TECHNICAL PAPER PRESENTATION ON

K SERIES ENGINE

SUBMITTED BY

Mr. Sudhir Ranganath Aitawade

TE MECH – S/W
ROLL NO. –12005
UNIVERSITY EXAM NO. – T 3021201

UNDER THE GUIDANCE OF

Prof. S. A. DAYANE

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INTRODUCTION:

 A straight-4 cylinder with SOHC and DOHC.

 K-series engine is small; matching stylish and compact vehicle

is pleasant to drive.

 The K-series consist 2.5-litre V6 DOHC, 2.0-litre V6 DOHC and

1.8-litre V6 DOHC engines.

HISTORY:

 Built by Power train Ltd.

 Introduced in 1988 by Rover Group.1.1 L, 1.4 L.

 by long through-bolts

 which held the engine under compression

 Compared to OHV pushrod systems with the same number of valves

the reciprocating components of the OHC system have a lower total

mass

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DESIGN CONSIDERATION
SOHC:
 less reciprocating mass
 Reduced complexity like push rods, tappets, rocker arms.

DOHC:

Two camshafts located within the cylinder head

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Cylinder Block:

 LM25 cylinder block.

 High precision and ability to produce thin-walled components,

liner is honed with a GC grindstone, to achieve quietness and

improve reliability.

Cylinder Head:

 Low-pressure casting was utilized to proper the aluminium micro-

structure, improving strength and thus reliability

 The gear housing is mounted supported by camshaft caps.

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  Asbestos-free laminated cylinder head gaskets are composed of two
sheets of stainless steel.

 Have the ability to resist the high explosive pressures of the

combustion chamber. Effective seal against oil.

Camshaft Friction Gear:

 Between the two camshafts, drive and driven gears with 55 teeth

each and a friction gear with 56 teeth are used.

 Superimposed on the driven-gear by spring force.

 Tooth flank precision is optimized through simulation techniques to

eliminate gear engagement noise.

Piston:

 The die-cast aluminium.

 By applying Molybdenum disulfide coating, Decrease in piston
clearance, friction

Connecting Rod:

 Cast in aluminium.
 A connecting cap is joined to the rod by means of plastic-region
tightening bolts (without nuts). Reduced weight in the large end.
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Crankshaft:

 Crankshaft is composed of forged steel.

 Five counterweights for well balanced, light weight.

 The journals are high-frequency hardened, then mirror finished

 Heavy-duty three-layer copper-lead bearings are used to ensure

adequate durability.

Lubrication System:

 Efficient trochoid oil pump.

 To reduce vibration and noise oil pressure fluctuations on the
delivery side, the clearance with the inner rotor on the crankshaft is
adjusted.
 To control output loss caused by crankshaft oil diffusion and to
reduce the amount of air in the oil, superior oil baffle plates are
adopted.

Cooling System:

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. To prevent the temperature of the coolant in the cooling circuit from
rising too rapidly, such as during a cold start, an inlet thermostat
mechanism is utilized.

Fuel System:
 Microcomputer-controlled SFIS.

 First side-feed method, where fuel is supplied from the side of the

injectors, is used to reduce the discharge of vapour produced from

rising fuel temperatures improved engine restart ability.

 Second, the weight of the injector’s mobile parts is reduced to

reduce operating noise.

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  Third, an internal fuel control mechanism will not change with vehicle

age.

TECHNIQUES FOR HIGH PERFORMANCE:

Combustion improvement:

 An optimum intake air throat diameter was selected to maintain volumetric

efficiency, thus enhancing volumetric efficiency in all speed ranges.

 The valve angle 27 degrees for optimization and the combustion chamber
made more compact to reduce cooling loss.

 Squish area to bore area ratio17.3.

 The throat diameter is 28.5 mm intake side; and 25 mm exhaust side.

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  The emissions of hydrocarbons are greatly reduced by eliminating the crevice
volume, the space around the piston top land, valves, and spark plug that
extinguishes the flame

Optimization of Control:

 For low fuel consumption, low emissions, and other targets handled by a

microcomputer.

 Each injector’s fuel & timing controlled by SFIS.

 Each bank's A/F ratio is enhanced with air/fuel ratio feed-back control to

reduce emission.
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  Enhancing fuel economy.

Lightweight:

 Lightest, among V6 engines

 LM cylinder blocks, utilizing a short stroke.

 Decreasing the exhaust manifold size.

 Careful associated design of the block.

 By having as low a reciprocating mass.

 K is a well balanced engine ( Ford, Alfa)

High Continuous Torque Characteristics:

 In the VRIS, surge tanks in both banks are connected to each other

by resonance tubes.

 The resonant frequency changes by changing the tube's length.

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  First, to improve the control of ignition timing in the high speed

range, a new direct crank-angle- detection method (crank-angle-

sensor) was chosen

 With trace knock control, single sensor in V-banks detects small

knocking.

 Ignition timing is actively controlled with crank angle sensor which

detects changes in angular velocity of engine during acceleration.

Reduction of Inertia Weight of Rotating Parts:

 Finite Element Method (FEM) analysis.

 Through bolts.
 To reducing the mass.
 Torque at 64Nm brings the bolt to its yield point.
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Engine sound:

 Elimination of unpleasant rumbling sounds

 Caused by crankshaft bending vibration due to flywheel

face run out, main bearing.

 To reduce the noise, the engine mount's vibration level,

which responds to excitation in the cylinder resonance,

should be lowered.

 Reduction of low-frequency sounds.

A two-piece cylinder block was employed to increase rigidity of

both the cylinder block itself and its crankshaft supporting area

Compactness:

 The engine height, width and length is reduced due to valve drive

system.

 A compact intake manifold.

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  Compact cylinder block.

 A compact exhaust manifold has reduced engine width.

SALIENT FEATURES AND CONCLUSION:

 All-aluminium light-weight

 By long through-bolts which held the engine under compression.

 Rocker-less DOHC cam shaft and improve fuel efficiency

 By applying Molybdenum disulfide coating on piston.

 Optimized cylinder block, light piston and nut-less con rod for light

weight configuration.

APPLICATIONS:

1. Rover 200

2. Lotus Elise

3. Landover free Lander

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 4. Caterham Seven

5. zen Estilo

6. Huindai i10

7. Maruti Suzuki A-star.

REFERENCES
 H. Yamamoto et al., "A Study Based on Investigation of

Consciousness for Drive Feeling", Mazda Technical Report.

 K. Hatamura et al., "Mazda's New V-6 Gasoline Engine and Its

Innovative Induction System", SAE Paper No. 871977.

 H. Abe et al., "Study on Evaluation and Improvement of Acoustic

Quality in Vehicle Passenger Compartment", Mazda Technical

Report.

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