Pp9a

CHAPTER 9 Lubrication System Operation and Diagnosis
OBJECTIVES
After studying Chapter 9, the reader will be able to:
1.
2. 3.
4.
5.
Prepare for Engine Repair (A1) ASE certification test content area D (Lubrication and Cooling Systems Diagnosis and Repair). Explain engine oil ratings. Describe how an oil pump and engine lubrication work. Discuss how and when to change the oil and filter. Explain how to inspect an oil pump for wear.
Automotive Engine Performance, 3/e By James D. Halderman
Copyright 2010, 2007, 2003 Pearson Education, Inc., Upper Saddle River, NJ 07458 All rights reserved.
KEY TERMS

boundary lubrication Hydrodynamic lubrication Longitudinal header oil gallery
positive displacement pump pressure regulating valve viscosity windage tray
LUBRICATION PRINCIPLES

Engine oil is the lifeblood of any engine. The purposes of engine oil include the following:

Lubricating all moving parts to prevent wear Helping to cool the engine Helping to seal piston rings Cleaning, and holding dirt in suspension in the oil until it can be drained from the engine Neutralizing acids that are formed as the result of the combustion process Reducing friction Preventing rust and corrosion
4
Lubrication between two moving surfaces results from an oil film that separates the surfaces and supports the load.
FIGURE 91 Oil molecules cling to metal surfaces but easily slide against each other.
FIGURE 92 Wedge-shaped oil film developed below a moving block.
FIGURE 93 Wedge-shaped oil film curved around a bearing journal.

ENGINE LUBRICATION SYSTEMS
The primary function of the engine lubrication system is to maintain a positive and continuous oil supply to the bearings. Engine oil pressure must be high enough to get the oil to the bearings with enough force to cause the oil flow that is required for proper cooling. The normal engine oil pressure range is from 10 to 60 PSI (200 to 400 kPa) (10 PSI per 1000 engine RPM). However, hydrodynamic film pressures developed in the high-pressure areas of the engine bearings may be over 1,000 PSI (6,900 kPa). The relatively low engine oil pressures obviously could not support these high bearing loads without hydrodynamic lubrication.
OIL PUMPS
All production automobile engines have a fullpressure oil system. The oil is drawn from the bottom of the oil pan and is forced into the lubrication system under pressure. In most engines that use a distributor, the distributor drive gear meshes with a gear on the camshaft.
FIGURE 94 An oil pump driven by the camshaft.
OIL PUMPS
FIGURE 95 The operation of a rotor-type oil pump.

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OIL PUMPS
FIGURE 96 A typical oil pump mounted in the front cover of the engine that is driven by the crankshaft.
11
OIL PUMPS
FIGURE 97 Gerotor-type oil pump driven by the crankshaft.

Automotive Engine Performance, 3/e By James D. Halderman 12
OIL PUMPS
FIGURE 98 In a gear-type oil pump, the oil flows through the pump around the outside of each gear. This is an example of a positive displacement pump, where everything entering the pump must leave the pump.
13
OIL PRESSURE REGULATION
In engines with a full-pressure lubricating system, maximum pressure is limited with a pressure relief valve. The relief valve (sometimes called the pressure regulating valve) is located at the outlet of the pump. The relief valve controls maximum pressure by bleeding off oil to the inlet side of the pump.
14
FIGURE 99 Oil pressure relief valves are spring loaded. The stronger the spring tension, the higher the oil pressure.
15
FIGURE 910 A typical engine design that uses both pressure and splash lubrication. Oil travels under pressure through the galleries (passages) to reach the top of the engine. Other parts are lubricated as the oil flows back down into the oil pan or is splashed onto parts.
FACTORS AFFECTING OIL PRESSURE
As the engine parts wear and clearance becomes greater, more oil will leak out. The oil pump capacity must be great enough to supply extra oil for these leaks. The capacity of the oil pump results from its size, rotating speed, and physical condition. If the pump is rotating slowly as the engine is idling, oil pump capacity is low. If the leaks are greater than the pump capacity, engine oil pressure is low.
17
The viscosity of the engine oil affects both the pump capacity and the oil leakage. Thin oil or oil of very low viscosity slips past the edges of the pump and flows freely from the leaks. Hot oil has a low viscosity, and therefore, a hot engine often has low oil pressure. Cold oil is more viscous (thicker) than hot oil. This results in higher pressures, even with the cold engine idling.
18
High oil pressure occurs with a cold engine, because the oil relief valve must open farther to release excess oil than is necessary with a hot engine. This larger opening increases the spring compression force, which in turn increases the oil pressure. Putting higher-viscosity oil in an engine will raise the engine oil pressure to the regulated setting of the relief valve at a lower engine speed.
19
OIL PUMP CHECKS
The cover is removed to check the condition of the oil pump. The gears and housing are examined for scoring. If the gears and housing are heavily scored, the entire pump should be replaced. If they are lightly scored, the clearances in the pump should be measured.
20
OIL PUMP CHECKS
FIGURE 911 (a) A visual inspection indicated that this pump cover was worn. (b) An embedded particle of something was found on one of the gears, making this pump worthless except for scrap metal.
21
OIL PUMP CHECKS
FIGURE 912 (a) The oil pump is the only part in an engine that gets unfiltered engine oil. The oil is drawn up from the bottom of the oil pan and is pressurized before flowing to the oil filter. (b) If debris gets into an oil pump, the drive or distributor shaft can twist and/or break. When this occurs, the engine will lose all oil pressure.
OIL PASSAGES IN THE BLOCK
From the filter, oil goes through a drilled hole that intersects with a drilled main oil gallery or longitudinal header. This is a long hole drilled from the front of the block to the back. Inline engines use one oil gallery; V-type engines may use two or three galleries. Passages drilled through the block bulkheads allow the oil to go from the main oil gallery to the main and cam bearings.
23
OIL PASSAGES IN THE BLOCK
FIGURE 913 An intermediate shaft drives the oil pump on this overhead camshaft engine. Note the main gallery and other drilled passages in the block and cylinder head.
24
VALVE TRAIN LUBRICATION
The valve train components are the last parts to get oil from the oil pump. The oil gallery may intersect or have drilled passages to the valve lifter bores to lubricate the lifters. When hydraulic lifters are used, the oil pressure in the gallery keeps refilling them. On some engines, oil from the lifters goes up the center of a hollow pushrod to lubricate the pushrod ends, the rocker arm pivot, and the valve stem tip.
25
VALVE TRAIN LUBRICATION
FIGURE 914 Oil is sent to the rocker arms on this Chevrolet V-8 engine through the hollow pushrods. The oil returns to the oil pan through the oil drainback holes in the cylinder head.
26
OIL PANS
As the vehicle accelerates, brakes, or turns rapidly, the oil tends to move around in the pan. Pan baffles and oil pan shapes are often used to keep the oil inlet under the oil at all times. As the crankshaft rotates, it acts like a fan and causes air within the crankcase to rotate with it. A baffle or windage tray is sometimes installed in engines to eliminate the oil churning problem. This may be an added part,
27
OIL PANS
FIGURE 915 A typical oil pan with a built-in windage tray used to keep oil from being churned up by the rotating crankshaft.
28
OIL PANS
FIGURE 916 A straightedge and a feeler gauge are being used to check that the oil pan has been correctly installed on the 5.7-liter Chevrolet V-8 engine. The oil pan is part of the engine itself and must be properly installed to ensure that other parts attached to the engine are not being placed in a bind.
29
OIL COOLERS
Oil temperature must also be controlled on many highperformance or turbocharged engines.
FIGURE 917 A typical engine oil cooler. Engine coolant flows through the cooler adjuster that fits between the engine block and the oil filter.
30
OIL PRESSURE WARNING LAMP
All vehicles are equipped with an oil pressure gauge or a warning lamp. The warning lamp comes on whenever the engine oil pressure has dropped to 3 to 7 PSI. Normal oil pressure is considered to be 10 PSI per 1,000 RPM. An electrical switch is used to convert the ground circuit of the oil pressure warning lamp if the oil pressure is below the rating of the sending unit.
31
FIGURE 918 The oil pressure switch is connected to a warning lamp that alerts the driver of low oil pressure.
32
FIGURE 919 A typical oil pressure sending unit on a Ford V-8.
33
What Is Acceptable Oil Consumption?
There are a number of opinions regarding what is acceptable oil consumption. Most vehicle owners do not want their engine to use any oil between oil changes even if they do not change it more often than every 7,500 miles (12,000 kilometers). Engineers have improved machining operations and piston ring designs to help eliminate oil consumption. Many stationary or industrial engines are not driven on the road; therefore, they do not accumulate miles, yet they still may consume excessive oil. A general rule for acceptable oil consumption is that it should be about 0.002 to 0.004 pounds per horsepower per hour.
34
What Is Acceptable Oil Consumption?
Therefore, oil consumption is based on the amount of work an engine performs. Although the formula may not be usable for vehicle engines used for daily transportation, it may be usable by the marine or industrial engine builder. Generally, oil consumption that is greater than 1 quart for every 600 miles (1,000 kilometers per liter) is considered to be excessive with a motor vehicle.
35
SUMMARY
1.
2.
3.
4.
5.
Normal engine oil pump pressure ranges from 10 to 60 PSI (200 to400 kPa) or 10 PSI for every 1000 engine RPM. Hydrodynamic oil pressure around engine bearings is usually over 1,000 PSI (6,900 kPa). The oil pump is driven directly by the crankshaft or by a gear or shaft from the camshaft. The last components to get oil from the oil pump are the valve train parts. Some engines use an oil cooler.
36
REVIEW QUESTIONS
1.
2. 3.
4.
5.
What causes a wedge-shaped film to form in the oil? What is hydrodynamic lubrication? Explain why internal engine leakage affects oil pressure. Describe how the oil flows from the oil pump, through the filter and main engine bearings, to the valve train. What is the purpose of a windage tray?
37
CHAPTER QUIZ 1. Normal oil pump pressure in an engine is ________.

a. b. c. d.
3 to 7 PSI 10 to 60 PSI 100 to 150 PSI 180 to 210 PSI
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CHAPTER QUIZ 2. The oil pump pressure relief valve is also called ________.
a. b. c. d.
Oil pump valve Pressure valve Pressure regulating valve Pressure dump valve
39
CHAPTER QUIZ 3. A typical oil pump is what type of pump?

a. b. c. d.
Positive displacement Centrifugal Piston-type Hydraulically driven
40
CHAPTER QUIZ 4. Engine oil passages in an engine block are called ________.
a. b. c. d.
Oil passages Oil galleries Weep holes Oil holes
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CHAPTER QUIZ 5. Technician A says that the oil pump draws unfiltered oil from the bottom of the oil pan. Technician B says that the oil pump is driven from the front of the crankshaft in some engines. Which technician is correct?
a.
b.
c. d.
Technician A only Technician B only Both Technicians A and B Neither Technician A nor B
42
CHAPTER QUIZ 6. Technician A says that oil pressure is affected by the amount of main and rod bearing clearance. Technician B says that the oil pressure is lower when the oil gets hot than when it is cold. Which technician is correct?
a.
b.
c. d.
43
CHAPTER QUIZ 7. Technician A says that many engines use a windage tray in the oil pan. Technician B says that some engines are equipped with an oil cooler. Which technician is correct?
a. b.
c.
d.
44
CHAPTER QUIZ 8. The oil pressure warning light normally comes on to warn the driver if the oil pressure drops below ________.
a. b. c. d.
50 PSI 30 PSI 10 PSI 3 to 7 PSI
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CHAPTER QUIZ 9. A typical oil pump can pump how many gallons per minute?
a. b. c. d.
3 to 6 gallons 6 to 10 gallons 10 to 60 gallons 50 to 100 gallons
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CHAPTER QUIZ 10. In typical engine lubrication systems, what components are the last to receive oil and the first to suffer from a lack of oil or oil pressure?
a. b. c. d.
Main bearings Rod bearings Valve train components Oil filters
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CHAPTER 9 Lubrication System Operation and Diagnosis

Automotive Engine Performance, 3/e By James D. Halderman

boundary lubrication Hydrodynamic lubrication Longitudinal header oil gallery

positive displacement pump pressure regulating valve viscosity windage tray

Automotive Engine Performance, 3/e By James D. Halderman

Automotive Engine Performance, 3/e By James D. Halderman

Automotive Engine Performance, 3/e By James D. Halderman

FIGURE 92 Wedge-shaped oil film developed below a moving block.

Automotive Engine Performance, 3/e By James D. Halderman

FIGURE 93 Wedge-shaped oil film curved around a bearing journal.

ENGINE LUBRICATION SYSTEMS

Automotive Engine Performance, 3/e By James D. Halderman

Automotive Engine Performance, 3/e By James D. Halderman

FIGURE 95 The operation of a rotor-type oil pump.

Automotive Engine Performance, 3/e By James D. Halderman

FIGURE 97 Gerotor-type oil pump driven by the crankshaft.

Automotive Engine Performance, 3/e By James D. Halderman

OIL PRESSURE REGULATION

Automotive Engine Performance, 3/e By James D. Halderman

OIL PRESSURE REGULATION

Automotive Engine Performance, 3/e By James D. Halderman

OIL PRESSURE REGULATION

FACTORS AFFECTING OIL PRESSURE

Automotive Engine Performance, 3/e By James D. Halderman

FACTORS AFFECTING OIL PRESSURE

Automotive Engine Performance, 3/e By James D. Halderman

FACTORS AFFECTING OIL PRESSURE

Automotive Engine Performance, 3/e By James D. Halderman

OIL PUMP CHECKS

Automotive Engine Performance, 3/e By James D. Halderman

OIL PUMP CHECKS

Automotive Engine Performance, 3/e By James D. Halderman

OIL PUMP CHECKS

OIL PASSAGES IN THE BLOCK

Automotive Engine Performance, 3/e By James D. Halderman

OIL PASSAGES IN THE BLOCK

Automotive Engine Performance, 3/e By James D. Halderman

VALVE TRAIN LUBRICATION

Automotive Engine Performance, 3/e By James D. Halderman

VALVE TRAIN LUBRICATION

Automotive Engine Performance, 3/e By James D. Halderman

Automotive Engine Performance, 3/e By James D. Halderman

Automotive Engine Performance, 3/e By James D. Halderman

Oil temperature must also be controlled on many highperformance or turbocharged engines.

Automotive Engine Performance, 3/e By James D. Halderman

OIL PRESSURE WARNING LAMP

Automotive Engine Performance, 3/e By James D. Halderman

OIL PRESSURE WARNING LAMP

Automotive Engine Performance, 3/e By James D. Halderman

OIL PRESSURE WARNING LAMP

FIGURE 919 A typical oil pressure sending unit on a Ford V-8.

Automotive Engine Performance, 3/e By James D. Halderman

What Is Acceptable Oil Consumption?

Automotive Engine Performance, 3/e By James D. Halderman

What Is Acceptable Oil Consumption?

Automotive Engine Performance, 3/e By James D. Halderman

Automotive Engine Performance, 3/e By James D. Halderman

Automotive Engine Performance, 3/e By James D. Halderman

CHAPTER QUIZ 1. Normal oil pump pressure in an engine is ________.

3 to 7 PSI 10 to 60 PSI 100 to 150 PSI 180 to 210 PSI

Automotive Engine Performance, 3/e By James D. Halderman

Automotive Engine Performance, 3/e By James D. Halderman

CHAPTER QUIZ 3. A typical oil pump is what type of pump?