ATTC

Automotive Technology
Department

Part 2
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Engine Diagnosis, Tune-up, and Performance Testing
(AUTO -5315)

Inspection of Engine
Oil and battery

Elias Haile (MSc)

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 Inspection of Engine Oil
Introduction
▪ Engine oil is the lifeblood of any engine.
▪ The purposes of a lubrication system include the following:
1. Lubricating all moving parts to prevent friction and wear
2. Helping to cool the engine/Remove the heat generated by friction
3. Helping to seal/ prevent leakage such as piston, ring, and cylinder
4. Act as a cleaning agent. Wash away dirt, carbon particles and abrasive metal
worn from the friction surfaces.
5. Neutralizing acids that are formed as the result of the combustion process
6. Absorbs shock between bearings and other engine parts, thus reducing engine
noise and extended engine life
7. Preventing rust and corrosion
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 Lubrication System Operation

FIGURE A typical lubrication system, showing the oil pan, oil pump, oil filter, and oil passages.
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Lubrication System Operation

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 Parts of lubrication system
▪ Oil Pump: The pump is driven by the engine and takes oil from the oil pan
through the strainer and pickup pipe.
▪ The strainer is provided to prevent any foreign matter present in the oil
from reaching the pump. Oil leaving the pump is directed to the filter.
▪ Relief (or) Regulator Valve: This valve regulates pressure in the system.
As the engine speed increases, pump output increases and this must be
controlled to prevent excessive pressure in the system. When the
specified pressure for the engine is reached, the relief valve opens to
regulate the pressure. Excess oil from the relief valve is then bypassed to
the intake side of the pump.

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 Parts of lubrication system
▪ Oil Filter: Filters out foreign particles from the oil. The filter also includes
a relief or bypass valve which will open if the filter becomes blocked.
▪ Main Oil Gallery: The main oil gallery is a passage that runs full length of
the crankcase. A number of drillings and passages from the gallery to
other parts of the lubrication system.

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 Parts of lubrication system
▪ Crankshaft Main Bearings: Each of the crankshaft main bearings is
supplied with oil through a separate drilling from the main oil gallery.
▪ Connecting Rod Bearings: Oil from the drillings in the crankshaft
lubricates the connecting rod bearings.
▪ Oil spray nozzles (Oil Jets) are used to direct a stream of engine oil onto
the bottoms of the engine pistons, timing gears or chain, and other
moving engine parts.

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 Parts of lubrication system
▪ Camshaft Bearings: The camshaft receives its oil supply from the main oil
gallery
▪ Rocker Shafts: Drillings in the rocker shafts provide oil to the rocker arms
and these in turn have a small drilling to provide lubrication to the cams.
▪ Timing Chain: Where a timing chain is fitted, oil is provided from the end
of camshaft bearing or similar source to that the chain and sprockets are
lubricated.
▪ Return Oil: After lubricating the various components, oil from the
cylinder head drains back to the oil pan through oil drain holes provided
for this purpose. Oil from the camshaft drops directly back to the oil pan.

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 Types of oil pumps
1. Gear pump

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2. Rotary Oil Pumps

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3. Crescent Pump

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 Lubrication System Operation
PURPOSE AND FUNCTION
▪ The primary function of the engine lubrication system is to maintain a positive
and continuous oil supply to the bearings.
▪ Engine oil pressure must be high enough to get the oil to the bearings with
enough force to cause the oil flow that is required for proper cooling.

FIGURE The dash oil pressure gauge may be

a good indicator of engine oil pressure.

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 Lubrication System Operation And Diagnosis
NORMAL OIL PRESSURE
▪ The normal engine oil pressure range is from 10 to 60 PSI (200 to 400 kPa)

▪ Higher oil pressure when the engine is cold due to the oil being cold and at a
higher viscosity

▪ Lower oil pressure when the engine is at normal operating temperature due to
the oil becoming thinner even though it is multi-viscosity oil

▪ Lower oil pressures at idle and higher pressures at higher engine speeds
because oil pumps are “positive displacement” pumps

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 Lubrication System Operation And Diagnosis
PURPOSE AND FUNCTION Oil Pumps
▪ All production automobile engines have a full-pressure oil system.
▪ The oil pump is required to: Provide 3 to 6 gallons per minute of engine oil to lubricate the
engine
▪ Maintain pressure, by forcing the oil into the lubrication system under pressure
PARTS AND OPERATION
▪ In most engines that use a distributor, the distributor drive gear meshes with a gear on the
camshaft

FIGURE In an external gear-type oil pump, the oil flows

through the pump around the outside of each gear 18
 Lubrication System Operation And Diagnosis
Two gears and a crescent The inner rotor has one fewer teeth
stationary element are used than the outer rotor and both rotate.

FIGURE A typical internal/external oil pump mounted in the FIGURE Gerotor-type oil pump driven
front cover of the engine that is driven by the crankshaft. by the crankshaft
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 Lubrication System Operation And Diagnosis
OIL PRESSURE REGULATION
▪ In engines with a full-pressure lubricating system, maximum pressure is limited with a pressure
relief valve.
▪ The relief valve /pressure regulating valve is located at the pump outlet.
▪ The relief valve controls maximum pressure by bleeding off oil to the inlet side of the pump

▪ A pressure relief valve limits maximum oil

pressure.
▪ It is a spring-loaded bypass valve in the oil pump,
engine block, or oil filter housing.

FIGURE Oil pressure relief valves are spring loaded. The stronger the spring
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tension, the higher the oil pressure.
Lubrication System Operation And Diagnosis

FIGURE A dry sump system 21

FIGURE A typical engine design that uses both pressure and splash lubrication. Oil travels under
pressure through the galleries (passages) to reach the top of the engine. Other parts are lubricated as
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the oil flows back down into the oil pan or is splashed onto parts.
 Diagnostics – Lubrication
OIL FILTERS
• Sources of Lubricating Oil Contamination: Abrasive and corrosive particles such
as:
▪ carbon particles due to incomplete combustion
▪ Acids formed from condensed crankcase vapors
▪ metal particles from the wear of the metal surfaces
▪ silica or dust enters through the crankcase or carburetor

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 Diagnostics – Lubrication
Types of oil filters
1. Full-flow filters
• All the oil delivered from the pump
passes through the filter on its
way to the bearings and other
engine parts
• So that only filtered oil is used for
lubrication
• provided the filter is in good
condition

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 Diagnostics – Lubrication
Types of oil filters
2. Bypass filters
• Bypass filters filter only a portion of
the oil delivered from the pump to
the oil galleries of the engine.
• An oil line is tapped into the oil
gallery and a restricted amount of
oil is allowed to flow to the filter
and then back to the oil pan.

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 Diagnostics – Lubrication
Test equipment
Oil pressure test gauge
▪ This is a simple pressure gauge that can be fitted with
suitable adapters into the oil pressure switch hole.
▪ The engine is then run and the pressure readings
compared to data.

Figure Oil pressure testing kit

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 Diagnostics – Lubrication
Systematic testing
▪ If the reported fault is that the low oil pressure light comes on at low speed,
proceed as follows:
1. Run the engine and see when the light goes off or comes on.
2. Is the problem worse when the engine is hot? Check the oil level. When was it
last serviced?
3. If the oil level is correct, then you must investigate further.
4. Carry out an oil pressure test to measure the actual pressure.
5. If the pressure is correct, then renew the oil pressure switch. If not, engine
strip-down is likely.
6. Run and test for leaks.
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 Lubrication System Diagnosis

Condition Possible causes Correction

Low oil 1. Oil level low 1. Add oil to engine

Pressure 2. Oil too thin 2. Add heavier oil
3. Defective oil gauge 3. Replace gauge
4. Bad sending unit 4. Replace sending unit
5. Excessive bearing clearance 5. Replace bearings
6. Worn oil pump 6. Replace oil pump
7. Loose or disconnected oil 7. Repair oil pickup
pickup 8. Repair valve in pump or
8. Clogged pickup screen block
9. Clean or replace screen

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 Lubrication System Diagnosis
High oil 1. Stuck pressure relief valve 1. Repair valve
pressure 2. Incorrect relief valve spring 2. Replace spring
3. High oil viscosity 3. Drain oil, Replace with
4. Oil gallery restriction recommended viscosity oil
5. Inaccurate indicator 4. Remove blockage
5. Repair circuit Replace gauge or
sending unit, if necessary

Swelled oil 1. High oil pressure 1. See high oil pressure

filter
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Lubrication fault diagnosis table 1 Symptom

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Lubrication fault diagnosis table 2 Symptom

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 Inspection of Battery
Introduction
PURPOSE AND FUNCTION
▪ Everything electrical in a vehicle is supplied current
from the battery.
▪ The battery is one of the most important parts of a
vehicle because it is the heart or foundation of the
electrical system.
▪ The primary purpose of an automotive battery is to
provide a source of electrical power for starting and
for electrical demands that exceed alternator output.

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 Inspection of Battery
Construction

Figure Vehicle battery components. 33

 Inspection of Battery
HOW A BATTERY WORKS

During discharge. The acid (SO4) is leaving the During charging. The acid (SO4) is being
electrolyte and getting onto both plates forced from both plates and enters the
electrolyte.
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 Inspection of Battery
HOW A BATTERY WORKS

FIGURE As the battery becomes discharged, the specific gravity of the battery acid decreases. 35
 Inspection of Battery
CHARGE INDICATORS

A comparison showing the relationship among

specific gravity, battery voltage, and state of charge

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 Battery Testing and Service
▪ SYMPTOMS OF A WEAK OR DEFECTIVE BATTERY
▪ The following warning signs indicate that a battery is near the end of its useful
life.
▪ Uses water in one or more cells.
▪ Excessive corrosion on battery cables or connections.
▪ Slower than normal engine cranking

electrolyte level was below the plates in all cells. Corrosion on a battery cable 37
 Battery Testing and Service
▪ BATTERY MAINTENANCE
▪ NEED FOR MAINTENANCE
▪ BATTERY TERMINAL CLEANING
▪ BATTERY HOLD-DOWN

FIGURE Besides baking soda and water, a sugar-free

diet soft drink can also be used to neutralize the battery
acid.
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 Battery Testing and Service
▪ BATTERY VOLTAGE TEST
▪ State of Charge
▪ Hydrometer Testing
▪ Battery Load Testing

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 Battery Testing and Service
▪ BATTERY VOLTAGE TEST

The estimated state of charge of a 12 volt battery after the

surface charge has been removed.
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 Battery Testing and Service
▪ HYDROMETER TESTING

Measuring the specific gravity can detect a defective battery.

A battery should be at least 75% charged before being load tested.

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 Battery Testing and Service
▪ BATTERY LOAD TESTING
▪ One test to determine the condition of any battery is the load test.
▪ The amount of the load is determined by the original CCA rating of the battery, which should be
at least 75% charged before performing a load test.
▪ The capacity is measured in cold-cranking amperes, which is the number of amperes that a
battery can supply at 0°F (18°C) for 30 seconds.
▪ TEST PROCEDURE To perform a battery load test
▪ STEP 1 Determine the CCA rating of the battery.
▪ STEP 2 Connect the load tester to the battery.
▪ STEP 3 Apply the load for a full 15 seconds.
▪ Observe the voltmeter during the load testing and check the voltage at the end of the 15 sec.
period while the battery is still under load.
▪ A good battery should indicate above 9.6 V.

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 Battery Testing and Service
▪ BATTERY LOAD TESTING
▪ STEP 4 Repeat the test.
▪ Many battery manufacturers recommend performing the load test twice, using
the first load period to remove the surface charge on the battery and the second
test to provide a truer indication of the condition of the battery.
▪ Wait 30 seconds between tests to allow time for the battery to recover.
▪ Results: If the battery fails the load test, recharge the battery and retest.
▪ If the load test is failed again, replacement of the battery is required

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 Battery Testing and Service
ELECTRONIC CONDUCTANCE TESTING

Most light-duty vehicles equipped with two Many heavy-duty trucks and buses use two 12 volt
batteries are connected in parallel as shown batteries connected in series to provide 24 volts.

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 Battery Testing and Service
▪ BATTERY CHARGING
▪ If the state of charge of a battery is low, it must be recharged. It is best to slow
charge any battery to prevent possible overheating damage to the battery.
Perform the following steps.
▪ STEP 1 Determine the charge rate. The charge rate is based on the current
state of charge (SOC) and charging rate.
▪ STEP 2 Connect a battery charger to the battery.
▪ Be sure the charger is not plugged in when connecting a charger to a battery
▪ STEP 3 Set the charging rate
▪ • Fast charge: 15 A maximum
▪ • Slow charge: 5 A maximum

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 Battery Testing and Service
▪ BATTERY CHARGING
▪ CHARGING AGM BATTERIES
▪ Charging an AGM battery requires a different charger than is used to recharge
a flooded-type battery.
▪ The differences include:
▪ The AGM can be charged with high current, up to 75% of the ampere-hour
rating due to lower internal resistance.
▪ The charging voltage has to be kept at or below 14.4 volts to prevent damage.

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 Battery Testing and Service
▪ BATTERY CHARGING

Battery charging guideline showing the charging times that vary according to state of charge, temperature,
and charging rate.
It may take eight hours or more to charge a fully discharged battery.
*Correct for temperature
**If colder, it’ll take longer

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 Battery Testing and Service
▪ JUMP STARTING

FIGURE Jumper cable usage guide.

Notice that the last connection should be the engine block
of the disabled vehicle to help prevent the spark that
normally occurs from igniting the gases from the battery.
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 Battery Testing and Service
▪ BATTERY SYMPTOM GUIDE
▪ The following list will assist technicians in
troubleshooting batteries

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Table Battery faults

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