Product Manual

ManualsBrandsSmithsonian ManualsEducational ToysWorking Model of a 4-Cylinder Engine

Insert a piston pin (part 1)

through the small end of the

connecting rod (part 2).

Assembling the pistons

Fit two piston half-heads (part 3)

onto the piston pin. Join the piston

half-heads by pressing firmly

against the sides. They should be

solidly connected, and the piston

should be able to rotate freely

around the piston pin. Repeat

operations 1 and 2 to assemble

the other three pistons.

Mounting the pistons on the crankshaft

NOTE!

1. Break off the small tongue (marked with a ‘4’) on

the crankshaft prior to making the following

assembly. Any remaining burrs could subsequently

hinder rotation of the crankshaft, so trim them off

with a knife. Adult participation is recommended

when trimming.

2. Before screws, need to match the male/female

ﬁtment for connecting rods (part 2) and connecting

rod keepers (part 5).

On the crankshaft (part 4) and on the drawing,

identify the four locations at which the piston/

connecting rod assembly will be mounted. At

each location, attach the big end of the

connecting rod to the crankshaft by means

of two screws through the keeper (part 5).

When all four piston/

connecting rods have

been mounted, check

the complete assembly

for proper operation as

follows:

Grasp the ends of the

crankshaft between the

thumb and forefinger of

each hand.

Rotate the crankshaft.

The pistons should dangle

freely without binding on the

crankshaft.

Mounting the oil pan on the

lower housing

Set the oil pan (part 6) on the four

lugs protruding from the bottom of the

lower crankcase (part 7), as shown in

the drawing. Secure the oil pan

using

our screws.

Insert the four mounting

studs on the bottom of

the lower crankcase/oil

pan assembly into the

matching receptacles on

the engine stand (part 8).

Installing the piston-crankshaft

assembly in the cylinder block

Position the piston-

crankshaft assembly and the

cylinder block (part 9) as

shown in the drawing.

Carefully insert the four

piston heads into their

respective cylinders in the

cylinder block.

(Pay close attention to

the drawing.)

SPECIAL NOTE: Pay close

attention to the three screw

posts. They need to be on the

left side.

Position the oil pan/lower

crankcase/engine mounting stand

assembly as shown in the drawing.

Grasp the ends of the crankshaft/

cylinder block assembly with the

fingers of each hand, as shown by the

drawing. Turn the assembly upside

down so it is positioned as shown in

the drawing. Set the cylinder block

Mounting the cylinder block

assembly on the lower crankcase

assembly on the lower crankcase unit.

Make sure the units are aligned as shown

in the drawing, and that you have not

reversed the orientation of either unit (lower

crankcase and cylinder block studs should

stick out to your left.)

Fasten the two units together

with six screws. Check the

overall assembly, at this point,

for proper operation: Rotate

the crankshaft by hand. The

cylinders should move freely

up and down inside their

respective cylinders.

Installing the springs on the

valve stems

Slide the spring over

each of the eight valve

stems (part 12)

Position the lower cylinder

head (part 11) as shown

in the drawing. Locate the

small holes. These are the

holes for the exhaust

valves. First, insert the

ends of four valve stems in

these holes, one by one

Installing the valves in the cylinder head

(the springs are too large to

slip through the holes).

Now repeat the following

operations for each of the

four valve stems:

• Using your finger, press

down on the upper end

of the valve stem to

compress the spring.

The other end of the valve

stem will now be exposed

below the cylinder head.

• Press the exhaust valve

(part 13-the small ones)

onto the lower end of the

valve stem.

• Press firmly so the two

parts will remain locked

together.

In the same manner, install the other four valve stems

(and springs), this time in the large holes. Press an

intake valve (part 14-the large ones) onto the lower

end of each valve stem. Press firmly so the two parts

will remain locked together. Check to see that all eight

of the valves you have just installed work properly:

Press on the spring end of each valve, one by one.

The valves should open and close their respective

holes as you press and release each valve stem. The

action should be smooth, somewhat like the keys of

a piano.

NOTE: Upper cylinder head has a small cover. Make sure

it is in place;

otherwise the valves will fall through.

Mounting the rocker arms

on the rocker arm shaft

Collect the eight rocker arms

(part 24) and the rocker arm

shaft (round shaft, 3 mm in ø,

156 mm long) . Slip each

rocker arm onto the shaft,

one by one. Rotate every

other rocker arm 180° so

that the long and short

segments of each arm

alternate (see diagram).

As a check, the first and the last

rocker arms should not be orientated

the same way.

Installing the rocker arm assembly

in the upper cylinder head

Hold the rocker arm unit that you

have just finished assembling

(step 13) over the upper cylinder

head (part 23). Carefully lower

the rocker arm unit into position

(see drawing). Two rocker arms

go into each of the four openings.

Use your fingers to separate the

four pairs of arms. Each arm of

these four pairs should have a

different orientation.

Position the five

bearings (part 25) as

shown in the drawing.

Attach them to the cylinder

head by means of 10

screws. When finished,

check that the rocker arms

pivot freely around their

common shaft.

Installing the head gasket on

the cylinder block

The head gasket (part 10) is attached by

means of six screws passing through holes

in the gasket: two at each end and two in

the middle. There are also two holes used

for alignment. Using a ballpoint pen, punch

the cardboard out of these eight holes in

the head gasket. Place the head gasket on

the upper lip of the cylinder block. Note

the two lugs protruding from the upper lip.

They keep the head gasket in the correct

position prior to final installation with the

six screws. Use these lugs as a guide.

Mounting the lower cylinder head on

the cylinder block

Position the lower cylinder head over the cylinder

block. Prior to joining the two units make a final

check on the orientation of the cylinder head and

block. Note how the screws line up with the dashed

lines on the drawing. When you are satisfied that

everything is lined up properly, fasten the lower

cylinder head to the cylinder block with six screws.

NOTE!

Before starting this step, carefully note the

details shown in the drawing. This will help

you properly orient the cylinder head.

Assembling the camshaft

There are two ways you

can identify the cams:

• Each cam is stamped

with a letter (A-H)

• Each cam is marked

with a line; the position

of each line must

correspond to

the drawing.

Now, slide the cams on

the camshaft (half-round

shaft).

NOTE: Strictly follow the mounting sequence given below

because each cam has a different orientation angle.

Slide the cams onto the camshaft in the following order:

1st=A; 2nd=B; 3rd=C; 4th=D; 5th=E; 6th=F; 7th=G; 8th=H.

Camshaft

(half-round rod, 3 mm ø, 206 mm long)

Notches should always face to the left

The notch on Cam H is not seen.

It is on the back side.

Installing the

camshaft on the

lower cylinder head

First, make sure the splined (grooved) end of

the crankshaft is to your left. With the

camshaft oriented as shown in the drawing

(cam H to your left), place the camshaft on

the lower cylinder head. Each end of the

camshaft is supported by grooves (bearings)

in the lower cylinder head.

Attaching the upper cylinder head

to the lower cylinder head

Place the upper cylinder

head/rocker arm unit

(assembled in step 15) over the

lower cylinder head/camshaft

unit (assembled in step 19).

Check the orientation of the two

units carefully; the screw holes

in the two units must line up.

NOTE!

Before attaching the upper

cylinder head with screws, you

should check that the rocker

arms are correctly positioned

over the top of the valve stems.

The way to do this is to actuate

each rocker arm with your

finger. The arms should push

against the valves. Take care

not to pull on the

ends of the

camshaft. Otherwise, the cams may

shift their position and you will have

to realign them again.

When you are satisfied that everything is properly positioned, attach

the upper cylinder head to the lower cylinder head by means of four

screws, as shown in the drawing.

Attaching the rocker arm cover

Place the rocker arm cover

(part 26) over the upper

cylinder head. Attach the cover

to the upper cylinder head by

means of six screws.

Mounting the timing gear on the crankshaft

Put the timing gear (part 27) on the

splined end of the crankshaft.

NOTE!

There is only one correct position for

this part. Note the reference marks on

the drawing. Make sure the reference

marks on the parts match those shown

in the drawing. This gear must slide

freely onto the crankshaft. If you

have to force it, then the positioning

is incorrect.

Mounting the timing wheel on the camshaft

Press the timing wheel (part 28)

onto the camshaft while pushing

against the opposite end of the

camshaft with your finger to

prevent the camshaft from

moving. If the camshaft moves,

you will have to realign the cams.

Installing the alignment tool

Installing the timing belt and timing belt pulley

Place the timing belt (green color) over

the timing gear and timing wheel.

Mount the belt pulley (part 30) on the

upper post sticking out from the

cylinder block (the smooth side of the

timing belt rests against the pulley).

Once these two steps have been

performed, remove the alignment tool;

must

not remain attached to the

engine.

Installing the timing belt cover

Mount the timing belt cover (part 31)

as shown in the drawing. Attach with

four screws.

Installing the water pump

Press the rear half of the water

pump (part 32) onto the three

studs on the timing belt cover;

make sure it is oriented as

shown in the drawing. Place

the front half of the water pump

(part 33) against the rear half.

Join the two halves by means

of three screws.

Installing the fan belt pulley and fan

Place the fan belt pulley (part 34) over

the shaft sticking out from the water

pump. Make sure it is oriented as

shown in the drawing. Attach the

pulley to the shaft using a screw and

a washer. Identify the outside face of

the fan (part 35) (the outside face has

ribs - see drawing!) Hold the

fan against the fan belt pulley

with the outside of the fan

facing towards you. Attach the

fan with two screws.

Installing the crankshaft pulley and fan belt

Place the crankshaft pulley (part 36) against

the circular shoulder at the bottom of the

timing belt cover. Position the pulley as

shown in the drawing. Attach the

pulley using

a screw and washer. The screw passes

through the hole in the timing belt cover and

screws into the end of the crankshaft. Pass

the fan belt (black color) over

the top of the fan blades and

install it

on the fan belt and

crankshaft pulleys.

Installing the flywheel clutch

Mount the flywheel clutch (part 37) on

the opposite end of the crankshaft.

Next, we’ll check the entire engine by

rotating the crankshaft by hand.

Notice carefully what happens.

Positioning the pistons and camshaft

Preliminary adjustment:

Gently rotate the crankshaft by

hand until piston Number 1 is at

the top of its vertical travel. (This

position is called “dead center”).

The flat portion of the half-round

camshaft should be horizontal,

with the flat portion facing

upwards. Once you have verified

that the piston and the camshaft

are in the correct position,

continue with the next step.

Installing the distributor assembly

Mount the distributor on the camshaft

such that the identification marks 1, 2, 3,

and 4 are at the top. Attach the distributor

with three screws, but do not tighten them

yet. Mind that the position of the piston

and camshaft (established in step 31) do

not shift. The distributor has an inner

socket that spins. Turn this socket using

the screwdriver until the flat side is facing

up. Two of the wires from the

distributor have a phone jack on one end.

Plug this jack into the socket on

the battery box.

Adjusting the ignition

Carefully identify lamp Number 1 by following

the blue wire from the “1” mark on the

distributor. (Lamp # 1 is the “spark plug” for

cylinder #1.) Adjust the ignition system as

follows:

• Gently rotate the distributor housing until

lamp #1 lights.

• With lamp #1 lit, tighten the three

distributor screws.

• Remove the distributor plug from the

battery box socket.

The ignition system is now fully adjusted.

You can now continue with the next step or

repeat this step; take all the time you need.

Installing the spark plugs

Insert the four spark plugs in

their respective receptacle in the

lower cylinder head.

NOTE!

Pay careful attention to the order

in which the four spark plugs are

installed. Trace each blue wire to

ensure that plug # 1 goes to the

“1” hole in the lower cylinder head,

# 2 goes to the “2” hole, etc.

Mounting the carburetor and the intake manifold

Place the carburetor bowl

(part 39) on the intake manifold

(part 40). Attach the carburetor

cover (part 41) by means of a

screw into the intake manifold/

carburetor bowl assembly.

Now install the intake manifold/

carburetor assembly you have

just finished on the engine. Note

that it goes

on the side opposite

the spark plugs.

Attaching the drive module

Position the drive module by

meshing its gear teeth with those

on the flywheel clutch. Attach

the module to the engine with

three screws.

Installing the dipstick

Insert the dipstick (part 43) in the

cylinder block. The hole for the

dipstick is also on the side

opposite the spark plugs.

On the spark plug side of

the engine, install the

exhaust manifold (part 42)

in the lower cylinder head.

The long-awaited moment has arrived! You will now have

the opportunity to run your engine for the first time. First,

plug the cables from the distributor and the drive module

into the battery box. When the latter cable is connected, the

engine should start to turn. Note the direction in which the

fan blades turn. Theoretically, the fan blades of all

automotive engines turn in the same direction. Did you

know this? Removing the drive module plug from the

battery box stops the engine. By successively connecting and disconnecting this plug, you can

start and stop the engine just as if you were turning it on and off with a switch. Note, in each

instance, the position of the pistons and

the sequence

in which the spark plugs are “firing”.

This will help you understand the operating principle for a 4-stroke internal combustion engine.

The alignment tool is used to

lock the position of the timing

wheel while the timing belt is

being installed. Carefully identify

the reference marks and holes

that let you correctly position

the alignment tool (part 29)

between the timing wheel and

the timing gear.

Install the alignment tool.

Installing the exhaust manifold

Operating the engine

Installing the batteries

In the Motor Works kit, electric

power is provided by two 1.5 volt

batteries (type AA). Take a look at

the battery box: inside the box you

will see the outline of two batteries

showing the polarity (+ and -) of

each battery. Install the batteries

as follows:

• Push the + end of the battery

against the spring.

• Press the - end of the battery

downwards until it is firmly seated

in its compartment.

Any type of 1.5 volt battery will

work: AA, SP7, LR6, MN 1500

(alkaline), etc.

BATTERY SAFETY

INFORMATION:

• Only batteries of the

same or

equivalent type as

recommended are to

be used.

• Do not mix old and

new batteries.

• Do not mix alkaline,

standard (carbon-

zinc) or rechargeable

(nickel-

cadmium) batteries.

• Do not attempt to

burn batteries.

• Dispose of

batteries safely

and correctly.

CAUTION

Never attempt to

connect the kit to

the AC mains supply

(110-220 volts).

Never connect the

circuits of the kit

to any unit powered

by the mains, even

if the unit is

switched off.

Feed the wire from the drive module

through the opening in the clutch

cone (part 38).

Line up the three holes in the clutch

cone with the three studs on the

engine. Attach the clutch cone with

three screws.

Attaching the clutch cone

battery box

2 washers (7mm in Ø)

fan belt (black)

timing belt (green)

drive module

distributor assembly

8 valve springs

67 screws

1 shaft, 3 mm Ø, 206 mm long (half-round)

1 shaft, 3 mm Ø, 156 mm long

Clutch cone

(part 38)

39 41

3 3

A B C D E F G H

DESCRIPTION

8 timing cams

4 piston pins

4 connecting rods

8 piston halves

1 crankshaft

4 connecting rod keepers (big end)

1 oil-pan

1 lower crankcase

1 engine mounting stand

1 cylinder block

1 head gasket

1 lower cylinder head

8 valve stems

4 exhaust valves

4 intake valves

1 upper cylinder head

8 rocker arms

5 bearings

1 rocker arm cover

1 timing gear

1 timing wheel

1 positioning jig

1 belt tensioning pulley

1 timing belt cover

1 rear half of water pump

1 front half of water pump

1 fan pulley

1 fan

1 crankshaft pulley

1 flywheel clutch

1 clutch housing

1 carburetor bowl

1 intake manifold

1 carburetor cover

1 exhaust manifold

1 dipstick

2 washers, 7 mm ø

1 shaft, 3 mm ø, 156 mm long

1 shaft, 3 mm ø, 206 mm long

(half round)

1 fan belt

1 timing belt (green)

8 valve springs

1 distributor assembly

1 drive module

1 battery pack

67 screws

Requires 2 (1.5V) ''AA'' Batteries

and screwdriver (Not Included.)

Number

A-H

MOTORWORKS™

ITEM # 49013

Adult Supervision required.

• Non-rechargeable batteries are not to be recharged.

• Rechargeable batteries are to be removed from the toy before being charged.

• Rechargeable batteries are only to be charged under adult supervision.

• Different types of batteries or new and used batteries are not to be mixed.

• Only batteries of the same or equivalent type as recommended are to be used.

• Batteries are to be inserted with the correct polarity.

• Exhausted batteries are to be removed from the toy.

• The supply terminals are not to be short circuited.

• Keep packaging for reference since it contains important information.

IMPORTANT BATTERY INFORMATION

CHOKING HAZARD

Small parts.

Not for children under 3 years.

WARNING:

• Name of item

• Date of purchase

• Purchase price (please include sales slip)

• Model number

• Place of purchase

• Brief description of the problem

Please do not contact Smithsonian

or return the kit to the store where

you purchased it. They will not

have the replacement!

Send all correspondence to:

Dear Customer,

NSI International, Inc. is the manufacturer of this kit.

We hope you enjoy your kit. If you find that we have

made an error or if something is missing or

damaged, let us know so that we can correct the

problem for you. Please include the following:

NSI International Inc.,

30 W 22nd Street 3rd Floor New York, NY 10010

Attn: Quality Control Department

Telephone: 888-425-9113

email: custserv@nsi-int.com

Printed in China

Ages 8 and Up

49013 : sms Motor-Works Poster Back - instructions Size: 22.8”(W) x 34.6”(H) 1 Color : Black

4-April-2015