ELTSD302- ENGINE LUBRICATING SYSTEM REPAIRING

AUTLS
301
BDCPC301
-

Competence:REPAIR ENGINE
LUBRICATING
SYSTEM
RQF Level: 3 Learning Hours
60
Credits: 6

Sector: Transport and logistics

Trade: Automobile Technology

Module Type: Specific

Curriculum: TRLAUT3001
- TVET Level3 Automobile Technology

Copyright: © Rwanda TVET Board, 2022

Issue Date:uly
J 2022

Compiled by Trainer Daniel MAHIRE Tel: 0789950813 1

 Purpose This module describes the skills, knowledge and attitude required to
statement repair car engine lubricating system. At the end of this module,
learners will be able to identify, describe, repair and test car engine
lubricating system components and test engine lubricating system
under minimum supervision.

Elements of Competency and Performance Criteria

Elements of Performance criteria
competency
1. Prepare the 1.1. PPE are properly selected and worn as per safety measures
workplace
1.2. Safety precautions of working area are appropriately applied
and apply before the work
safety
1.3. Workplace is properly cleaned and arranged according to the
standard
2. Describe 2.1. Engine lubricating systems are properly classified according
engine to the types of lubricating system
lubricating
2.2. Engine lubricating system components are adequately
systems identified according to the specifications

2.3. Engine lubricating system components are adequately

described according to the specifications

3. Repair engine 3.1. Tools, materials, and equipment are properly selected based
lubricating on their function
system
components 3.2. Engine lubricating system components faults are properly
detected according to the diagnosis procedure.

3.3. Engine lubricating system components faults are

conveniently corrected according to the faults detected.

3.4. Lubricants are properly filled and measured according to the

manufacturer’s recommendations

3.5. Test Engine lubricating performance

Compiled by Trainer Daniel MAHIRE Tel: 0789950813 2

LO 1: Prepare the workplace and apply safety
1.1. Identification of PPE
PPE in full word “Personal Protective Equipment” is clothing or equipment
that is worn or used in order to provide protection against hazardous
substances or environments.
All PPE clothing and equipment should be of safe design and construction,
and should be maintained in a clean and reliable fashion. Employers should
take the fit and comfort of PPE into consideration when selecting appropriate
items for their workplace.
Selection of PPE
PPE include:
1. Head protection: which protect the head against the falling or flying
objects, overhead objects. Examples: head covers, cask and bump caps.
2. Eye and Face protection: which protect the face against dangerous
objects, for examples when you are welding Examples: Safety
glasses, goggles, face shields, and visors.
3. Hand and arm protection: Protect our hands against sharp or hot
objects, chemicals, biological, or electrical hazards. Examples: Gloves,
sleeves, and gauntlets.
4. Body protection: protect you from the contamination of clothing with
potentially infectious materials. Examples: high visibility hat, vest,
pants, overall, overcoat, Coveralls, aprons,
5. Feet protection: protect our feet against falling or rolling objects,
sharp or heavy objects, wet and slippery surfaces, uneven surfaces, hot
surfaces, electrical hazards. Examples: Safety shoes, boots, and
metatarsal guards
6. Respiratory protection: protects our noses and mouth from splattered
of body fluid. Examples: Respirators, masks, and facepieces
7. Hearing protective: protects against loud tools and machinery from
poorly maintained equipment. Ex: Earplugs and earmuffs
When selecting PPE, the following factors should be considered:
1. Effectiveness: The PPE must be effective in protecting against the
identified hazards.
2. Comfort: The PPE must be comfortable to wear, as discomfort can
discourage workers from using it properly
3. Fit: The PPE must fit properly to provide adequate protection
4. Compatibility: Different types of PPE should be compatible with each
other to avoid creating additional hazards.
5. Cost: The PPE should be cost-effective while still meeting the necessary
safety standards.
6. Regulations: Certain industries or jobs may have specific regulations
regarding the type of PPE required.

Compiled by Trainer Daniel MAHIRE Tel: 0789950813 3

1.2. Apply Safety
Safety are measures taken at workplace to prevent hazards (accidents and
injuries)
Hazard is a potential source of harm or adverse health effect on a person or
persons
Types of hazards
Common types of hazards that can be present at workplace.
1. Physical hazards: These hazards can cause physical injury or death,
such Noise, vibration, extreme temperatures, radiation, and ergonomic
stressors
2. Chemical hazards: These hazards can cause a variety of health
problems, such as Corrosives, irritants, toxic fumes, gases, and dust.
3. Biological hazards: These hazards can cause infections and diseases,
such as bacteria, viruses, and fungi.
4. Ergonomic hazards: These hazards can cause repetitive strain injuries
(RSIs) and other musculoskeletal problems.
5. Psychosocial hazards: These hazards can cause stress, anxiety, and
depression.
6. Mechanical hazards: Falling objects, sharp edges, moving
machinery, and electrical hazards.
Methods used to avoid hazards

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Tool & Shop Safety
Tools are such a common part of our lives that it is difficult to remember that
they may pose hazards. Tragically, a serious incident can occur before steps
are taken into to identify and avoid or eliminate tool-related hazards.

Five basic safety rules can help prevent hazards associated with the use
of hand and power tools:

 Keep all tools in good condition with regular maintenance

 Use the right tool for the job
 Examine each tool for damage before use and do not use damaged tools
 Operate tools according to the manufacturers’ instructions
 Provide and properly use appropriate personal protective equipment.

Hand Tool Safety: Hand tools are tools that are powered manually and
include anything from axes to wrenches. The greatest hazards posed by hand
tools result from misuse and improper maintenance.

Guidance on hand tool use:

 Wear safety glasses when striking objects with tools or the potential for
breakage, chips, dust or any other hazard exists.
 Tap fasteners such as nails to start.
 Remove free hand to avoid impact to hand and fingers before striking
fastener with force.
 Do not cut towards yourself with sharp tools.
 Avoid storing sharp tools with sensitive tools and equipment.
 Be cautious of wrenches and tools slipping from fasteners to avoid hand
injuries and loss of balance.
 Use insulated tools when working with energized circuits.
 Do not operate power tools with cut or frayed power cords, or inoperable
or missing safety guards or devices.
 Never carry sharp tools in your pockets.

Power Tool Safety: The following general practices should be followed when
using electric tools:

 Wear appropriate eye and hearing protection

 Read manual and operate electric tools within their design limitations.
 Ensure tool is in the off position prior to connecting to outlet.
 Use gloves and appropriate safety footwear when using electric tools.
 Always use a GFCI protected device for outside and damp location
power tool use.
 Do not use electric tools in damp or wet locations unless they are
approved for that purpose.
 Do not use portable power tools which have cords that are cut, frayed,
or separated from the tool housing. Such cords should be repaired
before continued use.

Compiled by Trainer Daniel MAHIRE Tel: 0789950813 5

 Keep work areas well lighted when operating electric tools.

Ensure that cords from electric tools do not present a tripping hazard.

Never place power cords over shoulders or around neck.

Secure long hair and loose clothing prior to power tool use.

Allow the tool to do the work. Never force or apply excessive pressure to

the tool.
 Maintain sure footing and well balanced stance.
1.3. Cleaning and arrangement of the workplace
Cleaning is the process of removal of unwanted matter, contaminants or
pollutants from the workplace to ensures safety and health of employees and
injuries can be prevented.
[Link] of types of cleaning
2. Maintaining a clean and hygienic environment at the workplace is
important for employee health, well-being, and productivity. Different
types of cleaning are required to address various levels of dirt,
contamination, and specific needs. Here is a breakdown of the most
common types of cleaning encountered at the workplace:
3. 1. Routine Cleaning: done daily or multiple times a day, depending on
foot traffic and usage. Like, Sweeping, vacuuming, and mopping floors,
Dusting surfaces, furniture, and equipment, Emptying trash bins and
recycling bins.
4. To maintain a clean and presentable environment, prevent the spread of
5. 2. Deep Cleaning: Less frequently than routine cleaning, typically weekly
or bi-weekly. Like, cleaning windows, blinds, and light fixtures.
6. To remove stubborn dirt and grime, restore surfaces to their original
condition, and ensure a deeper level of hygiene.
7. 3. Specialized Cleaning: As needed, depending on specific requirements.
Like, cleaning and disinfecting equipment and machinery, window
washing. To handle specific cleaning needs not addressed by routine or
deep cleaning, ensuring proper hygiene and sanitation in specialized
areas.
8. 4. Maintenance Cleaning: Regularly scheduled based on manufacturer
recommendations or equipment needs. Like cleaning and lubricating
machinery and equipment, maintaining air filters and ventilation
systems, replacing worn-out cleaning supplies and equipment. To prevent
equipment malfunction and ensure its optimal performance, extending its
lifespan and contributing to a safer work environment.
9. 5. Green Cleaning: Can be incorporated into any cleaning routine. Like
using eco-friendly cleaning products and chemicals. To minimize
environmental impact and promote a more sustainable workplace while
maintaining a clean and healthy environment.

Compiled by Trainer Daniel MAHIRE Tel: 0789950813 6

[Link] of workplace, tools, materials, and equipment
Essential cleaning tools, materials and equipment’s are:
1. Scrub brushes. Get yourself 10. Whisk broom and
at least one great cleaning dustpan.
brush. ... 11. Lobby broom.
2. Toilet brush. 12. Dusters (short, long, or
3. Multi-purpose duster. extendable)
4. Sponges. 13. Vacuum cleaner (with
5. Vacuum. attachments for hardwood
6. Spray bottle. and carpet)
7. Microfiber cleaning cloths. 14. Microfiber cloths
8. Broom and dustpan. (color-coded for different
9. Mop and bucket (including a rooms)
wet mop and dry mop) 15. Paper towels.
16. Glass cleaning cloths

[Link] of workplace layout

There are many factors to consider when arranging a workplace layout,
including:
1. The type of work being performed
2. The flow of traffic, This includes both people traffic and the movement of
materials
3. Safety: The layout of the workplace should be safe for employees. This
means having clear walkways, adequate lighting, and proper ventilation
4. Ergonomics: The layout of the workplace should be ergonomic to reduce
the risk of musculoskeletal injuries. This means having workstations that
are designed to fit the human body and that allow employees to work in a
comfortable position
Tips for arranging a workplace layout for maximum efficiency and
productivity
1. Group similar tasks together: This will reduce the amount of time that
employees spend walking around and looking for things
2. Place commonly used items in easy-to-reach locations: This will save
employees time and effort
3. Create a logical flow of traffic: This will help to reduce congestion and
accidents
4. Provide adequate space for employees to work and move around
comfortably: This will help to reduce fatigue and improve productivity
5. Use ergonomic furniture and equipment: This will help to reduce the risk
of musculoskeletal injuries

Compiled by Trainer Daniel MAHIRE Tel: 0789950813 7

[Link] of first aid tool kit
First aid tool kit is a box containing the essential items for first aid at the
time of injuries or accidents
Essential items (tools) include in a first aid kit

1. Bandages: Bandages of various sizes and shapes to cover cuts and

wound
2. Antiseptic wipes: Antiseptic wipes to clean and disinfect wounds
3. Gauze: Gauze to pack wounds and to control bleeding
4. First aid tape: First aid tape to secure bandages and dressings
5. Scissors: Scissors to cut bandages and other materials
6. Tweezers: Tweezers to remove splinters and other small objects from
wounds
7. Safety pins: Safety pins to secure bandages and dressings
8. Instant cold compress: An instant cold compress to reduce swelling
and pain
9. Pain reliever: A pain reliever, such as ibuprofen or acetaminophen, to
relieve pain and inflammation. etc

A first aid kit should be located in a central and easily accessible location. It
should also be in a well-lit area.
[Link] of fire extinguishers
Fire extinguishers should be located in easily accessible locations, such as
near doorways and exits. They should also be mounted at a height that is easy
to reach
Fire triangle or fire forming factors
Fire can occur when 3 fire-forming factors are met, namely heat, fuel and
oxygen. If one only one factor is insufficient, then the fire will not be formed.

Compiled by Trainer Daniel MAHIRE Tel: 0789950813 8

Safe Operating of a fire extinguisher

However, before you use a fire extinguisher to put out a fire, it's very important
that you determine whether or not it's appropriate for you to be fighting the
fire, and whether or not you'll be able to put it out. If you don't think you can
fight the fire, or if you have any doubts, evacuate the building immediately
and call the fire department

It is important to know how to operate a fire extinguisher. By using the

acronym P.A.S.S., you can easily remember how to use your fire extinguisher
in the event of a fire.
P: Pull the safety pin from the handle.
A: Aim the extinguisher nozzle or hose at the base of the fire. (not directly at
the flames)
S: Squeeze the handle slowly to discharge the agent.
S: Sweep from side to side, while maintaining a safe distance from the fire.

Fire extinguishers are not meant to fight large or growing fires. Only attempt
to fight a fire if the flames are shorter than you, and if the flames are contained
in a small space. Evacuate immediately if the flames are taller than you, or if
the fire is spreading and growing
During use remember:
.
1. Instruct someone to call the fire department (Triple Zero 000) or call
them yourself. Evacuate everybody from the building.
2. Stand with your back to an exit.
3. Hold Fire Extinguisher upright while pulling safety pin
4. Move to the proper distance. Many fire extinguishers have a range of
between 2.4 to 3.7 m. Before discharging the extinguisher, move toward
or away from the fire so you're standing 1.8 to 2.4 m away.
5. Pull the pin. Pull pin at the top of the extinguisher, breaking the seal.
When in place, the pin keeps the handle from being pressed and
accidentally operating the extinguisher. Immediately test the
extinguisher.
6. Aim at base of fire
7. Squeeze lever

Compiled by Trainer Daniel MAHIRE Tel: 0789950813 9

 8. Sweep side to side
9. Leave immediately if you're unable to extinguish the fire. The average
extinguisher will have enough agent inside to go for about 10 seconds.
Back away and leave immediately if the fire isn't out when the extinguisher
is fully discharged.

Below is a summary of the classes of fire, and a quick list showing which types
of extinguisher should be used on each. We then provide a detailed explanation
of each type of fire extinguisher below.
The classes of fire
There are six classes of fire: Class A, Class B, Class C, Class D, ‘Electrical’,
and Class F.
1. Class A fires – combustible materials: caused by flammable solids, such
as wood, paper, and fabric
2. Class B fires – flammable liquids: such as petrol, turpentine or paint
3. Class C fires – flammable gases: like hydrogen, butane or methane
4. Class D fires – combustible metals: chemicals such as magnesium,
aluminum or potassium
5. Electrical fires – electrical equipment: once the electrical item is removed,
the fire changes class
6. Class F fires – cooking oils: typically a chip-pan fire
Types of fire extinguishers
1. Water Extinguisher
Water Fire extinguishers are for Class A fires only - they should not be used on
Class B or E fires. The discharge stream could spread the flammable liquid in a
Class B fire or could create a shock hazard on a Class E fire.
A Water extinguisher is identified by its all red cylinder and red band that runs
around the top of the tank.
2. Dry Chemical Powder Extinguisher
Dry Chemical Powder fire extinguishers extinguish the fire primarily by
interrupting the chemical reaction of the fire triangle.
They are effective on Class A, B, and E fires. They contain a chemical powder
called monoammonium phosphate which extinguishes the fire when it spreads
and melts over the flames.
3. Carbon Dioxide Extinguisher
Carbon Dioxide fire extinguishers extinguish fire by taking away
the oxygen element of the fire triangle and also be removing the heat with a very
cold discharge.
CO2 fire extinguishers contain a non-conductive and non-corrosive
extinguishing agent therefore will cause no damage to electrical equipment which
make it perfect for areas such as electrical switch rooms, server/data rooms,
electrical machinery and offices..
Compiled by Trainer Daniel MAHIRE Tel: 0789950813 10
Carbon dioxide can be used on Class B & E fires. They are usually ineffective on
Class A fires.
A CO2 extinguisher is identified by its all red cylinder and black band that runs
around the top of the tank.
4. Foam Extinguisher
Foam fire extinguishers work by forming a layer over the top of the burning
substance which stops the fire by cutting off access to oxygen. Foam
extinguishers are effective to combat Class B fires. They can also be used for
Class A fires which include wood, plastic, textiles, and paper.
Foam fire extinguishers are generally used within warehouse’s, petrol stations
and storage facilities and are not recommended for use on class F fires (cooking
oils and fats).
A Foam fire extinguisher is identified by its all red cylinder and blue band that
runs around the top of the tank.
5. Wet Chemical Extinguisher
Wet Chemical Extinguishers contain a solution of potassium, this solution
smothers the fire and removes the element of heat. It prevents re-ignition by
creating a barrier between the oxygen and fuel elements.
Wet chemical Class F extinguishers were developed for modern, high efficiency
deep fat fryers in commercial cooking operations. They may also be used on Class
A fires in commercial kitchens.
A Wet chemical fire extinguisher is identified by its all red cylinder and yellow
band that runs around the top of the tank
[Link] of fire blanket
Remember that fire can occur when three fire-forming factors are met, namely
heat, fuel and oxygen. If one only one factor is insufficient, then the fire will not
be formed. This extinguishers works by blocking one of the fire-tringles factor
namely oxygen.

During use, follow the following rules or steps

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1.4. Friction
When a body is moved on its base is F the friction force Fr opposes the direction
of motion.

Figure 2: view of clearance between moving parts shows how oil film keeps
parts from touching rubbing [Link]: Modern automotive
technology book on 16/07/2016
Effective force during friction, friction force Fr is the resistance against
movement of one body on another.
Compiled by Trainer Daniel MAHIRE Tel: 0789950813 12
 The value of friction force is determined by:
 Normal force
 Surface quality
 Pairing of material
 Types of friction
 State of lubrication
 Temperature
Normal friction (FN); -this is always acts vertically to the friction [Link]
friction coefficient µ (mµ) determine in tests record the other influence variables.
It is inserted as a constant value in the formula. The following formulas are
applied for friction;Friction= Normal force * friction coefficient
FR = FN * µ
Thus the friction force Fr is proportion to the normal force Fn. If the normal force
Fn is increased so the friction force Fr increase in the same proportion.
II.2. [Link] of friction
The types of friction are as the follow:
 Static friction
 Sliding friction
 Rolling friction
Under those types of friction, there are other types of friction which are
distinguished depending on the state of lubrication [Link] types are:
• Dry friction: The surface sliding on each other come on contact with each other
directly without a separated lubricants film.
• Mixed friction: The surface sliding on each other come into partial contact with
each other because they are only partially separated by lubricant film.
• Fluid friction: The surface sliding on each other do not come into contact with
each other because they are fully separated by lubricant film.

1.5. Lubricating oil

Lubricating oil is the oil used in lubrication system either in engine or other
machines which need lubricating oil in its operation.
There are some examples of lubricating oil such as: S.A.E, A.T.F, etc…..

Types of lubricating oil

According to their origin, the lubricating oil may be classified as:

• Animal’s oil: These are obtained from animals’ fat. These oils are not all
suitable for automotive engine lubrication because they are oxidized easily and
became gummy after some use.

• Vegetable oils:There are produced from seeds, fruits of plants < trees etc… Like
animals oil they are also easily oxidized and become [Link], castor
oil, which is vegetable oil once found extensive use in automobile industry
because of its high viscosity and high film strength.

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• Mineral oils: Mineral oils derived from petroleum are perhaps the most widely
used in automobiles.

 Advantages of mineral oil.

Mineral oils have some advantages possess over the animals and vegetable
[Link] are:
• Greater chemical stability at high temperature.
• Fewer tendencies to form emulsions with water.
• More plentiful and cheaper.
Chiefly the mineral oil contains hydrocarbons.
1. Synthetic lubricants

Examples of synthetic lubricants are:

• Silicon fluid
• Polyglycol ethers
• Aliphatic diester oil
Advantages of synthetic lubricants are as follow:
1. High viscosity index.
2. Reduced loss due to evaporation.
3. Less engine deposits.
4. Less frequent changes of lubricating oil.
5. Increased fuel economy.
2. Greases: They are suspension of metallic soaps (solid soaps of fatty acids)
disposed lubricating oil. Greases find used in automobiles at a place where
retention of liquid lubricants is difficult and where high temperature is
encountered, example: in axles.

3. Solid lubricants: graphite has been used as a cylinder lubricant both in powder
and colloidal form .It is suitable at high temperatures and has low coefficient of
friction. The special feature of graphite is that it fills the pores of the metal and
makes it friction free.

Gear lubricants
The demands and specification for gear oils vary from those applicable to engine
oils in several respects:
1. Wear protection on gear tooth flanks and on bearing surfaces.
2. Different friction properties.
3. Protection against ageing extending throughout the service life.
4. Suitability for use with gasket and seal materials, such as elastomers.
Both API classification and SAE grades are used to describe gear lubricants.

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Table: Gear oil performance classes

Manual gearbox, final drive unit .API SAE 75, 80 ,90

without axle offset GL4

Manual gearbox(synchronization API SAE 80,90,140

not critical), Final drive unit with GL5 SAE 75W
large axle offset SAE80W-90
SAE 85W-140
Table 1: Gear oil performance classes
Viscosity number is set by SAE (Society of Automotive Engineers)
Single viscosity oils SAE 5W, SAE 10W (winter) and SAE 20, SAE30 …
(summer).
Multiple viscosity oils SAE [Link] means that the oil is same as SAE
10W when cold and SAE30 when hot.
Automatic Transmission Fluid (ATF):This fluid must meet supplementary
demands extending beyond these applicable to basic gear lubricants.
This fluid can be used in:
1. Lubrication for planetary gear sets and on one way clutches.
2. Actuation of brake bands and clutches.
3. Torque transmission from the pump to the converter turbine.
Lubricating greases: Lubricating greases consist of an oil and thickening
[Link] depth of greases to which standard sphere penetrates a grease serves
as the basis for its NLGI classification (National Lubricating Grease Institute)
Selection of lubricating greases: oil greases are selected according to the
operating principle as well as the loads to be encountered, and depends to the
base soap used and where they are used to lubricate
The table below is explained well.
Properties of lubricating greases

Soap basis Drop point Water Application

0c resistant

Calcium soap Up to 200 Yes Automotive joints

greases greases

Sodium soap greases 120…..250 No Roller bearing greases

Lithium soap 100…..200 Yes Multipurpose greases

greases
Table 2: Properties of lubricating greases

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 Designations of lubricating oil greases
Example: K PF 2 K -30
K: Greases for roller bearing (G for gearbox)
PF: P for EP/AW additives, F for solid lubricant
2: Automotive joint grease
K: Upper operating limits 1200c
-30: Lower operating limit in 0c
Department Of Transport (DOT): This fluid is mainly used in brake system
as brake fluid. The boiling point defined in the DOT standards in (U.S. DOT).
The minimum boiling points for brake fluids are: DOT3 2500C, DOT4 2300C,
DOT5.1 2600C.

LO 2: Engine lubricating system description

2.1. Introduction
Engine Lubrication System: Must supply the engine components with an
adequate amount of lubricating oil. The correct pressure must be guaranteed in
the process, and are used to keep the wear between moving parts as low as
possible. They are intended to prevent the surface that slide on each other
coming into contact by mean friction. Without oil, an engine would succumb to
overheating and seizing very quickly. Lubricants help mitigate (remove) this
problem, and if properly monitored and maintained, can extend the life of your
motor.
2.2. Identification the Purpose of Engine Lubrication System
The purpose of Engine Lubrication System is to:
1. Lubricate: in order to reduce energy losses and wear inducing friction
between those.
2. Cool: in order to protect the engine components against overheating
because these components cannot give off heat directly to the coolant or
to the cooling air.
3. Seal: in order to guarantee the precision seal, seal between parts that slide
on or against each other (e.g. piston ring against cylinder well)
4. Clean: in order to remove abrasion, deposits and combustion residuals or
bind them in the oil so as to render them harmless to the engine
5. Protect against corrosion
6. Damp engine noise and vibration damping effect

Compiled by Trainer Daniel MAHIRE Tel: 0789950813 16

2.3. Motor oil
All engine oils have two components: additives and base oil. The total volume
of additives in motor oil can range from 20 to 30 percent, depending on brand,
formulation and application. These additives can enhance, suppress or add
properties to the base oil.

Most vehicle engines use some form of multi-grade oil. This type of oil has an
additive called a viscosityindex (VI) improver. A common example would be
10W-30 or 5W-40. These VI improvers are longchain organic molecules that
change shape as the temperature of their environment changes.

2.3.1. Commonly used viscosity grade are:

a) Single weight oil viscosity is greatly affected by the temperature of the

oil.
At low temperatures the oil has a higher viscosity.
At high temperatures the oil becomes thinner and its viscosity lowers.
Ex: SAE5; SAE10; SAE20; SAE30; SAE40.
SAE 40 oil performs well at higher temperatures, but becomes thick at low
temperatures.
For this reason, most engines use multi-grade oils that are more stable at
temperature changes.
b) Multi grade(Viscosity)
Multi-Viscosity oil can perform well across a larger range of oil.
Retains a specific viscosity at 0 F.
Increase in viscosity at high temperatures
Ex: 5W20: 20W50
5 Low viscosities at cold temperatures
W Winter
20 High viscosity at high temperatures

2.3.2. Identification the properties of oil

Lubricity: It is the ability of oil to reduce wear and friction even in extreme
conditions, it is important oil properties which help oil to perform its function
between moving parts by providing low friction
Viscosity: is a measurement of oil’s thickness, or resistance to flow. It is the
property of the liquid which tends to prevent relative movement between
adjacent parts within itself. Generally, thicker the fluid, higher is its viscosity;
whereas thinner liquids have lower viscosity.

Compiled by Trainer Daniel MAHIRE Tel: 0789950813 17

Viscosity Index: is a term which is mainly related to marine lubricating oils. It
can be defined as the change in viscosity of the oil which takes place as a result
of change of temperature.
Fire point of oil: Is the temperature at which heated oil will continue to burn
for at least five seconds after the ignition source has been removed.
Flash point of oil: Is a temperature at which heated oil can be ignited by an
external source. But when the source of ignition is removed, the vapour will
cease to burn.
Cloud point: is the point indicates the temperature at which waxes begin to form
in the oil
Pour point: it can be defined as the temperature at which the oil stops to flow.
Oxidation and corrosion: oiling forms a protective coating for the metal and
hence prevents it from rusting. Oil can penetrate the oxide-water on the metal
and stabilize it.
Flash Point: it can be defined as the lowest temperature at which the oil will
give off sufficient inflammable vapour to produce a flash when a small flame is
brought to the surface of the oil.
SAE: Society of Automotive Engineers is responsible
SAE 10W-30: means that the oil is SAE certified and has a grade 10 when it is
cold (W stands for winter) and 30 when it is hot.
NLGI: National Lubricating Grease Institute
API: American Petroleum Institute
Auto ignition point: auto ignition temperature or kindling point of a substance
is the lowest temperature at which it spontaneously ignites in normal
atmosphere without an external source of ignition, such as a flame or spark.

Viscosity rating
Viscosity of oil is determined by use of a viscometer. This device determines the
length of time required for the definite amount of oil to flow through an opening
of a definite size. Temperature is taken into consideration during this test
Lubricating oil is general rated using a viscosity scale established by Society of
Automotive Engineers (SAE)

2.3.3. Oil additives:

Additives are substances that are added to engine oil, transmission oil and
coolant to improve their properties.
Types of oil additives

 Anti-wear additives: These reduces wear especially in heavily loaded

areas such as between cam lobes and lifters

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  Rust &corrosion inhibitors: These protect metal parts of the engine
against rust and corrosion
 Viscosity index improvers: These increase the VI of the oil.
 Anti-foam agents: These minimize foam during use
 Oxidation inhibitors: These minimize oil thickening and varnish
formation at high temperatures
 Detergents and dispersants: They minimize the deposit build up in the
engine
 Pour point depressants: These enable the oil to flow at low temperature
 Friction modifiers: These reduce friction and increase fuel economy

IC2.4. Identification of engine lubricating system components

2.4.1. Introduction
The process of lubrication in an internal combustion engine begins in the sump,
commonly referred to as the oil pan where oil is stored. From here, the oil is
pulled from the sump by a pump through a strainer (pickup) where larger
contaminants in the oil is removed. After that, the oil is then moved via oil
passages or galleries and filter to remove small particles remaining in the oil to
the engine is lubricating parts (points) to be lubricated. After lubricating gravity
then pulls the oil back down to the bottom of the motor to drain back into the
sump, and the cycle repeats.

Engine lubricating system components

 Oil pan: holds the oil required for the system, provides a means of draining
the oil through the oil plug and houses the oil pump and pick up tube.
 Oil pump: provides a continuous supply of oil at sufficient pressure and
quantity to provide adequate lubrication to the entire engine. The pump is
driven either by the crankshaft, camshaft, distributor or timing belt.
 Pressure regulator: usually an internal part of the oil pump assembly,
relieves excess oil pressure by a spring and check valve.

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 Oil filter: the function of the oil filter is to remove dust, dirt, sludge, and water
before it reaches engine parts.
 Oil galleries: passages for oil to flow to various engine parts.
 Oil pressure indicator: gauge or light to indicate oil pressure problems. The
indicator is connected electrically to an oil pressure switch or “sending unit”.
 Oil cooler: cools motor oil to reduce oxidation. Not all vehicles are equipped
with this item.
 Oil level indicator: also known as dipstick, indicates the level of the oil in the
oil pan and sometimes has information such as the type of oil recommended
by the manufacturer. Some vehicles have an electronic sensor in the oil pan
to indicate low oil levels.

1. oil sump (oil pan)

The oil pan - or sump as it's also called - acts as a reservoir for the engine oil in
a car, it store the engine oils and cover the bottom of engine. oil pan is attached
to the bottom of the engine block. It serves as the reservoir for the engine’s oil.
It is designed to hold the amount of oil that is needed to lubricate the engine.
The oil pan also helps to cool the oil through its contact with the outside [Link]
oil pan is normally made of thin sheet metal especial steel or aluminium and
bolted to the bottom side of the engine block (cylinder block). It has drain plug
(drain valve) for oil change
The sump is the lowest area in oil pan where the oil collects as oil drains from
the engine. The oil pump can pull oil out of the oil pan for circulation.
It has baffles may be keep the oil from the suction point (side) during cornering,
acceleration and breaking. Oil pan also acts as a cooling surface. Oil pan sealed
by flat gasket or increasingly by liquid seals with silicon

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 2. Oil strainer/mesh filter or pickup tube
The engine oil strainer is designed to prevent debris and larger contaminants
from entering the vehicle's engine oil, remove contaminants as oil passes
through it before entering in the oil pump, it is also called pick up screen tube.

3. Oil pump
Oil pump – provides a continuous supply of oil at sufficient pressure and
quantity to provide adequate lubrication to the entire engine. The pump is driven
either by the crankshaft, camshaft, distributor or timing belt.
It picks up oil from the reserve in the oil pan through the inlet screen and pickup
tube. The oil is forced out of the pump outlet to a pressure regulator valve,
incorporated in the pump. Bearing clearances and metered oil holes in the engine
restrict the flow of oil from the pump resulting in a pressure build-up. To limit
this pressure, oil is returned to the oil pan through the pressure regulator valve.
Types of oil pumps
Types of oil pumps used in engine lubrication –
1. Gear pump
2. internal gear pump or crescent pump
3. rotor gear pump
4. vane pump
5. plunger pump
1. Gear pump
a. External gear pump
In these types of pump, the oil carried in the tooth spaces and delivered along
the inner pump wall to the other side the meshing of the teeth of two gears
prevents the oil from flowing back. A vacuum pressure and an over pressure are
generated on the section side and the pressure side respectively

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 2. Internal gear pump
This is a special type of gear pump
It located opposite side of fly wheel
Its inner gear is usually seated direction the engine crank shaft
An outer gear mounted in the pump housing is arranged eccentrically to the
inner gear
This creates a suction chamber and a pressure chamber which are separated
from each other by a crescent shaped space
The oil is delivered in the tooth spaces a long both the crescent-shape spacer

Advantage of oil crescent pump over conventional gear pump is that it has
higher delivery rate, especially at low engine speed
3. Rotary oil pump
This consist of an internal toothed outer rotor and externally toothed inner rotor
The inner rotor has one less tooth than the outer rotor and is connected to drive
shaft
The tooting of the inner rotor is shaped as such a way that each tooth touches
the outer rotor and largely seals the chamber created
As the rotors rotate, the pump chambers on suction side continually increase in
size and the pump draws in oil.

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The chambers on the pressure side decrease in size and the oil is forced into the
pressure line
The oil is simultaneously forced by several narrowing pump cells into the
pressure line so that the rotor pump operates uniformly
It is able to generate high pressure with a high delivery flow.

 Vane pump
This type of pump consists of cylindrical housing within which is eccentrically
mounted a driver rotor. The rotor contains a number of vanes in the rotor slots
equally spaced around its periphery.
These vanes can slip back and forth into the slots. The movements of sliding
vane are guided by means of control rings. When the pump operates the vanes
are pressed outwards against the housing by their centrifugal force. The oil
enters into the inlet port and is swept by the vanes to the outlet port.
This type of pump has an advantage as follows:
Oil continues flow compared to the pulsating oil flow in the case of gear

Figure 12: Vane pump

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 Plunger pump
Plunger pump is reciprocating type of pump in which the oil gets communicated
from the inlet to the outlet by alternate suction and pressure created by a
reciprocating plunger. This is way once used in the engine using splash
lubrication for filling the oil through, but is absolute now.

Figure 13: Plunger pump

4. Pressure relief valve
Pressure Relief Valve: This valve allows excess oil flow generated by the engine
oil pump to return to the sump.
A pressure relieving device in the lubrication system, directs excess oil pressure
in the oil pan ( tank).
If a pressure relieving device is not installed the lubrication system, pressure
could build up and create a process upset, instrument or equipment failure, or
fire.
Closed position
The relief valve spring tension determines the maximum oil pressure. when the
pressure delivered by the oil pump is acceptable by lubrication system
components, the relief valve is closed ( this means that the pressure delivered by
the oil pump is less or equal to the relief valve spring tension pressure)

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Open position
As the engine’s rotation speed increases, the quantity of oil that the pump
supplies to the lubrication system increases and the oil pressure of course
increases, this cause the oil pressure to be greater than the relief valve spring
tension pressure. This cause the spring loaded ball to be compressed and open
the passage then the excess oil is bleeded off either to the inlet of pump or to the
oil sump.

1. Oil filter
The oil filter removes most of the impurities that have been picked up by the oil
as it circulates through the engine.

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Oil filtration is typically achieved by two –stage filter system .
The first stage filtration known as the primary filters is of fairly coarse
wire mesh and prevents relatively large particles of dirt or swart from entering
the pump
Second stage filtration known as secondary oil filters are much finer filters
and are filtered on the pressure side of the pump to remove small particles
remaining in the oil
Designed to be replaced readily, the filter is mounted in an accessible location
outside the engine. There are two basic filter element configurations-the
Types of oil filter
They are some types of oil filter due to the position of filter as follows:
Primary or suction filter: this is also known as surface filter since the
impurities are retained on the outer surface of the filter. It uses coarse filter
material and also installed on the inlet side of oil pump.

Secondary filter: this filter is installed on the outside of the oil pump, the
impurities in these are retained progressively along the depth of the filter
materials, it is also known as depth filter. These filters are commonly used in
automobile engines and are various kinds or configurations, the important
ones out of them being are: cartridge type and spin-on type.
The cartridge-type element fits into a permanent metal container. Oil is
pumped under pressure into the container where it passes from the outside
of the filter element to the centre. From here, the oil exits the container. The
element is changed easily by removing the cover from the container.
The spin-on filter is completely self-contained, consisting of an integral metal
container and filter element. Oil is pumped into the container on the outside
of the filter element. The oil then passes through the filter medium to the
centre of the element where it exits the container. This type of filter is screwed
onto its base and is removed by spinning it off.

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They are also other different types of oil filter used in lubrication system
according on where they are located in the oil flow position.
Those types are:
Full flow oil filter and
Partial flow oil filter
Combination of full flow and partial flow oil filter
Differences Among Full-Flow, Bypass,
combination of full and partial flow and Dual
Oil Filters
A full-flow oil filter is the type of oil filter that is
standard on most of the vehicles that we drive
every day. If you have only one oil filter on your
vehicle, it is most likely a full-flow design. The oil
that goes through this filter goes on to lubricate
the entire engine. This filter removes the larger
particles of contaminant from the oil that may be
harmful to the engine.

A solo bypass( partial flow) oil filter is not

common. This type of filter may be found on older
applications.
The by-pass filter receives anywhere from 10 to
20 percent of the oil going to the engine. The
media used in this filter is very efficient and is
designed to remove the smallest particles of
contaminant. Oil that has gone through a by-pass
filter typically gets returned to the sump.

Using a full-flow oil filter along with a bypass

oil filter is a common practice( combination of
partial and full flow oil filter) and will typically
allow for longer oil change intervals. This is due
to the fact that cleaner oil is being introduced to
the full-flow oil filter as the bypass filter removes
the smallest contaminants. As a result, the full-
flow filter does not plug with contaminant as
quickly as it would without the by-pass filter.

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Dual-flow filters are designed with both full-
flow and bypass oil filter functions within the
same canister.

2. Overflow valve (by pass valve): If the filter is clogged or the oil became
too thick, the oil can flow unfiltered through the overflow valve past the
filter to the lubrication points.

Figure 17: Overflow valve

3. Return check valveThis can additionally be installed in the filter inlet

and outlet lines to prevent the full flow oil filter from running dry when
the engine is stopped.

Figure 18: Return check valve

How to find the correct oil filter for your vehicle or application.
 Look in the vehicle’s owner’s manual and/or service manual.
 Look on the old filter and find the number.
 Find the year, make, model and engine size of the vehicle and look it up in
the reference book or data base or contact the dealer.
 Use the Vehicle Identification Number (VIN) on the registration or the
vehicle and look it up in the reference book or data base or contact the
dealer.

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 4. Oil Cooler
Some engines require an additional oil cooler to help lower and control the
operating temperature of the engine oil. It consists of a radiator-like device,
called a heat exchanger, connected to the lubrication system by the use of an
oil cooler adapter. Oil is pumped through the cooler before it flows back into
the engine. The heat exchanger looks like a small radiator that is fitted onto
the vehicle in front of the radiator. Air flows across the fins of the heat
exchanger, cooling the oil before it goes back into the engine. The oil cooler
adapter is a device that fits between the filter and the oil filter housing. It
provides hose connections for the oil lines leading to and from the heat
exchanger.

There are two main types of oil coolers

1. Air-cooled oil coolers use a fan to blow air over the oil cooler fins to
cool the oil
2. Liquid-cooled oil coolers use a coolant to cool the oil. The coolant
circulates through the oil cooler passages and absorbs heat from the oil
5. Oil Level Gauge
The oil level gauge, also known as a dipstick, is usually of the bayonet type It
consists of a long rod or blade that extends into the oil pan. It is marked to
show the level of oil within the oil pan. Readings are taken by pulling the rod
out from its normal place in the crankcase, wiping it clean, insert it again,
and again removing and noting the height of the oil on the lower or marked
end. This should be done with the engine stopped unless the manufacturer
recommends otherwise. It is important that the oil level not drop below the
low mark or rise above the full mark.

6. Oil Galleries
Oil galleries are small passages through the cylinder block and head for
lubricating oil. They are cast or machined passages that allow oil to flow to
the engine bearings and other moving parts.

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The main oil galleries are large passages through the center of the block. They
feed oil to the crankshaft bearings, camshaft bearings, and lifters. The main
oil galleries also feed oil to smaller passages running up to the cylinder heads.
7. Oil Pressure Indicators
Oil pressure indicators inform the driver of the pressure or lack of pressure
in the lubrication system. There are two types:
1. oil warning light
2. pressure gauges
Oil pressure gauge
As its name, it is a gauge or indicator which indicates or records oil pressure
prevalent in the pressure system.
This allows the current oil pressure to be read off directly. A pressure sensor
is required in the pressure line after oil pump for pressure measurement.
Oil indicators are used to check when there are safe oil levels in an engine.
Pressure gauges may be electrical or mechanical
In the mechanical type, the gauge on the instrument panel is connected to an
oil line tapped into an oil gallery leading from the pump. The pressure of the
oil in the system acts on a diaphragm within the gauge, causing the needle to
register on the dial.
In the electrical type, oil pressure operates a rheostat connected to the engine
that signals electrically to the pressure gauge indicating oil pressure within
the system.

Oil pressure warning light

This goes out during the engine operation and indicates to the driver, whether
there is sufficient oil pressure available in the system. If, oil from the pressure
line presses on the switch contact body the earth ground contact from the
[Link] pressure telltale lamp is interrupted and the lamp goes out.

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The oil pressure warning light is used in place of a gauge on many vehicles.
The warning light, although not as accurate, is valuable because of its high
visibility in the event of a low oil pressure condition. Because the engine can
fail or be damaged in less than a minute of operation without oil pressure, the
warning light is used as a backup for a gauge to attract instant attention to a
malfunction.
The warning light receives battery power through the ignition switch. The
circuit to ground is completed through the oil pressure-sending unit that
screws into the engine and is exposed to one of the oil galleries. The sending
unit consists of a pressure- sensitive diaphragm that operates a set of contact
points. The contact points are calibrated to turn on the warning light anytime
oil pressure drops below approximately 15 psi in most vehicles.
8. Crankcase ventilation
In spark ignition engines and in particular turbocharged diesel engines are
subjected to blow- by gases which enter in the crankcase from the
combustion.
These gases which are contaminated by super fine, oil drop lets the fuel
residues, water vapour and soot particles are returned to the engine intake
air and oil separator. In order to decrease oil consumption, protect sensitive
engine components against contamination and thereby reduce emission, it is
essential for this gas to be filtered prior to recirculation. This operation is
performed by the oil separator.

9. The oil breather prevents pressure from building up in the engine

crankcase. This pressure build-up can cause oil leaks and other
problems. If the oil breather is clogged, pressure can build up in the
engine crankcase. This can cause oil leaks, damage to the engine seals,
and other problems
10. The oil baffle is a plate that prevents the oil from splashing
around too much in the sump. This helps to keep the oil pump from
becoming starved of oil, especially when the engine is cornering or
braking hard

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 11. The oil mist separator removes oil mist from the crankcase
gases before they are vented to the atmosphere. This helps to reduce oil
consumption and emission

2.5. Identify lubrication types

1. Splash lubrication
Splash Lubrication is pretty primitive. A hook, cast or bolted onto the
crankshaft, dips into the oil in the sump and splashes it around the inside of
the engine. This system was used on some of the first motorcycles in the early
1900s.

2. Forced-feed lubrication: lubricating internal combustion engines in

which a pump forces oil into the engine bearings

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Engine oil is stored in the oil pan or sump, The oil pump draws the oil from
the sump and passes it through a filter where dirt is removed. The oil is then
moved throughout the engine via oil passages or galleries. Because the oil
pump is a positive displacement pump, an oil pressure relief valve is used to
prevent excessively high system pressures from occurring as engine speed is
increased. After circulating through the engine, the oil returns to the sump.

The oil pump pickup is a line from the oil pump to the oil stored in the oil
pan. It usually contains a filter screen (strainer) which is submerged in the
oil at all times and a by-pass valve that allows oil to enter the pump if the
screen becomes totally plugged
The screen serves to keep large particles from reaching the oil pump. This
screen should be cleaned any time the oil pan is removed.

3. Wet sump oil lubrication system: The term sump is used to describe
a location where oil is stored or held. In most engines, oil is held in the
oil pan and the oil pump draws the oil from the bottom. The supply oil
is limited by the sump capacity. This type of system is called a wet
sump oil system.

4. Dry-sump lubrication system: the dry sump lubrication system use

two separate reservoir and two pumps (pressure pump and scavenge
pump)

In a dry-sump, the oil still falls to the base of the engine, however instead of
collecting in a reservoir-style oil sump, it falls into a much shallower sump,
where one or more scavenge pumps draw it away and transfer it to a (usually

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external) reservoir, where it is both cooled and de-aerated before being re-
circulated through the engine by a pressure pump.

Advantages of this system

 A smaller oil pan allows the engine to be mounted lower in the vehicle
 The oil capacity can be greatly expanded because the size of the
reservoir is not limited.
 cornering and braking for long period of time which is not able to be
done with a wet sump system due to oil being thrown to one side and
away from the oil pickup
 A dry sump system also allows the engine to develop more power as the
oil is kept away from the moving crankshaft
 Improved fuel economy
 Engine wear and startup emissions are reduced because oil is stored in
a thermo- type oil tank
Disadvantages of this system

 Dry sump systems add cost, complexity, and weight.

 The extra pumps and lines require additional oil and maintenance.
 Also, the performance-enhancing features of dry sump lubrication can
hurt a car's day-to-day drivability
 The oil never achieved the correct operating temperature because the
system was so efficient at cooling the oil.
Likewise in two-stroke engines:
5. Mixture lubrication: Lubricating oil is mixed with the fuel, either
manually beforehand (the petrol and oil method), or automatically via
an oil pump.
6. Total loss lubrication system

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LO3. Check of lubrication system
2.1. Selection of tools, materials and equipment

Equipment Computer, projector

car lift, PPE
Materials Drain pan, Engine oil, Oil filter, Rag, dump truck, Rags, engine
lubricating system components, white board, Marker pen and
Chalks, Black board. Drain pan, Engine oil, Oil filter, Rag,
dump truck, Rags

Tools Oil funnel, Complete tool box, Pliers, Spanners, Filter oil
wrench, Oil funnel, Complete tool box, Spanners, Oil filter
wrench, Pliers, Allen key, Filler gauge, Complete tool box.
Filter oil wrench, Spanners, Oil filter wrench, Pliers , Allen key
,Filler gauge ,Complete tool box.

2.2. Proper checking of oil pump

Methods of checking of oil pump

 Visual inspection
 Measurement
 Checking oil pump for wear like:
 Rotor tip clearance: by using feeler gauge and ruler, you put feeler
gauge between rotor and pump body. The clearance should not be
more than 0.01 inch (0.25mm)
 check the clearance between the tips of inner and outer rotor lobes
also using a filler gauge. measurement not more than 0.01 inch
(0.25mm)
Visual inspection
To inspect the pump in accordance with the manufacture’s specification this
will normally involve the use of feller blades, micrometre and verniers and
straight edge. These instruments are used in conjunction with a through
visual inspection.
How to check if an Oil Pump is bad
Keeping a close eye on your car's oil pump is extremely important because a
bad oil pump can deprive your engine of oil pressure and severely damage or
ruin it.
Step 1
Look at the dashboard when you slow down and when you take off. If the
"check oil pressure" light appears when you are stopped and disappears when
you begin moving, this is a sign that your oil pump is having problems.
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Step 2
Pop open your hood and remove your oil dipstick to check your oil. If your oil
measures low on your dipstick, there may be a crack in your oil pump, debris
stuck in the pump, or some other problem with your oil pump.
Step 3
Listen carefully for any noises coming from your engine, such as a rattling or
whining noise. A bad oil pump will cause the engine to lose oil pressure and
become damaged.
Step 4
Park your car and look underneath. If there is a large amount of oil on the
ground, the oil pump has gone out.
Take your car to a mechanic, who will have to remove your oil pump and
disassemble it. Reassembling the oil pump and putting it back in your car
is the only way to know for sure that your oil pump is the culprit of your car
problems
Low oil pressure - indicated on the oil-pressure gauge or dashboard warning
light - could provide an indication of wear or damage to the pump.
Checking oil for wear:
The oil pump wear can be checked by measuring on end plate clearance,
side (rotor) clearance, rotor tip clearance and gear end play clearance. The
clearance here should generally be no more than .010 in. (.25 mm).
There are many warning signs to tell you that your oil pump is about to fail.
Let’s learn about five of the most common signs:
A Drop in Oil Pressure
Increase in Engine Temperature
Noisy Hydraulic Lifters
A Loud Valve-Train
Low Sound from the Engine Oil Pump
Check oil pressure (How to Test an Oil Pump)
Engine oil pump may start to wear down over time and make your oil flow
inefficiently. While there are no ways you or a mechanic can directly test the
pump, you can check your oil pressure to determine if there’s an underlying
problem by following these methods or steps
1. Find the normal oil pressure for your engine in your vehicle’s manual.
2. Remove the oil pressure sender from your vehicle’s engine block with a
wrench
3. Attach an oil pressure gauge onto the sender port on your engine.
4. Turn on your vehicle and take a reading from the meter.
5. Take a reading from the gauge after the engine warms up. Leave your
car running for an additional 10-15 minutes after you first took a
reading so the oil warms up and starts to thin out.
6. Test the oil pressure at 2-3 different RPM levels to see any differences.
7. While your vehicle is still in park, lightly press down on the accelerator
and watch the engine speed dial on your dashboard. When you reach
1,000 or 1,500 RPM, keep your foot steady and check the reading on
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 your oil pressure gauge. Once you take the first reading, take another
at 2,500-3,000 RPM to compare how the pressure changes as you speed
up.
8. If the readings do not match the normal pressures listed in the manual,
then you may have an issue with the oil pump.

 Static testing of engine lubricating performance involves testing the

lubricating system components and fluids without running the engine.
This can be done by visually inspecting the components for wear or
damage, and by testing the fluids for viscosity, acidity, and other
properties.
 Static testing is a relatively inexpensive and non-invasive way to test
the lubricating system. It can be used to identify potential problems
before they cause engine damage. But its merits it cannot identify all
potential problems with the lubricating system. For example, it cannot
detect problems with the oil pump or the oil passages

Common static tests performed on the engine lubricating system

Visual inspection of the oil pan, oil filter, and oil pump for wear
1.
or damage
2. Testing the oil for viscosity, acidity, and water content
 Dynamic testing of engine lubricating performance involves testing the
lubricating system components and fluids while the engine is running.
This can be done by measuring the oil pressure, oil temperature, and
other parameters.
 Dynamic testing can identify all potential problems with the
lubricating system. It is also more accurate than static testing but is
more expensive and invasive than static testing. It also requires
specialized equipment.

Common dynamic tests performed on the engine lubricating system

1. Measuring the oil pressure at different engine speeds and loads

2. Measuring the oil temperature at different engine speeds and loads
3. Analyzing the oil for wear particles

Steps to follow while replacing an oil pump

1. Find a dry clean area (in workshop or garage)
2. Secure the vehicle with jack and jack stand
3. Position the oil drip pan and remove the draining bolt for draining
oil
4. Remove the oil pan bolts
5. Remove the oil strainer and remove the oil pump
6. Replace the old oil pump with a new pump
7. Seal the oil pan and reinstall it
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 2.3. Proper checking of oil filter
Open the filter and inspect the element. If the same is found clogged , the
same may be cleaned and reused but the better practice is to discard clogged
element and replace it with a new one. To check whether the filter is really
clogged, touch the same after running the engine for same time. If the filter is
hot to touch, it means it is clean
Procedures for changing Engine oil filter

1. put the vehicle on level surface

2. Locate and clean oil filter
3. Using filter wrench remove filter
4. Cleaning mounting location of the oil filter
5. Lubricate oil filter seal
6. Using hand install new oil filter
7. Tighten the filter according to the manufacturer’s recommendation
8. Check leakage for oil filter

The process of replacing defective oil strainer

1. Put the vehicle on service bay
2. Park the vehicle on level surface
3. Hand brake applied
4. Locate the oil pan
5. Perform draining procedures
6. Remount oil pan
7. Unscrew strainer bolts
8. Remove strainer
9. Check old strainer and
10. Change if necessary

2.4. LUBRICATION SYSTEM SERVICE

Oil level check with dipstick
Engine oil level must be checked at time before to start an engine, when you
are checking oil level we use the dipstick. On dipstick, there are different
marks that tell the level of oil. The fine oil level fill must be between those
marks. During filling oil don’t exceed oil over the maximum mark.
Process of checking engine oil level

1. First make sure your engine is off (no matter which temperature you’re
after).
2. Open your hood and find the dipstick.
3. Pull out the dipstick and wipe off the oil.
4. Reinsert the dipstick into its tube. Be sure to push it all the way in.
5. Pull the dipstick out again and check the oil level, looking at both sides. If
the top of the oil streak is between the upper/lower (maximum/minimum)
marks, then the level is good. However, if the oil is below the minimum mark,
it’s time to add some oil.

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Oil change
Vehicle manufacturers recommended on oil change at a specific interval. This
change can be performed by draining or drawing off engine oil with the engine
at normal operating temperature.
Draining engine oil
Procedure that must be followed during draining engine oil
1. Check the oil and oil filter that is recommended by the vehicle's
manufacturer.
2. Prepare the tools to be used. (pan, rag, spanners, jack, safety stand…)
3. Run your engine for about 5 minutes.
4. Hoist the vehicle. If a jack has to be used, remember to secure the
vehicle with a safety stand.
5. Place the drain pan under the rain plug
6. Loosen or unscrew the drain plug
7. Let the used oil flow into the drain pan
8. Tighten the drain plug
9. Remove the oil filter and clean the filter compartment
10. Place the new oil filter.
11. open the hood, locate engine oil filler cap and open it
12. Add new engine oil and close the filler cap
13. check egine oil level ( using a deepstick)
14. Jack down the vehicle
15. Start your car’s engine and let it run for a few minutes (to let the oil
circulate) then check for leakages
Mistakes to avoid when changing your engine oil
1. Using the wrong type of oil
2. Overfilling or under filling the engine with oil
3. Not changing the oil filter
4. Not disposing of the old oil and filter properly

Ways by which engine oil is lost

1. Leakage
2. Passing out of the crankcase in the form of mist
3. Burning in combustion chamber
3.5. Identification of oil pollution

There are 4 main elements of engine oil pollution

1. Temperature: When the engine temperature increase the oil start to lose
their original properties according to the change of temperature in the engine.
2. Dust: During refilling engine oil dust can get into the oil so that they can
pollute the oil
3. Metal particles: Particles from friction of internal components are the
source of dirty to the engine oil.
4. Carbon deposit: According to the operation of different moving parts dirty
can stack in the joints of components so that the can cause the oil to be
damaged.

Note: Mechanical contamination through dust; metal abrasion and

combustion residues can be largely eliminating by suitable filters.
Compiled by Trainer Daniel MAHIRE Tel: 0789950813 39
The stress of engine oil
1. Mechanical stress
2. Chemical stress
3. Thermal stress

The reason for regular oil changes:

Oil pollutions (stresses, contaminations) cause the following effects to
the oil.
Oil ageing: Air and combustion gases force their way into the crankcase
between the piston and the cylinder. This causes the oil to oxidase (age). Acids
may be formed in the process.
Oil slugging: separated oleoresins, road sweepings, metallic abrasion and
released combustion residues cause oil sludge to form.
Oil dilation: the high-boiling fuel constituents, which get into the oil
particularly when the engine is cold, result in oil dilution. The high
temperature causes oil becomes thin
Oil thickening: the heavy oil oxidation combined with the depositing of soot
particles, occasionally cause the oil to become thicken, mainly in diesel
engines.
Oil consumption: every engine has a certain level of normal oil consumption,
which must be compensated. This comes about because the oil gets in to the
combustion chamber (e.g. oil film on the cylinder wall, valve guides), where it
burns.

Note: For these reasons, it is necessary to check the oil level at regular
intervals and if necessary to top up the oil. Oil changes must be carried out
within the framework of vehicle servicing in accordance with the
manufacturer’s recommendations or in accordance with the flexible interval
display.

3.6. Troubleshooting table and repair.

Faults that can occur in engine’s lubrication system

 High oil consumption

 Low oil pressure
 High oil pressure
 Defective indicator or gauge circuit
 oil leaks
 noise ( usually from oil pump)

Number of things you can do to prevent problems (faults) with the engine
lubrication system

1. Change the oil regularly: Changing the oil regularly helps to remove
dirt, dust, and other contaminants from the oil. It also helps to prevent
sludge buildup.

Compiled by Trainer Daniel MAHIRE Tel: 0789950813 40

 2. Use the correct type of oil: The correct type of oil for your engine is
specified in your owner's manual.
3. Check the oil level regularly: Check the oil level regularly and add oil as
needed.
4. Inspect the lubrication system for leaks: Inspect the lubrication system
for leaks regularly. If you find any leaks, have them repaired
immediately.
5. Have the lubrication system inspected and serviced by a qualified
mechanic on a regular basis: A qualified mechanic can inspect and
service the lubrication system to ensure that it is in good working order.
6. Active lubrication systems: Active lubrication systems use sensors and
actuators to control the flow of oil to different parts of the engine. This
can help to improve engine performance and durability.
The table follows shows the faults and possible causesof lubrication
system and how to correct those problems:

FAULTS POSSIBLE CAUSES REMEDIES

Valve stem seals Replace the valve

Excessive oil faults seals
consumption High loss through Check for engine
leakage gaskets and
replace if
Piston rings necessary
damaged Oil Replace the rings
consumption due to Check the
bad cooling system engine
Damaged drain cooling system
plug gasket or bad and correct
drain plug the faults.
untighten Replace the gasket
Loss due to and tighten the
excessively high drain plug well
vehicle speed. Reduce the speed
Damaged engine and drive due
seals to
Too high oil level recommended rpm.
Replace the seals
Drain to specified
level

Compiled by Trainer Daniel MAHIRE Tel: 0789950813 41

 Oil level over period Petrol in the oil due Repair or replace if
of time to fault mechanical necessary.
pump.
Short journey use Drain oil or drawn
that cause petrol to off with fine gasket.
flow into
Test where water
the oil
pass and replace
damaged
Water seeping into line
the tank.
Oil level drops Worn piston rings Replace the piston
rapidly between which cause rings
services with no cylinder engine to
evident leaks. burn engine oil. Replace engine
Broken engine breather.
breather causing
engine to burn oil.
oil flows into Check the piston
the rings and on
combustion cylinder wall.
chamber
High oil pressure Use of incorrect oil Use oil with
specification correct oil
Defective oil specification
pressure gauge Inspect and repair
Clogged pressure Repair or replace
relief relief valve
valve Adjust valve
Excessively strong spring at correct
valve springs condition Clean
Oil line, galleries the lines and
may be clogged replace if
necessary
Oil pressure warning Low oil pressure Check oil pressure
lamp remain on Low engine oil level Fill the correct
Faulty oil pressure amount of oil
switch or circuit. Check and replace
Damaged of telltale the switch if
lamp necessary.
Replace the lamp

Compiled by Trainer Daniel MAHIRE Tel: 0789950813 42

Oil pressure too low Low oil level in tank Fill engine oil
Defective oil line Replace line
Incorrect use of Verify the oil
engine oil Repair or replace if
Oil pump damaged necessary
Clogged oil filter Replace filter
Weak relief valve Replace the
spring defective spring
Table 3: Troubleshooting table and repair

Compiled by Trainer Daniel MAHIRE Tel: 0789950813 43