SERVICE ENGINE SYSTEM

1. Service Starting System

OBJECTIVES
After completing the topic, the students should be able to:
1. Acquire knowledge of the function of starting system and its
components.
2. Test/ wiring starting system components and identify faults using multi-
tester.
3. Disassemble starter
4. Repair/replace and assemble starter components/parts

INTRODUCTION
1. The starting system is a combination of mechanical and electrical
parts that work together to start the engine.
2. You will be performing activities to develop your skill in testing/wiring
starting system components and identify faults, disassemble starter,
repair/replace parts and reassemble starter components.
3. You will also review underpinning knowledge such as electrical
principles, measuring and testing procedures.

I. DEFINITION
The starting system performs the function by changing electrical
energy from the battery to mechanical energy in the starting motor.
(fig.1. Actual and schematic diagram of starting system)

fig.1. Actual and circuit diagram

of starting system
II. HOW THE STARTING SYSTEM WORKS
A. When ignition key turn to the "Start" position, the battery voltage
goes through the starter control circuit and activates the starter
solenoid, which in turn energizes the starter motor.
 B. The starter motor cranks the engine. This motor transfers the
mechanical energy, through gears (pinion and ring), to the flywheel
on the engine's crankshaft.
C. During cranking, the flywheel rotates and the air-fuel mixture is
drawn into the cylinders, compressed, and ignited to start the engine.
(fig.2 is wiring diagram of starting system)

III. COMPONENTS
A. Automotive Battery
1. A device that converts chemical energy into electric energy.
2. It supplies electric current to the starter motor and to the ignition
switch when the engine is being cranked.
B. Starting Motor
1. A device that converts electric energy into mechanical energy.
2. It is designed to produce a large amount of torque for a short
period of time.

3. It operates when the ignition switch is turned to the start position.

Its purpose is to crank the engine for starting.
C. Starter Cables
A cable wiring that carries direct current from the battery to the
starting motor.
D. Ignition Switch
A mechanical switch which connect and controls electrical
current from the battery to the starting motor.
E. Fusible Link
A safety device installed in a circuit that interrupt short-circuit
and maintains constant flow of voltage.

IV. PREPARING FOR TEST/ WIRING OF STARTING SYSTEM

COMPONENTS.
A. Scale reading of an Analog/Digital Multi-tester
Scale reading is very important in testing the starting system of
automobile. The problem can be identified using any of these
equipment/instruments:
1. Digital meter 4. Ammeter
2. Analog meter 5. Ohmmeter
3. Voltmeter 6. Analog Multi meter
B. Definition of Analog/Digital Multi-tester
An instrument designed to measure electrical quantities. A
typical multimeter can measure alternating- and direct-current
potential differences (voltages), current, and resistance, with
several full-scale ranges provided for each quantity. Sometimes
referred to as a volt-ohm meter (VOM), it is a logical development of
the electrical meter, providing a general-purpose instrument.
C. Parts of Analog Multi-tester
 D. Measuring Current, Voltage and Resistance
1. Direction
a. Turn the zero position adjuster so that the pointer may align
right to the zero position.
b. Select a range proper for the item to be measured, set the
range selector knob accordingly.
NOTE: When determining a measuring range, select such one
for higher voltage than the value to be measured as well as where
the pointer of a meter moves to a considerable extent. However,
select the maximum range and measure in case the extent of value
to be measured cannot be predicted.

2. MEASURING DCV (Direct Current Voltage)

a. Set the range selector knob to an appropriate DCV range.
b. Apply the black test pin to the minus potential of measured
circuit and the red test pin to the plus potential.
c. Read the move of the pointer to V and A scale.

3. MEASURING ACV (Alternating Current Voltage)

a. Turn the range selector knob to an appropriate ACV range.
b. Apply the test leads to measured circuit.
c. Read the move of the pointer by V and A scale. (Use AC 10V
scale for 10V range only.)
 • Since this instrument employs the mean value system for its
AC voltage measurement circuit, AC waveform other than sine
wave may cause error.
•There occurs error under such frequencies other than specified
in the specification.

4. MEASURING DCA (Direct Current Amperes)

a. Turn the range selector knob to an appropriate DCA range.
b. Take out measured circuit and apply the black test pin to the
minus potential of measured circuit and the red test pin to the plus
potential.
c. Read the move of the pointer by V and A scale.

5. MEASURING OHMS ()

NOTE: Do not measure resistance in a circuit where a voltage is
present.
a. Turn the range selector knob to an appropriate  range.
b. Short the red and black test pins and turn the  adjustment so
that the pointer may align exactly to . (If the pointer fails to swing
up to  even when the  adjuster is turned clockwise fully, replace
the internal battery with a fresh one.)
c. Apply the test pin to measured resistance.
d. Read the move of the pointer to  scale.
Note: The polarity of + and - turns reverse to that of the test leads
when measurement is done in  range.

Self-check 1.1
Date:__________
Score:_________
Question:
1. What is referred to as to perform the function by changing electrical
energy from the battery to mechanical energy in the starting motor?
2. Sketch the schematic diagram of starting system and label its
components?
3. Discuss how starting system works?
4. Why scale reading important?
5. What scale instruments use to test and identify problem of starting
system of automobile?
6. What is referred to as a volt-ohm meter (VOM)?
7. Identify and pinpoint the parts of an analog tester?
8. Convert each of the following digital multimeter readings.
a. 340 mV to volts e. 7.5 ohms to kilohms
 b. 0.75 V to millivolts f. 2.2 kilohms to ohms

c. 2 A to milliamps g. 1.5 Megaohms to ohms

d. 1950 mA to amps

9. Scale reading of multi tester

Given the Settings on the Selector Knob:

a. Resistance (Ω) b. DC Voltage (V) c. Current (I)
a.1. X1k:_________ b.1. 10V:_______ c.1. 50µA:_________
a.2. X10:_________ b.2. 25V:_________ c.2. 2.5mA:________

Given the Settings on the Selector Knob:

d. Resistance (Ω) e. DC Voltage (V) f. Current (I)
d.1. X1k:_________ e.1. 10V:_______ f.1. 50µA:_________
d.2. X10:_________ e.2.. 25V:_________ f.2. 2.5mA:________
 Job sheet 1.1
Activity 1:
2. Perform electrical wiring of starting system correctly.
3. Name the parts of starting system.

Assessment Criteria:
1. Safety is observed while performing the task ------------ 30%
2. Correct electrical wiring.------------------------------------ 40%
3. Correct identification of parts.------------------------------ 30%
100%

V. PREPARING FOR REPAIR OF STARTER MOTOR

A. Starter Motor Operations
1. Conventional Starter Motor
a. IGNITION SWITCH IN “ST”
a.1. Current flows from the
battery through terminal “50”
to the hold-in and pull-in
coils. Then, from the pull-in
coil, current flows through
terminal “C” to the field coils
and armature coils.
a.2. Voltage drop across
the pull-in coil limits the
current to the motor, keeping
its speed low.
a.3. The solenoid plunger
pulls the drive lever to mesh the pinion gear with the ring gear.
a.4. The screw spline and low motor speed help the gears
mesh smoothly.

b. PINION AND RING GEARS

ENGAGED
b.1. When the gears are
meshed, the contact plate on
the plunger turns on the
main switch by closing the
connection between
terminals “30” and “C.”
b.2. More current goes to
the motor and it rotates with
greater torque (cranking
power).
b.3. Current no longer flows in the pull-in coil. The plunger is
held in position by the hold-in coil's magnetic force.

c. IGNITION SWITCH IN “ON”

 c.1. Current no longer
flows to terminal “50,” but the
main switch remains closed to
allow current flow from
terminal “C” through the pull-
in coil to the hold-in coil.
c.2. The magnetic fields in
the two coils cancel each
other, and the plunger is
pulled back by the return
spring.
c.3. The high current to the
motor is cut off and the pinion gear disengages from the ring
gear.
c.4. A spring-loaded brake stops the armature.

Job Sheet 1.2

Date:_____________
Score:___________
Activity 2:
1. Disassemble and assemble starter motor.
2. Name the parts of starter motor.

Assessment Criteria:
1. Safety is observed while performing the task ------------ 30%
2. Correct disassembly and assembly procedure------------ 40%
3. Correct identification of parts.------------------------------ 30%
100%
2. Service Charging System

Objectives:
After completing the topic, the students should be able to:
1. Acquire knowledge of the function of charging system and its
components.
 2. Test/ wiring charging system components and identify faults using multi-
tester.
3. Disassemble alternator; and
4. Repair/Replace and assemble alternator components/parts.

I. Introduction
1. The vehicle's charging system provides the electricity for maintaining
the battery's state of charge necessary to start the engine. It also
provides current for the spark plugs, lights, etc., while the engine is
running.
2. You will be performing activities to develop your skill in testing/wiring
charging system components and identify faults, disassemble
alternator, repair/replace parts and reassemble alternator components.
3. You will also review underpinning knowledge such as electrical
principles, repair procedures, electrical measuring and testing
procedures and vehicle safety requirements.
4. After doing the learning activities in this learner's guide you will be
assessed by your instructor on testing/wiring charging system
components and identify faults, disassemble alternator, repair/replace
parts and reassemble alternator components.
II. COMPONENTS AND FUNCTIONS OF THE CHARGING SYSTEM
The charging system (fig.1.) converts mechanical energy into
electrical energy when the engine is running. This energy is needed to
operate the loads in the vehicle's electrical system. When the charging
system's output is greater than that needed by the vehicle, it sends
current into the battery to maintain the battery's state of charge.

A. Operation
1. When the engine is running, battery power energizes the charging
system and engine power drives it.
2. The charging system then generates electricity for the vehicle's
electrical systems such as ignition and lighting.
3. At low speeds with some electrical loads "on" (e.g., lights and
ventilation), some battery current may still be needed.
4. At high speeds, the charging system supplies all the current
needed by the vehicle. Once those needs are taken cared of, the
charging system then sends current into the battery to restore its
charge.

B. Typical charging system components includes:

1. IGNITION SWITCH - When the ignition switch is in the ON position,
battery current energizes the alternator.
2. ALTERNATOR - Mechanical energy is transferred from the engine
to the alternator by a grooved drive belt on a pulley arrangement.
Through electromagnetic induction, the alternator changes this
mechanical energy into electrical energy. The alternating current
generated is converted into direct current by the rectifier, a set of
diodes which allow current to pass in only one direction.
 3. VOLTAGE REGULATOR - Without a regulator, the alternator will
always operate at its highest output. This may damage certain
components and overcharge the battery. The regulator controls the
alternator output to prevent overcharging or undercharging. On older
models, this is a separate electromechanical component which uses
a coil and contact points to open and close the circuit to the
alternator. On most models today, this is a built-in electronic device.
4. BATTERY - The battery supplies current to energize the alternator.
During charging, the battery changes electrical energy from the
alternator into chemical energy. The battery's active materials are
restored. The battery also acts as a "shock absorber" or voltage
stabilizer in the system to prevent damage to sensitive components in
the vehicle's electrical system.
5. INDICATOR - The charging indicator device most commonly used
on cars today is a simple ON/OFF warning lamp. It is normally off. It
lights when the ignition is turned "on" for a check of the lamp circuit.
And, it lights when the engine is running if the charging system is
undercharging. A voltmeter is used on current models to indicate
system voltage. ... it is connected in parallel with the battery. An
ammeter in series with the battery was used on older models.
6. FUSING - A fusible link as well as separate fuses are used to
protect circuits in the charging system.

Fig.1. Charging system

C. Schematic diagram of charging system (conventional type)

1. Charge warning lamp type voltage regulator, 6 leads (Fig.2)
 Voltage Regulator
Alternator
B
E F
L
-- _ -- F IG

N N E
B

Light Indicator

+ --
AM IG
-- + Ignition Switch
Battery Ammeter ACC ST

Fig.2 Schematic diagram of Charge Warning Lamp Type voltage

regulator (6 leads)

2. Ammeter Type Voltage Regulator, 3 leads

Voltage Regulator
Alternator
E F F IG
-- _ --
E
N
B Light Indicator

+ --
AM IG
-- + Ignition Switch
Battery Ammeter ACC ST

Fig. 3. Schematic diagram of Ammeter Type Voltage Regulator, 3

leads

LEGEND:
 B – battery E - Ground/ Earth
N – neutral IG – ignition
L – light F – field

III. PREPARING FOR TEST/ WIRING OF CHARGING SYSTEM

COMPONENTS.
A. Ohms Law
1. Discovered by George Simon Ohm on 1926
2. The relationship between the current, voltage and resistance.
3. Ohms Law states that: “The higher the voltage, the larger the
current, and the higher the resistance, the lower the current.”
4. Presented in the following equations: I= V / R V = IR R = V / I

Where: I = Current flow (in unit amperes)

V = Electromotive force (in unit volts)
R = Resistance (in unit Ohms)

B. Comparison of AC and DC Electricity

1. Electric current is classified as: Direct Current (DC) and
Alternating Current (AC)
a. Direct Current (DC) – Flows in one direction, from negative to
positive. The normal source is dry cell or storage battery.
b. Alternating Current (AC) – Constantly reverses its direction of
flow. Generated by a machine called generator.
2. Power Formula
a. DC electricity: P = I x V (unit is watts)
b. AC electricity: P = I x V (unit is volt-ampere)
P = I x V x pf (unit is watts)
where: P = Power
pf = power factor
3. Further Algebraic Manipulation of the Formula
P = I2 x R I=P/I V=P/I R = P / I 2 P = V2 / R I=

√ P
R
V = √Px R R = V2 / P

C. Types of Circuits
There are three basic types of circuits: series,
parallel, and series-parallel. The type of circuit is determined by how
the power source, conductors, loads, and control or protective devices
are connected.

1. SERIES CIRCUIT
a. A series circuit is the simplest
circuit. The conductors, control and
 protection devices, loads, and power source are connected with
only one path for current.
b. The resistance of each device can be different. The same amount
of current will flow through each. The voltage across each will be
different.
c. If the path is broken, no current flows.
d. Formula: RT = R1 + R2 + R3 ...
I T = I1 = I2 = I3 ...
V T = V1 + V2 + V3 ...

2. PARALLEL CIRCUIT
a. A parallel circuit has more than one
path for current flow.
b. The same voltage is applied across
each branch. If the load resistance in
each branch is the same, the current
in each branch will be the same. If
the load resistance in each branch is
different, the current in each branch
will be different.
c. If one branch is broken, current will continue flowing to the other
branches.
d. Formula: VT = V1 = V2 = V3 ...
1/R T = 1/R1 + 1/R2 + 1/R3 ...
IT = V/R1 + V/R2 +V/R3 ...
= V(1/R1 + 1/R2 + 1/R3 ...)

3. SERIES-PARALLEL CIRCUIT
a. A series-parallel circuit has some
components in series and others
in parallel.
b. The power source and control or
protection devices are usually in
series; the loads are usually in
parallel.
c. The same current flows in the
series portion, different currents in
the parallel portion. The same
voltage is applied to parallel devices, different voltages to series
devices.
d. If the series portion is broken, current stops flowing in the entire
circuit. If a parallel branch is broken, current continues flowing in
the series portion and the remaining branches.

EXERCISE:

ACTIVITY 1 Calculation on Types of Electrical Circuit

 1. Basic Circuit
Example
Given: If Resistance; R=2 ohms
Voltage; V = 12.0 volts
Required: What would the current be?
R
Solution:
From Ohms Law
V=IxR
By cross multiplication;
V I xR
=
1 1
V
I=
R
12 v
I=
2Ω
I = 6A

2. Series Circuit
Example
Given: If R1=2 ohms, R2=3 ohms, V = 12.0 volts
Required: What would the current be?
Solution: R1
RT = R1+ R2= 2 + 3 = 5 ohms (Resistance Total)
V
I= R2
R
I =12/5 = 2.4 Amps

Exercise: Solve what is required.

1. AT = 2, VT = 12, RT = _________
2. R1 = 4,R2 = 4, V = 12, A = ____________
3. R1 = 4, R2 = 2, AT = 2, VT = ____________
4. VT = 12, AT = 6, RT = ___________
5. AT = 3, RT = 8, VT =_____________

Parallel Circuit
VT
Example:
Given: If R1 = 3 ohms, R2 = 6 ohms + _-
V = 12.0 volts
Required:
A. What would the current be for the R1 branch? The R2 Branch?
B. What would be the total circuit current? R1 R2
C. What would be the total resistance?
Solution: AT R2 R1
V
A. I1 = = 12/3 = 4 amps ( R1 branch current)
R
V
I2 = =12/6 = 2 amps (R2 branch current)
R
B. I T =I 1 + I 2=¿ 4 + 2 = 6 amps (Total circuit current)
1 1 1
C. = +
Rt R 1 R 2
1 1 1
= +
Rt 3 6
find the LCD
1 2+1 3 1
= = =
Rt 6 6 2
Cross multiply
1 1
=
Rt 2

Rt = 2Ω

Exercise: Solve what is required.

1. R1 = 2, R2 = 1, R3 = 2, R4 = 1, RT = ____
2. Using RT from Question 1, VT=12, AT = ____
3. R1 = 2, R2 = 1, R3 = 2, R4 = 4, RT = ___
4. Using RT from Question 3, VT =12, AT =___

3. Series- parallel Circuit

Example
Given: R1 = 8Ω, R2 = 6 Ω, R3 = 2 Ω, Vt =24v, It = 6A
Required: A. Rt =?
B. V1 = ?
Solution:
A. Rt = R1 + R2-3 R1
find R2-3
1 1 1 R2 R3
= +
R 2 −3 R 2 R 3
1 1 1
= +
R 2 −3 6 2
Find the LCD
1 1+ 3 4
= =
R 2 −3 6 6
Cross multiply
1 4
=
R 2 −3 6
R2-3 =0.67Ω
Substitute
Rt = R1 + R2-3 = 8 + 0.67
Rt = 8.67Ω

B. Ohm’s Law
V1 = I1 x R1
Where I1= It = 6A
Substitute
V1 = 6A x 8Ω
V1 = 48v
 Self-check 2.1

1. Determine the current flow in a circuit having a resistance of 5 Ohms on

a 120 volts and 240 volts current supply.
2. A circuit has a resistance of 20 Ohms and the current flows at 12
amperes. Determine the voltage.
3. A 12 amperes electric fan and blower with a power factor of 0.85 was
connected to a 240 volts convenient outlet. Calculate the current and
power in the circuit.
4. An electric motor has a trade mark label of 2 horse power, 240 volts, 15
amperes. Calculate the motor power factor.
5. Series/parallel circuit problems.
a. We have a series circuit like this. What is the total voltage, resistance
and current?

b. What is the total resistance and voltage? And voltage and current on
A, B, and C?

c. What is voltage on A, B, and D?

What is current on A, B, C, and D?
What is resistance on C?
What is total current and resistance?

.
 Job Sheet 2.1

Date:_____________
Score:___________
Activity 1:
2. Perform electrical wiring of charging system correctly.
3. Name the parts of charging system and principles of operation.

Assessment Criteria:
1. Safety is observed while performing the task ------------ 30%
2. Correct electrical wiring.------------------------------------ 40%
3. Correct identification of parts.------------------------------ 30%
100%

PARTS AND FUNCTIONS OF AN ALTERNATOR

After you have disassembled the alternator, you are ready to identify and
sequentially state the function of each part. You may use the Parts Identification
Sheet showing the disassembled parts in numerical order. Identify each part indicated
by the arrow and number correspondingly.

Components of an Alternator (Tirrill Regulator Type)

1. Through Bolt 7. Insulator

2. Space Collar, Pulley & Fan 8. Rear End Cover (except RN)

3. Space Collar 9. Rear End Frame

4. Drive End Frame & Front Bearing
5. Space Collar 10. Insulator

6. Rotor & Rear Bearing 11. Brush Holder & Rectifier Holder

12. Stator Coil

Separate IC Regulator Type

1. Through Bolt 7. Noise Suppression Condenser

2. Space Collar, Pulley & Fan 8. Insulator

3. Space Collar 9. Rear End Frame

4. Drive End Frame & Front Bearing 10. Insulator

5. Space Collar 11. Brush Holder & Rectifier Holder

6. Rotor & Rear Bearing 12. Stator Coil

Built-in IC Regulator Type

1. Through Bolt 8. Insulator

2. Space Collar, Pulley & Fan 9. IC Regulator

3. Space Collar 10. Rear End Frame

4. Drive End Frame & Front Bearing 11. Insulator

5. Space Collar 12. Brush Holder & Rectifier Holder

6. Rotor & Rear Bearing 13. Stator Coil

7. Noise Suppression Condenser

FUNCTIONS of an Alternator

1. Space collar - a spacer installed in the rotor shaft which is separates the rotor, drive
end frame and front bearing.

2. Pulley and fan - a pulley attached to the rotor shaft with a lock washer and nut. A V-
belt or a ribbed belt is usually installed through the grooved pulleys of the alternator
and the cooling fan of the radiator. A built-in fan inside the alternator provides a flow
of cooling air to its internal parts. The fan is located behind the pulley.

3. Drive end frame - the front end housing of the stator coil and rotor assembly.

4. Rotor - the rotating part of an alternator that usually contains the field windings.

5. Noise suppression condenser - provides a storage place of electricity.

6. IC Regulator - IC connected between a battery supply and electronic control circuit

or alternator to keep the circuit voltage steady when the battery voltage changes.

7. Brushes - small blocks of carbon that conducts electric current to the slip rings of an
alternator rotor.

8. Rectifier - an electric circuit that changes alternating current (AC) into direct current
(DC).

9. Stator/Core - this is found in the middle of the alternator. The stator has a number of
coils which are the main windings which carry alternator voltage.

10. Rear-end bracket - this is the rear part of the alternator. It encloses the rear of the
alternator and also forms part of the alternator mounting.
 Job Sheet 2.2

Date:_____________
Score:___________
Activity 2:
1. Disassemble and assemble alternator.
2. Name the parts of alternator and principles of operation.

Assessment Criteria:
1. Safety is observed while performing the task ------------ 30%
2. Correct disassembly and assembly procedure------------ 40%
3. Correct identification of parts.------------------------------ 30%
100%

QUIZ ON THE COMPONENTS AND FUNCTIONS OF THE CHARGING

SYSTEM

Test I. True or False. Write “True” if the statement is correct and

“false” if the statement is wrong. (10 items)
1. The electrical energy from charging system is needed to operate the
loads in the vehicle's electrical system.
2. When the charging system's output is greater than that needed by the
vehicle, it sends current into the battery to maintain the battery's state
of charge.
3. Starting system generates electricity for the vehicle's electrical
systems.
4. At low speeds with some electrical loads "on" (e.g., lights and
ventilation), some battery current may still be needed.
5. Once energy needed from electrical loads are taken cared of, the
charging system then sends current into the battery to restore its
charge.
6. The direct current generated by alternator is converted into
alternating current by the rectifier, a set of diodes which allow current
to pass in only one direction.
7. The fuse controls the alternator output to prevent overcharging or
undercharging.
8. The battery also acts as a "shock absorber" or voltage stabilizer in
the system to prevent damage to sensitive components in the
vehicle's electrical system.
9. The rectifier, brush holder, and IC regulator are bolted onto the end
frame.
10. When the ignition switch is "on," battery current is supplied to
the regulator through a wire connected between the switch and
terminal "IG".
Test II. Multiple Choice. Write the letter that corresponds to your
answer. (5 items)
11. What engine system that converts mechanical energy into
electrical energy when the engine is running.
a. lighting system b. charging system c. starting
system d. ignition system
12. Mechanical energy is transferred from the engine to the
_________ by a grooved drive belt on a pulley arrangement.
a. starter motor b. voltage regulator c. alternator
d. ignition switch
13. When the ____________is in the ON position, battery current
energizes the alternator.
a. voltage regulator b. alternator c. ignition switch
d. battery
14. Without a _________ the alternator will always operate at its
highest output.
a. alternator b. ignition switch c. battery d.
voltage regulator
15. It lights when the ignition is turned "on" for a check of the lamp
circuit. And, it lights when the engine is running if the charging
system is undercharging.
a. charging indicator b. alternator c. regulator
d. fuse
16. Used to protect circuits in the charging system.
a. charging indicator b. fuse c. regulator
d. fuse

Test II. Give what is required. (18 items)

a. Name the components of charging system (6 items)
b. Name the components of alternator as shown the drawing below
(12 items)
 Engine Cooling System

Objectives: After completing the topic, the students should be able to:
1. Explain coolant circulation within cooling system
2. Check thermostat condition
3. Perform leakage test on cooling system
4. Repair/replace water pump
5. Apply coolant additives

I. Facts About Cooling System

1. High or extreme temp. is enough to melt the cylinder block in 20
minutes.
2. 1/3 of the heat is converted to mechanical energy though reciprocating
of piston.
3. 1/3 or 33.3% goes out of the tail pipe as exhaust gas.
4. the remaining 1/3 has to handle the cooling system.
5. effects of extreme heat in the engine gives:
a. greatly accelerated wear of engine parts.
b. increase fuel consumption
c. increase of sludge/scale contents or deposits in lubricating oil.

II. Definition
Cooling system remove excessive heat and maintain the proper working
temperature of the engine.

III. How Cooling System Works?

1. Engine heat gets rid by circulating coolant.
2. Coolant flows through cylinder water jackets.
3. Hot water is pumped through the radiator where water gives off the
heat through the airflow.
4. The cold water from the radiator flows back to the cylider jackets to
absorb heat.

IV. Types of Engine Cooling System

Engines use either of two types of cooling systems: air cooling and
liquid cooling.

1. Liquid-Cooled System
The most popular and efficient method of engine cooling is the
liquid-cooled system. In this system, heat is removed from around
the combustion chambers by a heat-absorbing liquid (Coolant)
circulating inside the engine. This liquid is pumped through the engine
and, after absorbing the heat of combustion, flows into the radiator
where the heat is transferred to the atmosphere. The cooled-liquid is
then returned to the engine to repeat the cycle. Excessive cooling
capacity can decrease engine efficiency. Therefore, systems are
designed to keep engine temperatures within a range where they
provide peak performance.
 Major components of a typical liquid-cooling system. Arrows indicate the
coolant flow.

1. Air-Cooled System
Few engines use a coolant system that employs air rather than
liquid as the medium to transfer heat from the engine components to the
atmosphere. Cylinders and heads have fins and are enclosed in a
surface area to airflow for better dissipation. Ducts and shrouds direct
the overflow over the engine components, especially over the hotter
cylinder head area. A belt-driven or electric blower provides the means
for airflow. Fresh air is taken in and heated air expelled into the
atmosphere. A thermostat connected to a control valve or door
regulates airflow to control engine temperature.

V. Cooling-System Components and their Functions

1. Water Jacket – space between the inner and outer shells of the
cylinder block or cylinder head, through which coolant circulates
2. Water Pump – an engine-driven centrifugal pump that circulates
coolant between the engine water jacket and the radiator.
3. Engine Fan or Cooling Fan – pulls or pushes the additional air through
the radiator. It maybe either a mechanical fan or an electric fan.
4. Drive Belt – a continuous loop of reinforced rubber used to transmit
power between to shafts.
5. Radiator – heat exchanger that removes heat from coolant passing
through it; receives hot coolant from the engine and returns the
coolant to the engine at a lower temperature.
6. Thermostat – a heat-operated valve that regulates the flow of liquid-
coolant between the engine and the radiator, thereby controlling coolant
temperature; a control device containing a temperature-sensitive
element that automatically reacts to temperature changes by bending
and straightening, or expanding or contracting.
VI. The Cooling System and Its Effects to the Engine
The cooling system is often neglected. A customer will spend a great
deal of money on an overhaul but will not get a complete repair if the
cooling system is not put in good order. Radiators often become plugged
or rotten. If the radiator cannot conduct enough heat away, the engine will
overheat.

The following may cause overheating to the engine and have to be

checked:
1. low coolant level
2. loose belt (belt-driven water pump)
3. defective pressure cap
4. defective thermostat
5. idle speed too low
6. defective thermal control fan
7. defective electric fan circuit
8. plugged radiator coolant passages
9. Plugged air passages in the radiator
10. defective water pump
11. defective cylinder heated gasket

VII. Thermostat
The automotive thermostat functions somewhat like a typical home
thermostat. It attempts to control the engine’s operating temperature by
routing the coolant either to the radiator or through by-pass or sometimes
by a combination of both.

A. Location of a Thermostat
While a thermostat might be situated in several locations, the most
common spot is at the front of the engine on top of the engine block. The
heat element fits into a recess in the block where it will be exposed to hot
coolant. The top of the thermostat is then covered by the water outlet
housing, which holds it in place and provides a connection to the upper
radiator hose.

B. Parts of a Thermostat
C. Procedure in Removing the Thermostat
Objective:
Given an engine, set of sockets, screwdrivers, mechanical pliers and
container, you will remove the thermostat from the engine and observe
Occupational Health and Safety practices.

Instructions:
1. Prepare tools and materials needed.
2. Wear protective clothing and goggle
3. Open the radiator drain plug
4. Loosen the screw of the radiator hose clip
5. Remove the hose from the radiator and turn it aside.
6. Loosen the nuts and bolts in the water outlet connection and remove
them.
7. Remove the thermostat.
D. Testing the Thermostat
Objective:Given the instrument and materials needed, you will test the
condition of a thermostat. Observe Occupational Health and Safety
practices while this.

Instructions:
If the thermostat is removed from the engine after the coolant has
been drained, suspend the thermostat completely submerged in a small
container of water so that it so does not touch the bottom. Place a
thermometer in the water so that it does not touch the container and only
measures water temperature. Heat the water. When the thermostat valve
barely begins to open, read the thermometer. This is the opening
temperature of this particular thermostat. If the valve stays open after the
thermostat is removed from the water, the thermostat is defective and must
be replaced.
 Job Sheet 3
Procedure on the Installation of the Thermostat
Objective:Given an engine, set of socket wrench, flat head screwdriver,
mechanical pliers, vellunoid gasket, gasket maker, thermostat,
container and gasket scraper, you will install thermostat in the
cooling system and observe Occupational Health and Safety
practices.
Instructions:

1. Prepare tools and materials needed

2. Wear protective clothing and goggles.
3. Scrape the worn-out gasket on the water outlet connection surfaces.
4. Install the thermostat in the water outlet connection.
5. Apply gasket maker in the water outlet connection surfaces
6. Mount the water outlet connection and tighten the nuts and bolts.
7. Install the radiator hose and tighten the clip.
8. Close the radiator drain plug.
9. Pour water into the radiator.
[Link]-run the engine.
 Servicing Lubricating System

Objectives:
After completing the topic, the students should be able to:
1. Explain oil cycle within the engine.
2. Identify type, classification and application of engine oil.
3. Overhaul oil pump, replace oil filter and change oil.

Purpose of Lubricating System

The lubricating system supplies lubricating oil to all moving parts in

the engine. Figure 1-1 shows the lubricating system for a four – cylinder
OHC spark – ignition engine.

Figure 1-1. Lubricating system for a four-cylinder OHC spark-ignition

engine, which also has a turbocharger and oil cooler. (Mazda Motors of
America, Inc.)

Figure 1-2 shows an in–line six-cylinder engine. Oil flows up through

the hollow pushrods to lubricate the rocker arm and valve stems. Some of
the oil thrown off the connecting-rod bearings land on the cylinder wall. In a
V – type engine, the oil splashes on the cylinder wall of the opposing
cylinder in the other cylinder bank. This lubricates the pistons, piston rings,
and piston pins.

Many engines have small matching grooves or an oil-spurt hole (Figs,

1-3) in each connecting rod. The opening provides additional piston and
cylinder-wall lubrication. A spurt of oil sprays out when the hole in the rod
aligns with the crankshaft – journal oil hole once each revolution.
 Figure 1-3. When a hole in the
Figure 1-2 Lubricating system for an connecting rod aligns with a hole
inline OHV engine. Arrows show the in the crankshaft journal, a spurt
flow of oil to the moving parts in the of oil sprays onto the cylinder
engine. (Buick Division of General walls to lubricate the piston and
Motors Corporation) rings. (Ford Motor Company)

LUBRICATING – SYSTEM COMPONENTS

1.) OIL PUMP

The gear–type (fig.1-4) pump

has a pair of meshing gears. As
the gears unmeshed, the spaces
between the teeth fill with oil
from the pump inlet. The gears
mesh and force the oil out
through the pump outlet.

Figure 1-4. Disassembled gear-type oil

pump. (Chevrolet Division of General
Motors Corporation)
The rotor–type oil pump (fig.1-5)
uses an inner rotor and an outer
rotor. The inner rotor is driven
and drives the outer rotor. As the
rotors turn, the spaces between
the lobes fill with oil. When the
lobes of the inner rotor move
into the spaces in the outer
rotor, oil is forced out through
the pump outlet.

Figure 1-5. Disassembled rotor-type oil

pump. (Chrysler Corporation)
 Various arrangements are used to drive the oil pump. In camshaft –
in – block engines, the camshaft spiral gear that drives the ignition
distributor usually drives the oil pump. Some engines drive the distributor
directly from the end of an overhead camshaft. The oil pump on these
engines may be driven by a separate drive shaft or jackshaft. An engine
with distributor less ignition may have a crankshaft – driven oil pump. Other
engines have a crankshaft – driven rotor – type.

An oil pump, consists of the following parts:

 Pickup and screen  Gears or rotors

 Housing and cover  Oil pressure relief valve

Pickup and Screen

The oil pickup is a hollow, flat cup mounted at the end of a tube.
Mounted over the cup is a screen to prevent large particles from entering
the pump and damaging the gears and housing. The pickup tube leads to
the intake, or low pressure, side of the pump.

Housing and cover

The housing encloses the gears or rotors and contains a drive shaft
for one of the gears.

Gears or rotors

Two gears or rotors are meshed in the housing. One of the gears is
driven, in most cases by a shaft from the distributor drive gear. At the point
where the oil pump gears unmeshed, or separate, a low pressure area is
created. Atmospheric pressure forces the oil up through the pickup to the
low pressure area. The oil is then carried around the outside of the gear, in
the chambers formed between the teeth, housing, and side plates. As the
oil reaches the outlet port, it is forced out, under pressure, as the teeth go
back into mech. Thus, oil is forced out of the pump under pressure to the oil
filter.

Oil pressure relief valve

To prevent excess pressure from developing, a relief valve is used. A

spring holds a check valve or ball on a seat in the oil outlet. When oil
pressure develops more force against the check valve than the spring, the
valve is pushed open. This action uncovers a relief passage that allows oil
to be redirected to the inlet side of the oil pump. In action, the valve acts as
a controlled leak and allows only enough oil out to maintain a controlled
pressure.
2.) OIL COOLER

It prevents the oil from getting too

hot. In the oil cooler (fig.1-6),
engine coolant flows past tubes
carrying the hot oil. The coolant
picks up the excess heat and
carries it back to the engine
radiator. Outside air passing
through the radiator carries away
the heat.

Another arrangement that

transfers heat to the engine
coolant. A hose from the oil filter
carries engine oil to oil–cooler
tube in the side tank of the
radiator. As the oil flows down the
tube, the oil loses heat to the Figure 1-6. Reassembly steps:
coolant. The cooled oil then flows 1. Oil Filter Body
back to the oil filter and to the  2. Relief valve
engine. A similar arrangement 3. Safety valve (oil cooler)
cools the fluid in automatic 4. O-ring
transmission and transaxles.  5. Oil cooler
 6. Oil filter cartridge
Engines in severe service such as  7. Drain plug
those in taxis and police cars use
a radiator–like oil cooler that
mounts in front of the engine
radiator. The excess heat
transfers from the oil to the
outside air passing through the oil
cooler. A similar system cools
automatic–transmission fluid.

3.) OIL FILTERS

All automotive engine lubricating

systems have an oil filter (Fig.1-
7). The oil from the pump flows
through the filter before reaching
the engine bearings. The filter
has a pleated – paper filtering
element. It allows the oil to pass
through while trapping particles of
dirt and carbon.

The filter has a spring–

loaded particles bypass valve. It Figure 1-7. Connection to engine oil
opens to protect the engine from cooler, located in the left radiator tank.
oil starvation if the filter becomes (Chevrolet Division of General Motors
clogged. Then unfiltered oil Corporation)
bypasses the filter and goes
directly to the engine. However,
the filter should be changed
before this happens.

Some oil filters have an anti–

drain back valve. It helps prevent
oil from draining out of the filter
while the engine is off. A full
supplies oil quickly on starting.
This reduces wear and possible
damage. They attach to the
outside of the engine. Some
engines have an internal oil filter.
It mounts inside the pan and
attaches directly to the oil pump.
Removing a large drain plug
allows the filter to be changed. Oil filter, cutaway to show the built-in
bypass valve. (Chrysler Corporation)

4.) OIL PAN

The oil pan (fig.1-8), bolted to the

engine crankcase area, serves
as a reservoir for oil. A drain plug
can be removed to allow the
engine oil to drain out during oil
changes. An oil pump and pickup
are mounted on the crankcase
inside the oil pan.

Figure 1-8. Internal oil filter, which

attaches to the oil pump inside the oil
pan. (Pontiac Division of General
Motors Corporation)

LUBRICATING – SYSTEM INDICATORS

5.) OIL – PRESSURE
INDICATORS

An oil–pressure indicator in the

instrument panel warns the driver if
engine oil pressure is too low.
There are six types of oil –
pressure indicators.

1. Indicator Light. The light

connects in series with the
battery, the ignition switch, and
an oil-pressure switch on the Figure 1-9. Electric circuit of an oil-
engine (Fig.1-9). The oil indicator lamp.
pressure switch is closed when
the engine is not running. When
the ignition key is turned to ON,
the indicator light glows.
As soon as the engine starts, pressure builds up in the lubricating system.
This opens the oil–pressure switch and the light goes out. Anytime engine
oil pressure falls below a preset minimum, the pressure switch closes and
the light comes on.

2. Electric Gauge- Fig.1-10

shows analog oil – pressure
gauge. The operation is
similar to the fuel gauge. The
oil–pressure gauge may be a
magnetic gauge or a thermal
gauge. In the magnetic oil–
pressure gauge the engine
unit has a diaphragm
connected to a sliding
contact. Engine oil pressure
pushes the diaphragm up.
This moves the sliding Figure 1-10. Electric circuit of an oil-
contact along the resistance. pressure gauge.
An increase in oil pressure
causes the sliding contact to
increase the resistance in the
circuit. The amount of current
flowing decreases. This
allows the right coil to pull the
pointer to the right, indicating
the increased oil pressure.
3. Electronic Gauge (fig.1-11).
Many cars have an electronic
instrument cluster. Part of the
cluster is electronic oil–
pressure gauge. It usually is a
bar–graph display made up of
a series of segments. The
gauge is similar to the Figure 11. ELECTRONIC FUEL-LEVEL
electronic fuel – level display. DISPLAY Fuel Level indicators. (Ford
The more segments displayed, Motor Company)
the higher the oil pressure.
High or low oil pressure
causes the bar graph to flash.

4. Digital Gauge. Some cars with an electronics instrument cluster have

digital oil–pressure gauge (fig.1-12). The number displayed tells the oil
pressure in pounds per square inch (psi) or kilopascals [kPa].

Figure 1-12. An electronic instrument cluster that displays fuel-level

and / or driver information. Ford Motor Company)
5. Oil–Level Indicators. An oil–
level indicator or dipstick (fig.1-
13) is used to measure the
crankcase oil level. The dipstick
extends down into the oil. To
determine the oil level, pull out
the dipstick and see how high
the oil reaches on the dipstick.
Markings usually indicate FULL
or ADD OIL. The dipstick tube
seals at the top when the
dipstick is in place. This
prevents unfiltered air from
entering the crankcase and
crankcase gases from
escaping. Some vehicles have
Figure 1-13. Lubrication system for an
a low oil–level indicator light.
inline OHV engine. Arrows show the
flow of oil to the moving parts in the
engine. (Buick Division of General
Motors Corporation)
An oil – level sensor (fig.1-14)
in the oil pan connects to a
CHECK OIL LEVEL light in the
instrument panel. Turning the
ignition key to CRANK or
START causes the sensor to
check the oil level in the pan. If
the oil is not low, the light goes
out when the ignition key
returns to RUN. If the engine
needs a quart [liter] or more of Figure 1-14. Location of the low oil-
oil, the sensor turns on the level sensor in the oil pan. (Ford Motor
CHECK OIL LEVEL light. Company)

6. Oil–Change Indicator. The instrument panel of some cars includes oil–

change indicator light. The body–control module (BCM) monitors the
coolant–temperature sensor, engine-speed sensor, and vehicle–speed
sensor. Then the BCM calculates the remaining useful life of the oil. This
is based on the actual driving conditions of the car. When the remaining
useful life is zero, the BCM turns on the CHANGE OIL SOON light. Cars
with an electronic instrument cluster may display the message CHANGE
OIL.
 SELF – CHECK 4.1

A. Label the following:

1. Parts of lubricating system

2. Parts of oil pump

a. Gear type

b. Rotor type
B. Explain briefly the function of the following:

1. oil pump

2. oil filter

3. oil cooler

4. oil level indicator

5. pressure–relief valve
 Job Sheet 4
Date:_____________
Score:___________

Activity 4:
1. Disassemble and assemble Oil pump.
2. Name the parts of oil pump.

Assessment Criteria:
1. Safety is observed while performing the task ------------ 30%
2. Correct disassembly and assembly procedure------------ 40%
3. Correct identification of parts.------------------------------ 30%
100%

Assignment:
1. Determine the maintenance requirements of engine lubricating
system.
2. List down the troubles and remedy of engine lubricating system.