ENGINE SYSTEM OVERVIEW

Every engine requires many systems to function correctly.

The following are the systems integrated in the engine for the engine to function correctly;
1. Cooling System
2. Lubrication System
3. Air Intake System
4. Fuel System
5. Starting and Charging System
6. Ignition System
7. Emission Control System

1.0 Cooling System

Most of the older engines were air cooled but all engines currently in production are
liquid cooled. Coolant is circulated by a water pump (coolant pump) through passages in
the cylinder block and cylinder head, the passages are called water jackets. The coolant is
a mixture of antifreeze and water to provide protection from corrosion and freezing. After
the coolant picks up the heat from the engine, it flows through a radiator, which cools the
coolant by releasing the heat into the air, the temperature of the coolant is maintained by
using a thermostat located in the coolant passage, which opens to allow coolant to flow to
the radiator or closes until the coolant is hot enough to need cooling.
The cooling system is an integral part of the engine, and the operation of one depends on
the operation of the other. The cooling system will not operate unless the engine is
running; the engine will not operate (for very long) if the cooling system is not operating.
The purpose of the engine cooling system; The purpose of the cooling system is to keep
the engine at its most efficient operating temperature at all engine speeds and all
driving conditions. During the combustion of the air-fuel mixture in the engine cylinders,
temperatures as high as 4500°F (2482°C) may be reached by the burning gases. Some of
this heat is absorbed by the cylinder walls, cylinder head, and pistons. They, in turn must
be provided with some means of cooling, so that their temperatures must not reach
excess values. Cylinder-wall temperatures must not increase beyond about 400°F(204°C)
or 500°F(260°C). The temperatures higher than this will cause lubricating-oil film to
break down and lose its lubricating properties. But it is desirable to operate the engine
at temperatures as close to the limits imposed by oil properties as possible. Removing
too much heat through the cylinder walls and head would lower engine thermal
efficiency (or heat efficiency).
Cooling systems are designed to remove 30% to 35% of the heat produced in the
combustion chambers by the burning of the air-fuel mixture.
Since the engine is quite inefficient when cold, the cooling system includes devices that
prevent normal cooling action during engine warm-up. These devices allow the working
parts to reach operating temperatures more quickly and shorten the inefficient cold-
operating time. Then, when the engine reaches operating temperatures, the cooling
system begins to function.
Thus, the cooling system cools rapidly when the engine is hot, and it cools slowly or not
at all when the engine is warming up or cold.
Low-temperature Engine Problems
Engine operating temperatures must be above a minimum temperature form proper
engine operation. If the coolant temperature does not reach the specified temperature as
determined by the thermostat, then the following engine-related faults can occur.
 A P0128 diagnostic trouble code (DTC) can be set. This code indicates
“coolant temperature below thermostat regulating temperature,” which is
usually caused by a defective thermostat staying open or partially open
 Moisture created during the combustion process can condense and flow
into the oil. For each gallon of fuel used, moisture equal to a gallon of
water is produced. The condensed moisture combines with unburned
hydrocarbons and additives to form carbonic acid, sulfuric acid, nitric
acid, hydrobromic acid, and hydrochloric acid.
To reduce engine problems and to help start engines in cold climates, most manufacturers
offer block heaters as an option. These block heaters are plugged into households current
(110 volts AC) and the heating element warms the coolant.
High-temperature Engine Problem
Maximum temperature limits are required to protect the engine. Higher than normal
temperatures can cause the following engine-related issues.
 High temperatures will oxidize the engine oil producing hard carbon and
varnish. The varnish will cause the hydraulic valve lifter plungers to stick.
 Higher than normal temperatures will also cause the oil to become thinner
(lower viscosity than normal). Thinned oil will also get into the
combustion chamber by going past the piston rings and through valve
guides to cause excessive oil consumption.
 The combustion process is very sensitive to temperature. High coolant
temperatures raise the combustion temperatures to a point that may cause
detonation (also called spark knock or ping) to occur.

2.0 Cooling System Operation

Purpose and Function
Coolant flows through the engine, where it picks up heat. It then flows to the radiator,
where the heat is given up to the outside air. The coolant continually recirculates through
the cooling system, as shown in figures below.
1. Lubrication system
2. Air intake system
3. Fuel System
4. Starting and Charging System
5. Ignition System
6. Emission Control system