Engine Lubrication Heating and

Welcome Systems Induction Systems Exhaust Systems Content Sources

Cooling Systems
Basic Engine Systems
Study Manual
Table of Contents

Welcome...........................................................................................................................................................................................................................................................................................................1

Welcome
Basic Engine Systems KM04 .................................................................................................................................................................................................................................................................. 2
Module Purpose ....................................................................................................................................................................................................................................................................................... 2
Specific Outcomes and Assessment Criteria ..................................................................................................................................................................................................................................... 2

Engine Lubrication
Prescribed text book ................................................................................................................................................................................................................................................................................ 2

Systems
Recommended reading .......................................................................................................................................................................................................................................................................... 2
Computer Requirements ........................................................................................................................................................................................................................................................................ 2
Engine Lubrication Systems ....................................................................................................................................................................................................................................................................... 3
KM101 Functions of the Lubricating System ...................................................................................................................................................................................................................................... 4

Cooling Systems
Heating and
Engine lubrication system. ................................................................................................................................................................................................................................................................. 5
How an Engine’s Lubrication System Works ................................................................................................................................................................................................................................ 5
Parts and Operation of Lubricating System ................................................................................................................................................................................................................................. 5
Lubricating System Indicators ........................................................................................................................................................................................................................................................... 6

Induction Systems
KM102 Construction and operating principles of various types of lubrication systems ....................................................................................................................................................... 7
Engine Lubrication System ................................................................................................................................................................................................................................................................ 7
Pressure type lubrication system ..................................................................................................................................................................................................................................................... 7
Splash type lubrication system ......................................................................................................................................................................................................................................................... 7

Exhaust Systems
KM103 Limitations of each type of lubrication system ................................................................................................................................................................................................................... 8
Mist Lubrication System ..................................................................................................................................................................................................................................................................... 8
KM104 Concepts, terms and terminology related to lubrication systems ................................................................................................................................................................................ 8
Lubricant Terminology ....................................................................................................................................................................................................................................................................... 8
KM105 Names, locations, structure and functions of lubrication system components and parts ..................................................................................................................................... 9

Content Sources
Functions of Lubrication System ...................................................................................................................................................................................................................................................... 9
System Components .......................................................................................................................................................................................................................................................................... 11
KM106 Specifications and parameters including fits, clearances, reusability and calculations for lubrication systems .............................................................................................. 11
Lubricant Specifications ..................................................................................................................................................................................................................................................................... 11
 KM107 Typical faults in lubrication systems and their identification, related tests and causes. ........................................................................................................................................ 12
The problems that most often occur in the lubrication system are as follows: ................................................................................................................................................................ 12
5 ways poor lubrication can cause problems ............................................................................................................................................................................................................................ 13

Welcome
Lubrication System Faults ................................................................................................................................................................................................................................................................ 15
KM108 Maintenance requirements and methods for lubrication systems ............................................................................................................................................................................. 15
Lubricating System Maintenance: ................................................................................................................................................................................................................................................. 15

Engine Lubrication
KM109 Safety, health and environmental issues related to lubrication level, damaged oil pan, or other troubles that relate to the symptoms.............................................. 16

Systems
Discussion Points .................................................................................................................................................................................................................................................................................... 17
Heating and Cooling Systems ................................................................................................................................................................................................................................................................. 18
KM201 Function of heating and cooling systems .......................................................................................................................................................................................................................... 19
Cooling System Function ................................................................................................................................................................................................................................................................. 19

Cooling Systems
Heating and
Heating System................................................................................................................................................................................................................................................................................... 19
KM202 Construction and operating principles of various types of heating and cooling systems including coolant, air, restricted- and full-flow bypass systems ............ 19
Components of the Cooling System ............................................................................................................................................................................................................................................ 19
KM203 Limitations of each type of heating and cooling system ............................................................................................................................................................................................. 20

Induction Systems
Types of Engine heating and Cooling System .......................................................................................................................................................................................................................... 20
Direct Air-cooled Engine System. ................................................................................................................................................................................................................................................. 20
Indirect Liquid-cooled Engine System. ........................................................................................................................................................................................................................................ 21
KM204 Concepts, terms and terminology related to heating and cooling systems ........................................................................................................................................................... 21

Exhaust Systems
Circulation ............................................................................................................................................................................................................................................................................................ 21
Antifreeze ............................................................................................................................................................................................................................................................................................. 21
The Radiator ........................................................................................................................................................................................................................................................................................ 21
Radiator Fan ........................................................................................................................................................................................................................................................................................ 21
Pressure cap and reserve tank ...................................................................................................................................................................................................................................................... 22

Content Sources
Water Pump ....................................................................................................................................................................................................................................................................................... 22
Thermostat .......................................................................................................................................................................................................................................................................................... 22
Bypass System .................................................................................................................................................................................................................................................................................... 22
Freeze Plugs ....................................................................................................................................................................................................................................................................................... 22
 Head Gaskets and Intake Manifold Gaskets .............................................................................................................................................................................................................................. 22
Heater Core ........................................................................................................................................................................................................................................................................................ 22
Hoses .................................................................................................................................................................................................................................................................................................... 23

Welcome
KM205 Names, locations, structure and functions of heating and cooling system components and parts ............................................................................................................... 23
Components of a Vehicle’s heating and Cooling System ..................................................................................................................................................................................................... 23
Discussion Points: .................................................................................................................................................................................................................................................................................. 24

Engine Lubrication
Induction Systems ...................................................................................................................................................................................................................................................................................... 25

Systems
KM301 Function of induction systems.............................................................................................................................................................................................................................................. 26
Induction system ............................................................................................................................................................................................................................................................................... 26
KM302 Construction and operating principles of various types of induction systems and layouts including naturally aspirated, forced induction and after-cooled
systems ..................................................................................................................................................................................................................................................................................................... 26

Cooling Systems
Heating and
Forced induction ............................................................................................................................................................................................................................................................................... 26
A naturally aspirated system ...........................................................................................................................................................................................................................................................27
KM303 Limitations of each type of induction system.................................................................................................................................................................................................................. 28
Turbo Failures and Engine Issues ................................................................................................................................................................................................................................................. 28

Induction Systems
KM304 Concepts, terms and terminology related to induction systems ............................................................................................................................................................................... 28
Air Intake Components: .................................................................................................................................................................................................................................................................. 28
Fuel Injection: ..................................................................................................................................................................................................................................................................................... 29
Miscellaneous Terms: ....................................................................................................................................................................................................................................................................... 29
KM305 Names, locations, structure and functions of induction system components and parts .................................................................................................................................... 30

Exhaust Systems
Air Intake Components: .................................................................................................................................................................................................................................................................. 30
Fuel Injection Components: ........................................................................................................................................................................................................................................................... 30
Forced Induction Components: ..................................................................................................................................................................................................................................................... 31
Other Components: .......................................................................................................................................................................................................................................................................... 31

Content Sources
KM306 Typical faults in induction systems and their identification, related tests and causes .......................................................................................................................................... 31
KM307 Maintenance requirements and methods for induction systems ............................................................................................................................................................................... 31
Air Filter Maintenance: ..................................................................................................................................................................................................................................................................... 32
Throttle Body Maintenance: ........................................................................................................................................................................................................................................................... 32
 Mass Air Flow (MAF) Sensor Maintenance: ............................................................................................................................................................................................................................... 32
Idle Air Control (IAC) Valve Maintenance: ................................................................................................................................................................................................................................. 32
Fuel Injector Maintenance: ............................................................................................................................................................................................................................................................. 32

Welcome
Intake Manifold Maintenance: ....................................................................................................................................................................................................................................................... 32
Check for Vacuum Leaks: ............................................................................................................................................................................................................................................................... 33
Inspect Turbocharger or Supercharger (if equipped):............................................................................................................................................................................................................ 33

Engine Lubrication
Perform Throttle Position Sensor (TPS) Calibration:................................................................................................................................................................................................................ 33

Systems
Monitor Engine Codes and Sensors: ........................................................................................................................................................................................................................................... 33
General Tips: ....................................................................................................................................................................................................................................................................................... 33
Discussion Points: .................................................................................................................................................................................................................................................................................. 34
Exhaust Systems ......................................................................................................................................................................................................................................................................................... 35

Cooling Systems
Heating and
KM401 Function of exhaust systems ................................................................................................................................................................................................................................................. 36
KM402 Construction and operating principles of various types of exhaust systems ..........................................................................................................................................................37
Header ..................................................................................................................................................................................................................................................................................................37
Exhaust Pipe ........................................................................................................................................................................................................................................................................................37

Induction Systems
Catalytic Converter ........................................................................................................................................................................................................................................................................... 38
Resonator, Muffler, and Tail Pipe ................................................................................................................................................................................................................................................. 38
KM403 Limitations of each type of exhaust system ..................................................................................................................................................................................................................... 38
Limitations ........................................................................................................................................................................................................................................................................................... 38

Exhaust Systems
KM404 Concepts, terms and terminology related to exhaust systems .................................................................................................................................................................................. 38
Terminology ....................................................................................................................................................................................................................................................................................... 38
With or without catalytic converter .............................................................................................................................................................................................................................................. 40
KM405 Names, locations, structure and functions of exhaust system components and parts ....................................................................................................................................... 40
Exhaust Manifold ............................................................................................................................................................................................................................................................................... 40

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Mufflers ................................................................................................................................................................................................................................................................................................. 41
Catalytic converter ............................................................................................................................................................................................................................................................................. 41
Tailpipe................................................................................................................................................................................................................................................................................................. 42
KM406 Specifications and parameters including fits, clearances, reusability and calculations for exhaust systems ................................................................................................. 42
 Installing an Exhaust System .......................................................................................................................................................................................................................................................... 42
KM407 Typical faults in exhaust systems and their identification, related tests and causes............................................................................................................................................. 43
Common faults with the Exhaust System ................................................................................................................................................................................................................................... 43

Welcome
KM408 Maintenance requirements and methods for exhaust systems ................................................................................................................................................................................. 43
Hangers ............................................................................................................................................................................................................................................................................................... 43
Shields .................................................................................................................................................................................................................................................................................................. 44

Engine Lubrication
Exhaust Joints ..................................................................................................................................................................................................................................................................................... 44

Systems
Damper Weights ............................................................................................................................................................................................................................................................................... 44
Discussion Points: .............................................................................................................................................................................................................................................................................. 45
Content Sources ......................................................................................................................................................................................................................................................................................... 46

Cooling Systems
Heating and
Induction Systems
Exhaust Systems
Content Sources
 Welcome

Welcome
Welcome
The AIE is a revolutionised family of brands, people, and students. Our curriculum is modelled on workplace scenarios to provide students with a practical
understanding of how they can use their skills in the real world. The Academic Institute of Excellence aims to provide innovative, quality education, along with
excellent service delivery and a modern outlook to learning technology.

Engine Lubrication
Systems
We take pride in developing and supporting students through innovative programs that will create well-rounded, employable and professionally developed
individuals.

Learning paths are designed meticulously through the observation of global skill demands as well as the needs of modern students.

Cooling Systems
Heating and
Our facilitators are qualified subject matter experts with both practical industry experience and tertiary education experience.

All our campuses are conveniently placed in Greenside, Midrand (Johannesburg) and De Waterkant (Cape Town). We strive to provide our students with the best
experience with a range of recreational possibilities and space to work in, from computer studios and libraries —to a fully operational Makers Lab. Learners have

Induction Systems
access to lecturers, resources and the latest software to help them fulfil their course requirements

Each of our programmes are benchmarked against local and international standards to ensure that
Our VISION
each learner receives the highest level of quality education.
To deliver demand-driven education, built upon the
HOW TO
principle of quality education through innovation and
We strive towards excellence and empowering future generations to become problem solvers, technology.
insert the

Exhaust Systems
critical thinkers and innovators to create the leaders of tomorrow. subtitle Text
Boxes

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HOW TO
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The AIE (Academic Institute of Excellence) has been granted provisional
subtitle Text
The AIE (Academic Institute of Excellence) has been granted
registration as private higher education institution of Section 54(3) of the
Act and Regulation 14(4)(b)(i) of the Department of Higher Education and Boxes provisional registration as a private college in terms of Section
31(3) of the CET Act and Regulation 12(4), with registration
Training until 31 December 2025. Registration Certificate No number 2018/FE07/003 for a period of three years.
2022/HE07/005.
Study Manual – Automotive Motor Mechanics

Basic Engine Systems KM04

Welcome
Module Purpose

Engine Lubrication
The main focus of the learning in this knowledge module is to build an understanding of engine lubrication, heating, cooling and exhaust systems, their construction
and operating principles, the structure and functions of their components and parts, and the related maintenance methods and requirements, tests, calculations,

Systems
typical faults and safety, health and environmental issues

Specific Outcomes and Assessment Criteria Recommended reading

Cooling Systems
Specific Outcome Assessment Criteria

Heating and
Engine lubrication systems List the assessment criteria and
assessment tasks for the module
Heating and cooling systems List the assessment criteria and
assessment tasks for the module
Induction systems List the assessment criteria and

Induction Systems
assessment tasks for the module
Exhaust systems List the assessment criteria and Computer Requirements
assessment tasks for the module
It is advisable that students make use of their own personal computers to
complete this module.
Prescribed text book

Exhaust Systems
Content Sources
Engine Lubrication Systems

Welcome
Unit 1

Engine Lubrication
Systems
System
The following topics are covered in this unit:

Cooling Systems
Heating and
 KM101 Function of lubrication systems
 KM102 Construction and operating principles of various
types of lubrication systems
 KM103 Limitations of each type of lubrication system

Induction Systems
 KM104 Concepts, terms and terminology related to
Unit Overview

lubrication systems
 KM105 Names, locations, structure and functions of
lubrication system components and parts
 KM106 Specifications and parameters including fits,
clearances, reusability and calculations for lubrication

Exhaust Systems
systems
 KM107 Typical faults in lubrication systems and their
identification, related tests and causes
 KM108 Maintenance requirements and methods for
lubrication systems

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 KM109 Safety, health and environmental issues related to
lubrication systems
Unit 1 – Engine Lubrication Systems

KM101 Functions of the Lubricating System  Load Distribution:

Welcome
o Lubrication helps distribute loads evenly across surfaces,
reducing localized pressure points and preventing
The lubricating system in machinery and engines is crucial for ensuring premature wear in specific areas.
smooth operation, reducing friction, and preventing wear and damage to
 Noise Reduction:
moving parts.

Engine Lubrication
o By minimizing friction and reducing vibrations, lubrication

Systems
contributes to the reduction of noise generated by moving
The primary functions of a lubricating system include: parts. This is particularly important in precision machinery
 Friction Reduction: and automotive applications.
o The primary function of lubrication is to reduce friction  Enhanced Efficiency:
between moving parts. By providing a thin film of lubricant o Proper lubrication ensures that mechanical systems operate

Cooling Systems
Heating and
between surfaces, the system minimizes the resistance to efficiently by reducing energy losses associated with friction.
motion, allowing parts to move smoothly. This is important for optimizing fuel efficiency in engines and
 Wear Prevention: overall energy consumption in various machinery.
o Lubrication helps prevent wear and tear on components by  Cushioning and Shock Absorption:
creating a protective layer between surfaces. This is o Lubricants can provide a degree of cushioning and shock

Induction Systems
especially important in high-stress areas where metal-to- absorption, especially in applications with high impact loads.
metal contact could lead to rapid wear. This helps protect components from sudden forces and
 Heat Dissipation: impacts.
o As parts move against each other, heat is generated due to  Viscosity Control:
friction. The lubricating oil absorbs this heat and carries it o The viscosity of the lubricant influences its ability to flow and
away from the contact areas, preventing overheating of provide adequate lubrication. Lubricating systems help

Exhaust Systems
components. control viscosity under different operating conditions to
 Corrosion Protection: ensure optimal performance.
o Lubricants often contain additives that provide protection  Flush Contaminants:
against corrosion. This is particularly important in o Some lubrication systems incorporate filters or separators to
environments where moisture or harsh chemicals could lead remove contaminants, ensuring the lubricant remains clean
to the degradation of metal surfaces.

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and effective.
 Seal and Contamination Control:  Cooling:
o The lubricating system helps create a seal between moving o In addition to heat dissipation, lubrication can contribute to
parts, preventing the entry of contaminants such as dirt, dust, the cooling of components by carrying heat away from
and debris. It also helps maintain a clean and controlled critical areas.
environment within the system.
Unit 1 – Engine Lubrication Systems

 Extended Component Life:  The oil performs the function of a cleaning agent by picking up dirt

Welcome
o Proper lubrication significantly extends the life of mechanical particles and taking them to oil pan. Larger particles are retained at
components by reducing wear and minimizing the impact of the bottom while smaller particles are filtered out by oil filters.
operating stresses.
Parts and Operation of Lubricating System

Engine Lubrication
Understanding the functions of the lubricating system is essential for proper  Oil Pump: The gear-type oil pump has a pair of meshing gears.

Systems
maintenance and operation of machinery, engines, and other mechanical The spaces between the teeth are filled with oil when the gears
systems, ensuring they operate efficiently and have a longer lifespan. unmet. The oil pump obtains oil from the oil pan and sends oil
through the oil filter to the oil galleries and main bearings. Some
Engine lubrication system. oil passes from the holes in the crankshaft to the rod bearings.
Main bearings and rod bearings are lubricated adequately to

Cooling Systems
One of the functions of the engine lubrication system is to maintain a

Heating and
achieve their desired objectives. In the rotor type oil pump, the
positive and continuous oil supply to the bearings. Engine oil pressure is inner rotor is driven and drives the outer rotor. As the rotor
high enough to get the oil to the bearing with sufficient force to produce revolves, the gaps between the lobes are filled with oil. When
adequate oil flow for proper cooling. the lobes of the inner rotor move into the gaps in the outer
rotor, oil is forced out through the outlet of pump. An oil pump
can also be driven by a camshaft gear that drives the ignition

Induction Systems
How an Engine’s Lubrication System Works
distributor or by the crankshaft.
Purpose of Lubricating System  Oil Pan: Oil also flows to the cylinder head through drilled
The lubricating oil performs the following functions in an engine: passages that make up the oil gallery, lubricates camshaft
 The oil lubricates moving parts to minimize wear by sealing the bearings and valves, and then returns to oil pan. Some engines
clearances between moving parts such as bearings, shafts, etc. Thus, have grooves or holes in connecting rods, which provide extra
the parts move on layers of oil, and not in direct contact with each lubrication to pistons and walls of cylinders.

Exhaust Systems
other, which reduces power loss in the engine.  Oil Cooler: Oil cooler prevents overheating of oil, by flow of
 The oil obtains heat from the moving parts of the engine which is engine coolant past tubes carrying hot oil. The coolant picks
transferred into the cooler oil in the oil pan. Therefore, the oil excess heat and carries it to the radiator.
performs the function of a cooling agent. Some engines have oil  Oil Filter: The oil from oil pump flows through oil filter before
nozzles which spray oil at the underside of the pistons, thereby reaching the engine bearings. The oil filter retains the dirt

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removing heat from the pistons. particles and allows only clean filtered oil to pass.
 The oil fills the clearances between rotating journals and the
bearings. When heavy loads are abruptly placed on the bearings, the
oil acts as a cushioning agent, which reduces the wear on bearings.
 The oil creates a seal between the walls of the cylinder and the piston
rings, thereby reducing exhaust gas blowby.
Unit 1 – Engine Lubrication Systems

Lubricating System Indicators oil condition, contamination levels, and the presence of

Welcome
wear particles.
Lubricating system indicators are tools or features that provide information
about the status and performance of a lubrication system in machinery or  Filter Differential Pressure Gauge:
engines. Monitoring these indicators is crucial for ensuring proper o Measures the pressure drop across the oil filter. An
lubrication, preventing issues, and optimizing the lifespan of mechanical increasing pressure drop suggests a clogged or

Engine Lubrication
components. saturated filter that needs replacement.

Systems
 Automatic Lubrication System Status Indicators:
Here are common lubricating system indicators: o In systems with automated lubrication, indicators may
 Oil Pressure Gauge: signal the status of the lubrication system, including
pump operation, cycle frequency, and any faults.
o Measures the pressure of the lubricating oil in the
 Visual Inspection Ports:

Cooling Systems
system. A sudden drop in oil pressure may indicate a

Heating and
problem with the oil pump, a leak, or insufficient oil o Transparent or translucent ports in the lubrication
levels. system that allow visual inspection of oil flow and
condition. These are often found in oil filters and
 Oil Level Sight Glass or Dipstick:
reservoirs.
o Provides a visual indication of the oil level in the system.
Low oil levels can lead to inadequate lubrication,  Warning Lights or Alarms:

Induction Systems
causing increased friction and potential damage to o Illuminated warning lights or audible alarms may
components. indicate low oil pressure, high oil temperature, or other
 Oil Temperature Gauge: critical issues that require immediate attention.

o Monitors the temperature of the lubricating oil. Elevated  Reservoir Level Sensors:
temperatures can accelerate oil degradation and o Sensors that detect the oil level in the reservoir and
trigger alarms or warnings if the level falls below a safe

Exhaust Systems
reduce its effectiveness. Overheating may also indicate
problems with cooling systems. threshold.
 Oil Quality Sensors:  Vibration Monitoring:
o Sensors that measure the quality and condition of the o Excessive vibrations may indicate problems with the
lubricating oil. They can detect contaminants, such as lubrication system or components. Vibration monitoring
metal particles or sludge, and provide early warnings of systems can provide early detection of issues such as

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potential issues. misalignment, imbalance, or bearing wear.
 Oil Analysis Programs:  Oil Change Interval Alarms:
o Regular oil analysis involves sending oil samples to a o Alerts or alarms that signal when it is time to change the
laboratory for testing. This can reveal information about lubricating oil based on factors such as operating hours
or usage conditions.
Unit 1 – Engine Lubrication Systems

Monitoring these lubricating system indicators as part of a regular Engine lubrication system is classified into two types.

Welcome
maintenance routine helps identify potential problems early, prevents  Pressure type lubrication system
equipment failures, and ensures optimal performance of machinery or
 Splash type lubrication system
engines. Regular inspections and adherence to recommended
maintenance schedules are essential for effective lubrication system
management. Pressure type lubrication system:

Engine Lubrication
 pressure type lubrication system in the lubrication oil is

Systems
pressurized by using a gear pump.
KM102 Construction and operating principles of various
 Oil supplied to lubricate various parts of the moving elements
types of lubrication systems
in the system.

Cooling Systems
Engine Lubrication System

Heating and
Splash type lubrication system:
 Engine lubrication system is serving several functions essential  The splash type lubrication system in this a dipper made up of
to the safe and reliable operations of the engine. metal rod attached at the lower end and of the connecting rod
 The lubrication system keeps the clean and cools the many used to splash the oil.
moving parts in an engine as they thousands of times every  Then the oil spread over parts and lubricate them.

Induction Systems
minute.
 Lubrication system process is useful for the keep the engine Mist Lubrication System
components from the wear.
 This system is used where crankcase lubrication is not suitable
 The lubrication system it is ensure everything work efficiently at
 In 2-stroke engine as the charge is compressed in the crankcase,
controlled temperatures
it is not possible to have the lubricating oil in the sump.

Exhaust Systems
 In such engines the lubricating oil is mixed with the fuel, the
usual ratio being 3% to 6%.
 The oil and the fuel induced through the carburettor the fuel is
vaporized and the oil is in the form of mist goes via the
crankcase in to the cylinder.

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Unit 1 – Engine Lubrication Systems

Pressure feed system KM104 Concepts, terms and terminology related to

Welcome
 The oil is forced to all the main bearings of crankshaft lubrication systems
 Pressure relief valve is fitted to maintain the predictable pressure
values
 Oil hole is drilled from the centre of each crankpin to the centre
Lubricant Terminology

Engine Lubrication
of an adjacent main journal through which oil can pass from the  Paraffinic

Systems
main bearing
o Good stability, used most commonly in hydraulic and
 To the crankpin production oils.
 Naphthenic
Wet Sump Lubrication System o Oxidizes easily, most commonly used in cutting or

Cooling Systems
 The bottom of the crankcase contains an oil pan or sump from soluble oils.

Heating and
which  Aromatics
 The lubricating oil is pumped to various components by a o Used mostly in the manufacturing of plastics and rubber
pump.
 Viscosity
 After lubricating the parts, the oil flows back to the sump by
o The thickness of the oil at a certain temperature.

Induction Systems
gravity
 Viscosity / Temperature
o As temperature rises viscosity goes down.
KM103 Limitations of each type of lubrication system
 Viscosity Index
o The number to use relating to how well the lubricant will
Mist Lubrication System withstand high and low temperature extremes.

Exhaust Systems
 Oxidation Inhibitor
o Reduces oil breakdown due to excessive heat.
Limitations
 Anti-Wear Agents
 Causes heavy exhaust smoke
o Reduce the metal to metal contact, can withstand
 Get contaminated with acids and result in the corrosion of
heavier loads.
bearings surface

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 Extreme Pressure Agents
 Calls for through mixing for effective lubrication (this requires
either separate mixing prior to use of some additive to give the o Stronger than anti wear, for the heaviest of loads.
oil good mixing characteristics)
 The engine will suffer from insufficient lubrication as the supply
of fuel is less
Unit 1 – Engine Lubrication Systems

 Rust Inhibitor  Detergents

Welcome
o Prevent corrosion usually found in the EP oils and some o Added to clean carbon deposits and reduce acid levels
others. in high sulphur fuels.
 Adhesive Agents  DE Emulsifiers
o Helps retain film strength uniformly on the metal o Added to oil where exposed to water to separate the

Engine Lubrication
surfaces. water and added to help inhibit rust.

Systems
 Friction Modifier  Drop Point Additives
o General category of materials that apply to natural or o These can raise the operating temperature of the
synthetic fatty additives: They have two primary grease where the thickeners will not separate from the
purposes: oils. They also can control how easily the greases can be
pumped through lines, systems and components. The

Cooling Systems
To increase the lubricity or slipperiness where friction

Heating and
coefficient may be needed. higher the drop point, the higher the operating
temperature.
To improve fuel economy or for energy conservation.
 Water Repulsion Additives
 Defoam ant
o These are added to prevent the washing away of the
o Used to reduce bubbles in oils or for the rapid breakup
lubricants in areas where water is present or exposed to

Induction Systems
of foam.
in the systems or components.
 Viscosity Improvers
o Added to oils that require a maintained viscosity at
extremely high temperature ranges. KM105 Names, locations, structure and functions of
 Pour Point Depressants lubrication system components and parts
o Added to oils that require the lowest temperatures to

Exhaust Systems
maintain fluidity or pour ability and reduces wax build Functions of Lubrication System
up at these low temperatures.
 Flash or Flame Depressants The lubrication system in machinery and engines performs several critical
functions to ensure proper operation, reduce friction, and extend the
o Added to oils that are usually in mist or fog type oil bath lifespan of components.
lubrication systems or in fire resistant fluids. For

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example: For safety concerns near welding operations.
 Dispersants
o Suspends organic deterioration products to minimize
them as harmful deposits and carries them to the filters.
Unit 1 – Engine Lubrication Systems

The key functions of a lubrication system include:  Noise Reduction:

Welcome
 Friction Reduction: o By minimizing friction and reducing vibrations,
o The primary function of the lubrication system is to lubrication contributes to the reduction of noise
reduce friction between moving parts. By providing a generated by moving parts. This is particularly
layer of lubricant, the system minimizes the resistance important in precision machinery and automotive

Engine Lubrication
to motion, allowing parts to move smoothly. applications.
Enhanced Efficiency:

Systems
 Wear Prevention: 

o Lubrication helps prevent wear and tear on components o Proper lubrication ensures that mechanical systems
by creating a protective layer between surfaces. This is operate efficiently by reducing energy losses associated
crucial for extending the life of bearings, gears, and with friction. This is important for optimizing fuel
other moving parts. efficiency in engines and overall energy consumption in

Cooling Systems
various machinery.

Heating and
 Heat Dissipation:
 Cushioning and Shock Absorption:
o As parts move against each other, heat is generated
due to friction. The lubricating oil absorbs this heat and o Lubricants can provide a degree of cushioning and
carries it away from the contact areas, preventing shock absorption, especially in applications with high
overheating of components. impact loads. This helps protect components from
sudden forces and impacts.

Induction Systems
 Corrosion Protection:
 Viscosity Control:
o Lubricants often contain additives that provide
protection against corrosion. This is especially important o The viscosity of the lubricant influences its ability to flow
in environments where moisture or harsh chemicals and provide adequate lubrication. Lubricating systems
could lead to the degradation of metal surfaces. help control viscosity under different operating
conditions to ensure optimal performance.
 Seal and Contamination Control:

Exhaust Systems
 Flush Contaminants:
o The lubrication system helps create a seal between
moving parts, preventing the entry of contaminants o Some lubrication systems incorporate filters or
such as dirt, dust, and debris. It also helps maintain a separators to remove contaminants, ensuring the
clean and controlled environment within the system. lubricant remains clean and effective.

 Load Distribution:  Cooling:

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o Lubrication helps distribute loads evenly across surfaces, o In addition to heat dissipation, lubrication can
reducing localized pressure points and preventing contribute to the cooling of components by carrying
premature wear in specific areas. heat away from critical areas.
Unit 1 – Engine Lubrication Systems

 Extended Component Life: Oil Cooler

Welcome
o Proper lubrication significantly extends the life of  The engine oil picks up heat as it is used for cooling of the lubricated.
mechanical components by reducing wear and  Necessary to have an oil cooler in re-circulatory oil systems
minimizing the impact of operating stresses.
 Air-cooled or Fuel- cooled (FCOC)
Bypass valves ensures availability of lubrication oil in the event of

Engine Lubrication

Understanding these functions is essential for selecting, installing, and blockage.

Systems
maintaining lubrication systems in mechanical systems, ensuring they
operate efficiently and have a longer lifespan.
Magnetic Chip Detector
 Permanent magnet to collect ferritic debris
System Components
 Strategically placed downstream of the engine components

Cooling Systems
Oil reservoir

Heating and
(e.g. bearings) to check the health of the engine components
• Usually mounted on the engine or the gearbox  Warns of impending failure of gears and bearings
 Provisions for:  Checked periodically
o Oil replenishment  Cockpit indication
o Oil drainage

Induction Systems
Sight glass or dipstick to check oil level
o
KM106 Specifications and parameters including fits,
o De-aerating device to remove the air from the returning
clearances, reusability and calculations for lubrication
oil.
systems
Oil Pump

Exhaust Systems
 Delivers oil to the engine’s lubrication system – Lubricant Specifications
 Pressure feed system (directs oil to components)  The process of creating lubricant specifications should first begin by
Scavenge system (returns scavenged oil to oil tank) developing or updating the database of machines, lubrication points
and lubricants in the plant or fleet. Product recommendations will
 Oil pump failure may cause catastrophic engine failure
come primarily from OEMs, lubricant suppliers, consulting
 Types of oil pumps: companies or internal experience. Other technical references may

Content Sources
o Gear type pumps used in re- circulatory oil systems also be consulted, such as the AGMA, ISO, NLGI and others.
o Single shot pumps used in total loss lubrication system  For critical machines, additional validation may be needed to ensure
the selected lubricant fulfils the lubrication requirements based on
the equipment’s current operating conditions.
Unit 1 – Engine Lubrication Systems

 Once the database of lubricants and lubrication points has been KM107 Typical faults in lubrication systems and their

Welcome
completed, it is time to consider product consolidation.
identification, related tests and causes.
 The goal is to minimize the number of lubricants used in the plant
while still maintaining appropriate lubrication of all machines.
 The consolidation process should help identify products that are The problems that most often occur in the lubrication system are as

Engine Lubrication
equivalent, lubricants that have similar specifications, machines that follows:
can utilize multi-purpose lubricants and when it is practical to use a

Systems
Various issues can arise in lubrication systems, impacting their efficiency and
higher quality lubricant.
the overall health of machinery. Identifying and addressing these problems
 At this point, a consolidated list of lubricants can be generated, is crucial to prevent damage to components and ensure optimal
including all equipment applications for each product. The next step performance.
is to create specifications for every lubricant or lubricant family.

Cooling Systems
Whenever possible, all lubricants that have similar properties but

Heating and
differ only by viscosity grade. If there is a single lubricant with special Here are some common problems that often occur in lubrication systems:
properties for a specific application, a lubricant specification  Low Oil Level:
document should be produced just for it. o Inadequate oil levels can lead to insufficient lubrication,
 Creating these specifications may involve several different causing increased friction and wear on moving parts.
departments such as engineering, maintenance and pur-chasing. Regularly checking and maintaining the proper oil level is

Induction Systems
Lubrication know-ledge will be required as well as access to essential.
equipment manuals and lubricant requirements.  Oil Contamination:
o Contaminants such as dirt, dust, metal particles, and water
In conclusion, lubricant specifications are effective guidelines for selecting can compromise the quality of lubricating oil. Contaminated
and using the right lubricants in the right applications. oil can lead to increased wear, reduced efficiency, and
potential damage to components.

Exhaust Systems
These documents not only can help ensure quality products are acquired
at the best possible price, but they can also provide guidance to lubricant  Oil Leaks:
suppliers, simplify lubricant handling and application. o Leaks in the lubrication system can result in a loss of oil,
leading to inadequate lubrication. Leaks may occur at
connections, seals, gaskets, or other points in the system.
 Clogged Filters:

Content Sources
o Oil filters are essential for removing contaminants from the
lubricating oil. Clogged filters reduce oil flow, affecting
lubrication efficiency and potentially causing damage to
components.
Unit 1 – Engine Lubrication Systems

 Over-Lubrication:  Faulty Pump Operation:

Welcome
o Applying excessive amounts of lubricant can lead to o Issues with the lubrication pump, such as wear, damage, or
problems such as overheating, increased energy incorrect settings, can lead to insufficient oil delivery to
consumption, and seal damage. Over-lubrication may also critical components.
result in unnecessary costs.  Inadequate Maintenance:

Engine Lubrication
 Under-Lubrication: o Regular maintenance, including oil changes, filter

Systems
o Conversely, insufficient lubrication can cause increased replacements, and system inspections, is crucial for
friction, heat generation, and accelerated wear. It may result preventing lubrication system problems. Neglecting
from low oil levels, blocked oil passages, or inadequate maintenance can lead to a range of issues.
lubricant supply.
 Wrong Lubricant Selection: Addressing these lubrication system problems requires a proactive

Cooling Systems
Heating and
o Using the wrong type or grade of lubricant can negatively approach to monitoring, regular maintenance, and adherence to
impact the performance of the lubrication system. It may recommended procedures. Implementing a comprehensive lubrication
lead to reduced efficiency, increased wear, and potential management program helps prevent breakdowns, extend equipment life,
damage to components. and improve overall operational efficiency.
 Aging or Degraded Oil:

Induction Systems
o Over time, lubricating oil can degrade due to oxidation, 5 ways poor lubrication can cause problems
contamination, and thermal breakdown. Aging oil may lose
its viscosity, reducing its ability to provide effective Assets with moving parts rely on the consistent application of lubricants to
lubrication. function properly. Facility managers who work to improve their condition
monitoring strategies benefit from improved asset uptime and cost
 Air Entrapment: reductions. These two concepts go hand-in-hand. Lubrication is an essential
o Air pockets or bubbles in the lubrication system can impede facet of condition monitoring.

Exhaust Systems
proper oil flow, leading to inadequate lubrication and
increased friction. It may result from improper bleeding,
foaming, or aeration of the oil. To ensure your program functions properly, avoid these four common
lubrication mistakes:
 Incorrect Oil Viscosity:
Over-lubrication
o Using lubricating oil with an incorrect viscosity for the
You can have too much of a good thing. When an asset lacks grease, it will

Content Sources
operating conditions can lead to inadequate lubrication. It's
important to choose the right viscosity grade based on quickly make the problem known, usually by failing. At the other end of the
temperature, load, and speed requirements. spectrum, over greasing can have a similar effect. That’s why it’s important
to remember that lubricants have volume of their own. Too much grease
could actually cause an asset to jam, necessitating additional maintenance
and hours of downtime.
Unit 1 – Engine Lubrication Systems

Likewise, over-greasing may lead to seal failure. Grease guns can produce Mixing lubricants

Welcome
an extraordinary level of pressure, and, in excess, harm bearings. Similarly, Not all lubricants are created equal. In fact, mixing the wrong kinds of
when grease dries and cracks, the pressure of additional lubricant can cause lubricants together can be just as damaging as not lubricating at all.
it to break apart, further damaging the bearings. An ultrasound reading can According to Machinery Lubrication magazine, mixing synthetic and
help technicians know when enough is enough. mineral-based lubricants can cause major problems, leading to leakages

Engine Lubrication
and complete failures.
Under-lubrication According to the source, when the wrong lubricants mix, they risk

Systems
A lack of lubricant is likely one of the easiest problems to spot. Assets that expanding or shrinking nearby seals, causing them to fail. Such problems
aren’t properly maintained will make themselves known in short order. result in increased spending, as those assets must be replaced.
Typically, excess heat and sound will radiate from the asset until failure.
Alone, these symptoms are easy to detect, but within a noisy facility, they Similar problems occur when an incompatible thickener is added to grease.

Cooling Systems
could go unnoticed. The mixture can become unstable and inappropriate for use on most

Heating and
Ultrasound equipment such as the Ultra probe® 201 Grease Caddy can machinery. The consistency of the lubricant may vary greatly and become
help facilities save on operating costs by providing a visualization of unreliably. Not only does the machinery suffer as a result, but the grease
ultrasonic waves. In doing so, personnel will know exactly when an asset must be tossed out too, leading to further expenses.
needs lubricating and when it’s in working order. This process saves man-
hours so they can be applied to situations of greater need. Plus, the device

Induction Systems
Lubricant contamination
is easy to use, even in crowded and noisy environments.
One of the chief causes of premature bearing failure is lubricant
contamination. Not only does contaminated lubricant harm machinery, but
Using the wrong lubricant it can also be expensive to remove and clean. Understanding how and why
Not only can using the wrong lubricant lead to asset failure, but it may also contamination occurs is the first step to preventing premature failures. For
void the machinery’s warranty. Machine manufacturers will typically instance, contamination may come from particles in the ambient air, dirt

Exhaust Systems
recommend specific lubricants for each asset. These guidelines should be from outside the facility or from agents within the machine itself.
taken seriously, or else the money for a replacement will likely come from
your department’s budget.
A condition monitoring policy that includes housekeeping protocols will
As reported in Machinery Lubrication magazine, viscosity is one of the most ensure that contamination has a minimal impact on asset uptime. However,
important properties of a lubricant. Using an oil or grease with a viscosity visual inspection may not be sufficient to determine if contamination has
that varies from the manufacturer’s recommendation is a recipe for failure. occurred. An ultrasound tool can pinpoint discrepancies in the ultrasonic

Content Sources
Read all documentation carefully, and follow guidelines exactly. output of a bearing, notifying maintenance personnel in well in advance of
equipment failure.
Unit 1 – Engine Lubrication Systems

An improved lubrication program starts with accurate data. Whether your KM108 Maintenance requirements and methods for

Welcome
facility utilizes a condition-based lubrication strategy or a preventive
lubrication systems
method, your technicians need more data if they’re going to make any
progress. Lubricating System Maintenance:
 There are certain lubricating system service jobs that are more or less

Engine Lubrication
Lubrication System Faults done automatically when an engine is repaired.

Systems
If properly and routinely serviced, lubrication systems will give little or no  For example, the oil pan is removed and cleaned during such engine
trouble. Most faults arise through a lack of preventive maintenance and overhaul jobs as replacing bearing or rings.
routine servicing.  When the crankshaft is removed, it is usual procedure to clean out
the oil passages in the crankshaft.
Also, the oil passages in the cylinder block should be cleaned out as

Cooling Systems
Typical system faults including: 

Heating and
part of the overhaul.
 Leaks in the system allow oil to leak out, but also allow dirt to get in.
If leaks are left unchecked, all the oil in the system will eventually leak  This maintenance normally consists of changing the oil and filter(s).
out. Deal with leaks as soon as they are identified.  Occasionally will be required to perform such maintenance tasks as
 Oil seals harden after a period of time in service. They must then be replacing lines and fittings, servicing or replacing the oil pump and
replaced. Pulleys such as the crankshaft engine pulley also wear, or relief valve, and flushing the system.

Induction Systems
get damaged. In this case, re-site the oil seal to run on a different  The following discussion provides information that will carrying out
part of the pulley, or replace both the seal and the pulley. these duties.
 Pay attention to the engine crankcase ventilation system. If it is not  Oil and Filter Change It is extremely important that the oil and filter(s)
properly serviced, blow-by gas pressure can build up in the of the engine are serviced regularly.
crankcase, blowing oil seals in the process.  Lack of oil and filter maintenance will greatly shorten engine service

Exhaust Systems
 Oil wears out, and becomes contaminated with blow-by gasses, fuel, life.
coolant, dirty air, and tiny particles of metal worn off the engine. It is  Manufacturers give a maximum number of miles or hours a vehicle
vital to change the oil and filters in strict accordance with the can be operated between oil changes.
manufacturer’s specifications. Dirty oil and blocked filters destroy
engines very quickly.  Newer automotive vehicles can be operated 5,000 miles between
changes.
 Worn bearings increase the clearance between themselves and the
Older automotive vehicles should have their oil changed about every

Content Sources
shafts they support. If the clearance becomes too great, oil will fall 
away, and cannot maintain a film between the two metals. 3,000 miles.
 Most construction equipment average between 200 and 250 hours
of operation between oil changes.
Unit 1 – Engine Lubrication Systems

KM109 Safety, health and environmental issues related to  Certain compounds in used oil can be very dangerous to one’s

Welcome
health. Some are carcinogenic and mutagenic.
lubrication level, damaged oil pan, or other troubles that
 The PAH content of engine oil increases with operating time,
relate to the symptoms.
because the PAH formed during combustion in petrol engines
accumulates in the oil.

Engine Lubrication
When the lubricants are drained from say engines, gearboxes, hydraulic  Lubricating oil is transformed by the high temperatures and stress of
an engine’s operation.

Systems
systems, turbines and air compressors:
 the oil is contaminated with wear debris; the lubricating base oil has  This results in oxidation, nitration, cracking of polymers and
deteriorated and degraded to acids; the additives have decomposed decomposition of organ-metallic compounds.
into other chemical species; and process fluids such as degreasers  Environmental Impacts
and solvents have mixed into the used oil.
o An important cause of soil biodiversity loss in urban areas is

Cooling Systems
Heating and
 It was also noted that used oil contains wear metals such as iron, tin the pollution of soils by petroleum products. Engine
and copper as well as lead from leaded petrol used by motorists. lubricating oil is a major product of petroleum which helps
 Zinc arises from the additive packages in lubricating oils. the engine move smoothly.
 Many organic molecules arise from the breakdown of additives and o Spent or waste engine oil is oil that has been used, and as a
base oils. result contaminated by chemical impurities which contribute

Induction Systems
 The molecule potentially the most harmful is the polycyclic aromatic to chronic hazards including mutagenicity and
hydrocarbon (PAH) such as Benz(a)pyrene and chrysene. carcinogenicity as well as environmental hazards with global
ramifications. Waste engine lubricating oil is oil that has
 Used oil has been established that it can damage the environment served its service properties in a vehicle withdrawn from the
in several different ways such as: meant area of application and considered not fit for initial
 Spilled oil tends to accumulate in the environment, causing soil and purpose.
water pollution.

Exhaust Systems
 Oil decomposes very slowly. It reduces the oxygen supply to the
microorganisms that break the oil down into non-hazardous
compounds.
 Toxic gases and harmful metallic dust particles are produced by the
ordinary combustion of used oil. The high concentration of metal

Content Sources
ions, lead, zinc, chromium and copper in used oil can be toxic to
ecological systems and to human health if they are emitted from the
exhaust stack of uncontrolled burners and furnaces.
 Some of the additives used in lubricants can contaminate the
environment.
Unit 1 – Engine Lubrication Systems

 Environmental Effects of Used Oil

Welcome
o Lubricant Additive Impacts on Human Health and the
Environment gallons of lubricating oils ended up in landfills
or were dumped.
o Hydraulic fluids are of increasing importance for applications

Engine Lubrication
in environmentally sensitive areas where a potential total loss
could be encountered, such as excavators, earthmoving

Systems
equipment and tractors, in agricultural and forestry
applications and in fresh water (groundwater) sensitive areas.
Mineral oils are toxic for mammals, fish and bacteria.
o Considering the sump capacities of such machinery the

Cooling Systems
ecological impact is obvious, as are the economics of the

Heating and
resulting clean-up operations.

Discussion Points
 IAC0101 Describe and explain, with the aid of sketches where

Induction Systems
applicable and using the correct terms and terminology, the
functions, operating principles and concepts for various types of
lubrication systems
 IAC0102 Discuss the limitations of various types of lubrication
systems and related safety, health and environment issues
IAC0103 Identify, describe, with the aid of sketches where applicable,

Exhaust Systems

and explain the function of lubrication system components and parts
 IAC0104 Describe typical faults, their causes, methods of testing and
maintenance requirements for lubrication systems

Content Sources
Heating and Cooling Systems

Welcome
Unit 2

Engine Lubrication Heating

Systems Cooling
The following topics are covered in this unit:

Heating
Systems
and Cooling
Systems
and
 KM201 Function of heating and cooling systems
 KM202 Construction and operating principles of various types of heating
and cooling systems including coolant, air, restricted- and full-flow bypass

Induction Systems
systems
Unit Overview

 KM203 Limitations of each type of heating and cooling system

 KM204 Concepts, terms and terminology related to heating and cooling
systems
 KM205 Names, locations, structure and functions of heating and cooling

Exhaust Systems
system components and parts
 KM206 Specifications and parameters including fits, clearances, reusability
and calculations for heating and cooling systems
 KM207 Typical faults in heating and cooling systems and their
identification, related tests and causes
KM208 Maintenance requirements and methods for heating and cooling

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
systems
 KM209 Safety, health and environmental issues related to heating and
cooling systems
Unit 2 – Heating and Cooling Systems

KM201 Function of heating and cooling systems Here are the main components of a typical cooling system:

Welcome
 Radiator:
o The radiator is a heat exchanger that plays a central role in
Cooling System Function cooling. It contains a network of tubes and fins through
The air and fuel mixture exploding inside the engine produces the power which coolant (usually a mixture of water and antifreeze)

Engine Lubrication
needed to move the vehicle. This combustion process also produces great flows. As air passes through the fins, heat is transferred from
the coolant to the air.

Systems
heat that, if left uncontrolled, can damage the engine and reduce its
operating efficiency. The cooling system removes enough heat to keep the  Coolant (Antifreeze):
engine at a safe temperature for best performance. A secondary function o Coolant, often a mixture of water and antifreeze, circulates
of the cooling system is to provide interior cabin heat during cold winter. through the engine and radiator to absorb and carry away
heat. It also helps prevent freezing in cold temperatures and

Cooling Systems
protects against corrosion.

Heating and
Heating System
 Water Pump:
A small fan blows on the heater core. This fan blows through an air filter
and into the car, sending hot air into the passenger compartment. The fan o The water pump is responsible for circulating coolant
is usually adjustable, with at least three different speeds. The vents are throughout the cooling system. It is typically belt-driven and
typically adjustable as well. Heating ducts can be opened or closed to direct helps maintain a consistent flow of coolant through the

Induction Systems
heat near the windows, directly at the passengers, or into the foot wells. engine and radiator.
There is also a temperature control, which mixes air from the heater core  Thermostat:
without side air, allowing the riders to control the temperature of the air o The thermostat regulates the flow of coolant by controlling
coming into the car the opening and closing of a valve. It ensures that the engine
operates within an optimal temperature range. When the
engine is cold, the thermostat restricts coolant flow until the
KM202 Construction and operating principles of various

Exhaust Systems
engine warms up.
types of heating and cooling systems including coolant, air,  Coolant Reservoir (Expansion Tank):
restricted- and full-flow bypass systems o The coolant reservoir provides a space for the coolant to
expand and contract with temperature changes. It also
serves as a convenient point for checking and topping up
Components of the Cooling System
the coolant level.

Content Sources
The cooling system in a vehicle or industrial machinery is essential for  Coolant Hoses:
managing engine or equipment temperatures, preventing overheating, and
o Coolant hoses are flexible conduits that carry coolant
ensuring efficient operation. The cooling system typically consists of several
between the engine, radiator, water pump, and other
key components that work together to regulate and dissipate heat.
components. They are usually made of rubber or reinforced
with fabric or metal to withstand pressure and heat.
Unit 2 – Heating and Cooling Systems

 Radiator Cap: KM203 Limitations of each type of heating and cooling

Welcome
o The radiator cap is a pressure-relief valve that helps maintain system
the proper pressure in the cooling system. It allows excess
coolant to escape into the overflow reservoir when the
system is under pressure. Types of Engine heating and Cooling System

Engine Lubrication
 Fan:
Two basic systems of removing the heat from the engine are air-cooled

Systems
o Cooling fans are used to enhance airflow through the system and liquid-cooled system.
radiator. In many systems, fans are electrically or
mechanically driven and can be controlled based on engine
temperature. Direct Air-cooled Engine System.
 Fan Clutch (if applicable): Cool circulating air comes in contact with the exposed and enlarged

Cooling Systems
Heating and
o In some vehicles, a fan clutch is used to engage or disengage external surfaces of the cylinder and head. As a result, their heat is
the cooling fan based on temperature conditions. It helps dissipated to the surrounding air.
optimize cooling and improve fuel efficiency.
 Heater Core: Limitations
o The heater core is a small radiator-like component used to  The cooling fans require a relatively large amount of power to

Induction Systems
provide heat to the interior of the vehicle. It is part of the run.
engine's cooling system and is connected to the HVAC  Due to the large quantities of intake air passing into the cooling
(heating, ventilation, and air conditioning) system. system, the engine may become noisy.
 Temperature Sensor (Thermosensor):  The cooling fins can vibrate and amplify noise under certain
o The temperature sensor monitors the coolant temperature conditions.
and provides feedback to the engine control unit (ECU). The

Exhaust Systems
 For proper positioning of the fins between cylinders, the pitch
ECU uses this information to adjust fuel injection and ignition between cylinder centres has to be greater than in liquid-cooled
timing for optimal engine performance. engines.
 Each cylinder is required to be cast individually unlike liquid-
These components work together to manage heat generated during engine cooled engines where a rigid mono-block construction is used.
operation, ensuring that the engine operates within a safe temperature  (/) To prevent overheating of the lubricant, the air-cooling is

Content Sources
range. Regular maintenance, such as checking coolant levels and inspecting frequently supplemented by an oil heat exchanger.
hoses, is essential to prevent cooling system issues and maintain proper
engine function.  The presence of the guide cowling and baffles around the
cylinders may hinder maintenance.
Unit 2 – Heating and Cooling Systems

Indirect Liquid-cooled Engine System. Antifreeze

Welcome
A liquid coolant transmits the heat from the cylinders and head to a heat The coolant that courses through the engine and associated plumbing must
exchanger, known as the radiator. Movement of air through this radiator be able to withstand temperatures well below zero without freezing. It must
then extracts the unwanted heat and dissipates it to the surroundings. also be able to handle engine temperatures in excess of 250 degrees
without boiling. A tall order for any fluid, but that is not all. The fluid must

Engine Lubrication
also contain rust inhibiters and a lubricant.
Limitations

Systems
 Liquid-coolant joints may develop leakage.
The Radiator
 Care must be taken to avoid freezing of the coolant.
 Liquid-cooled units require more time to warm up than the air- The radiator core is usually made of flattened aluminium tubes with
cooled engines. aluminium strips that zigzag between the tubes. These fins transfer the heat

Cooling Systems
in the tubes into the air stream to be carried away from the vehicle. On

Heating and
 The boiling point of liquid-coolant limits maximum temperature
each end of the radiator core is a tank, usually made of plastic that covers
of operation, whereas air-cooled engines can operate at slightly
the ends of the radiator.
higher temperatures.
 (c) Formation of scale takes place in the coolant passages, and
the hoses and radiator tubes deteriorate with time. Radiator Fan

Induction Systems
Mounted on the back of the radiator on the side closest to the engine is
KM204 Concepts, terms and terminology related to heating one or two electric fans inside a housing that is designed to protect fingers
and to direct the air flow. These fans are there to keep the air flow going
and cooling systems through the radiator while the vehicle is going slow or is stopped with the
engine running. If these fans stopped working, every time you came to a
stop, the engine temperature would begin rising. On older systems, the fan
Circulation

Exhaust Systems
was connected to the front of the water pump and would spin whenever
The coolant follows a path that takes it from the water pump, through the engine was running because it was driven by a fan belt instead of an
passages inside the engine block where it collects the heat produced by the electric motor. In these cases, if a driver would notice the engine begin to
cylinders. It then flows up to the cylinder head where it collects more heat run hot in stop and go driving, the driver might put the car in neutral and
from the combustion chambers. It then flows out past the thermostat, rev the engine to turn the fan faster which helped cool the engine.
through the upper radiator hose and into the radiator. The coolant flows

Content Sources
through the thin flattened tubes that make up the core of the radiator and
is cooled by the air flow through the radiator. From there, it flows out of
the radiator, through the lower radiator hose and back to the water pump.
Unit 2 – Heating and Cooling Systems

Pressure cap and reserve tank Freeze Plugs

Welcome
As coolant gets hot, it expands. Since the cooling system is sealed, this When an engine block is manufactured, a special sand is melded to the
expansion causes an increase in pressure in the cooling system, which is shape of the coolant passages in the engine block. This sand sculpture is
normal and part of the design. When coolant is under pressure, the positioned inside a mild and molten iron or aluminium is poured to form
temperature where the liquid begins to boil is considerably higher. This the engine block. When the casting is cooled, the sand is loosened and

Engine Lubrication
pressure, coupled with the higher boiling point of ethylene glycol, allows removed through holes in the engine block casting leaving the passages
that the coolant flows through. Obviously, if we don't plug up these holes,

Systems
the coolant to safely reach temperatures in excess of 250 degrees.
the coolant will pour right out.

Water Pump
Head Gaskets and Intake Manifold Gaskets
A water pump is a simple device that will keep the coolant moving as long

Cooling Systems
as the engine is running. It is usually mounted on the front of the engine All internal combustion engines have an engine block and one- or two-

Heating and
and turns whenever the engine is running. The water pump is driven by cylinder heads. The mating surfaces where the block and head meet are
the engine through one of the following machined flat for a close, precision fit, but no amount of careful machining
will allow them to be completely water tight or be able to hold back
combustion gases from escaping past the mating surfaces.
Thermostat

Induction Systems
The thermostat is simply a valve that measures the temperature of the
Heater Core
coolant and, if it is hot enough, opens to allow the coolant to flow through
the radiator. If the coolant is not hot enough, the flow to the radiator is The hot coolant is also used to provide heat to the interior of the vehicle
blocked and fluid is directed to a bypass system that allows the coolant to when needed. This is a simple and straight forward system that includes a
return directly back to the engine. The bypass system allows the coolant to heater core, which looks like a small version of a radiator, connected to the
keep moving through the engine to balance the temperature and avoid hot cooling system with a pair of rubber hoses. One hose brings hot coolant

Exhaust Systems
spots. Because flow to the radiator is blocked, the engine will reach from the water pump to the heater core and the other hose returns the
operating temperature sooner and, on a cold day, will allow the heater to coolant to the top of the engine. There is usually a heater control valve in
begin supplying hot air to the interior more quickly. one of the hoses to block the flow of coolant into the heater core when
maximum air conditioning is called for.

Bypass System

Content Sources
the coolant to bypass the radiator and return directly back to the engine.
Some engines use a rubber hose, or a fixed steel tube. In other engines,
there is a cast in passage built into the water pump or front housing. In any
case, when the thermostat is closed, coolant is directed to this bypass and
channelled back to the water pump, which sends the coolant back into the
engine without being cooled by the radiator.
Unit 2 – Heating and Cooling Systems

Hoses Water pump

Welcome
There are several rubber hoses that make up the plumbing to connect the The water pump is one of the important parts of the cooling process. It
components of the cooling system. The main hoses are called the upper draws cooled water or coolant from radiator through thermostat. It then
and lower radiator hoses. These two houses are approximately 2 inches in passes the cooled water and coolant to the engine with a constant velocity
diameter and direct coolant between the engine and the radiator. Two so that the engine doesn't overheats

Engine Lubrication
additional hoses, called heater hoses, supply hot coolant from the engine
to the heater core. These hoses are approximately 1 inch in diameter. One

Systems
Thermostat
of these hoses may have a heater control valve mounted in-line to block
Thermostat is an effective component of vehicle's cooling system. It is
the hot coolant from entering the heater core when the air conditioner is
critical in cooling the engine and maintaining minimum operating
set to max-cool. A fifth hose, called the bypass hose, is used to circulate
temperature of the engine. Thermostat closes when the engine is cold and
the coolant through the engine, bypassing the radiator, when the
allows it to warm up and opens up to pass the coolant when minimum

Cooling Systems
thermostat is closed. Some engines do not use a rubber hose. Instead,
operating temperature is reached.

Heating and
they might use a metal tube or have a built-in passage in the front housing.

Pressure cap
KM205 Names, locations, structure and functions of heating
The pressure cap is also known as radiator cap. The pressure cap is
and cooling system components and parts designed to maintain the pressure in the cooling system. It helps in avoiding

Induction Systems
unnecessary boiling of the coolant. As a whole, the function of the pressure
cap is to ensure that the cooling system does not blow up.
Components of a Vehicle’s heating and Cooling System
Radiator Bypass system
The radiator is the main part of a vehicle's cooling system. It is a flattened The bypass system is a passage that allows the coolant to move through
sheet of aluminium. The function of the radiator is to lower the temperature the engine and then to bypass the radiator to balance the temperature. In

Exhaust Systems
of the hot coolant that passes from the engine and to send it back to the this way, the bypass system avoids hot spots.
engine through hoses, thermostat and water pump.

Hoses
Radiator fan
The cooling system has a number of hoses connecting to all the
The role of the radiator fan in a vehicle's cooling system is to cool the engine components of the cooling system. The hoses are made of either rubber or

Content Sources
system and to draw air into the radiator to prevent the engine from metal. The main function of the hoses is to move the fluid from one part of
overheating. the engine to another. These are designed to withstand the inside pressure.
Unit 2 – Heating and Cooling Systems

Heater core

Welcome
The heater core looks like a small radiator. It is connected to the cooling
system through a pair of hoses. One hose takes the hot coolant from the
water pump to the heater core and the other hose returns the coolant to
the engine. The blowers take heat from heater core and sends it to the

Engine Lubrication
interior of the car whenever needed.

Systems
Discussion Points:
 IAC0201 Describe and explain, with the aid of sketches where
applicable and using the correct terms and terminology, the

Cooling Systems
function, operating principles and concepts for various types of

Heating and
heating and cooling systems
 IAC0202 Discuss the limitations of the various types of heating and
cooling systems and related safety, health and environment issues
 IAC0203 Identify, describe, with the aid of sketches where applicable,
and explain the function of heating and cooling system components

Induction Systems
and parts
 IAC0204 Describe typical faults, their causes, methods of testing and
maintenance requirements for heating and cooling system

Exhaust Systems
Content Sources
Induction Systems

Welcome
Unit 3

Engine Lubrication
Systems
The following topics are covered in this unit:

Cooling Systems
Heating and
 KM301 Function of induction systems
 KM302 Construction and operating principles of various
Unit Overview

types of induction systems and layouts including naturally

Induction Systems
aspirated, forced induction and after-cooled systems
 KM303 Limitations of each type of induction system
 KM304 Concepts, terms and terminology related to
induction systems
 KM305 Names, locations, structure and functions of
induction system components and parts

Exhaust Systems
 KM306 Typical faults in induction systems and their
identification, related tests and causes
 KM307 Maintenance requirements and methods for
induction systems

Content Sources
Unit 3 – Induction Systems

KM301 Function of induction systems The formation of an oil film depends on the viscosity of the oil and the

Welcome
viscosity the oil depends on The Temperature:
 Will decrease the oil viscosity which will cause: metal-to-metal
contact and resulting excessive wear of the load- bearing parts.
 Will lead to condensation in the crankcase, causing acids and

Engine Lubrication
sludge to form in the lubrication oil, and condensation of
corrosive gases in the cylinder walls.

Systems
At low Temp: Excessive clearances between parts will cause pounding
Excessive clearances between the bearings and the Journals will allow the
oil to escape. At High Temp: the parts will expand and insufficient clearances

Cooling Systems
between the moving parts will result. As the clearances are Reduced, in

Heating and
adequate Lubrication will cause metal-to-metal contact. High temperatures
change the strength and physical properties of the various metals used in
an engine. Excessive expansion of the metal, which may result in shearing
of the cylinder-head bolts.

Induction Systems
KM302 Construction and operating principles of various
Induction system types of induction systems and layouts including naturally
 After the combustion process, only 1/3 of the heat energy from aspirated, forced induction and after-cooled systems
the fuel changes into mechanical energy, & the rest: •
Hot exhaust gases•

Exhaust Systems

Forced induction
 Frictional heat from the rubbing surfaces• Heating of the metal
walls to prevent: •  The process of delivering compressed air to the intake of an internal
o Overheating and the resulting breakdown of lubricating combustion engine? A forced induction engine uses a gas
oil film compressor to increase the pressure, temperature and density of the
air. An engine without forced induction is considered a naturally
o Overheating and the resulting loss of strength of the

Content Sources
aspirated engine.
metal itself
 Forced induction is used in the automotive and aviation industry to
o Excessive stresses in or between the engine parts
increase engine power and efficiency.
resulting from unequal temperatures
Unit 3 – Induction Systems

 A forced induction engine is essentially two compressors in series. Intercoolers increase the efficiency of the induction system by reducing

Welcome
The compression stroke of the engine is the main compression that induction air heat created by the supercharger or turbocharger and
every engine has. An additional compressor feeding into the intake promoting more thorough combustion. This removes the heat of
of the engine causes forced induction of air. compression that occurs in any gas when its pressure is raised.
 A compressor feeding pressure into another greatly increases the

Engine Lubrication
total compression ratio of the entire system. This intake pressure is A decrease in intake air charge temperature sustains use of a denser intake
called boost. This particularly helps aviation engines, as they need to charge into the engine, as a result of forced induction. The lowering of the

Systems
operate at higher altitudes with lower air densities. intake charge air temperature also eliminates the danger of pre-detonation
 An intercooler is any mechanical device used to cool a fluid, of the fuel/air charge prior to timed spark ignition. This preserves the
including liquids or gases, between stages of a multi-stage benefits of more fuel/air burn per engine cycle, increasing the output of the
compression process, typically a heat exchanger that removes waste engine.
heat in a gas compressor.

Cooling Systems
Heating and
 They are used in many applications, including air compressors, air Intercoolers also eliminate the need for using the wasteful method of
conditioners, refrigerators, and gas turbines, and are widely known lowering intake charge temperature by the injection of excess fuel into the
in automotive use as an air-to-air or air-to-liquid cooler for forced cylinders' air induction chambers, to cool the intake air charge, prior to its
induction (turbocharged or supercharged) internal combustion flowing into the cylinders. This wasteful practice nearly eliminated the gain
engines to improve their volumetric efficiency by increasing intake in engine efficiency from forced induction, but was necessitated by the

Induction Systems
air charge density through nearly isobaric cooling. greater need to prevent at all costs the engine damage that pre-detonation
engine knocking causes.

A naturally aspirated system

 is an internal combustion system in which oxygen intake depends

Exhaust Systems
solely on atmospheric pressure and which does not rely on forced
induction through a turbocharger or a supercharger?
 Many sports cars specifically use naturally aspirated engines to avoid
turbo lag.
 In a naturally aspirated engine, air for combustion or an air/fuel
mixture is drawn into the engine’s cylinders by atmospheric pressure

Content Sources
acting against a partial vacuum that occurs as the piston travels
downwards toward bottom dead centre during the intake stroke.
 Owing to innate restriction in the engine's inlet tract which includes
the intake manifold, a small pressure drop occurs as air is drawn in,
resulting in a volumetric efficiency of less than 100 percent – and a
less than complete air charge in the cylinder.
Unit 3 – Induction Systems

 The density of the air charge, and therefore the engine's maximum  Many head gaskets that are used in factory turbocharged engines

Welcome
theoretical power output, in addition to being influenced by are multi-layer steel (MLS). An MLS head gasket typically has three
induction system restriction, is also affected by engine speed and to five layers of steel. The external layers are usually embossed and
atmospheric pressure, the latter which decreases as the operating coated with some type of high-temperature synthetic rubber, while
altitude increases. the centre layer may be flat and functions more like a shim. MLS
gaskets are more durable than the typical composition head gasket,

Engine Lubrication
 This is in contrast to a forced induction engine, in which a
mechanically driven supercharger, or an exhaust-driven and can handle the higher temperatures and pressures in turbo

Systems
turbocharger is employed to facilitate in increasing the mass of applications. Aftermarket MLS head gaskets are often available as an
intake air beyond what could be produced by atmospheric pressure upgrade for replacing head gaskets on many naturally aspirated
alone. engines as well as older turbocharged engines that may not have an
MLS head gasket.
 Nitrous oxide can also be used to artificially increase the mass of
oxygen present in the intake air. This is accomplished by injecting

Cooling Systems
Heating and
liquid nitrous oxide into the intake which supplies significantly more
oxygen in a given volume than is possible with atmospheric air.
KM304 Concepts, terms and terminology related to
induction systems
KM303 Limitations of each type of induction system
Induction systems play a crucial role in internal combustion engines, serving

Induction Systems
as the pathway through which air and fuel are drawn into the combustion
Turbo Failures and Engine Issues chamber. Understanding the concepts, terms, and terminology related to
induction systems is essential for comprehending the functioning and
 Turbocharger failures are often the result of poor lubrication or oil performance of engines.
breakdown. The high temperature in the turbo exhaust housing
transfers a lot of heat to the shaft bearings in the centre housing. If
Air Intake Components:

Exhaust Systems
the supply of coolant or oil to the turbo housing is restricted or lost,
it can cause bearing failure.  Air Filter:
 Synthetic oil is recommended for turbo engines because it can o A device that removes impurities and contaminants from the
handle higher temperatures better than conventional oil. Regular oil air before it enters the engine. It helps maintain the
changes are also a must. cleanliness of the combustion air.
 Because turbochargers increase compression and power, they also  Air Cleaner Housing/Box:

Content Sources
increase heat and pressure inside the engine’s combustion
o The housing or box that encloses the air filter. It protects the
chambers. This can make life difficult for the head gasket unless the
filter from external elements and helps streamline the airflow.
gasket is capable of handling the extra boost.
Unit 3 – Induction Systems

 Mass Air Flow (MAF) Sensor:  Turbocharger:

Welcome
o A sensor that measures the mass flow rate of air entering the o A device that uses exhaust gases to drive a turbine, which, in
engine. This information is crucial for the engine control unit turn, compresses incoming air before it enters the
(ECU) to adjust fuel injection for optimal air-fuel mixture. combustion chamber. This increases engine efficiency and
 Throttle Body: power.

Engine Lubrication
o The component that regulates the amount of air entering the

Systems
engine by controlling the size of the throttle opening. It is Miscellaneous Terms:
connected to the accelerator pedal.
 Intake Manifold:
 Throttle Plate/Butterfly Valve:
o A system of tubes or passages that distribute air (and
o A plate or valve within the throttle body that can be opened sometimes fuel) to the engine's cylinders.
or closed to control the airflow into the engine.

Cooling Systems
 Intake Valve:

Heating and
o A valve that opens and closes to allow air (and fuel in port-
Fuel Injection: injected systems) to enter the combustion chamber.
 Fuel Injector:  Intake Runner:
o A component that sprays fuel into the combustion chamber o A passage in the intake manifold that directs air to a specific

Induction Systems
or intake manifold. Fuel injectors are controlled by the ECU cylinder.
to precisely manage the air-fuel mixture.  Ram Air Intake:
 Port Fuel Injection (PFI): o A system that uses the forward motion of a vehicle to force
o An injection system where fuel injectors are located in the air into the engine, increasing air pressure and potentially
intake ports, spraying fuel directly onto the intake valves. enhancing performance.
 Direct Fuel Injection (DI):  Vacuum:

Exhaust Systems
o An injection system where fuel is injected directly into the o The pressure below atmospheric pressure in the intake
combustion chamber, bypassing the intake ports. manifold, created by the piston's downward motion during
 Forced Induction: the intake stroke.

 Supercharger:  Velocity Stack:

A device that forces more air into the combustion chamber o A tapered tube or trumpet-shaped device designed to

Content Sources
o
by compressing it. This leads to increased power and increase the air velocity entering the engine, optimizing
efficiency. airflow.
 Boost Pressure:
o In forced induction systems, the additional air pressure
created by a supercharger or turbocharger.
Unit 3 – Induction Systems

KM305 Names, locations, structure and functions of  Throttle Body:

Welcome
induction system components and parts o Location: At the entrance of the intake manifold.
o Structure: Contains a throttle plate or butterfly valve.
o Function: Regulates the amount of air entering the engine
The induction system in an internal combustion engine is responsible for
by controlling the size of the throttle opening.

Engine Lubrication
drawing in air and, in some cases, fuel into the combustion chambers. This
system includes various components and parts that work together to ensure  Throttle Plate/Butterfly Valve:

Systems
proper air intake and mixing with fuel for combustion. o Location: Within the throttle body.
o Structure: A flat plate or valve that can be opened or closed.
Air Intake Components: o Function: Controls the airflow into the engine by adjusting
the size of the throttle opening.
Air Filter:

Cooling Systems


Heating and
o Location: Inside the air cleaner housing/box.
Fuel Injection Components:
o Structure: Typically a paper or fabric element.
o Function: Filters out impurities and contaminants from the  Fuel Injector:
incoming air to protect the engine. o Location: Near the intake port or in the intake manifold.

Induction Systems
 Air Cleaner Housing/Box: o Structure: A nozzle that sprays fuel into the intake port or
o Location: Connected to the throttle body or carburetor. combustion chamber.

o Structure: A plastic or metal box containing the air filter. o Function: Injects fuel into the air for combustion; controlled
by the ECU for precise fuel delivery.
o Function: Protects the air filter from external elements and
helps streamline the airflow.  Fuel Rail:

Mass Air Flow (MAF) Sensor: o Location: Connected to the fuel injectors.

Exhaust Systems

o Location: Between the air filter and the throttle body. o Structure: A pipe or rail that supplies fuel to the injectors.

o Structure: A sensor with a heated wire or film. o Function: Distributes fuel to the injectors from the fuel supply
system.
o Function: Measures the mass flow rate of incoming air,
providing data to the engine control unit (ECU) for fuel  Intake Manifold Components:
injection adjustments.  Intake Manifold:

Content Sources
o Location: Attached to the engine block.
o Structure: A system of tubes or passages.
o Function: Distributes air (and sometimes fuel) to the engine's
cylinders.
Unit 3 – Induction Systems

 Intake Valve: KM306 Typical faults in induction systems and their

Welcome
o Location: In the cylinder head. identification, related tests and causes
o Structure: A movable valve that opens and closes.
o Function: Allows air (and fuel in port-injected systems) to
Faults in induction motors can be categorized as follows:
enter the combustion chamber.

Engine Lubrication
Electrical-related faults:
 Intake Runner:

Systems
 Faults under this classification are unbalance supply voltage or
o Location: Inside the intake manifold.
current, single phasing, under or over voltage of current, reverse
o Structure: A passage that directs air to a specific cylinder. phase sequence, earth fault, overload, inter-turn short-circuit fault,
o Function: Guides the airflow to optimize cylinder filling. and crawling.
Mechanical-related faults:

Cooling Systems
Heating and
Forced Induction Components:  Faults under this classification are broken rotor bar, mass unbalance,
air gap eccentricity, bearing damage, rotor winding failure, and
 Supercharger: stator winding failure.
o Location: Typically mounted on the engine. Environmental-related faults:
o Structure: Contains a compressor driven by a belt.  Ambient temperature as well as external moisture will affect the

Induction Systems
o Function: Compresses air before it enters the combustion performance of induction motor. Vibrations of machine, due to any
chamber, increasing power. reason such as installation defect, foundation defect, also will affect
 Turbocharger: the performance.
o Location: Connected to the exhaust system.
o Structure: Includes a turbine and a compressor. KM307 Maintenance requirements and methods for

Exhaust Systems
o Function: Uses exhaust gases to drive a turbine, compressing induction systems
incoming air to increase engine efficiency.

Maintaining the induction system of an internal combustion engine is crucial

Other Components: for optimal performance, fuel efficiency, and overall engine health. Regular
 Idle Air Control (IAC) Valve: maintenance helps prevent issues related to air intake, fuel delivery, and

Content Sources
combustion.
o Location: Attached to the throttle body.
o Structure: A valve that controls the amount of air bypassing
the throttle plate.
o Function: Regulates engine idle speed by adjusting airflow
during idling.
Unit 3 – Induction Systems

Air Filter Maintenance: Idle Air Control (IAC) Valve Maintenance:

Welcome
 Requirement: Regular inspection and replacement.  Requirement: Cleaning and testing.
 Method:  Method:
o Check the air filter according to the manufacturer's o Remove the IAC valve and clean it using an appropriate solvent.

Engine Lubrication
recommendations. o Test the IAC valve's operation and replace if necessary.
Replace the air filter if it is dirty, clogged, or damaged.

Systems
o o Follow the manufacturer's guidelines for maintenance.
o Use the correct replacement filter specified for your vehicle.

Fuel Injector Maintenance:

Throttle Body Maintenance:
 Requirement: Periodic cleaning and testing.

Cooling Systems
 Requirement: Periodic cleaning.

Heating and
 Method:
 Method: o Use fuel injector cleaner additives in the fuel system.
o Remove the intake tube and inspect the throttle body for carbon o Consider professional cleaning or testing if fuel delivery issues
buildup. are suspected.
o Clean the throttle body and throttle plate using a recommended o Replace injectors if they fail testing or are found to be faulty.

Induction Systems
throttle body cleaner.
o Be cautious not to damage sensitive components during
cleaning.
Intake Manifold Maintenance:
 Requirement: Inspection for carbon buildup.
Mass Air Flow (MAF) Sensor Maintenance:  Method:
Inspect the intake manifold for carbon deposits, especially in

Exhaust Systems
o
 Requirement: Cleaning as needed.
direct injection systems.
 Method:
o Perform carbon cleaning as needed, using specialized cleaning
o Use a MAF sensor cleaner to remove dirt or deposits. agents.
o Follow the manufacturer's instructions for proper cleaning
techniques.

Content Sources
o Avoid touching the sensor wires.
Unit 3 – Induction Systems

Check for Vacuum Leaks: Monitor Engine Codes and Sensors:

Welcome
 Requirement: Regular inspection.  Requirement: Regular scanning for diagnostic trouble codes (DTCs).
 Method:  Method:
o Inspect vacuum hoses and connections for signs of wear, cracks, o Use an OBD-II scanner to check for any stored DTCs related to

Engine Lubrication
or leaks. the induction system.
Use a smoke machine or a propane torch with a regulator to Address and resolve any issues indicated by the codes.

Systems
o o
detect vacuum leaks.

General Tips:
Inspect Turbocharger or Supercharger (if equipped):
 Follow Manufacturer Guidelines:

Cooling Systems
 Requirement: Regular inspection for leaks or abnormal noises. o Always refer to the vehicle's service manual and follow

Heating and
 Method: manufacturer recommendations for maintenance intervals and
o Check for oil leaks around the turbocharger or supercharger. procedures.

o Listen for unusual sounds that may indicate bearing or impeller  Use Quality Products:
issues. o Use high-quality replacement parts and fluids specified by the

Induction Systems
o Follow manufacturer recommendations for inspection and manufacturer.
maintenance.  Regular Inspection:
o Regularly inspect induction system components for signs of
Perform Throttle Position Sensor (TPS) Calibration: wear, damage, or abnormal operation.

 Requirement: Calibration after certain maintenance procedures.

By adhering to these maintenance requirements and methods, you can

Exhaust Systems
 Method: ensure that the induction system operates efficiently, preventing issues that
o If the throttle body is removed or cleaned, recalibrate the TPS could affect engine performance and longevity. Regular maintenance is key
using a scan tool. to achieving optimal fuel efficiency and reducing the risk of costly repairs.
o Follow manufacturer guidelines for TPS calibration procedures.

Content Sources
Unit 3 – Induction Systems

Discussion Points:

Welcome
 IAC0301 Describe and explain, with the aid of sketches where
applicable and using the correct terms and terminology, the
function, operating principles and concepts for various types of
induction systems

Engine Lubrication
 IAC0302 Discuss the limitations of the various types of induction

Systems
systems and related safety, health and environment issues
 IAC0303 Identify, describe, with the aid of sketches where applicable,
and explain the function of induction system components and parts
 IAC0304 Describe typical faults, their causes, methods of testing and

Cooling Systems
maintenance requirements for induction systems

Heating and
Induction Systems
Exhaust Systems
Content Sources
Exhaust Systems

Welcome
Unit 4

Engine Lubrication
Systems
Cooling Systems
The following topics are covered in this unit:

Heating and
 KM401 Function of exhaust systems
 KM402 Construction and operating principles of various
types of exhaust systems

Induction Systems
Unit Overview

 KM403 Limitations of each type of exhaust system

 KM404 Concepts, terms and terminology related to exhaust
systems
 KM405 Names, locations, structure and functions of exhaust
system components and parts

Exhaust
Exhaust Systems
 KM406 Specifications and parameters including fits,
clearances, reusability and calculations for exhaust systems

Systems
 KM407 Typical faults in exhaust systems and their
identification, related tests and causes
 KM408 Maintenance requirements and methods for
exhaust systems

Content Sources
Unit 4 – Exhaust Systems

KM401 Function of exhaust systems  Exhaust Gas Recirculation (EGR):

Welcome
o In some vehicles, the exhaust system is connected to the EGR
system, which recirculates a portion of the exhaust gases
An exhaust system carries waste gases and other combustion products back into the engine cylinders. This helps reduce nitrogen
away from an automobile engine. It allows the vehicle to operate with oxide emissions by lowering combustion temperatures.
minimal noise, smoke and pollution transmitted to the environment. A

Engine Lubrication
 Cooling of Exhaust Gases:
properly maintained exhaust system is essential to the clean and efficient

Systems
operation of the car. o The exhaust system allows hot gases produced during
combustion to cool before being released into the
environment. This cooling process can help prevent damage
Here are the key functions of an exhaust system: to surrounding components and reduce the risk of ignition
 Gas Removal: in case of contact with flammable materials.

Cooling Systems
Direction and Disposal of Exhaust Gases:

Heating and
o The primary function of the exhaust system is to remove and 
carry away the combustion gases produced during the o The exhaust system directs the flow of exhaust gases away
engine's power strokes. This includes the expulsion of carbon from the engine and passenger compartment, preventing
dioxide (CO2), nitrogen oxides (NOx), unburned the accumulation of harmful gases inside the vehicle. It
hydrocarbons, and other byproducts of combustion. disposes of these gases safely and effectively.
Noise Reduction:

Induction Systems
  Oxygen Sensors:
o The exhaust system helps minimize noise generated by the o Modern exhaust systems often include oxygen sensors that
engine during the exhaust stroke. It includes components monitor the level of oxygen in the exhaust gases. This
such as mufflers and resonators that attenuate sound waves, information is used by the engine control unit (ECU) to adjust
reducing the overall noise emitted by the vehicle. the air-fuel mixture for optimal combustion and fuel
 Emission Control: efficiency.

Exhaust Systems
o The exhaust system plays a crucial role in reducing harmful  Backpressure Regulation:
emissions that can contribute to air pollution. Catalytic o The design of the exhaust system, including the diameter
converters, part of the exhaust system, convert harmful gases and length of pipes and the presence of mufflers, helps
like carbon monoxide (CO), nitrogen oxides (NOx), and regulate backpressure. Proper backpressure is essential for
unburned hydrocarbons into less harmful substances. optimizing engine performance and efficiency.
 Catalytic Conversion: Enhanced Fuel Efficiency:

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
o Catalytic converters contain catalysts (usually made of o An efficiently designed exhaust system contributes to better
platinum, palladium, and rhodium) that facilitate chemical engine scavenging, which can improve overall fuel efficiency
reactions to convert harmful gases into less harmful by helping the engine expel exhaust gases more effectively.
substances. For example, they convert carbon monoxide to
carbon dioxide, nitrogen oxides to nitrogen and oxygen, and
unburned hydrocarbons to carbon dioxide and water.
Unit 4 – Exhaust Systems

Understanding and maintaining the exhaust system is vital not only for the Exhaust manifolds are generally simple cast iron or stainless-steel units

Welcome
performance of the vehicle but also for environmental considerations, as it which collect engine exhaust gas from multiple cylinders and deliver it to
plays a crucial role in reducing harmful emissions. Regular inspection and the exhaust pipe. These consist of individual exhaust head pipes for each
proper functioning of exhaust system components contribute to cleaner air, cylinder, which then usually converge into one tube called a collector.
reduced noise pollution, and compliance with emission standards.

Engine Lubrication
The most common types of aftermarket headers are made of mild steel or
KM402 Construction and operating principles of various stainless-steel tubing for the primary tubes along with flat flanges and

Systems
possibly a larger diameter collector made of a similar material as the
types of exhaust systems
primaries. They may be coated with a ceramic-type finish or painted with a
heat-resistant finish, or bare. Chrome plated headers are available but these
tend to blue after use. Polished stainless steel will also colour, but less than
Header
chrome in most cases.

Cooling Systems
Heating and
Another form of modification used is to insulate a standard or aftermarket
manifold. This decreases the amount of heat given off into the engine bay,
therefore reducing the intake manifold temperature. There are a few types
of thermal insulation but three are particularly common.

Induction Systems
The goal of performance exhaust headers is mainly to decrease flow
resistance, and to increase the volumetric efficiency of an engine, resulting
in a gain in power output.

Exhaust Pipe

Exhaust Systems
The exhaust pipe connects to the bottom of the exhaust manifold. In most
standard systems, this consists of a Y pipe, which connects both sides of the
exhaust manifold together into a single line, forming the basis of a single
exhaust system. True dual exhaust systems do not use a Y pipe, but instead
have two separate exhaust pipes, with each one connecting to one side of

Content Sources
In automotive engineering, an exhaust manifold collects the exhaust gases
the exhaust manifold.
from multiple cylinders into one pipe.
Unit 4 – Exhaust Systems

Catalytic Converter KM403 Limitations of each type of exhaust system

Welcome
Limitations
 As the engine rpm increases, back pressure rises abruptly,
generating higher turbulence and degrading exhaust gas flow

Engine Lubrication
characteristics.

Systems
 Exhaust gases face restriction in being expelled, and contaminate
the fresh air/charge drawn into the cylinder on the next stroke.
 Hence, there is a reduction in power and engine performance at
higher rpm.
 A poorly designed 4-2-1 exhaust system can cause peaks and

Cooling Systems
Heating and
troughs in the power curve.
 Naturally, this is undesirable, because shifting gears to match rpm
The catalytic converter attaches to the exhaust pipe midway through the
and power requirements would be a challenge.
vehicle. Early automobile systems lacked a catalytic converter, but it is
standard on modern vehicles to remove the major pollutants from engine
gases. These include nitrogen oxides, hydrocarbons, and carbon monoxide. KM404 Concepts, terms and terminology related to exhaust

Induction Systems
While the catalytic converter cannot remove all of these gases, it does lower
systems
their content within the gas mixture. There are two main types of catalytic
converters: the pellet-type that uses hundreds of small beads to scrub and
absorb the gases, and the monolithic converter that uses a honeycomb
Terminology
design. Either type causes a chemical reaction within the converter that
changes some hydrocarbons and carbon monoxide into carbon dioxide In most production engines, the manifold is an assembly designed to collect

Exhaust Systems
and water vapour. the exhaust gas from two or more cylinders into one pipe. Manifolds are
often made of cast iron in stock production cars, and may have material-
saving design features such as to use the least metal, to occupy the least
Resonator, Muffler, and Tail Pipe space necessary, or have the lowest production cost. These design
The last three parts of the exhaust system all serve the same function of restrictions often result in a design that is cost effective but that does not
noise reduction. A muffler's job is to reduce engine noise by turning the do the most efficient job of venting the gases from the engine. Inefficiencies

Content Sources
sound waves into heat through tubes and chambers. A resonator acts as a generally occur due to the nature of the combustion engine and its
second muffler, further reducing noise. Finally, the tail pipe is the exit point cylinders. Since cylinders fire at different times, exhaust leaves them at
of the exhaust system. Some tail pipes also have a small resonator inside for different times, and pressure waves from gas emerging from one cylinder
additional noise reduction. might not be completely vacated through the exhaust system when another
comes. This creates a back pressure and restriction in the engine's exhaust
system that can restrict the engine's true performance possibilities.
Unit 4 – Exhaust Systems

Regardless of the negative attributes focused upon by potential sellers of Headers are generally made by aftermarket automotive companies, but

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steel tube exhaust outlet configurations, engineers who design engine sometimes can be bought from the high-performance parts department at
components choose conventional cast iron exhaust manifolds can similarly car dealerships. Generally, most car performance enthusiasts buy
list positive attributes, such as an array of heat management properties and aftermarket headers made by companies solely focused on producing
superior longevity than any other type of exhaust outlet design. For the reliable, cost-effective well-designed headers specifically for their car.
average consumer, having trouble with an exhaust outlet system may Headers can also be custom designed by a custom shop. Due to the

Engine Lubrication
qualify as 'poorer performance'. advanced materials that some aftermarket headers are made of, this can be

Systems
expensive. Luckily, an exhaust system can be custom built for any car, and
generally is not specific to the car's motor or design except for needing to
properly connect solidly to the engine. This is usually accomplished by
correct sizing in the design stage, and selecting a proper gasket type and
size for the engine.

Cooling Systems
Heating and
Header-back
 The Header-back is the part of the exhaust system from the outlet
of the header to the final vent to open air everything from the
header back.

Induction Systems
 Header-back systems are generally produced as aftermarket
performance systems for cars without turbochargers.
Manifold or header is a manifold specifically designed for performance?
 During design, engineers create a manifold without regard to Turbo-back
weight or cost but instead for optimal flow of the exhaust gases. The Turbo-back is the part of the exhaust system from the outlet of a
This design results in a header that is more efficient at scavenging

Exhaust Systems
 turbocharger to the final vent to open air. Turbo-back systems are generally
the exhaust from the cylinders. produced as aftermarket performance systems for cars with turbochargers.
 Headers are generally circular steel tubing with bends and folds Some turbo-back systems replace stock catalytic converters with others
calculated to make the paths from each cylinder's exhaust port to having less flow restriction.
the common outlet all equal length, and joined at narrow angles to
encourage pressure waves to flow through the outlet, and not back

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towards other cylinders.
 In a set of tuned headers, the pipe lengths are carefully calculated
to enhance exhaust flow in a particular engine revolutions per
minute range.
Unit 4 – Exhaust Systems

With or without catalytic converter  The end of the final length of exhaust pipe where it vents to open

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air, generally the only visible part of the exhaust system part on a
 Some systems eliminate the catalytic converter. vehicle, often ends with just a straight or angled cut, but may include
 Converters may not be removed from a vehicle that is used only for a fancy tip.
off-road driving.  The tip is sometimes chromed. It is often of larger pipe than the rest

Engine Lubrication
 The main purpose of a catalytic converter on an automobile is to of the exhaust system. This produces a final reduction in pressure,
reduce harmful emissions of hydrocarbons, carbon monoxide and and sometimes used to enhance the appearance of the car.

Systems
nitrogen oxides into the atmosphere.
 They work by transforming the polluted exhaust components into
water and carbon dioxide.
KM405 Names, locations, structure and functions of exhaust
system components and parts

Cooling Systems
Cat-back

Heating and
 Cat-back refers to the portion of the exhaust system from the outlet Exhaust Manifold
of the catalytic converter to the final vent to open air.
 This generally includes the pipe from the converter to the muffler,
the muffler, and the final length of pipe to open air.

Induction Systems
 Cat-back exhaust systems generally use larger diameter pipe than
the stock system.
 The mufflers included in these kits are often glass packs, to reduce
back pressure.
 If the system is engineered more for show than functionality, it may
be tuned to enhance the lower sounds that are lacking from high-

Exhaust Systems
RPM low-displacement engines.
 The exhaust manifold is the first component of the exhaust system.
 It comprises a stainless steel, aluminium or cast-iron unit that
Tailpipe and exhaust
adjoins the engine's combustion cylinders and collects exhaust
 With trucks, sometimes the silencer is crossways under the front of gases from the combustion process.
the cab and its tailpipe blows sideways to the offside.
Car enthusiasts have the option of detailing their engine with

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
 The side of a passenger car on which the exhaust exits beneath the exhaust headers or extractors, which are a series of pipes that are
rear bumper usually indicates the market for which the vehicle was individually linked to the cylinders.
designed,
 The exhaust is funnelled into a collector that directs the exhaust to
the secondary components of the exhaust system.
 This arrangement allows the engine to run more efficiently.
Unit 4 – Exhaust Systems

Mufflers Catalytic converter

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Engine Lubrication
Systems
Cooling Systems
Heating and
 A system of exhaust pipes carries the exhaust gases through a
muffler, which contains a series of baffles that damp the noise of

Induction Systems
the engine combustion and escaping gases.
 Without a muffler, the noise of combustion would escape directly  A catalytic converter completes the ignition of gases that have been
from the exhaust pipe, creating a tremendous distraction for drivers incompletely burned within the engine's combustion chamber.
and pedestrians.  The catalytic converter prevents pollutants such as carbon
 Automobile mufflers must be in good working condition. monoxide and nitrogen oxides from escaping into the atmosphere.

Exhaust Systems
 the catalytic converter must be in good working condition, and
many states require annual testing of this component to assure that
the vehicle is emitting minimal pollutants into the atmosphere.

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Unit 4 – Exhaust Systems

Tailpipe  begin at the exhaust manifold, the crossover pipe, or the catalytic

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converter.
 Dry assemble and visually test fit all of the needed parts. Lay
everything out and visually test fit the assembly as accurately as
possible.

Engine Lubrication
 Unbolt the stock exhaust system starting from the back of the car
and working your way forward.

Systems
 Generally, the bolts are rusted and hard to get off unless an impact
gun. Use some penetrating oil to aid removal and remember that,
sometimes, tightening a nut or bolt just a bit, breaks it free, allowing
you to remove the bolt or nut.

Cooling Systems
Remove the exhaust components to replace. Remove the system

Heating and

 The engine exhaust finally reaches the tailpipe, which is made of from the hangers and set all parts aside.
stainless steel or steel tubing.
 new hangers, cut the old ones off with some kind of cutting tool. --
 The exhaust pipe vents the gases behind or above the vehicle. A high-speed rotary tool fitted with a cutting disk or a side grinder
 Modern exhaust systems have reduced automobile pollutants by a will work.
considerable amount in the past few decades and have helped to

Induction Systems
 Starting from the front of the car, hang the exhaust part up then
reduce smog and other pollution in most large cities. bolt it onto the upstream pipe.
 Start tightening each segment to the first, after all pipes are
KM406 Specifications and parameters including fits, attached. Use a good amount of torque on each bolt to make sure
its tight.
clearances, reusability and calculations for exhaust systems
 Double check and tighten all the bolts.

Exhaust Systems
Installing an Exhaust System
 Lift the car use a lift, jack up the back end so you can get under it.
Use ramps or a jack.
 Be sure to lock the emergency brake and chock at least one wheel

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that is still on the ground.
 Make sure to block the car using jack stands, wooden blocks or
other sturdy blocks.
 Assess the condition of all the parts of exhaust system before
beginning.
Unit 4 – Exhaust Systems

KM407 Typical faults in exhaust systems and their  If hear rattling under the vehicle it could mean something has

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become loose such as a bracket, heat shield or a piece of exhaust
identification, related tests and causes
pipe.
 It’s important to get your exhaust system examined if this is the case
Common faults with the Exhaust System  Loose exhaust parts or missing brackets can put additional

Engine Lubrication
structural stress on the exhaust system and damage other expensive
 The main culprit for exhaust damage or wear is rust and it can cause
components.

Systems
a multitude of problems.
 Depending on the severity it can lead to complete exhaust failure
or structural damage. KM408 Maintenance requirements and methods for
exhaust systems

Cooling Systems
Heating and
Hangers

Induction Systems
Exhaust Systems
 In rare cases the exhaust pipe can become so eroded or damaged

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that it will become loose and start dragging on the road.  If any hanger is broken, it has to be replaced, without delay--even
if the exhaust system seems to be hanging level. One broken
 If this happens one should take the vehicle to the nearest mechanic hanger means that when the system moves up and down as you
or exhaust specialist. drive, a whiplash effect goes through the clamped and welded
 If it is not safe to drive the vehicle one should ring for road side joints. Eventually clamps loosen and welds crack.
assistance and take care not to inhale any of the toxic fumes.
  These hangers also have a thick rubber section that resembles a  Reassemble and install a heavy-duty clamp, which can tolerate
flattened football or beach ball, with holes for a rod at each apex of much more torque, to provide a leak-free joint.
the rubber. Welding positively locates all the parts, and although  Many systems have a flange joint at the exhaust manifold or at the
you may have to tug and pry, replacing the rubber piece when it manifold's Y-pipe. That joint is held together with spring-loaded

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becomes cracked is very straightforward. bolts. The heat may weaken the springs, and the joint will loosen.
 Take a universal hanger that can twist and tilt and has an adjustable  Try simply tightening the bolts, but if the springs have cracked or
length setup, and attach it to the under body with a bolt through are weak, replace the bolts. They're sold, with new springs, in auto
that hole. parts stores.

Engine Lubrication
 make the connection around the pipe--a simple clamp and U-bolt  If a flange joint is badly rusted, it's worth trying to free it up with
usually works. Don't be surprised if a part of the welded-on bracket

Systems
penetrating solvent.
(from the broken hanger) has to be cut or ground off to provide
space for the clamp that will attach to the universal hanger.
 This will maintain system alignment and the balanced hang of the
Damper Weights
entire system.  Some exhaust systems have vibration dampers, which are weights

Cooling Systems
 If there is noise from exhaust system contact with the under body that are attached to a pipe or are part of a flange connection. If a

Heating and
or an under-body part, check for damage underneath. damper weight breaks off or is bent, the exhaust system will vibrate
noticeably.
 This not only makes for an uncomfortable ride, but it can affect the
Shields
life of welded and clamped joints.
 Exhaust system heat shields are prone to damage from driving on

Induction Systems
rough roads.
 To avoid the possibility of a grass fire, replace any that are missing
or barely hanging on. If a shield is dented, unbolt it, and check the
exhaust system for damage.

Exhaust Systems
Exhaust Joints
 If there has been a lot of exhaust system up-down travel because
of a broken hanger, the clamps and joint may be damaged. If a
welded joint is cracked at a muffler or resonator joint, replace the
parts.

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 If a clamped joint isn't cracked, but is leaking exhaust gas, remove
the old clamp. If the pipe ends are badly distorted, you'll have to
rent a pipe expander to reshape them.
 Otherwise, separate the pipes, sand them to remove any rust, then
apply a coat of exhaust pipe sealer.
Unit 4 – Exhaust Systems

 When using replacement parts, be sure to reinstall any original

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vibration-damping counterweights.
 Heat shields are necessary to prevent grass fires or cooked interior
carpet.

Engine Lubrication
Systems
Cooling Systems
Heating and
Induction Systems
Discussion Points:
 IAC0401 Describe and explain, with the aid of sketches where
applicable and using the correct terms and terminology, the
function, operating principles and concepts for various types of

Exhaust Systems
exhaust systems
 IAC0402 Discuss the limitations of the various types of exhaust
systems and related safety, health and environment issues
 IAC0403 Identify, describe, with the aid of sketches where applicable,
and explain the function of exhaust system components and parts

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 IAC0404 Describe typical faults, their causes, methods of testing and
maintenance requirements for exhaust systems
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Engine Lubrication
Systems
Cooling Systems
In this unit, the following resources will be included:

Heating and
Unit Overview

 The sources referenced in this content

Induction Systems
Exhaust Systems
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 Engine Lubrication Heating and
Welcome Systems Induction Systems Exhaust Systems Content Sources
Cooling Systems
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