oil leakage near the crankcase gasket
 Actions taken:
o Replaced the worn piston rings.
o Cleaned and replaced the air filter.
o Replaced the crankcase gasket to prevent further leakage.

Conclusion
The disassembly and assembly process provided hands-on experience with the internal
components of a single-cylinder engine. Key learnings included the identification of engine
parts, understanding their functionality, and performing basic repair and maintenance tasks.
After reassembly, the engine functioned properly, demonstrating the successful completion of
the activity.