A STUDY OF LUBRICATION SYSTEM ON

DIESEL ENGINE AT AUTO XPRESS LIMITED

JUNE, 2021
 A STUDY OF LUBRICATION SYSTEM ON
DIESEL ENGINE AT AUTO XPRESS LIMITED

BY
Md. Samir Hossen
ID: 17207077
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
AGRICULTURE AND TECHNOLOGY
FORWARDING LETTER

iii
ACCEPTANCE LETTER

iv
CERTIFICATE FROM ORGANIZATION

v
 DECLARATION

This practicum report has been prepared after three months of internship at AUTO XPRESS
LTD. 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. Samir Hossen

ID: 17207077

vi
 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.

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.

I would like to express my heartfelt thanks to the honorable Vice Chancellor Prof. Dr.
Abdur Rab of IUBAT for his guidance and leadership.

I sincerely acknowledge the contributions of the honorable Chair of the department of

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

I express my gratitude for the support provided by the Coordinator of mechanical engineering
department Dr. A. K. M. Pervej Iqbal.

My special thanks to my supervisor, Lecturer Nayem Hossain for his excellent guidance,
patience, and care. His understanding, knowledge, and ambition to the highest standards
inspired me to complete this work.

Also, I would like to pay my gratitude to Md. Hasan Mahmud, Chief Technical Trainer of
Auto Xpress Limited for his painstaking guidance and diligent struggle in teaching me the
practical aspects of my internship work.

I sincerely acknowledge the contributions of the Department of Mechanical Engineering

and IUBAT—International University of Business Agriculture and Technology for
continuous support to come up with this quality work and my faculties at IUBAT, the staffs
and employees of Auto Xpress Limited for their cooperation, support and motivation that
enabled me to complete my practicum report.

Finally, I would also like to thank my parents, family members and relatives for their
cooperation, affection, and help throughout the period of attending this study and their
support helped me a lot to come up with this good work.

__________________
Md. Samir Hossen
ID: 17207077

vii
 A STUDY OF LUBRICATION SYSTEM ON DIESEL ENGINE AT
AUTO XPRESS LIMITED

Candidate Supervisor

………………………. ……………………….

Md. Samir Hossen Nayem Hossain

ID: 17207077 Lecturer
Department of Mechanical Engineering

viii
 ABSTRACT

AUTO XPRESS LTD. is one of the best automobile workshops in Bangladesh. “AUTO

XPRESS LTD.”, 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. The Workshop

has the following section: Mechanical, Electrical, Engine, Wheel Alignment and Balancing,

Fuel System Cleaning Service, Vehicle Wash and Polish, Dent-Paint, Breakdown Attending,

Analyzer and Auto Logic Scanner. This report consists of engine overhauling, brake system

overhauling, Suspension system overhauling, fuel system, auto transmission work etc. This

report specially deals with lubrication system and its components. The lubrication system of

an engine provides a supply of lubricating oil to the various moving parts in the engine. Its

main function is to enable the formation of a film of oil between the moving parts, which

reduces friction and wear. Lubrication system is one vital system among other system in

engine. Like cooling without lubrication an engine cannot run. Without lubrication any parts

which is connected to engine excessive heat will developed and parts may crack or broken.

Piston inside the cylinder may be chocked and so on. The goal of internship in lubricating

system is to know in details about lubricating system and the function of its components.

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Table of Contents
FORWARDING LETTER............................................................................................ iii
ACCEPTANCE LETTER............................................................................................. iv
CERTIFICATE FROM ORGANIZATION ................................................................ v
DECLARATION............................................................................................................ vi
ACKNOWLEDGEMENT ............................................................................................ vii
ABSTRACT .................................................................................................................... ix
LIST OF FIGURES ..................................................................................................... xiii
LIST OF TABLES ....................................................................................................... xiv
LIST OF SYMBOLS AND ABBREVIATIONS ........................................................ xv
CHAPTER 1: INTRODUCTION .................................................................................. 1
1.1 Research Background ....................................................................................................... 1
CHAPTER 2: COMPANY PROFILE .......................................................................... 3
2.1 Background of AUTO XPRESS LTD. ............................................................................ 3
2.2 Overview of AUTO XPRESS LTD. ................................................................................ 4
Vision: ....................................................................................................................... 4

Mission: ..................................................................................................................... 4

Values: ....................................................................................................................... 4

Strength:..................................................................................................................... 5

Equipment’s: .............................................................................................................. 6

Service Offering: ....................................................................................................... 7

2.3 Company at a Glance: ...................................................................................................... 8

CHAPTER 3: LUBRICATION SYSTEM OF DIESEL ENGINE VEHICLE ......... 9
3.1 Introduction ...................................................................................................................... 9
3.2 Automobile System .......................................................................................................... 9
3.2.1 The Engine ...................................................................................................... 10

3.2.2 The Fuel System ............................................................................................. 11

3.2.3 The Ignition System........................................................................................ 11

3.2.4 The Electrical System ..................................................................................... 11

3.2.6 The Drive Train .............................................................................................. 11

3.2.7 The Suspension and Steering System ............................................................. 12

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 3.2.8 The Braking System ....................................................................................... 12

3.2.9 The Frame and Body ...................................................................................... 12

3.3 Lubrication System ........................................................................................................ 12

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 ................................................................................... 21

3.4.1 Lubricating Journal: ........................................................................................ 21

3.4.2 Seal: ................................................................................................................ 22

3.4.3 Cooling: .......................................................................................................... 22

3.4.4 Reducing Noise: ............................................................................................. 23

3.4.5 Absorbs Shock: ............................................................................................... 23

3.4.6 Absorbs Contaminants:................................................................................... 23

3.4.7 Protection against Wear and Corrosion: ......................................................... 23

3.4.8 Cleaning: ......................................................................................................... 24

3.5 Principles of Lubrication ................................................................................................ 24

3.5.1 Hydrodynamic (Full Film) Lubrication: ......................................................... 25

3.5.2 Boundary (Thin Film) Lubrication: ................................................................ 27

3.5.3 Mixed Film Lubrication: ................................................................................ 28

3.6 Lubricants ....................................................................................................................... 28

3.6.1 Types of Lubricants: ....................................................................................... 30

3.6.2 Properties of Lubricating Oil: ......................................................................... 34

3.6.3 Lubricant Additives: ....................................................................................... 34

3.7 Engine Lubrication Systems: ......................................................................................... 35

3.7.1 Mist Lubrication System: ............................................................................... 35

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 3.7.2 Wet Sump Lubrication System: ...................................................................... 36

3.7.3 Dry Sump Lubrication System: ...................................................................... 37

3.8 Essential Fluids in Automobile ...................................................................................... 37

3.8.1 Transmission Fluid: ........................................................................................ 37

3.8.2 Power Steering Fluid: ..................................................................................... 38

3.8.3 Brake fluid: ..................................................................................................... 39

3.8.4 Radiator Fluid ................................................................................................. 40

CHAPTER 4: PROBLEM FINDING, ANALYSIS AND SOLUTION ................... 41

4.1: Problem 1: Poor acceleration issue and high engine temperature................................. 41
4.2: Problem 2 ...................................................................................................................... 42
4.3 Problem 3 ....................................................................................................................... 42
4.4 Problem 4 ....................................................................................................................... 43
4.5 Problem 5 ....................................................................................................................... 43
CHAPTER 5: CONCLUSION AND RECOMMENDATIONS ............................... 46
5.1 Conclusion...................................................................................................................... 46
5.2 Recommendations for future work ................................................................................. 46
REFERENCES .............................................................................................................. 47

xii
 LIST OF FIGURES
FIGURE 2.1: AUTO XPRESS LTD. ...................................................................................................................................................... 4
FIGURE 3.2: AUTOMOBILE SYSTEM ............................................................................................................................................ 10
FIGURE 3.3: SCHEMATIC DIAGRAM OF ENGINE LUBRICATION SYSTEM .................................................................. 13
FIGURE 3.4: AUTO BODY LUBRICATION POINTS .................................................................................................................. 14
FIGURE 3.5: CHASSIS LUBRICATION POINTS ......................................................................................................................... 15
FIGURE 3.6: DIAGRAM OF ENGINE LUBRICATION ............................................................................................................... 16
FIGURE 3.7: OIL PAN .......................................................................................................................................................................... 17
FIGURE 3.8: OIL FILTER .................................................................................................................................................................... 18
FIGURE 3.9: PISTON COOLING NOZZLES .................................................................................................................................. 18
FIGURE 3.10: OIL PUMP .................................................................................................................................................................... 19
FIGURE 3.11: OIL GALLERIES ......................................................................................................................................................... 20
FIGURE 3.12: OIL COOLER ............................................................................................................................................................... 20
FIGURE 3.13: LUBRICATING JOURNAL ...................................................................................................................................... 21
FIGURE 3.14: BLOW BY ..................................................................................................................................................................... 22
FIGURE 3.15: OIL COOLING ............................................................................................................................................................. 22
FIGURE 3.16: NOISE REDUCTION ................................................................................................................................................. 23
FIGURE 3.17: CORROSION................................................................................................................................................................ 23
FIGURE 3.18: ENGINE CLEANING ................................................................................................................................................. 24
FIGURE 3.19: LUBRICATION PRINCIPLES ................................................................................................................................ 24
FIGURE 3.20: FULL FILM LUBRICATION ................................................................................................................................... 25
FIGURE 3.21: JOURNAL BEARING LUBRICATION ................................................................................................................. 26
FIGURE 3.22: BOUNDARY LUBRICATION ................................................................................................................................. 27
FIGURE 3.23: MIXED FILM LUBRICATION ................................................................................................................................ 28
FIGURE 3.24: LUBRICANTS ............................................................................................................................................................. 29
FIGURE 3.25: SOLID LUBRICANT .................................................................................................................................................. 30
FIGURE 3.26: LIQUID LUBRICANT ............................................................................................................................................... 31
FIGURE 3.27: BARREL OF CRUDE OIL ........................................................................................................................................ 32
FIGURE 3.28: SEMI SOLID LUBRICANT ...................................................................................................................................... 33
FIGURE 3.29: MIST LUBRICATION SYSTEM ............................................................................................................................. 36
FIGURE 3.30: DRY SUMP SYSTEM ................................................................................................................................................ 37
FIGURE 3.31: TRANSMISSION FLUID DRAIN .......................................................................................................................... 38
FIGURE 3.32: TRANSMISSION FLUID POUR ............................................................................................................................ 38
FIGURE 3.33: POWER STEERING FLUID.................................................................................................................................... 39
FIGURE 3.34: BRAKE FLUID ............................................................................................................................................................ 39
FIGURE 3.35: COOLANT .................................................................................................................................................................... 40
FIGURE 4.1: SLUDGE IN ENGINE ................................................................................................................................................... 41
FIGURE 4.2: BURNING OIL COMING OUT FROM ENGINE .................................................................................................. 42
FIGURE 4.3: BRAKE NOISE ............................................................................................................................................................... 42
FIGURE 4.4: ENGINE CREATE NOISE .......................................................................................................................................... 43
FIGURE 4.5: GEARBOX LEAK........................................................................................................................................................... 43

xiii
 LIST OF TABLES

TABLE 1: TROUBLESHOOTING FOR LUBRICATION SYSTEM .......................................................................................... 45

xiv
 LIST OF SYMBOLS AND ABBREVIATIONS

ABS Anti-Lock Braking System

A/C Air Conditioning/ Air Conditioner

AFS Air Flow Sensor

A/T Automatic Transmission

ATF Automatic Transmission Fluid

BA Brake Assist

CKD Completely Knocked Down

CV Constant Velocity

EFI Electronic Fuel Injection

ECM Electronic Control Module

EEC Electronic Engine Control

ESP Electronic Stability Program

EBD Electronic Brake Force Distribution

GVW Gross Vehicle Weight

HP Horsepower

KW Kilowatt

MAP Manifold Absolute Pressure Sensor

PDI Pre Delivery Inspection

PCV Positive Crankcase Ventilation

xv
RPM Revolution per Minute

SAE Society of Automotive Engineer

ULW Unladed Weight

xvi
 CHAPTER 1: INTRODUCTION

1.1 Research Background

Automobile has gained recognition and importance ever since motor vehicles capable for
transporting passengers has been in vogue. 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.

Starting with four wheels, the car market in Bangladesh is small compared to many of our
neighboring countries. Bangladesh's automobile density -- the number of vehicles per unit
length of the roadway -- is as low as 0.5 percent, compared to the global average of 12
percent. Data from Bangladesh Road Transport Authority (BRTA) shows that there are a total
of 4,471,625 registered vehicles in the country, of which only 370,519 are registered as
'Private Passenger Car' followed by 105,896 'Microbus' and 66,219 'Jeeps'.

Bangladesh has a large automobile plant that assembles passenger vehicles with technical
assistance from Mitsubishi, Japan via Pajero Sport. Very recent a new company has already
developed to assemble car with technical assistance from Malaysia via Proton. Commercial
vehicles are also assembled in small scale by importing chassis and other parts from Tata and
Mahindra. 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.

1
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,
productivity and performance. Due to this reason my objective is to learn about automobile
engineering specifically lubrication system. The objectives of the internship program are
given below:

 To know the several system exist in Diesel Engine.

 To study in detail about the lubrication system of Diesel Engine.
 To know the purpose of lubricating system.
 To know about the engine lubrication system.
 To learn how to detect problems related to lubrication system.

1.3 Organization of the Report

This report has been prepared on “A study of Lubrication System of Diesel Engine at “AUTO

XPRESS Limited”. At the beginning of this report started with Acknowledgment and

Abstract. Where chapter one refers to introduction part that includes objectives, outline of

the report. Chapter two discussed about company overview and the company activities.

Chapter three discussed 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 etc. Chapter four discussed about trouble-shooting,

analysis and solution of lubrication system of diesel engine at AUTO XPRESS Limited

during my internship. Chapter five consists of conclusion and recommendations. Finally, the

bibliography is included at the end of this report.

2
 CHAPTER 2: COMPANY PROFILE

2.1 Background of AUTO XPRESS LTD.

AUTO XPRESS Limited is the name which was born on 2016 at capital city, Dhaka,
Bangladesh. The AUTO XPRESS LTD. was built to not only provide the best of after-sales
service to their customers but to also build deeper relationships with their customers. They
always strive to understand the demands of the Bangladeshi market and cater to them as best
possible.

Their expectation is customers’ satisfaction & complete automobile solution. They have kept
all the arrangement of all modern equipment & experienced team with big workshop floor
space. Quality comes first profit is logical sequence.

Their workshop has top of the line equipment and a large team of experts who provide a full
range of mechanical and modification services required for automotive industries. They
believe in delivering premium auto parts, giving customers choices and the best service
offerings and connecting with them. Along with top notch maintenance and workshop
services, they are also official distributor for Mahindra & Mahindra and Volvo-Eicher
commercial vehicle parts in Bangladesh.

What set them apart are the years of experience that they have in this sector along with the
comfort zone that they share with their customers who are never hesitant to bring their
vehicles over to their workshop because they let their work speak for itself.

As per the requirements of their valued customer they are bound to support of deferent band
genuine parts in timely manner, they import the spare parts from different countries of the
world. Like as they do procure genuine parts from Japan, UAE, Malaysia, UK, USA
Germany and KSA through our internal source within short lead time.

3
2.2 Overview of AUTO XPRESS LTD.

Figure 2.1: AUTO XPRESS LTD.

Vision:
They set their vision to be a pioneer and good example in expanded business parts that take
into account each developing human need.

Mission:
Their main goal is to be the Best Workshop in Bangladesh. AUTO XPRESS LTD. wants to
ensure the best understanding of after-deals administrations.

Values:
Throughout the years AUTO XPRESS 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.

4
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:

 Low cost
 Sustainability
 Possibility
 Integrity
 Reliability
 Commitment
 Passion
 Determination

Strength:
They perform as per the requirement of their customer and they realize their customer’s
observance happiness. The satisfied customers advertise about their service to the others
clients as a result clients bring clients. They maintain close monitoring, final inspection,
supervising the overall service process. As well organized team can perform properly for the
valued customer.
They try their level best to do something different for every valued customer & make them
happy.
They are different from others:
 The Auto Xpress Limited is committed to serve a different service.
 They are here with a group of expert team for hi tech automobile solution.
 They provide excellent service by reasonable price.
 Their expertise engineers & technicians are trained by some other renowned training
places.
 Their team can perform on world famous brands of vehicle like Mercedes Benz,
BMW, Land Rover, Lexus, Jaguar, Nissan, Toyota, Hyundai, Mazda, and Land Rover
Etc.
 They would like to maintain and follow manufacturer guide line and sales close
monitoring.
 They are committed to provide genuine parts to the all kinds of vehicle.
 They have kept a modern paint booth where we can paint all seasons.
 They know how to find out the problem by world renowned automatic scanner and
provide outstanding solution.

5
Equipment’s:
There are all most hi – Tec all type of equipment’s covering all brands
 Computerized Engine Analyzer
 Computerized Wheel Aligner
 Computerized Wheel Balancing
 Auto Denting Machine
 Automatic Gear box Overhauling
 Spot Welding Machine
 Automatic Transmission Fluid Changer
 Engine Oil Changer
 Mechanical Stethoscope
 Ultrasonic Injector Cleaner
 Immobilizer Programmer
 Heavy Hydraulic Lift
 Diesel Engine Compressor Tester
 Petrol Compressor Tester
 Heat Chamber paint Booth
 Four Post Lift
 Two Post Lift
 Single Post Lift
 Fuel Pump / Pressure Tester
 Toyota Dealer Label Scanner
 BMW Auto logic Scanner
 A/C Service Station
 Mercedes – Benz Auto Scanner
 Power Tools
 Mechanical Fingers
 Multi Scanner
 Engine Host
 Headlight adjuster
 Auto Polish Device
 Air Impact Wrench

6
  Audi Dealer Label Scanner
 Volkswagen Dealer Label Scanner
 Spark Plug Taster & Cleaner
 T-300 Key Programmer for all Vehicles
 Toyota Smart key program with Device
 Tire changer (Largest Dia)
 Automatic Tyre Infiltrator

Service Offering:
 Engine Works
 Engine/Mechanical System
 Fuel System Cleaning Service
 CNG System Servicing
 Ignition System
 Cooling System
 Lubrication System
 Brake System
 Clutch System
 Suspension System
 Steering System
 Wheel Balancing
 Transmission System
 Electrical System
 A/C System Works
 Repair & Denting
 Printing with Booth
 Water Servicing
 Breakdown Attending

7
2.3 Company at a Glance:

 Established year : 10th May, 2016

 Location : Plot-492, Solmaid (Apollo Hospital Link Road), Vatara,
Dhaka-1212, Bangladesh
 Area : 22,000 sq. ft.
 Working bay : 40
 Parking bay : 40
 Washing bay : 02
 Paint booth : 16
 Denting : 10
 Service engineer : 20
 Technician : 70
 Other staff : 50
 Total manpower : 140

8
 CHAPTER 3: LUBRICATION SYSTEM OF DIESEL ENGINE

VEHICLE

3.1 Introduction

An Automobile is a wheeled motor vehicle used for transportation. A commercial vehicle is

used for transporting goods or paying passengers. The European Union defines a
"commercial motor vehicle" as any motorized road vehicle, that by its type of construction
and equipment is designed for, and capable of transporting, whether for payment or not, (i)
more than nine persons, including the driver; (ii) goods and "standard fuel tanks". Nicolas-
Joseph Cugnot developed a steam-powered vehicle for the purpose of hauling in 1769.
However, steam wagons were not common until the mid-19th century. The first semi-
trailer appeared in 1881, towed by a steam tractor manufactured by De Dion-Bouton. Steam-
powered wagons were sold in France and the United States until the eve of World War I, and
1935 in the United Kingdom, when a change in road tax rules made them uneconomic against
the new diesel lorries.

Although diesel engine had been invented in 1897, the diesel engine did not appear in
production trucks until Benz introduced it in 1923. The diesel engine was not common in
trucks in Europe until the 1930s. In the United States, Auto-car Company introduced diesel
engines for heavy applications in the mid-1930s. Demand was high enough that Auto-car
Company launched the "DC" model (diesel conventional) in 1939. However, it took much
longer for diesel engines to be broadly accepted in the US: gasoline engines were still in use
on heavy trucks in the 1970s.

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.

9
 Figure 3.2: Automobile System
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.
 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.

10
3.2.2 The Fuel System

The fuel system 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 (EES) whereby 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.

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

11
torque converter (automatic transmission) allows the drive train to be 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. 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.

12
 Figure 3.3: Schematic Diagram of Engine Lubrication System
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 working.

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

Vehicles body are 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 lose 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.

13
 Figure 3.4: Auto Body Lubrication Points
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 (CV joints are basically intricate ball and socket 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.

14
 Figure 3.5: Chassis Lubrication Points
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 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 passage ways 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.

15
 Figure 3.6: Diagram of Engine Lubrication
Benefits of 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

16
 13. Turbocharger bearings (if fitted)
14. Vacuum pump bearings (if fitted)
15. Air-compressor piston and bearings (in commercial vehicles for air-brake)

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.

Figure 3.7: Oil Pan

17
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.

Figure 3.8: Oil Filter

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.

Figure 3.9: Piston cooling nozzles

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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.

Figure 3.10: 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
through holes drilled in them as well as to valve lifters or tappets.

19
 Figure 3.11: 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.

Figure 3.12: Oil Cooler

20
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:

3.4.1 Lubricating Journal:

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

Figure 3.13: Lubricating Journal

21
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.

Figure 3.14: Blow By

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.

Figure 3.15: Oil Cooling

22
3.4.4 Reducing Noise:

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

Figure 3.16: Noise Reduction

3.4.5 Absorbs Shock:

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

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.

Figure 3.17: Corrosion

23
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.

Figure 3.18: 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
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

Figure 3.19: Lubrication Principles

24
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
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.

Figure 3.20: 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.

Application of hydrodynamic lubrication

 Delicate instruments.

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

 Scientific instruments.

25
  Large plain bearings like pedestal bearings, main bearing of diesel engines.

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

Figure 3.21: 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
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.

26
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.

Figure 3.22: 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.

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.

27
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.

Figure 3.23: 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
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 bio
applications on human body (e.g. lubricants for artificial joints), ultrasound examination, and
medical examination.

28
 Figure 3.24: 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.

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 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

29
 6. Highly anti-corrosive
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:

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.

Figure 3.25: Solid Lubricant

The four most commonly used solid lubricants are:
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.
Molybdenum disulfide (MoS2): Used in CV joints and space vehicles. Does
lubricate in vacuum.

30
 Hexagonal boron nitride: Used in space vehicles. Also called "white graphite."
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:

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.

Figure 3.26: 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.

31
 Figure 3.27: 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).

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

32
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.

Figure 3.28: 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 working 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.

33
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.

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.

Flash point: 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.

34
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 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.

35
 Figure 3.29: Mist Lubrication System
The following are its disadvantages:

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. This system requires thorough mixing of oil and fuel prior to enter into the engine. It
requires either separate mixing or use of some additives.

3.7.2 Wet Sump Lubrication System:

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

36
3.7.3 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 bars. The dry-sump lubrication system is generally used for
heavy-duty engines.

Figure 3.30: Dry Sump System

3.8 Essential Fluids in Automobile
Here are some of the important fluids used in an automobile besides lubricating oil.

3.8.1 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.

3.8.1.1 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.
3.8.1.2 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 transmission fluid.

37
 Figure 3.31: Transmission Fluid Drain
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.

Figure 3.32: Transmission Fluid Pour

3.8.2 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 fluid, find the
reservoir under the hood. It’s usually on the passenger side.

38
 Figure 3.33: Power Steering Fluid
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.

3.8.3 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 unscrews 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.

Figure 3.34: Brake Fluid

39
3.8.4 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.

Figure 3.35: Coolant

40
 CHAPTER 4: PROBLEM FINDING, ANALYSIS AND SOLUTION

Problem that I have witnessed during the internship at AUTO XPRESS LTD.

4.1: Problem 1: Poor acceleration issue and high engine temperature.

Figure 36: Sludge in Engine

Analysis:

The flow of coolant in cooling system when does not allowing the coolant to flow and cycle
through the radiator being cooled by the fans. That’s why the engine was so heated. At the
same time thermostat, the fuel can collect sludge over time that often comes from the fuel tank.
Dirt makes the fuel heavy, making it unable to move freely from the tank to the engine, the
electronic control unit (ECU) could also be the reason for vehicle won’t accelerate

Solution:

Replaced the filter with a new one to solve this issue.

41
4.2: Problem 2

Finding: Smell of burned lube oil coming from the engine.

Figure 37: Burning oil coming out from Engine

Analysis:

When a gasket or a gasket seal has failed, then this could lead to oil leaking. When this oil
comes into contact with a hot part of the engine (like an exhaust manifold) then the
passenger may get a burning smell. That is there was a leak in cooling system and smell
coming from engine.
Solution:

Changed the gasket and lubricant oil of the engine.

4.3 Problem 3

Finding: Noise coming from front brake when brake applied.

Figure 38: Brake Noise

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Analysis:

A grinding noise on braking is usually caused by a lack of brake pad material; the pads and
rotors are now metal to metal contact, with no braking material left.

Solution:

Replaced the brake pads.

4.4 Problem 4
Finding: Tappet noises while the engine running.

Figure 39: Engine Create Noise

Analysis:

Sludge buildup in the engine head.

Solution:

Engine overhauled and sludge cleaned.

Following this trouble shooting Table for lubrication system above repair and maintenance
work were done.
4.5 Problem 5

Finding: Gearbox Oil Leaks

Figure 40: Gearbox leak

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Estimated problems:
1. Timing Seals Leak
2. Manual Seals Leak
3. Propeller Shaft Seals Leak
After opening gearbox another two problems found.
1. Converter Seals Leak
2. Chambers Servicing
Analysis:
The most common causes of gearbox oil leaks:
Leak cause #1: Excessive Oil
Leak cause #2: Choked Gearbox
When it comes to leakage, the only real solution is to take down the machine and repair it in
order to stop the leak. Several manufacturers make compounds that can be added to the oil to
help mitigate leakage. Other types of products that can be used are touted as seals enhancers.
These fluids and pastes are manufactured with synthetic bases and will cause seals material to
swell. As the seals swells, it slows the leakage. When the machine is able to be taken out of
service, the seals should be replaced and the gearbox flushed to remove any traces of the
seals compound that has been introduced. Filling the gearbox with grease is another simple
solution that has been used successfully. Grease has lower flow characteristics than oil and
will not leak as fast. While grease will lubricate the gears effectively, more heat will be
generated within the gearbox. Since grease does not dissipate heat as well as oil, the
temperature should be monitored.

Solution:
All seals replaced.

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 Table 1: Troubleshooting for Lubrication System
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 Lubricant not changed Lube oil change every 3
regularly months or 3000 km

Tappet noise while waiting Sludge accumulation Engine Overhauling

in signal
Wrong SAE grade in oil Proper SAE grade lubricant

Poor acceleration Sludge accumulation Carbon clean engine

Oil level sensor lit Low on engine oil Top up oil

Engine operating Sludge accumulation Engine overhauling

temperature increase

Low engine oil pressure Defective oil pressure Remove oil pressure
regulator valve regulator valve and replace.

Squeaky noise from Lack of lubricant Rub some grease on the

suspension springs coils

Noise while breaking Callipers may be too dusty Put some silicon grease in
the calliper

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 CHAPTER 5: CONCLUSION AND RECOMMENDATIONS

5.1 Conclusion

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 of an

engine. So everybody should be careful about lubricating of his/her vehicle, because without

lubrication any type of accident may occur at any time, sometimes it may danger for the life.

5.2 Recommendations for future work

Working at Ranks Motors Workshop Limited 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.

 Modern equipment might be used to save the time during servicing.

 Required time for collecting the spare parts should minimize, it will be beneficial

for the company as well as improve the customer satisfaction.

 Training program should arrange for the technicians about the latest technologies.

 Working space should be increased

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Salimon, Jumat; Salih, Nadia; Yousif, Emad (2010), "Biolubricants: raw materials, chemical
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Don M. Pirro; Martin Webster; Ekkehard Daschner (2016). Lubrication Fundamentals (Third
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Eicher training manual

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Paul Baker, director of business development, Frontier Pro Services, www.frontierpro.com

“Windpower Engineering and Development”

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