Service Mechanical
Engine System
Learning Objectives:
LO 1. Service cooling system
LO 2. Service lubricating system
LO 3. Service fuel system
LO 4. Service diesel fuel injector
Cooling System
Lubricating System
Fuel System
Fuel Injector
1 COOLING SYSTEM
The cooling system serves three
important functions.
First, it removes excess heat from the engine;
Second, it maintains the engine operating
temperature where it works most efficiently.
Third, it brings the engine up to the right
operating temperature as quickly as possible.
DIAGRAM OF COOLING SYSTEM
• The cooling system is made up of: passages
inside the engine block and heads. A water
pump to circulate the coolant. A thermostat to
control the temperature of the coolant. A
radiator to cool the coolant.
• Only about 20% of heat is used as power at
crankshaft.
• 35% of heat is transmitted to the cylinder walls
which constitutes power loss.
• The heat should be prevented from being
transferred to cylinder walls as it causes pre-
ignition of charge.
• Lubricant might also be burned because of
excessive heat.
• The burning of lubricant lead to seizure of
the piston.
• While engine is running heat must be
removed continuously from the engine.
Types of Cooling System
1. Direct cooled/cooling by air - is a method of dissipating
heat. It works by making the object to be cooled have a
larger surface area or have an increased flow of air over its
surface or both.
2. Liquid cooled - Water fills up these jackets and the heat is
transferred to the water in the water jackets thus cooling
the cylinder.
Types of Liquid Cooling System
1. Thermosiphon System
It refers to a method of passive heat exchange based
on natural convection which circulates liquid without the
necessity of a mechanical pump.
2. Pump Cooling System
A water pump pushes the coolant through the
passages (water jackets) in the cylinder block and cylinder
head and then out into the radiator.
Components of Cooling
System
The purpose of a water pump
is to push coolant through the car's
engine block, radiator and hoses to
get the engine heat away from the
system. Typical water pump
problems include coolant leaks,
noisy or defective bearing,
damaged or corroded impeller.
Water Pump
Its job is to block the
flow of coolant to the
radiator until the
engine has warmed up.
Thermostat
The coolant
reservoir is a vital
component of the cooling
system.
Coolant Reservoir
It keeps the
cooling system
sealed from outside
contaminants. Radiator Cap
It is a type of heat
Radiator Hose exchanger. It is designed
to transfer heat from the
It is
typically a hot coolant that flows
rubber through it to the air
device that blown through it by the
manages the fan.
coolant flow
from an
engine's
water pump
to the heater.
Radiator
Signs You Have a Cooling System Problem
1. The engine overheats.
2. You can smell antifreeze when you
drive.
3. You notice antifreeze under the front of
your vehicle.
4. The coolant level is always low.
Proper Cooling System Maintenance
• Regularly check the radiator, belts and hoses
and have them replaced when they show
signs of excessive wear or aging.
• Replace the drive belt (also known as the
serpentine belt) before it breaks.
Have a cooling system service performed. During
this service the old fluid will be drained, the system
flushed and new coolant added. This service should
be performed at least once every two years.
2 LUBRICATING SYSTEM
The job of lubricating system is to
distribute oil to the moving parts to
reduce friction between surfaces which
rub against each other.
Objectives of Lubricating System
• To reduce the friction between the moving parts.
• To reduce wears of the moving parts.
• To act as cooling medium.
• To keep the engine parts clean.
• To absorb shocks between bearings and other engine
parts.
• To form good seal in piston ring and cylinder walls.
• To prevent deposition of carbon and metallic
components from corrosive attack.
• To resist oxidation.
Purposes of Lubrication System
CLEANING
As it circulates through the engine, the oil
picks up metal particles and carbon, and bring
them back down the pan.
COOLING
Picks up heat when moving through the
engine and then drops into the cooler oil pan,
giving up some of this heat.
REDUCTION OF NOISE
Lubrication reduces the noise of the engine.
ABSORB SHOCKS
When very loads are imposed on the bearings,
the oil helps to cushion the load.
ABSORBS CONTAMINANTS
The additives in oil helps in absorbing the
contaminants that enter the lubricating system.
2 TYPES OF ENGINE OIL
Mono grade multi_-grade
SAE- Society of Automotive Engineer
Viscosity number is determined by the
For winter use 5W,10W,20W
range of viscosities within it fall at the given
For normal use 20,30,40
temperature.
Lubricating parts of
Engine
• Main crankshaft
bearing
• Big end bearing
• Small end bearing
• Camshaft bearing
• Piston ring and
cylinder walls
• Timing gears
• Valve mechanism
Components of Lubricating
System
Oil Sump
It is also known
as oil pan. It
contains drain plug
at its lowest part to
drain out the oil.
Oil Cooler
Oil Pump
It cools the lubricating oil
The oil pumps in heavy duty engines. It
primary purpose is to is just like a simple heat
circulate engine oil exchanger.
Oil Filter Oil Pressure Gauge
The oil filter helps
remove contaminants from
your car engine's oil that can
accumulate over time as the It is used to indicate the
oil keeps your engine clean. oil pressure in the
engine.
Engine Oil Strainer Oil Level Indicator
It is designed to prevent
debris and contaminants It is use to check the
from entering the oil level in the
vehicle's engine oil. crankcase.
Always Remember!
Engine sound – if you think your engine is noisier than it
usually sounds, it might be because your oil has been
sitting there a bit too long.
Dark, even black, oil color – is a sign that you need to
flush the old oil and top your engine up with a fresh
batch. Fresh motor oil is light brown in color.
Lubricating System
Servicing
Common Problems
1. Higher Oil Consumption.
The main factors affecting oil consumption are
engine speed and engine wear. Engine temperature
increases at high speed due to which the oil
viscosity decreases.
Erratic Oil Pressure Indication.
If sometime light glows, or the gauge shows low
pressure reading, then either there is less oil in the
crankcase or the oil pickup is inconsistent.
1. a weak relief-valve spring,
2. a defective sender unit or oil pressure
indicator,
3. a worn oil pump,
4. obstructed or cracked or broken oil lines,
5. insufficient or excessively thin oil, and/or
Excessive oil pressure indication may be
due to:
1. a clogged oil line,
2. excessively viscous oil, (Hi) stuck
relief valve, and/or
3. excessively strong valve spring.
Lubricating System
Maintenance
1
Checking Oil Level
Checking of oil level using a dipstick. While
checking the oil level, the vehicle should be on
a level surface and the engine should be
stopped.
2 Changing Oil
The corrosion and rust inhibitors become
depleted, and corrosion begins to take place on the
bearing surfaces. The oil in slowly contaminated with
carbon. In some cases moisture gradually forms
sludge in the oil.
3 Servicing Oil Pump and Relief Valve
Oil pumps require very little service in
normal operation. If pump is badly worn, the
pump is to be removed and disassembled.
4
Servicing Oil Pump and Relief Valve
Oil pumps require very little service in
normal operation. If pump is badly worn,
the pump is to be removed and
disassembled.
5 Servicing
Servicing Oil
Oil Pressure
Pressure Indicators
Indicators
If the oil indicator light does not come on when
the ignition switch is turned on, the wire at the
pressure switch should be removed and
grounded.
3 FUEL SYSTEM
The function of the fuel system is to
supply a combustible mixture of air
and fuel to the engine.
The fuel used today is unleaded
gasoline. Unleaded gasoline, also called
no-lead or lead-free, does NOT contain
lead antiknock additives.
Properties of Gasoline
For a gasoline fuel system to function
properly, the fuel must have the right qualities
to burn evenly no matter what the demands of
the engine are.
Volatility
The ease with which gasoline vaporizes is called
volatility. A high volatility gasoline vaporizes
very quickly.
Octane Rating
A gasoline that detonates easily is called low
octane gasoline. A gasoline that resists
detonation is called high octane gasoline.
Air-Fuel Ratio
For proper combustion and engine
performance, the right amounts of air and fuel
must be mixed together.
For a gasoline engine, the perfect air-fuel
ratio is 14.7:1.
Lean Air-Fuel Mixture
A lean air-fuel mixture contains a large
amount of air. For example, 20:1 would be a
very lean mixture.
Rich Air-Fuel Mixture
A rich air-fuel mixture contains a little more
fuel mixed with the air.
For gasoline, 8:1(8 parts air to 1 part fuel) is
a very rich mixture.
Gasoline Fuel System
Components
Fuel Tank
An automotive fuel
tank must safely hold
an adequate supply of
fuel for prolonged
engine operation.
Fuel Gauges Fuel Pumps
It pumps gasoline
It indicates from the
the fuel level in vehicle's fuel tank
the fuel tank. to the engine.
Fuel Filters
Fuel Lines and Hoses
It is a filter in
the fuel line that It carries fuel
from the tank to the
screens out dirt
filter and fuel injection
and rust particles assembly.
from the fuel.
Carburetors
It is a device
that mixes air and
fuel for internal
combustion engines
in the proper air–
fuel ratio for
combustion.
Parts of Carburetor
1. Throttle Valve
It is an important part of a Carburetor.
It controls the mixture of charge
(air +fuel) supplied to the engine cylinder.
2. Strainer- It is a device that is used to filter the
fuel before entering the float chamber.
3. Venturi-
The venturi is the gradually decreasing cross-
sectional hollow tube. It helps to
decrease the air pressure of the chamber. For
which fuel comes out from the fuel pipe.
4. Metering System
The metering system controls the flow of fuel
into the nozzle. It is responsible to form a correct
mixture of air-fuel.
5. Float Chamber-
The float chamber serves as a storage tank of
fuel for a continuous supply of fuel.
6. Mixing Chamber
In the mixing chamber, the mixture of air + fuel
occurred. And then supplied to the engine cylinder.
7. Choke Valve- The main function of this valve is
to control the quantity of the air inside the mixing
chamber.
Carburetor Problems
1. Hard Cold Starting Problems- Hard starting
can be caused by a choke that fails to close and
causes a rich fuel mixture when the engine is cold.
2. Hard Hot Starting Problems- As for hot starting
problems, the carburetor is seldom to blame. A hot
start condition is usually the result of too much
heat in the vicinity of the carburetor, fuel lines or
fuel pump.
3. Hesitation or Stumble When Accelerating-
Hesitation is a classic symptom of a lean fuel
mixture and can be caused by a dirty or
misadjusted carburetor.
Carburetor Problems
4. Hesitation Under Load- A hesitation, stumble
or misfire that occurs when the engine is under
load can be caused by a faulty power valve inside
the carburetor.
5. Stalling- An engine can stall when cold if the
fast idle speed is not set high enough.
6. Rough Idle- A rough idle condition is usually
caused by an overly lean fuel mixture that results
in lean misfire.
7. Flooding- This is a problem that is usually (but
not always) the carburetor's fault. The carburetor
may flood if dirt enters the needle valve and
prevents it from closing.
WARNING:
Flooding can be a very dangerous
situation because it creates a serious fire
hazard if fuel spills out of the carburetor
onto a hot engine.
Poor Fuel Economy
Don't blame the carburetor if the real
problem is a lead foot on the accelerator
pedal, or the engine has low
compression.
Fuel System
Service
Featured snippet from the web
A full fuel system service should
include both a chemical cleaning of
your system and replacing any worn
components.
Fuel filters should be changed every 30,000 miles
or at the interval specified in your owner’s manual.
Fuel pumps and fuel injectors don’t normally
need to be replaced unless they are showing signs of
wear. For your fuel pump, this could include hard
starts or low fuel pressure.
4 FUEL INJECTOR
A fuel injector is nothing but an
electronically controlled valve.
It is supplied with pressurized fuel by
the fuel pump in your car, and it is capable
of opening and closing many times per
second.
A fuel injector is
used to inject the
fuel in the cylinder
in atomized form
and in proper
quantity.
Components of Fuel Injector:
Needle valve
Compression spring
Nozzle
Injector body
Types of Nozzles
Pintle
Bosch disc injector
Lucas disc injector
Ball
Why do I need to clean my
fuel injectors?
Carbon deposits form on the fuel
injectors during normal driving
conditions. The injectors particularly
the injector nozzles – exist in an
environment where tremendous heat is
generated.
Cleaning the Fuel Injectors
1. A fuel injector-cleaning chemical that is
poured into the fuel tank.
Provides a noticeable difference in power and
drive-ability after one use. The disadvantages are
that you can’t check the spray pattern, and the
filters may become plugged with contaminants
freed by the cleaner.
2.A cleaner that runs through the fuel
rails and injectors.
Uses stronger chemicals that the in
tank cleaners. Same disadvantages as 1.
3. An ultrasonic injector cleaner and injector
flow bench.
The preferred method of cleaning injectors.
Cycles the fuel injectors while the fuel injector
tips are immersed in an ultrasonic bath, which
uses an environmentally friendly cleaning fluid
to clean the fuel injectors.
The Clean Advantage
When all the fuel injectors are flowing the
correct amount of fuel to each cylinder, the
engine performance will be at its best supplying
the vehicle with maximum power and fuel
economy.
How does a Fuel Injection Cleaning help my
vehicle?
At Precision Tune Auto Care, we introduce a
liquid cleaning agent into the injection nozzle.
This removes the carbon deposits and restores
proper fuel flow into the combustion chamber,
which will:
Increase fuel efficiency.
Increase performance.
Reduce harmful emissions.
Extend engine and fuel injector life.
Here are the 5 most common symptoms of
faulty diesel fuel injectors:
• Trouble starting the vehicle or uneven
idling. The engine cranks but doesn't
start unless you crank it for a long time.
• Misfire
• Smell of fuel
• Dirty emissions
• Increased fuel consumption and poor
miles per gallon
Diesel Fuel Injectors
Generally have a shorter lifespan than
their predecessors, meaning they need to
be replaced more frequently for optimal
performance.
The life expectancy of a good
quality diesel fuel injector is around
150,000 kilometers.
Parts of Diesel Fuel Injector
Diesel Fuel Injector Tester