A STUDY ON LUBRICATION SYSTEM OF AUTOMOBILES AT

AUTOXPRESS WORKSHOP LIMITED

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 A STUDY ON LUBRICATION SYSTEM OF AUTOMOBILES AT
AUTOXPRESS WORKSHOP LIMITED

BY
Md.Fazle Rabbi
ID: 15107019
Program:BSME

A PRACTICUM REPORT SUBMITTED IN PARTIAL FULFILMENT OF

THE REQUIREMENTS FOR THE DEGREE OF BACHELOR OF SCIENCE
IN MECHANICAL ENGINEERING (BSME)

DEPARTMENT OF MECHANICAL ENGINEERING

IUBAT-INTERNATIONAL UNIVERSITY OF BUSINESS AGRICALTURE
AND TECHNOLOGY

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FORWARDING LETTER

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CERTIFICATE FROM ORGANIZATION

DECLARATION

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This practicum report has been prepared after three months of internship at AUTOXPRESS

Workshop Limited. The report is solely for academic requirement of the course MEC 490 and has

not been submitted in part or full elsewhere for any other degree, reward or for any other purpose. I

do solemnly and sincerely declare that all and every rights in the copyright of this practicum report

belong to IUBAT-International University of Business Agriculture and Technology. Any

reproduction or use in any form or by any means whatsoever is prohibited without the written

consent of IUBAT.

……………………
Md.Fazle Rabbi
ID: 15107019

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 ACKNOWLEDGEMENT

This Practicum Report is the result of guidance and support from many respected and honorable persons. I

would like to express my sincere gratitude to these persons as mentioned below.

Firstly, I gratefully remember the visionary leadership and contributions of our departed honorable founder

and first Vice Chancellor of IUBAT Late Prof. Dr. M. Alimullah Miyan.

Secondly, I would like to express my heartfelt thanks to the honorable Vice Chancellor Prof. Dr. Abdur Rab

of IUBAT for his guidance and leadership.

Thirdly, I sincerely acknowledge the contributions of the honorable Chair of the department of mechanical

engineering Prof. Dr. Engr. A.Z.A. Saifullah.

Fourthly, I express my gratitude for the support provided by the Coordinator of mechanical engineering

department Dr. A K M Foysal Ahmed

Finally, I sincerely appreciate the supervision provided by my internal supervisor Drs. Muammer

Din Arif in helping me to prepare the report.

Also, I would like to pay my gratitude to Mr. Md. Robiul Islam, Service Engineer of Autoxpress Workshop

Limited for his painstaking guidance and diligent struggle in teaching me the practical aspects of my

internship work.

Last but not the least, I also acknowledge the contributions of my faculties at IUBAT, and the staffs and

employees of Autoxpress Workshop Limited for enabling me to complete my practicum report.

………………………

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Md.Fazle Rabbi
ID: 15107019
A STUDY ON LUBRICATION SYSTEM OF AUTOMOBILES AT
AUTOXPRESS WORKSHOP LIMITED

Candidate Internal Supervisor

………………………. ……………………….

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Md.Fazle Rabbi Dr. Muammer Din Arif
ID: 15107019 Department of Mechanical Engineering

ABSTRACT

“Autoxpress Workshop”, located at Plot-492 Solmaid Vatara, Dhaka 1212, is one of the most well equipped

workshops in Bangladesh. They have many sate of the art equipment necessary to run a well-organized

automobile repair and maintenance center. I had the privilege to work at the workshop as an intern for three

months. And during that period I received in-depth theoretical and practical training about automobile repair

and maintenance. I worked on different engine systems, brake system, steering system, suspension system and

lot more. But my major concentration of work and training was in Lubricating system of automobiles. During

that period I learned firsthand how important the lubrication system is and how to address some of the repair

and maintenance issues. I learned how easy it is to keep the lubrication system updated and also how easy it is

to ruin it very fast. I also experienced lot of unique problems regarding the automobiles. All the service

managers and technicians were very helpful and accommodated all my queries. I am really blessed to have

this opportunity and I wish all the best to AutoXpress Workshop for having me.

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 Table of Contents
ACKNOWLEDGEMENT.............................................................................................vi

ABSTRACT..................................................................................................................viii

LIST OF FIGURES......................................................................................................xii

LIST OF TABLES........................................................................................................xiv

LIST OF SYMBOLS AND ABBREVIATIONS.........................................................xv

CHAPTER 1: INTRODUCTION..................................................................................1

1.1 Research Background.........................................................................................................1

1.2 Objectives...........................................................................................................................2

CHAPTER 2: COMPANY PROFILE...........................................................................4

2.1 Background of Autoxpress Group......................................................................................4

2.2 Overview of Autoxpress Workshop Limited:.....................................................................4

Vision:..................................................................................................................................4

Mission:................................................................................................................................5

Values:.................................................................................................................................5

Service Offering:..................................................................................................................5

2.3 Summary:...........................................................................................................................6

CHAPTER 3: LUBRICATION SYSTEM OF AUTIMOBILE..................................7

3.1 Introduction........................................................................................................................7

3.2 Automobile System............................................................................................................8

3.2.1 The Engine..................................................................................................................9

3.2.2 The Fuel System..........................................................................................................9

3.2.3 The Ignition System..................................................................................................10

3.2.4 The Electrical System................................................................................................10

3.2.6 The Drive Train.........................................................................................................10

3.2.7 The Suspension and Steering System........................................................................11

3.2.8 The Braking System..................................................................................................11

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 3.2.9 The Frame and Body.................................................................................................11

3.3 Lubrication System...........................................................................................................11

3.3.1 Automobile Body Lubrication...................................................................................13

3.3.2 Chassis Lubrication...................................................................................................14

3.3.3 Engine Lubrication....................................................................................................15

3.3.4 Components of Engine Lubrication Systems:............................................................17

3.4 Purpose of a Lubrication System......................................................................................22

3.4.1 Lubricating:...............................................................................................................23

3.4.2 Seal:...........................................................................................................................23

3.4.3 Cooling:.....................................................................................................................24

3.4.4 Reducing Noise:........................................................................................................24

3.4.5 Absorbs Shock:..........................................................................................................24

3.4.6 Absorbs Contaminants:..............................................................................................25

3.5 Principles of Lubrication..................................................................................................25

3.5.1 Hydrodynamic (Full Film) Lubrication:....................................................................26

3.5.2 Boundary (Thin Film) Lubrication:...........................................................................29

3.5.3 Mixed Film Lubrication:...........................................................................................30

3.6 Lubricants.........................................................................................................................31

3.6.1 Types of Lubricants:..................................................................................................33

3.6.2 Properties of Lubricating Oil:....................................................................................38

3.6.3 Lubricant Additives:..................................................................................................39

3.6.3 SAE Grade of Oil:.....................................................................................................44

3.6.4 API Standard Motor Oil:...........................................................................................45

3.7 Engine Lubrication Systems:............................................................................................46

3.7.1 Mist Lubrication System:..........................................................................................47

3.7.2 Wet Sump Lubrication System:.................................................................................48

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 3.8 Hybrid and All Electric Car Lubrication:.........................................................................52

3.9 Essential Fluids in Automobile.........................................................................................52

3.9.1 Transmission Fluid:...................................................................................................53

3.9.2 Power Steering Fluid:................................................................................................54

3.9.3 Brake fluid:................................................................................................................55

3.10 Engine Oil Sludge:.........................................................................................................56

CHAPTER 4: PROBLEM FINDING, ANALYSIS, AND DISCUSSION...............58

4.1 Problem1..........................................................................................................................59

4.2 Problem 2.........................................................................................................................59

4.3 Problem 3.........................................................................................................................60

4.4 Problem 4.........................................................................................................................61

4.5 Problem 5.........................................................................................................................61

CHAPTER 5: CONCLUSION.....................................................................................62

5.1 Conclusion........................................................................................................................62

5.2 Recommendations for future work...................................................................................62

REFERENCES..............................................................................................................64

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 LIST OF FIGURES
FIGURE 2. 1 AUTOXPRESS WORKSHOP 1................................................................4

FIGURE 2. 2 AUTOXPRESS WORKSHOP 2 1.............................................................6

FIGURE3. 1 AUTOMOBILE SYSTEMS.........................................................................8

FIGURE3. 2 SCHEMATIC DIAGRAM OF ENGINE LUBRICATION SYSTEM........12

FIGURE3. 3 AUTO BODY LUBRICATION POINTS...................................................13

FIGURE3. 4 CHASSIS LUBRICATION POINTS..........................................................14

FIGURE3. 5 ENGINE LUBRICATION SYSTEM..........................................................15

FIGURE3. 6 OIL PAN......................................................................................................17

FIGURE3. 7 OIL FILTER.................................................................................................18

FIGURE3. 8 PISTON COOLING NOZZLES.................................................................19

FIGURE3. 9 OIL PUMP...................................................................................................20

FIGURE3. 10 OIL GALLERIES......................................................................................21

FIGURE3. 11 OIL COOLER............................................................................................22

FIGURE3. 12 LUBRICATING JOURNAL......................................................................23

FIGURE3. 13 BLOW BY..................................................................................................23

FIGURE3. 14 OIL COOLING..........................................................................................24

FIGURE3. 15 NOISE REDUCTION................................................................................24

FIGURE3. 16 CORROSION.............................................................................................25

FIGURE3. 17 ENGINE CLEANING................................................................................25

FIGURE3. 18 LUBRICATION PRINCIPLES.................................................................26

FIGURE3. 19 FULL FILM LUBRICATION...................................................................27

FIGURE3. 20 JOURNAL BEARING LUBRICATION...................................................28

FIGURE3. 21 BOUNDARY LUBRICATION.................................................................29

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FIGURE3. 22 MIXED FILM LUBRICATION................................................................30

FIGURE3. 23 LUBRICANTS...........................................................................................31

FIGURE3. 24 SOLID LUBRICANT................................................................................34

FIGURE3. 25 LIQUID LUBRICANT..............................................................................35

FIGURE3. 26 BARREL OF CRUDE OIL........................................................................36

FIGURE3. 27 SEMI SOLID LUBRICANT......................................................................38

FIGURE3. 28 ADDITIVES IN BASE OIL......................................................................40

FIGURE3. 29 VISCOSITY INDEX..................................................................................45

FIGURE3. 30 API STANDARD CHART........................................................................46

FIGURE3. 31 MIST LUBRICATION SYSTEM.............................................................47

FIGURE3. 32 THE SPLASH SYSTEM...........................................................................49

FIGURE3. 33 THE SPLASH AND PRESSURE SYSTEM.............................................50

FIGURE3. 34 THE FULL PRESSURE FEED SYSTEM.................................................51

FIGURE3. 35 DRY SUMP SYSTEM...............................................................................52

FIGURE3. 36 TRANSMISSION FLUID DRAIN............................................................53

FIGURE3. 37 TRANSMISSION FLUID POUR..............................................................54

FIGURE3. 38 POWER STEERING FLUID.....................................................................54

FIGURE3. 39 BRAKE FLUID..........................................................................................55

FIGURE3. 40 COOLANT.................................................................................................56

FIGURE3. 41 SLUDGE....................................................................................................57

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 LIST OF TABLES
TABLE 1.........................................................................................................................58

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 LIST OF SYMBOLS AND ABBREVIATIONS

ABS- ……Anti-Lock Braking System

CKD- ……Completely Knocked Down

GVW- …...Gross Vehicle Weight

ULW- ……Unladen Weight

SAE-……..Society of Associate Engineer

PDI-………Pre Delivery Inspection

A/C - ……..Air Conditioning, Air Conditioner

AFS - …….Air Flow Sensor

A/T -…….. Automatic Transmission

ATF - ……Automatic Transmission Fluid

CV – ……..Constant Velocity

EFI – …….Electronic Fuel Injection

ECM – …..Electronic Control Module

EEC – ……Engine Electrical Control

HP – ……..Horsepower

KW –…… Kilowatt

MAP –……Manifold Absolute Pressure Sensor

PCV –……Positive Crankcase Ventilation

RPM –……Revolution per Minute

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ESP-……...Electronic Stability Program

BA-………Brake Assist

EBD-…….Electronic Brake Force Distribution

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 CHAPTER 1: INTRODUCTION

1.1 Research Background

Automobile or Automotive Engineering has gained recognition and importance ever since motor

vehicles capable for transporting passengers has been in vogue. Now due to the rapid growth of auto

component manufacturers and automobile industries, there is a great demand for Automobile

Engineers. Automobile Engineering is one of the most challenging careers in the field of engineering

with a wide scope. This branch deals with the designing, developing, manufacturing, testing and

repairing and servicing automobiles such as cars, trucks, motorcycles, scooters and the related sub

Engineering systems. For the perfect blend of manufacturing and designing automobiles, Automobile

Engineering uses the features of different elements of Engineering such as mechanical, electrical,

electronic, software and safety engineering. To become a proficient automobile engineer, specialized

training is essential and it is a profession, which requires a lot of hard work, dedication,

determination and commitment. 

The automotive industry in Bangladesh is the third largest in South Asia. Bangladesh has a few large

car plants that assemble passenger cars from Mitsubishi and Proton, as well as commercial vehicles

from Hino and Tata. Motorcycles, auto rickshaws and the locally designed three-wheelers are also

produced in Bangladesh. Bangladesh is moving towards achieving the sustainable development goal

by implementing and taking necessary steps for it. The government is giving efforts and taking

compulsory actions in the way of policy making. The government is concerned for the automobile

industry. The Automobile Policy Guideline and Roadmap 2012-2021 has been completed by the

Ministry of Industries aiming to boost up local automobile manufacturing sector and increase

national GDP. The demand for automotive engineers also known as mechanical engineers is

projected to grow in high percentage in the future. The need for design on the next generation of

vehicles such as electric cars and vehicle systems will keep the career in demand. The major task of

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an Automobile Engineer is the designing, developing, manufacturing and testing of vehicles from the

concept stage to the production stage. Along with the theoretical knowledge, an engineer must have

practical knowledge as well. Without practical knowledge, engineering study will not be complete.

Industrial training plays a significant role to build a bridge between the theoretical and practical

knowledge.

In order to fulfill the requirement to graduate with a Bachelor’s degree in Mechanical Engineering,

I took this internship (industrial training) program with “Autoxpress Workshop” under the

supervision of Md.Robiul Islam during my 12th semester of study. I tried to take full advantage of

this opportunity to gain some practical knowledge from the industry leaders to well equip myself for

the future. And I am sure that this training will open some new doors of opportunity for me in the

future.

1.2 Objectives

Training is teaching, or developing in oneself or others, any skills and knowledge that relates to

specific useful competencies. Training has specific goals of improving one's capability, capacity,

productivity and performance. The main objective of this internship program was to gain practical

experience in an engineering practice environment outside the teaching establishment for a minimum

of 12 weeks. My specific objective was to learn how the theoretical knowledge of lubrication system

is implemented in the real world to drive an automobile efficiently. The objectives of this report after

the completion of the internship program are given below:

 To gain a general understanding of the system in automobiles

 To learn in specific detail about the lubricating system of automobiles

 To learn how to detect problems related to lubricating system

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  To learn how to solve problems related to lubricating system

 To learn how to do maintenance on the lubricating system

1.3 Organization of the Report

This report has been prepared as an integral part of the internship program for the Bachelor of

Science in Mechanical Engineering (BSME) program at the Department of Mechanical Engineering

(ME) in IUBAT—International University of Business Agriculture and Technology. As a part of the

requirements that are needed to fulfill to have the degree of Bachelor of Science in Mechanical

Engineering (BSME), this report has been accomplished on “A study on The Lubrication System of

Automobile at “Autoxpress Workshop Limited”, was nominated as the organization for the

practicum while Dr. A K M Foysal Ahmed, Coordinator, Department of Mechanical Engineering,

rendered his kind consent to the internship program.

At the beginning I started with a Title page, Cover page, Student’s declaration, Acknowledgment and

Abstract.

Chapter one refers to introduction part that includes objectives, broad objectives, and specific objectives,

outline of the report.

Chapter two discussed the name of the company, company logo, company overview, location of company,

company organogram and company activities.

Chapter three discusses about the history and different systems of automobile, lubrication system, types of

lubrication system, types of lubricants, importance of using the right lubricant, uses of fluids in automobile.

Chapter four discusses various types of problem finding, analysis, solution, and discussion about the

lubrication system of automobile at Autoxpress Workshop Limited.

Chapter five includes conclusion with recommendations.

Finally, the bibliography is included as per APA format.

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 CHAPTER 2: COMPANY PROFILE

2.1 Background of Autoxpress Group

Autoxpress is the name which was born on 2016 at capital city, Dhaka,Bangladesh.Complete

Computerized Automotive Workshop.We started our journey with honesty and dignity.Autoxpress

has the provision to give the customers vehicle owners to their maintenance support and one stop

services. We have the ability to give the support of the customers for procuring the service items

from our Mini-store. (Such as: - lube-oil, oil-filter, air-filer, brake-oil, brake pad, tire, battery, shock

absorber and so many parts vehicle). As this shop provides incorporate, genuine parts to customer,

this service reduce customer’s valuable time money.

2.2 Overview of Autoxpress Workshop Limited:

Figure 2. 1 Autoxpress Workshop 1

Vision:

We set our vision to be a pioneer and good example in expanded business parts that take into

account each developing human need.

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Mission:

Our main goal is to be the Best Workshop in Bangladesh. We, Autoxpress Workshop Limited are

here to ensure the best understanding of after-deals administrations.

Values:

Throughout the years Autoxpress is giving clients with the very best in product selection and service.

The group ceaselessly puts resources into modernizing its administration framework and plans

particular in-house preparing programs focused towards enhancing the creative abilities of its people.

The huge experience of its administration, and the commitment of its work force, will empower the

association to lead Bangladesh towards a prosperous future. Their qualities are

 Commitment

 Passion

 Speed

 Integrity

 Determination

Service Offering:

 Engine overhauling

 Electrical scanning by latest scanner

 Brake system works

 All kinds of A/C & Electric works

 All kinds of mechanical works

 General servicing with car wash and polish

 Perfect denting with quality painting (Inside paint booth)

 Computerized wheel balancing

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  Computerized wheel alignment

 Injector testing & cleaning

 Engine & gear box replacement

 Suspension system overhauling

 Auto transmission fluid/CVTF change (by machine)

Figure 2. 2 Autoxpress Workshop 2 1

2.3 Summary:

 Established year : 2016

 Location : 492 Solmaid, Vatara, Bashundara R/A, Dhaka.

 Area : 6000 square foot

 Working bay : 20

 Parking bay : 35

 Washing bay : 01

 Paint booth : 01

 Service engineer : 05

 Technician : 30

 Other staff : 15

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 Total manpower : 50

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 CHAPTER 3: LUBRICATION SYSTEM OF AUTIMOBILE

3.1 Introduction

An Automobile is a wheeled motor vehicle used for transportation. Most definitions of

automobile say they run primarily on roads, seat one to eight people, have four tires, and

mainly transport people rather than goods. Cars came into global use during the 20th

century, and developed economies depend on them. The year 1886 is regarded as the birth

year of the modern car when German inventor Karl Benz patented his Benz Patent

Motorwagen. Cars became widely available in the early 20th century. One of the first cars

that were accessible to the masses was the 1908 Model T, an American car manufactured

by the Ford Motor Company. Cars were rapidly adopted in the US, where they

replaced animal-drawn carriages and carts, but took much longer to be accepted in Western

Europe and other parts of the world.

Cars have controls for driving, parking, passenger comfort and safety, and controlling a

variety of lights. Over the decades, additional features and controls have been added to

vehicles, making them progressively more complex. Examples include rear reversing

cameras, air conditioning, navigation systems, and in-car entertainment. Automobile these

days are propelled by an internal combustion engine, fueled by combustion of fossil fuels.

This causes air pollution and also contributes to climate change and global warming.

Vehicles using alternative fuels such as ethanol flexible-fuel vehicles and natural gas

vehicles are also gaining popularity in some countries. Electric cars, which were invented

early in the history of the car, began to become commercially available in 2008.

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3.2 Automobile System

An automobile is the result of combined work of a number of systems. Each system,

though primarily independent, is influenced by the effect of other systems interacting with

it. Before discussing the interaction of various systems, let us first enumerate the various

systems that are present in an automobile.

Figure3. 1 Automobile Systems

The following is a list of the major systems that make up the modern vehicle:

• The Engine – including lubrication and cooling.

• The Fuel System – including evaporative emission.

• The Ignition System

• The Electrical System – including starting and charging.

• The Exhaust System –including emission control.

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• The Drive Train – including the transmission.

• The Suspension and Steering Systems

• The Brake System

• The Frame and Body

3.2.1 The Engine

The engine is the vehicle’s main source of power. This is where chemical energy is

converted into mechanical energy. The most popular type of engine is referred to as the

Internal Combustion Engine. This engine burns an air/fuel mixture inside itself in order to

drive a series of pistons and connecting rods that in turn rotate a crankshaft providing us

with a continuous rotating motion with which to drive the vehicle and other components.

The engine also incorporates others systems, including the lubrication system and the

cooling system, all working efficiently together. The cooling system maintains the engine

at an ideal operating temperature while the lubrication system ensures that all the moving

parts are kept oiled in order to provide a long serviceable life.

3.2.2 The Fuel System

The fuel systems job it is to store and supply fuel to the engine. Early vehicle fuel systems

were completely mechanical systems delivering fuel through the use of a mechanical fuel

pump and using a carburetor to atomize and mix the fuel with air. Most of the system today

is either electronically controlled and/or monitored. The fuel system may also include the

Evaporative Emission System where by raw fuel vapors that would otherwise be vented to

the atmosphere are stored and then drawn in and burned in the engine under normal

operating conditions.

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3.2.3 The Ignition System

The ignition system provides the spark necessary to ignite the air/fuel mixture inside the

engine in order for it to burn. The spark must be provided at the correct time and sequence

to the various cylinders in order to produce maximum horsepower with the least amount of

fuel thus emitting the lowest amount of harmful emissions.

3.2.4 The Electrical System

The electrical system provides the voltage necessary to operate the many electrical

components on the vehicle such as the vehicle’s lighting system. The main source of power

for the electrical system is the battery. The electrical system also includes the starting

system and the charging system. The starting system uses a high output electric motor to

start the engine turning fast enough for the fuel and ignition system to take over. The

charging system consists of a large battery charger called an alternator which is powered by

the engine through the use of a drive belt.

3.2.5 The Exhaust System

The exhaust system moves the burnt exhaust fumes safely and quietly away from the

passenger compartment. The exhaust system consists of a series of pipes which

interconnect and direct the burned gases to the tail pipe at the rear of the vehicle. This

system also provides some emission control by means of the catalytic converter where any

unburned gases leaving the engine are burned before leaving the exhaust system.

3.2.6 The Drive Train

The drive train transmits the power of the engine to the drive wheels. The drive train

includes the transmission, drive shafts and other various parts. A clutch (manual

transmission) or torque converter (automatic transmission) allows the drive train to be

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disconnected from the engine so that the vehicle may be brought to a stall without having to

stop the engine.

3.2.7 The Suspension and Steering System

The suspension and steering system provided a means of safely controlling the vehicle. The

suspension system is designed to isolate most of the vehicle from any road shock and keep

the vehicle stable when driving straight or turning. The steering system is intended to allow

the operating to control the direction of the vehicle with the least amount of effort.

3.2.8 The Braking System

The braking system allows the vehicle to be brought to a stop safely. The braking system

includes both a mechanical and hydraulic system. The hydraulic brake system is the

primary braking system while the mechanical brake system is used mostly as a

supplementary system as well as for emergencies. Most modern brake systems include

some form of a brake assist often referred to as “power brakes.”

3.2.9 The Frame and Body

The frame and body provide a foundation on which to build the vehicle. Traditionally the

body and frame were built separately then brought together only in the later stages of

assembly. Today’s vehicles incorporate a unitized body, where the body and frame are built

together in order to reduce weight and increase passenger safety and comfort.

3.3 Lubrication System

A Lubrication system is a mean whereby a material is placed between two rubbing surfaces

to alleviate friction and therefore wear. For example if we rub our hands together they will

heat up due to the friction and eventually our skin will burn. However if we put soap on our

12
hands it will reduce the friction and therefore stop the damage. The same applies for all

surfaces which rub together and if there is no lubrication in moving metal machinery, it

means parts being replaced, and regularly in fast moving machines like vehicles,

manufacturing equipment, pistons, pumps, cams, bearings, turbines, cutting tools, chains,

and motors. To help stop this wear a substance called a lubricant, is put in between the

surfaces to carry or to help carry the load. The lubricant is most commonly oil or grease.

Keeping the lubricant between moving surfaces is difficult to do and that’s where a

lubrication system comes in. Depending on the application a different lubrication system is

used.

Figure3. 2 Schematic Diagram of Engine Lubrication System

Oil is the life-blood of the engine. An engine running without oil will last about as long as

human without blood. Oil is pumped to all the moving parts of the engine by and oil pump.

The oil pump is mounted at the bottom of the engine in the oil pan and is connected by a

gear to either the crankshaft or camshaft. This way, when the engine is running the pump is

pumping simultaneously. There is usually an oil pressure sensor near the oil pump that

monitors pressure and sends this information to a warning light on the dash board, when the

ignition key is turned on, but before the car is started the oil light should light, indicating

that there is no oil pressure yet, but also letting you know that the warning system is

13
working. The need for lubrication in mechanical systems is understood-and sometimes it

can be taken for granted.

Lubrication system of an automobile is primarily divided in the following parts:

 Automobile Body Lubrication

 Chassis Lubrication

 Engine Lubrication

3.3.1 Automobile Body Lubrication

Auto body is exposed to extreme weather conditions like extreme heat or cold, heavy

rainfall, sand storm, high wind, salt water, flood and so on. Because of that, auto body parts

that are exposed to the atmosphere on a daily basis loose their lubrication. Such body parts

are hood lock and latch, hood hinges, doorstop and hinges, door lock and keyhole, trunk lid

lock and keyhole, window regulator.

Figure3. 3 Auto Body Lubrication Points

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The body parts named above must be lubricated at least twice a year in order for them to

work efficiently and smoothly. Lubricants for body and exterior areas must be highly

effective over the specified temperatures and withstand salt, water and dust for many years.

3.3.2 Chassis Lubrication

Automobile chassis and driveline components are in constant motion. If the vehicle is front

wheel drive, the CV joints drive the wheels. Rear wheel drive vehicles use a driveshaft

with U joints for propulsion. Both require lubrication and will fail prematurely if they are

allowed to run dry. Most types of vehicles use flexible ball-in-socket joints in the

suspension. These joints provide pivot points so front wheels can turn and suspension can

absorb the bumps. Chassis should be inspected and lubricated in every six months.

Annoying suspension squeaks and creaks are an indication that a bushing is dry and needs

attention. Regular inspection and lubrication of under car chassis and suspension system

prevents expensive part failures that could strand on the highway.

Figure3. 4 Chassis Lubrication Points

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3.3.3 Engine Lubrication

Lubrication plays a key role in the life expectancy of an engine. Without oil, an engine

would succumb to overheating and seizing very quickly. Lubricants help mitigate this

problem, and if properly monitored and maintained, can extend the life of your motor. The

process of lubrication in an internal combustion engine begins in the sump, commonly

referred to as the oil pan. From here, the oil is pulled through a strainer, by the

oil pump, removing larger contaminants from the mass of the fluid. The oil then goes

through the oil filter. It is important to note that not all filters perform the same.

A filter’s ability to remove particles is dependent upon many factors, including the media

material (pore size, surface area and depth of filter), the differential pressure across the

media, and the flow rate across the media. Oil is pumped through passageways to the

various components of the engine such as the cam, main bearings, rod, pistons, etc. Gravity

then pulls the oil back down to the bottom of the motor to drain back into the sump, and the

cycle repeats.

Figure3. 5 Engine Lubrication System

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The Engine Lubrication System:

1. Minimizes power loss by reducing the friction between the moving parts.

2. Reduces the wear and tear of the moving parts.

3. Provides cooling effect to the hot engine parts.

4. Provides cushioning effect against vibrations caused by the engine.

5. Carries out the internal cleaning of the engine.

6. Helps piston rings to seal against high-pressure gases in the cylinder.

Engine lubrication system supplies the engine oil to the following parts:

1. Crankshaft main bearings

2. Big end bearings

3. Piston pins and small end bushes

4. Cylinder walls

5. Piston rings

6. Timing Gears

7. Camshaft and bearings

8. Valves

9. Tappets and push-rods

10. Oil pump parts

11. Water pump bearings

12. In-Line Fuel Injection Pump bearings

13. Turbocharger bearings (if fitted)

14. Vacuum pump bearings (if fitted)

15. Air-compressor piston and bearings (in commercial vehicles for air-brake)

17
3.3.4 Components of Engine Lubrication Systems:

1. Oil Sump

2. Engine oil filter

3. Piston Cooling Nozzles

4. Oil Pump

5. The Oil Galleries

6. Oil Cooler

7. The Oil pressure indicator/light

3.3.4.1 Oil Sump:

An Oil Pan (Sump) is just a bowl-shaped reservoir. It stores the engine oil and then

circulates it within the engine. Oil sump sits below the crankcase and stores the engine oil

when the engine is not running. It is located at the bottom of the engine in order to collect

and store the engine oil. The oil returns to the sump by pressure or gravity when the engine

is not in use.

Figure3. 6 Oil Pan

18
Bad road conditions could cause damage to the Oil Pan (Sump). So, the manufacturers

provide a stone guard/sump guard underneath the sump. The sump guard absorbs the hit

from the uneven road and protects the sump from any damage.

3.3.4.2 Engine oil filter:

An oil filter is a filter designed to remove contaminants from engine oil, transmission

oil, lubricating oil, or hydraulic oil. Oil filters are used in many different types of hydraulic

machinery. A chief use of the oil filter is in internal-combustion engines in on- and off-

road motor vehicles, light aircraft, and various naval vessels. Other vehicle hydraulic

systems, such as those in automatic transmissions and power steering, are often equipped

with an oil filter. 

Figure3. 7 Oil Filter

19
3.3.4.3 Piston cooling nozzles:

The maximum piston temperature must be controlled to prevent premature piston wear and

engine damage. The piston can be cooled by an oil spray jet directed at the bottom of the

piston, or by oil flowing through a cooling channel or gallery.

Figure3. 8 Piston cooling nozzles

3.3.4.4 The Oil Pump:

An Oil Pump is a device that helps to circulate the lubricant oil to all the moving parts

inside the engine. These parts include crankshaft & camshaft bearings as well as valve

lifters. It is generally located at the bottom of the crankcase, close to the oil sump. The oil

pump supplies the oil to the oil filter, which filters and sends it onward. The oil then

reaches different moving parts of the engine through oil galleries.

20
 Figure3. 9 Oil Pump

Even, small particles can choke the oil pump and galleries. If oil Pump gets blocked, then it

can cause the severe damage to the engine or even complete seizure of the engine. To avoid

it, the oil pump consists of a strainer and a by-pass valve. Hence, it is necessary to change

the engine oil and filter at regular intervals as recommended by the manufacturers.

3.3.4.5 Oil Galleries:

In order to get better performance and longer engine life, it is essential that the engine oil

quickly reach the moving parts of the engine. For this purpose, manufacturers provide oil

galleries within the engine. The Oil Galleries are nothing but series of interconnected

passages that supply the oil to the remotest parts of the engine. Oil galleries consist of big

and small passages drilled inside the cylinder block. The bigger passages connect to the

smaller passages and supply the engine oil up to the cylinder head and overhead camshafts.

The oil galleries also supply the oil to the crankshaft, crankshaft bearings and camshaft

bearings thru holes drilled in them as well as to valve lifters or tappets.

21
 Figure3. 10 Oil Galleries

3.3.4.6 Oil Cooler:

The Oil Cooler is a device that works just like a radiator. It cools down the engine oil that

becomes very hot. Oil cooler transfers the heat from the engine oil to the engine coolant

through its fins. Initially, manufacturers used the oil cooler only in the racing or high-

performance vehicles. However today, most vehicles use oil cooler system for better engine

performance. Oil cooler helps to maintain the engine oil temperature, also keeps its

viscosity under control. Additionally, It retains the lubricant quality, prevents the engine

from overheating and thereby saving it from wear and tear.

22
 Figure3. 11 Oil Cooler
3.3.4.7 Oil Pressure Indicator:

Auto manufacturers use an oil pressure warning light on the dashboard to warn the driver if

the oil pressure gets too low. Some vehicles are able to distinguish between low oil levels

and insufficient oil pressure so you’ll know if the pump is malfunctioning or if you just

need to add some more oil.

3.4 Purpose of a Lubrication System

The primary function of the lubrication is to reduce the friction and wear and tear of the

two rubbing parts. Two rubbing parts always produce friction and continuous friction

produces heat, which causes wearing of the different parts of the engine and power loss.

This friction can be reduced by proper lubrication. The lubricating oil forms a thin oil

film between moving surfaces and avoids direct contact. This also reduces noise

produced by the movement of two metal surfaces. Some of the important purposes are

described below:

23
3.4.1 Lubricating:

Reduces friction by creating a thin film (Clearance)between moving parts (Bearings and journals

Figure3. 12 Lubricating Journal

3.4.2 Seal:

The oil helps form a gastight seal between piston rings and cylinder wall(Reduces Blow-

By). Internal oil leak (blow-by) will result in blue smoke at the tail pipe.

Figure3. 13 Blow by

24
3.4.3 Cooling:

Picks up heat when moving through the engine and then drops into the relatively cooler oil

pan, giving up some of this heat.

Figure3. 14 Oil Cooling

3.4.4 Reducing Noise:

The lubricant cushions the parts against vibration and impact, thus reduces the engine

noise.

Figure3. 15 Noise Reduction

3.4.5 Absorbs Shock:

When heavy loads are imposed on the bearings, the oil helps to cushion the load.

25
3.4.6 Absorbs Contaminants:

The additives in oil help in absorbing the contaminants that enter the lubrication system.

3.4.7 Protection Against Wear and Corrosion:

A lubricant protects the metallic surfaces against the corrosive action and wear.

Figure3. 16 Corrosion
3.4.8 Cleaning:

As the lubricant circulates through the engine, it picks up metal particles and carbon, and

brings them back down to the pan.

Figure3. 17 Engine Cleaning

3.5 Principles of Lubrication

To understand the principles easily, consider a block resting on a flat surface covered with

a layer of lubricating oil. If the weight of the block is very high or the oil is thin, the oil will
26
squeeze out. In other words, thick oil can support a higher load than that supported by thin

oil. To maintain a film of lubricant between the surfaces the following principles of

lubrication prevails:

 Hydrodynamic (Full Film) Lubrication

 Boundary (Thin Film) Lubrication

 Mixed Film Lubrication

Figure3. 18 Lubrication Principles

3.5.1 Hydrodynamic (Full Film) Lubrication:

Hydrodynamic lubrication was first researched by Osborne Reynolds (1842-1912). When a

lubricant was applied to a shaft and bearing, Reynolds found that the rotating shaft pulled a

converging wedge of lubricant between the shaft and the bearing. He also noted that as the

shaft gained velocity, the liquid flowed between the two surfaces at a greater rate. This,

because the lubricant is viscous, produces a liquid pressure in the lubricant wedge that is

sufficient to keep the two surfaces separated. Under ideal conditions, Reynolds showed that

27
this liquid pressure was great enough to keep the two bodies from having any contact and

that the only friction is the system was the viscous resistance of the lubricant.

Figure3. 19 Full Film Lubrication

Hydrodynamic lubrication theory is a theory used to reduce friction and/or wear of rubbing

solids with the aid of liquid lubricant. For a vast majority of the surfaces encountered in

nature and used in industry, the source of friction is the imperfections of the surfaces. Even

mirror shining surfaces are composed of hills and valleys – surface roughness. The goal of

hydrodynamic lubrication is to add a proper lubricant, so that it penetrates into the contact

zone between rubbing solids and creates a thin liquid film, as shown in the figure below.

This film separates the surfaces from direct contact and it in general reduces friction and

consequently wear (but not always), since friction within the lubricant is less than between

the directly contacting solids.

The principle allows large loads to be supported by this film of oil is similar to that which

causes a car to aquaplane on a wet road surface. Aquaplaning occurs when water on the

road accumulates in front of vehicle tyre faster that the weight of vehicle and the pumping

action of the tyre tread can push it out of the way. The water pressure can cause your car to

rise up and slide on top of a thin layer of water between tyre and the road. Just like a car
28
has to be travelling at a certain speed before aquaplaning will occur (this varies according

to tyre condition and road surface but is generally about 55mph), a shaft must be rotating at

a certain speed before hydrodynamic lubrication takes place.

Application of hydrodynamic lubrication

 Delicate instruments.

 Light machines like watches, clocks, guns, sewing machines.

 Scientific instruments.

 Large plain bearings like pedestal bearings, main bearing of diesel engines.

The operation of hydrodynamic lubrication in journal bearings is illustrated below.

Figure3. 20 Journal Bearing Lubrication

Before the rotation commences the shaft rests on the bearing surface. When the rotation

commences the shaft moves up the bore until an equilibrium condition is reached when the

shaft is supported on a wedge of lubricant.  The moving surfaces are then held apart by the

pressure generated within the fluid film.   Journal bearings are designed such that at normal

operating conditions the continuously generated fluid pressure supports the load with no

29
contact between the bearing surfaces.   This operating condition is known as thick film

lubrication and results in a very low operating friction and extremely low bearing load.

3.5.2 Boundary (Thin Film) Lubrication:

Boundary lubrication exists when the operating condition is such that it is not possible to

establish a full fluid condition, particularly at low relative speeds between the moving or

sliding surfaces. The oil film thickness may be reduced to such a degree that metal to metal

contact occurs between the moving surfaces. The oil film thickness is so small that oiliness

becomes predominant for boundary lubrication.

Figure3. 21 Boundary Lubrication

Boundary lubrication happens when

 A shaft starts moving from rest.

 The speed is very low.

 The load is very high.

 Viscosity of the lubricant is too low.

30
Examples for boundary lubrication:

 Guide and guide shoe in two stroke engine.

 Lubrication of the journal bearing in diesel engines (mainly during starting and

stopping of engine).

 Piston rings and when cylinder liner is at TDC and BDC position when the piston

direction changes and if the relative speed is very slow.

3.5.3 Mixed Film Lubrication:

Mixed lubrication, also called partial lubrication, is an important lubrication regime in

internal combustion engines. Both full film lubrication and metal-to-metal contact occur

in mixed lubrication. The load is supported partly by the fluid film and partly by the surface

asperities. Many engine components operate in mixed lubrication, for example the piston

rings and the cams. The engine bearings may also operate in mixed lubrication under

severe instantaneous loading.

Figure3. 22 Mixed Film Lubrication

Understanding mixed lubrication is particularly important to a system engineer for the

following reasons. First, it is the lubrication regime in which an accurate prediction of the

31
friction is the most difficult, due to the interaction between the complex surface topography

and the fluid pressure (or the oil film thickness). The generated lubricant film is not enough

to separate the bodies completely, but hydrodynamic effects are considerable.

3.6 Lubricants

A lubricant is a substance, usually organic, introduced to reduce friction between surfaces in mutual

contact, which ultimately reduces the heat generated when the surfaces move. It may also have the

function of transmitting forces, transporting foreign particles, or heating or cooling the surfaces.

The property of reducing friction is known as lubricity. In addition to industrial applications,

lubricants are used for many other purposes. Other uses include cooking (oils  and fats in use

in frying pans, in baking to prevent food sticking), bio applications on humans (e.g. lubricants

for artificial joints), ultrasound examination, medical examination.

Figure3. 23 Lubricants
Many different substances can be used to lubricate a surface. Oil and grease are the most

common. Grease is composed of oil and a thickening agent to obtain its consistency, while

the oil is what actually lubricates. Oils can be synthetic, vegetable or mineral-based as well

as a combination of these. The application determines which oil, commonly referred to as

32
the base oil, should be used. In extreme conditions, synthetic oils can be beneficial. Where

the environment is of concern, vegetable base oils may be utilized.

Lubricants containing oil have additives that enhance, add or suppress properties within the

base oil. The amount of additives depends on the type of oil and the application for which it

will be used. For instance, engine oil might have a dispersant added.

A dispersant keeps insoluble matter together to be removed by the filter upon circulation.

In environments that undergo extremes in temperature, from cold to hot, a viscosity index

(VI) improver may be added. These additives are long organic molecules that stay bunched

together in cold conditions and unravel in hotter environments. This process changes the

oil’s viscosity and allows it to flow better in cold conditions while still maintaining its

high-temperature properties. The only problem with additives is that they can be depleted,

and in order to restore them back to sufficient levels, generally the oil volume must be

replaced.

The requirements that lubricants need to satisfy generally consist of the following.

1. High oil film strength

2. Low friction

3. High wear resistance

4. High thermal stability

5. Non-corrosive

6. Highly anti-corrosive

33
 7. Minimal dust/water content

8. Consistency of grease must not be altered to a significant extent even after it is

repeatedly

3.6.1 Types of Lubricants:

There are mainly four types of lubricants and they are:

 Solid Lubricants

 Liquid Lubricants

 Gaseous Lubricants

 Semi- solid Lubricants

3.6.1.1 Solid Lubricants:

Dry lubricants or solid lubricants are materials that, despite being in the solid phase, are

able to reduce friction between two surfaces sliding against each other without the need for

a liquid oil medium.

The two main dry lubricants are graphite and molybdenum disulfide. They offer

lubrication at temperatures higher than liquid and oil-based lubricants operate. Dry

lubricants are often used in applications such as locks or dry lubricated bearings. Such

materials can operate up to 350 °C (662 °F) in oxidizing environments and even higher in

reducing / non-oxidizing environments (molybdenum disulfide up to 1100 °C, 2012 °F).

The low-friction characteristics of most dry lubricants are attributed to a layered structure

on the molecular level with weak bonding between layers. Such layers are able to slide

34
relative to each other with minimal applied force, thus giving them their low friction

properties.

Figure3. 24 Solid Lubricant

The four most commonly used solid lubricants are:

1. Graphite. Used in air compressors, food industry, railway track joints, brass

instrument valves, piano actions, open gear, ball bearings, machine-shop works,

etc. It is also very common for lubricating locks, since a liquid lubricant allows

particles to get stuck in the lock worsening the problem. It is often used to lubricate

the internal moving parts of firearms in sandy environments.

2. Molybdenum disulfide (MoS2). Used in CV joints and space vehicles. Does

lubricate in vacuum.

3. Hexagonal boron nitride. Used in space vehicles. Also called "white graphite."

4. Tungsten disulfide. Similar usage as molybdenum disulfide, but due to the high cost

only found in some dry lubricated bearings.

3.6.1.2 Liquid Lubricants:

35
Liquid lubricants, generally referred to as oils, share the properties of all liquids, are able to

flow, and take the shape of their containers. Typically lubricants contain 90% base oil

(most often petroleum fractions, called mineral oils) and less than 10% additives. Vegetable

oils, esters, silicones, fluorocarbons and many others are sometimes used as base oils.

Additives deliver reduced friction and wear, increased viscosity, improved viscosity index,

resistance to corrosion and oxidation, aging or contamination.

Figure3. 25 Liquid Lubricant

Base oil of lubricating oil is found from crude oil. Crude oil is a mixture of hydrocarbons

that formed from plants and animals that lived millions of years ago. Crude oil is a fossil

fuel, and it exists in liquid form in underground pools or reservoirs, in tiny spaces within

sedimentary rocks, and near the surface in tar (or oil) sands.

36
 Figure3. 26 Barrel of Crude Oil

Characteristics of liquid lubricants:

 High boiling point

 Low freezing point

 High resistance to oxidation and heat

 Non corrosive properties

Classification of liquid lubricants:

 Mineral oil (The term "mineral oil" is used to refer to lubricating base oils derived

from crude oil).

 Synthetic oil (Petroleum-derived lubricant can also be produced using synthetic

hydrocarbons)

 Blended oil (with additives)

 Animal and vegetable oils (from crude fat and vegetable oil such as cotton seed oil,

castor oil)

37
3.6.1.3 Gaseous Lubricants:

Gas lubrication is used for ultra-thin film thickness. Although both gases and liquids are

viscous fluids, they differ in two important particulars. The viscosity of gases is much

lower and the compressibility much greater than for liquids. Film thicknesses and load

capacities therefore are much lower with a gas such as air. In equipment that handles gases

of various kinds, it is often desirable to lubricate the sliding surfaces with gas in order to

simplify the apparatus and reduce contamination to and from the lubricant. The list of gases

used in this manner is extensive and includes air, steam, industrial gases, and liquid-metal

vapors. Air, Nitrogen, and Helium are examples of gas lubricants.

Advantages of Gas Lubricants:

 Temperature range is high (from -200 to 2000 degree centigrade)

 No vaporization, cavitation, solidification, decomposition

 No seal required and very clean

Disadvantages of Gas Lubrication:

 Very low load capacity

 Ultra-low film thickness

 Smooth surfaces and very low clearance

3.6.1.4 Semi- solid Lubricants:

Semi solid lubricants are a gel-like substance such as grease, silicon grease, Vaseline,

waxes that reduce friction between two moving surfaces. Grease is a black or yellow sticky

mass used in the bearings for lubrication purpose.

38
 Figure3. 27 Semi Solid Lubricant
Conditions for using semi-solid lubricants:

 When it is necessary to seal the bearing or joint against the dirty & dust particles.

 When the machine is worked at low speed under high load.

 When the contamination of lubricating oil is unacceptable and harmful for products.

 When the lubricating oil is not suitable for machines.

3.6.2 Properties of Lubricating Oil:

Lubricity: Some lubricants are said to have high lubricity, or oiliness. This property comes

from the chemical compositions of the oils, which reduce wear and friction even in extreme

conditions.

Cloud Point: Petroleum-based lube oils contain dissolved wax. At a low enough

temperature, referred to as the cloud point, this wax will separate from the oil and form wax

crystals. These crystals can clog filters and small openings, deposit on surfaces such as heat

exchangers, and increase the viscosity of the oil.

39
Viscosity index: Viscosity index is an expression of effect of change of temperature on the

viscosity of oils. This change can be evaluated numerically and the result is expressed as

V.I.

Pour Point: Pour point of oil is an important quality. It is a temperature at which oil will

still remain fluid. It reflects on the capability of the oil to work at low temperatures.

Flashpoint: Flash point is the temperature at which the oil gives off sufficient vapor that

can be ignited. It reflects on the capability of the oil to work at higher temperature without

any fire hazard.

3.6.3 Lubricant Additives:

The purification and manufacturing processes impact good qualities to lubricating oils. But

still they cannot be used directly. They will be prone to contamination and decomposition

in the exacting working conditions. Hence certain chemical compounds and other agents

termed as additives are added to the oil. Lubricant additives are organic or inorganic

compounds dissolved or suspended as solids in oil. They typically range between 0.1 to 30

percent of the oil volume, depending on the machine.

 Additives have three basic roles: Enhance existing base oil properties with

antioxidants, corrosion inhibitors, anti-foam agents and demulsifying agents.

 Suppress undesirable base oil properties with pour-point depressants and viscosity

index (VI) improvers.

 Impart new properties to base oils with extreme pressure (EP) additives, detergents,

metal deactivators and tackiness agents.

40
 Figure3. 28 Additives in Base Oil
Conventional Lubricant Additives are stated below:

a. Friction Modifiers:

Friction modifiers reduce coefficient of friction, resulting in less fuel consumption. Crystal

structure of most of friction modifiers consists of molecular platelets (layers), which may

easily slide over each other.

The following Solid lubricants are used as friction modifiers:

 Graphite

 Molybdenum disulfide

 Boron nitride (BN)

 Polytetra fluoro ethylene (PTFE)

 Tungsten Disulfide (WS2)

41
b. Anti-wear Additives:

Anti-wear additives prevent direct metal-to-metal contact between the machine parts when

the oil film is broken down. Use of anti-wear additives results in longer machine life due to

higher wear and score resistance of the components. The mechanism of anti-wear additives:

the additive reacts with the metal on the part surface and forms a film, which may slide

over the friction surface. The following materials are used as anti-wear additives:

 Zinc dithiophosphate (ZDP)

 Zinc dialkyldithiophosphate (ZDDP)

 Tricresylphosphate (TCP)

c. Extreme Pressure (EP) Additives:

Extreme pressure (EP) additives prevent seizure conditions caused by direct metal-to-metal

contact between the parts under high loads. The mechanism of EP additives is similar to

that of anti-wear additive: the additive substances form a coating on the part surface. This

coating protects the part surface from a direct contact with other part, decreasing wear and

scoring.

The following materials are used as extra pressure (EP) additives:

 Chlorinated paraffins

 Sulphurized fats

 Esters

 Zinc dialkyldithiophosphate (ZDDP)

42
  Molybdenum disulfide

d. Rust and Corrosion Inhibitors:

Rust and Corrosion inhibitors form a barrier film on the substrate surface reducing the

corrosion rate. The inhibitors also absorb on the metal surface forming a film protecting the

part from the attack of oxygen, water and other chemically active substances. The

following materials are used as rust and corrosion inhibitors:

 Alkaline compounds

 Organic acids

 Esters

 Amino-acid derivatives

e. Anti –Oxidants:

Mineral oils react with oxygen of air forming organic acids. The oxidation reaction

products cause increase of the oil viscosity, formation of sludge and varnish, corrosion of

metallic parts and foaming. Anti-oxidants inhibit the oxidation process of oils. Most of

lubricants contain anti-oxidants.

The following materials are used as anti-oxidants:

 Zinc dithiophosphate (ZDP)

 Alkyl sulfides

 Aromatic sulfides

 Aromatic amines
43
  Hindered phenols

f. Detergents:

Detergents neutralize strong acids present in the lubricant (for example sulfuric and nitric

acid produced in internal combustion engines as a result of combustion process) and

remove the neutralization products from the metal surface. Detergents also form a film on

the part surface preventing high temperature deposition of sludge and varnish. Detergents

are commonly added to Engine oils. Phenolates, sulphonates and phosphonates of alkaline

and alkaline-earth elements, such as calcium (Ca), magnesium (Mg), sodium (Na) or

barium (Ba), are used as detergents in lubricants.

g. Dispersants:

Dispersants keep the foreign particles present in a lubricant in a dispersed form (finely

divided and uniformly dispersed throughout the oil). The foreign particles are sludge and

varnish, dirt, products of oxidation, water etc. Long chain hydrocarbons succinimides, such

as polyisobutylene succinimides are used as dispersants in lubricants.

h. Pour point Dispersants:

Pour point is the lowest temperature, at which the oil may flow.Wax crystals formed in

mineral oils at low temperatures reduce their fluidity.Pour point depressant inhibits

formation and agglomeration of wax particles keeping the lubricant fluid at low

temperatures. Co-polymers of polyalkylene methacrylates are used as pour point depressant

in lubricants.

44
i. Viscosity index Improver (VI):

Viscosity of oils sharply decreases at high temperatures. Low viscosity causes decrease of

the oil lubrication ability. Viscosity index improvers keep the viscosity at acceptable levels,

which provide stable oil film even at increased temperatures. Viscosity improvers are

widely used in multigrade oils, viscosity of which is specified at both high and low

temperature. Acrylate polymers are used as viscosity index improvers in lubricants.

j. Anti foaming Agents:

Agitation and aeration on lubricating oil occurring at certain applications (Engine oils, Gear

oils, Compressor oils) may result in formation of air bubbles in the oil - foaming. Foaming

not only enhances oil oxidation but also decreases lubrication effect causing oil starvation.

Dimethylsilicones (dimethylsiloxanes) is commonly used as anti-foaming agent in

lubricants.

3.6.3 SAE Grade of Oil:

The Society of Automotive Engineers (SAE) developed a grading system to designate the

viscosity level of single grade and multi grade motor oils. In single grade oils, the lower the

number, the better it flows at cold temperatures. Likewise higher number, the thicker the

oil. In regard to multi grade oils, the first number in the code, such as 10W in SAE 10W-

30, means that the oil can still be pumped by the engine at a temperature as low as a single

grade 10W oil. A 5W, like in SAE 5W-30, can be pumped at an even lower temperature,

and a 0W, like in SAE 0W-30, will pump at the lowest tested temperatures. The W in the

designation is commonly thought to represent weight, but in fact stands for winter. The

second number, 30, indicates how well the oil will flow when heated to 100°C /212F or

higher.

45
As engines have become more technologically advanced, engine clearance levels and

viscosity grade recommendations may have been reduced, hence the reason your father

swore by SAE 20W-50 and your engine calls for SAE 5W-30. If thicker oil is used in some

of today’s high-tech, small clearance engines, oil pressure may increase, but the possibility

of improper lubrication can result if the oil can’t adequately flow through the engine.

Engine manufacturers carefully select the recommended motor oil viscosity grade for each

specific engine, which is why the owner manual recommended viscosity should always be

used.

Figure3. 29 Viscosity Index

3.6.4 API Standard Motor Oil:

The American Petroleum Institute, API, is a U.S.A trade association for the oil and natural

gas industry. Specifications are important as these indicate the performance of the oil and

whether they have met or passed the latest tests, or whether the formulation is effectively

obsolete or out of date. There are two categories: gasoline and diesel. Category S is for

“Spark Ignition”, for Gasoline and category C is for “Compression Ignition’, for Diesel.

For both, the letter S or C is followed by another letter, for example, SM or CF. The higher

46
the letter, the more recent the technology of the oil. For recent oil, the higher specification

will supersede the lower letter grade. For example, if we have oil with specification SN, it

can also be used for vehicles that request API SM, SL and SJ; it is backward compatible.

However, we have to pay attention to the year of construction of the engine. If the engine is

too old, modern chemistry might not be adapted or compatible with old engine designs and

materials used to make the engine. Let’s see by category how it works.

Figure3. 30 API Standard Chart

3.7 Engine Lubrication Systems:

The Engine lubrication system is considered to give a flow to the clean oil at the accurate

temperature, with an appropriate pressure to each part of the engine. The oil is sucked out

into the pump from the sump, as a heart of the system, than forced between the oil filter and

pressure is fed to the main bearings and also to the oil pressure gauge. The oil passes

through the main bearings feed- holes into the drilled passages in the crankshaft and on to

the bearings of the connecting rod. The bearings of the piston-pin and cylinder walls get

lubricated oil dispersed by the rotating crankshaft. By the lower ring in the piston the

excess being scraped. Each camshaft bearing is fed by the main supply passage from a

branch or tributary. And there is another branch that supplies the gears or timing chain on

47
the drive of camshaft. The excesses oil then drains back to the sump, where the heat is

being transferred to the surrounding air. Lubrication plays a key role in the life expectancy

of an automotive engine. If the lubricating system fails, an engine would succumb to

overheating and seizing very quickly. Primarily the engine lubrication system can be

divided in to the following ways:

 Mist Lubrication System

 Wet Sump Lubrication System

 Dry Sump Lubrication System

3.7.1 Mist Lubrication System:

Mist lubrication system is a very simple type of lubrication. In this system, the small

quantity of lubricating oil (usually 2 to 3%) is mixed with the fuel (preferably gasoline).

The oil and fuel mixture is introduced through the carburetor. The gasoline vaporized and

oil in the form of mist enters the cylinder via the crank base. The droplets of oil strike the

crank base. The droplets of oil strike the crank base, lubricating the main and connecting

rod bearings and the rest of the oil lubricates the piston, piston rings and cylinder. The

system is preferred in two stroke engines where crank base lubrication is not required. In a

two-stroke engine, the charge is partially compressed in a crank base, so it is not possible to

have the oil in the crank base. This system is simple, low cost and maintenance free

because it does not require any oil pump, filter, etc. However, it has certain serious

disadvantages. Therefore, it is not popular among the lubrication system.

48
 Figure3. 31 Mist Lubrication System

Its disadvantages are the following:

1. During combustion in the engine, some lubricating oil also burnt and it causes
heavy exhaust and forms deposits on the piston crown, exhaust port and exhaust system.

2. Since the lubricating oil comes in contact with acidic vapors produced during the
combustion, it gets contaminated and may result in the corrosion of the bearings surface.

3. When the vehicle is moving downhill, the throttle is almost closed, and the engine
suffers lack of lubrication because the supply of fuel is less. It is a very serious drawback of
this system.

4. There is no control over the supply of lubricating oil to the engine. In normal
operating conditions, the two-stroke engines are always over-oiled. Thus consumption of
oil is also more.

5. This system requires thorough mixing of oil and fuel prior to admission into the

engine. It requires either separate mixing or use of some additives.

3.7.2 Wet Sump Lubrication System:

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A wet sump is a lubricating oil management design for piston engines that uses the

crankcases as a built-in reservoir for oil. It is divided into 3 systems:

 The Splash System

 The Splash and Pressure System

 The full Pressure Feed System

3.7.2.1 The Splash System:

Figure3. 32 The Splash System

Splash lubrication system is used on small, stationary four-stroke engines. In this system,

the cap of the big end bearing on the connecting rod is provided with a scoop which strikes

and dips into the oil-filled through at every revolution of the crank shaft and oil is splashed

all over the interior of crank case into the piston and over the exposed portion of the

cylinder is shown in the figure above. A hole is drilled through the connecting rod cap

through which the oil passes to the bearing surface. Oil pockets are provided to catch the

splashed oil over all the main bearings and also the cam shaft bearings. From these pockets
50
oil passes to the bearings through drilled hole. The surplus oil dripping from the cylinder

flows back to the oil sump in the crank case.

3.7.2.2 The Splash and Pressure System:

Splash and pressure lubrication system is combination of splash and pressure system as

shown in below figure. 

Figure3. 33 The Splash and Pressure System

In this system, the lubricating oil is supplied by a pump under pressure to main and

Camshaft bearings. The oil is also directed in the form of spray from nozzle or splashed by

a scoop or dipper on the big end to lubricate bearings at the big end of the connecting rod,

crank pin, gudgeon pin, piston rings and cylinder.

3.7.2.3 The full Pressure Feed System:

In pressurized lubrication system, the lubricating oil is supplied by a pump under pressure

to all parts requiring lubrication as shown in below figure. The oil under the pressure is

supplied to main bearings of the crankshaft and camshaft. Holes drilled through the main

crankshaft bearings journals, communicate oil to big end bearing and small end bearings

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through the hole drilled in the connecting rod. A pressure gauge is provided to confirm the

circulation of oil to various parts.

Figure3. 34 The full Pressure Feed System

This system provides sufficient lubrication to all parts and is favored by most of the engine

manufacturers. This is used in most heavy duty and high-speed engines.

3.7.2.4 Dry Sump Lubrication System:

In dry-sump lubrication system, the oil supply is carried from an external tank. The oil

from the sump is pumped by means of a scavenging pump through filters to the external

storage tank. The oil from the storage tank is pumped to engine cylinder through and oil

cooler. The oil pressure may vary from 3 to 8 bar. The dry-sump lubrication system is

generally used for heavy-duty engines.

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 Figure3. 35 Dry Sump System
3.8 Hybrid and All Electric Car Lubrication:

Oil changes may not be needed as often with a hybrid because the engine runs less during

low speeds and stop-and-go driving, but the oil still needs to be changed. Always use

premium engine oils for these vehicles. Some late-model hybrids call for 0W-20 or 5W-20

weight motor oil. Not using the correct weight will damage the top-end of the motor.

Hybrids regularly shut down and restart the engine more than a conventional vehicle, and

starting an engine is the greatest cause of wear on any engine. The Electric Motors don't

require lubrication from conventional oil. However, they do require a minimal amount of

grease for the bearings inside the motor. 

In electric car there is no internal combustion engine. It runs on electric motor. The motor

or differential unit aka the Drive Unit contains lubricating oil. Hubs and reduction gears

also use lubricants.

3.9 Essential Fluids in Automobile

Here are some of the important fluids used in an automobile besides lubricating oil.

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3.9.1 Transmission Fluid:

Transmission fluid helps to keep metal parts inside the gearbox from grinding down. This

fluid will also help to keep the different parts of the transmission cool. Shifting mechanical

gears is a hard task for the car. Transmission fluid allows the car to shift with ease while

protecting the metal parts that rub against each other from wearing down.

Automatic Transmission Fluid:

Automatic transmission fluid is used in all cars that have automatic transmissions, as well

as some more modern manual transmission cars. Automatic transmission fluid is optimized

for the requirements of an automatic transmission and helps with functions such as gear

lubrication, brake band friction, and valve operation.

Manual Transmission Fluid:

Also known as manual transmission oil is the fluid used in some manual transmission cars.

Manual transmission fluid is never used in any automatic transmission cars and just

because your car is a manual transmission does not mean that it uses manual

Figure3. 36 Transmission Fluid Drain

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transmission fluid. Manual transmission fluid can be a variety of different oils from normal

motor oil to heavyweight hypoid gear oil. Always be sure to check the specifications for the

car.

Figure3. 37 Transmission Fluid Pour

3.9.2 Power Steering Fluid:

Power steering fluid keeps your car’s power steering working by keeping it lubricated,

adding power to your ability to control the car’s wheels. To check the power steering

Figure3. 38 Power Steering Fluid

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fluid, find the reservoir under the hood. It’s usually on the passenger side. Either way, it’s

likely to be near the belts and the cap will probably say “steering” on it. Most cars have an

opaque container, so you should be able to see the fluid level without opening the cap.

Otherwise, before opening the cap, clean the area around it with a cloth so dirt doesn’t get

into the system. Then, open the cap and use the dipstick the same way you would with the

oil tank. If the fluid is low, you can easily add more yourself. You may also want to check

around the reservoir to make sure there isn’t a leak.

3.9.3 Brake fluid:

Brake fluid is pressurized and adds power to your braking and keeps us from running into

other vehicles. The brake fluid reservoir is usually near the back of the engine

compartment. Clean off the outside before you open the tank, as any dirt in the fluid can be

dangerous in your system. To open the reservoir just unscrew the cap or use a screwdriver

to pry off a clamp that may be holding it in place. Look inside to see where the fluid level

is. It should be within about a half-inch of the cap. If it isn’t, check the manual to see what

kind of fluid we should add. Also check the color of the brake fluid, if it looks dark in

color, we should have a mechanic replace it.

Figure3. 39 Brake Fluid

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3.9.4 Radiator Fluid

The radiator fluid keeps your engine from overheating. If you run low, you risk overheating

in traffic and getting stranded on the side of the road. Check this fluid when your car has

been driven, not when it’s cold. The contents of the radiator are pressurized, so never

remove the cap when the engine is hot or running. You’ll likely find the radiator cap in the

front and middle of the engine compartment. Open it carefully with a rag, and look into the

radiator to see if you can see the coolant. If you can’t see it near the top, you’ll need to add

more.

Figure3. 40 Coolant

3.10 Engine Oil Sludge:

Engine sludge is basically a dirty, sticky, grease-like substance, formed due to oxidation or

contamination of oil in the engine. During oxidation, the molecules of engine oil break

down and the resultant products combine with the dirt in carbon form, metallic particles,

fuel, gases, water and liquid coolant. Together the mixture forms a sticky sludge. Stop-and-

go driving in heavy traffic conditions and in areas where there are lots of traffic lights can

contribute to sludge buildup. Frequently driving over short distances can also cause sludge.
57
The resulting material blocks the engine’s lubricating system. In the worst case this can

cause the engine to seize.

Figure3. 41 Sludge
Causes of sludge:
1. Neglect of maintenance
2. Use of inferior oil
3. Low quality fuels
4. Excessive idling

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CHAPTER 4: PROBLEM FINDING, ANALYSIS, AND DISCUSSION

Table 1 Troubleshooting for Lubrication System

The table below gives the list of frequent troubles with lubrication system, cause and

remedy for the same:

Table 1
Problem Probable Cause Solution

Mechanical knocking Low octane rating of fuel Use better quality fuel

Carbon deposit Clean throttle body

Sludge accumulation Engine flush

Oil burning smell
Tappet noise while waiting in
signal
Poor acceleration
Oil level sensor lit
Engine operating temperature
increase
Low engine oil pressure
Squeaky noise from Lack of lubricant
suspension springs
Lubricant not changed Lube oil change every 3
regularly months or 3000Km
Sludge accumulation Engine Overhauling
Wrong SAE grade in oil Proper SAE grade lubricant
Sludge accumulation Carbon clean engine
Low on engine oil Top up oil
Sludge accumulation Engine overhauling
Defective oil pressure Remove oil pressure regulator
regulator valve valve and replace.
Rub some grease on the coils

Noise while breaking Caliper may be too dusty Put some silicon grease in the
caliper

Problem that I have witnessed during the internship at Autoxpress Workshop

Limited:

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4.1 Problem1

Finding

Car came in with poor acceleration issue and high engine temperature.

Figure4. 1 Sludge in Engine

Analysis

Witnessed very old and dirty engine oil and signs of sludge accumulation

Solution
Engine overhauled properly and removed sludge buildup.

4.2 Problem 2

Finding

Smell of burned lube oil coming from the engine.

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 Figure4. 2 Lube Oil Change

Analysis

Lubricant oil not changed frequently according to manufacturer specification

and found the lube oil very very thick.

Solution

Performed oil change with proper viscosity lubricant oil.

4.3 Problem 3

Finding

Noise coming from front brake when brake is applied

Figure4. 3 Brake Noise

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Analysis

Removed front disc brake and calipers and observed lack of lubricant on the calipers

Solution

Applied silicon grease on the calipers and disc resurfaced. Finally the noise was gone.

4.4 Problem 4

Finding

Tappet noise while the car stops with the engine on

Analysis

After proper examination of the car found sludge buildup in the engine

Solution

Engine overhauled and sludge cleaned

4.5 Problem 5

Finding

Car came in with low engine oil pressure

Analysis

Found oil pressure regulatory valve not working

Solution

Changed valve and problem was solved

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 CHAPTER 5: CONCLUSION

5.1 Conclusion

Lubricating oil is often called the blood of an engine. Proper lubrication of all moving parts

is essential for the operation of an IC engine. The lubrication primarily decreases the power

required to overcome friction and reduces wear between the rubbings and bearing surfaces,

thereby increases the power output and the engine service life, and avoids seizure and

serious damage of the components. Additionally the lubricant acts as a coolant, carrying

heat away from the bearings, cylinders and pistons. The lubricating film on the cylinder

wall acts as a seal to prevent the gases of combustion from blowing by the piston rings and

entering the crankcase. Thus the effectiveness of engine lubrication plays an important role

in determining the service life and the performance characteristics of an engine.

The lubrication system is consisted of oil pan, oil pump, oil filter, and oil passages. The

chapter starts with purpose of lubricating oil and the lubricating system, and the principle

of lubrication. Oil additives, deterioration, ratings, properties and classifications have been

discussed before discussing the lubrication system and their components. I had a great

opportunity to work on Nissan, Toyota, Honda and Mitsubishi cars at Autoxpress

Workshop for the last three months. Repair, maintenance and troubleshooting were among

my key responsibility as a Trainee Engineer. Waiting to apply the knowledge I gathered

from here in real life. It has been a great experience.

5.2 Recommendations for future work

Working at Autoxpress Workshop for the last three months taught me a lot of things. I experienced

a lot of strength they possess during the period. But also witnessed a few weaknesses as well and

would love to recommend a few tips for them to improve.

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 As all original auto parts are lot more expensive than other similar ones,

AutoXpress Workshop employees should take time to explain to the customers the

importance of using original parts.

 Service quality should not be compromised to give customers express service.

 They can hold free diagnostic service once a week for customers.

 Safety of employees and customers should be top priority.

 Technicians should be trained to look clean.

 Technicians should use all the modern apparatus all the time.

 Work station must be kept clean at all times.

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 REFERENCES
Spikes, Hugh (2015-10-01). "Friction Modifier Additives". Tribology Letters. 60 (1):

doi:10.1007/s11249-015-0589z. hdl:10044/1/25879 ISSN 1023-8883

Salimon, Jumat; Salih, Nadia; Yousif, Emad (2010). "Biolubricants: raw materials,
chemical modifications and environmental benefits". European Journal of Lipid
Science and Technology. 112: 519–530. doi:10.1002/ejlt.200900205

Don M. Pirro; Martin Webster; Ekkehard Daschner (2016). Lubrication

Fundamentals(Third Edition, Revised and Expanded ed.). CRC Press. ISBN 978-1-
4987-5290-9 (print) ISBN 978-1-4987-5291-6(eBook)

Products, R. (2018, July 25). Rancon Products. Retrieved from Web:

https://www.rancon.com.bd/products/
Mitsubishi Training Manual

Toyota training manual

William Crouse, Donald Anglin, “Automotive Mechanics”, Career Education, 10th

edition, January,1993.

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