Automotive Engine System Maintenance

 Engine system it includes cooling system, lubrication system and fuel systems

1.1. Objectives

The main objective of this training is to identify maintenance procedures applicable to cooling
systems, lubrication and fuel system includes Inspect, diagnostic and tests.

1.2. Description

The engine system's function is to maintain an efficient engine operating temperature during all
engine speeds at operating conditions using the cooling and lubrication system and also increase
performance of the engine by testing the injection and carburetor correctly according the
specification of service manual.

1.3. Engine system demonstration, inspection, service and test

No Engine systems Duration (hrs) Remarks

Demostration engine system according: (4)
1 Lubrication system
2 conventional fuel system
 Gasoline
 Diesel
3 cooling system
 Air (direct) cooling
 Water(indirect)cooling
cooling system (24)
4 Flushing the cooling System 3
5 inspect water pump 2
6 Inspect water pump coupling 1
7 Check engine coolant level at reservoir tank/ radiator itself. 1
8 Check engine coolant quality 1
9 Replace engine coolant 3
10 Remove water pump 3
11 Thermostat test 2
12 Radiator cap test 2
13 Cooling system leaks test 2
14 water pump test 4

Continued in the next page……

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No Engine systems Duration (hrs) Remarks
lubrication system (12)
15 inspect relief valve 3
16 Inspection of oil pump 4
 inspect drive and driven rotors
 inspect rotor body clearance
 inspect rotor side clearance
17 oil pump test 3
18 oil pressure test 2
Fuel system (40)
19 fuel tank ( crack, bent, leakage, rust and corrosion) 2
20 fuel lines ( crack, bent, leakage) 1
21 fuel filter( dirt, bent and damage and remove, 4
clean/wash or replace)
22 injection pump(inline and rotary) adjustment check 5
23 Carburetor quick check 2
24 fuel pump vacuum pressure 2
25 fuel pump delivery capacity or volume 2
26 carburetor tests 6
 Float level adjustment
 Idle system
 Accelerator pump system
 Main metering system
27 Injection(inline or rotary) testing: 8
 Fuel pump capacity (cc)
28 Injector testing: 8
 Opening pressure test,
 Leakage or valve seat test,
 Back leakage test and
 Spray pattern test
total (80)

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 1.4. Laboratory Information

Name of Laboratory Engine Performance and Emission Testing Laboratory

Location Block No. Floor No. Room No. Phone Ext.
Auto. W/Shop Auto. W/Shop 01 334
Capacity (Number of 10-20 students per setup
trainees/ Group/
List of Lab Engine whose condition is to be determined, chemical ( antirust) ,
Equipment’s Thermostat, Oil pressure gauge, Thermometer, Radiator cap tester
/Hardware/ ,water jacket pressure test, Filler gauge, Ruler, Fuel pump tester,
stop watch and, Inspection pipe, Appropriate hand tools and
Service manual.

Software, simulator /
mockups/

Fig. radiater cap test fig.carburater fuel system

Fig. lubrication system fig. hand fuel injecter tester

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Fig.sectinal view of inline fuel injection