Engine block : tamil

Engine blocks:
The engine block , also called the cylinder block or just the block , is the biggest and heaviest part of the engine. Strip everything off an engine and this lump of cast metal will be the last thing left. Its main purpose is to house the cylinders in which the pistons run, and it also contains passages through which oil and coolant are pumped. Virtually all modern blocks also form the housing for the crankshaft, an area called the crankcase .
Because the block is huge and strong it makes an ideal mounting place for many other parts of the engine - the alternator, water pump, power steering pump and starter motor are all bolted onto the block.
Blocks are a one-piece casting of either cast iron or aluminium alloy. Over the past two decades, aluminium alloy has been more frequently used for engine block manufacture due to its light weight. Prior to this, the block was made from cast iron which is far heavier. Cast iron blocks are stronger than aluminium and are still widely used, especially for diesel engines due to the higher compression forces at work.
Components of an engine block
Cylinders
Cylinders are spaces in which the pistons travel. They are large, precisely formed holes which run all the way through the block, with smooth walls to create a seal with the piston.
In blocks made from cast iron, the cylinders are usually machined directly into the block, with the walls bored smooth and then finished in a process called honing. Aluminium is softer and more prone to wear, so aluminium alloy blocks will use harder metal cylinder liners or sleeves which are placed into the mould before the molten aluminium is poured or pumped in. Such liners are sometimes also used where a cylinder needs to be repaired or made larger.
The size and number of cylinders is the main measure of an engine’s size. More cylinders, and bigger cylinders will give more power.
Coolant
When the engine is running, the cylinder walls get extremely hot - and deliberately so; one of their core functions is to carry heat away from the piston. The cylinders are surrounded by cavities called water jackets through which coolant is pumped by the water pump. Once the engine is up to temperature, this coolant will travel through the radiator where it is cooled
Oil passages
The oil passages inside the engine are called galleries . Oil is pumped up from the sump and through the galleries by the oil pump. These passages allow oil to reach the crankshaft, and the cylinder head. In this Mazda engine there are galleries which carry oil to little nozzles which spray the underside of the pistons to keep them cool.
Oil galleries are drilled into the block after it has been cast. There will be plugs which are inserted to blank off the ends of galleries after they have been machined.
The oil filter and oil pressure sensor will probably be attached to the block.
Deck
The top surface of the block, where the cylinder head sits, is called the deck . It is machined perfectly flat and mated to the bottom face of the cylinder head . In between the block and the head there will be a head gasket . On an engine with more than one cylinder head, such as in a V, W or flat layout, there will be a deck where each of the cylinder heads meet the block.
Crankcase
Almost all modern engine blocks have an area at the bottom which houses the crankshaft . This area that surrounds the crankshaft is called the crankcase .
The crankshaft sits in saddles, surrounded by bearings and then clamped down with main bearing caps.
The opening at the bottom of the crankcase will be sealed by an oil pan, or sump, that holds the engine oil. There may be a gasket between the oil pan and the block or, for this Mazda, the oil pan is sealed with a liquid gasket that is essentially like a silicone sealant.
Engine mounts
The engine block is used as the mounting point between the engine and the chassis. Brackets called engine mounts are bolted to the engine block and then, through rubber mounts, to the chassis or subframe.
Core plugs
Around the outside of the block are holes which have been plugged with metal core plugs , also called freeze plugs or expansion plugs . Despite their name, these plugs are just remnants of the casting process: the mold for the block uses compressed sand to form the spaces such as water jackets inside. When the metal has solidified, this sand is shaken and washed out of the engine through these large holes. Sometimes machining is also done through the holes. A thin metal plug is then pressed into the hole to seal it. If the coolant inside the block freezes, due to insufficient anti-freeze for the outside temperature, then it will expand.
Ancillary mountings
At various points around the block, there are threaded holes with surfaces that are machined flat. These mounting points are called bosses .

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