AN

INTRODUCTORY TO ENGINE AND TRANSMISSION SYSTEMS

MODULE

© SEPTEMBER 2023

Musonda Emmanuel

Diploma- Auto-Mech (USA)

Diploma-Teaching Methodology (Tvtc)

Cert- Teaching Methodology (Tvtc)

Cert- Education Management (Tvtc)

Craft Cert -Agric-Mech (Kabwe Institute of Tech)

Craft Cert Auto Elect (Kabwe of Institute Tech)

Cert Refrigeration & Air conditioning (Nortec)

0977277295/0965957227

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TABLE OF CONTENT
Introduction …………………………….…………………………………………………………………2
Identifying Fundamental Vehicle Systems……………………………………………………………4
Explaining Fundamental Vehicle Systems Functions ……………………………………………….6

Assignment ………………………………………………………………………………………………
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INTRODUCTION
This module offers a quick look at the major vehicle systems for learners who are
beginning to study Automotive Engineering in the first year. By knowing a little about
each of these systems, as a learner, you will be better prepared to learn the more
detailed information presented later in other modules of each of these systems.
As you progress in your studies, you will appreciate to identify that failure of one
system can affect the operation of an apparently unrelated system. This will enhance
your understanding of how the whole automobile works especially important and will
help you become a better motor vehicle technician by increasing your knowledge.
You will appreciate to learn that an automotive system is a group of related parts and
assemblies that performs a specific function on vehicle.

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CONTROLS

Objective

Outcomes
At the end of this topic you should be able to;
 Identify fundamental vehicle systems
 Explain fundamental vehicle systems functions

IDENTIFY FUNDAMENTAL VEHICLE SYSTEMS

You will learn that vehicle engine parts and systems can be organized into several major
categories as shown in figure 1.

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Figure 1. The general location of the major vehicle systems.

You will appreciate to learn that a part is a smallest removable item on a vehicle. A part is not
normally disassembled. While the word component is frequently used when referring for
example to an electrical or electronic part like a spark plug, which is an ignition system
component that ignites the fuel in the engine.
You will further learn that an assembly (is a group of parts that work together to perform a
function ) is a set of fitted parts designed to complete a function, for example, an engine is an
assembly which converts fuel into useable power to move the vehicle. You will learn that motor
vehicle technicians must sometimes take assemblies apart and put them back together
whenever carrying out maintenance, service, and repair operations. You will recognize that an
engine is an assembly which contains pistons, crankshaft, connecting rods, bearings etc.
You will understand that engine systems is organized in the following major category;

o Lubrication System
o Cooling System
o Fuel and Air System
o Exhaust System
o Emission Control System
o Exhaust System
o Ignition System

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EXPLAINING FUNDAMENTAL VEHICLE SYSTEMS FUNCTIONS

Lubrication System

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The lubrication system reduces friction and wear between internal engine parts by circulating
filtered oil to high friction points in the engine. Friction is heat generated when two objects rub
against each other. Motor or engine oil is the fluid used to lubricate the engine.
The lubrication system also helps cool the engine by carrying heat away from internal engine
parts. Several quantity of oil are stored in an oil reservoir oil called an oil pan bolted to the
bottom of the engine block. The oil pan is also called the crankcase or oil sump. When the
engine is running, an oil pump draws oil from the pan and forces it through oil galleries. These
galleries are small passageways that direct the oil to the moving parts of the engine.

Figure 2. Oil flow in a typical engine’s lubrication system.

Oil from the pan passes through an oil filter before moving through the engine (Figure 3–20).
The filter removes dirt and metal particles from the oil. Premature wear and damage to parts
can result from dirt in the oil. Regular replacement of the oil filter and oil is an important step in
a preventive maintenance program.

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Cooling system
The cooling system is designed to prevent engine damage and wear. The cooling system is
important because it prevents the engine from self-destructing. You will acknowledge that the
burning of the air-fuel mixture in the combustion chambers of the engine produces large
amounts of heat. This heat must not be allowed to build up and must be reduced. This heat can
easily damage and warp the metal parts of an engine. To prevent this, engines have a cooling
system which maintains a constant engine operating temperature.
The cooling system is designed to remove excess combustion heat to prevent engine damage
and also speeds engine war-up.

Figure 3. A typical engine cooling system.

A typical cooling system relies on a water pump, which circulates the coolant through the
system. The pump is typically driven by the engine. The coolant is a mixture of water and
antifreeze. The coolant is pushed through passages, called water jackets, in the cylinder block
and head to remove heat from the area around the cylinders’ combustion chambers. The heat
picked up by the coolant is sent to the radiator. The radiator transfers the coolant’s heat to the
outside air as the coolant flows through its tubes.
To help remove the heat from the coolant, a cooling fan is used to pull cool outside air through
the fins of the radiator. To raise the boiling point of the coolant, the cooling system is

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pressurized. To maintain this pressure, a radiator or pressure cap is fitted to the radiator. A
thermostat is used to block off circulation in the system until a preset temperature is reached.
This allows the engine to warm up faster. The thermostat also keeps the engine temperature at a
predetermined level. Because parts of the cooling system are located in various spots under the
vehicle’s hood, hoses are used to connect these parts and keep the system sealed.
You will learn also that few air-cooled engines are used in automobiles today because it is very
difficult to maintain a constant temperature at the cylinders. If the engine is kept at a constant
temperature, it will run more efficiently.

Fuel and Air System

You will study that the fuel and air system is designed to supply the correct amount of fuel
mixed with the correct amount of air to the cylinders of the engine. This system also:
o Stores the fuel for later use
o Delivers fuel to a device that will control the amount of fuel going to the engine
o Collects and cleans the outside air
o Delivers outside air to the individual cylinders
o Changes the fuel and air ratios to meet the needs of the engine during different
operating conditions
The fuel system is made up of different parts. A fuel tank stores the liquid gasoline/diesel. Fuel
lines carry the liquid from the tank to the other parts of the system. A pump moves the gasoline
from the tank through the lines. A filter removes dirt or other particles from the fuel. A fuel
pressure regulator keeps the pressure below a specified level. An air filter cleans the outside air
before it is delivered to the cylinders. An intake manifold directs the air to each of the cylinders
You will further learn that there are three basic types of automotive fuel system:

o Gasoline Injection Systems.

Modern gasoline injection systems use a control module, sensors, and electrically
operated fuel injectors (valves) to meter fuel into the engine. This is the most common
type of fuel system on gasoline, or spark ignition engines.
You will learn that an electric fuel pump forces fuel from the fuel tank to the engine via
the fuel lines. The control module, reacting to electrical data it receives from the sensors,
opens the injectors for the correct amount of time. Fuel sprays from the open injectors,
mixing with the air entering the combustion chambers.

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Figure 4. Engine sensors feed information (electrical signals) to computer about
the engine conditions. Computer can then open injector for right amount of time.
This maintains correct air-fuel ratio, the spark plug then ignites fuel.

You will accept that a throttle valve controls airflow, engine speed, and
engine power. You will further learn that when the throttle is open for more
engine power output, the computer holds the injectors open longer, allowing
more fuel to spray out, and when throttle valve is closed, the computer opens the
injectors for only a short period of time, reducing power output.

The throttle valve (air valve) is connected to the accelerator pedal. When the
pedal is pressed, the throttle valve will be open to increase engine power output.

Diesel Injection System

A diesel fuel system is primarily a mechanical system that forces diesel fuel
directly into the combustion chambers. The diesel engine does not use spark
plugs to ignite the air-fuel mixture, it uses the extremely high pressure produced
during the compression stroke to heat the air in the combustion chamber. The air
is squeezed until it is hot enough to ignite the fuel.

When the mechanical pump sprays the diesel fuel into a combustion chamber,
the hot air in the chamber causes the fuel to begin to burn. The burning fuel
expands and forces the piston down on the power stroke. You will acknowledge
that electronic devices are now commonly used to monitor and help control the
operations of today’s diesel injection systems.

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Figure 5. In the illustration above shows a diesel injection system in which a high
pressure mechanical pump spraying fuel directly into a combustion chamber. The piston
squeezing and heating the air enough to the ignite diesel. The fuel begins to burn as
soon as it touches the heated air. The amount of fuel injected into the chamber controls
diesel engine power and speed.

Carburetor Fuel System

In this system the engine uses engine vacuum (suction) to draw fuel into the engine. The
amount of the air-flow through the carburetor determines the amount of fuel used. This
will automatically maintain the correct air-fuel ratio.
You will notice that either a mechanical or an electric fuel pump draws fuel out of the
tank and deliver it to the carburetor. The engine’s intake stroke form a vacuum inside
the intake manifold and carburetor. This causes gasoline to be drawn from the
carburetor and into the air entering the engine as can be seen in figure 6.

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 Figure 6. In this system fuel pump fills carburetor with fuel. When the air flows through
the carburetor, the fuel is pulled into engine in the correct proportion. The throttle valve
controls airflow and the engine power output.

Exhaust System
The exhaust system quiets the noise produced during engine operation and routes engine
exhaust gases to the rear of the vehicle body.
During the exhaust stroke, the engine’s pistons move up and push the burned air-fuel mixture,
or exhaust, out of the combustion chamber and into the exhaust manifold. From the manifold,
the gases travel through the other parts of the exhaust system until they are expelled into the
atmosphere. The exhaust system is designed to direct toxic exhaust fumes away from the
passenger compartment, to quiet the sound of the exhaust pulses, and to burn or catalyze
pollutants in the exhaust. A typical exhaust system contains the following components:
o Exhaust manifold and gasket
o Exhaust pipe, seal, and connector pipe
o Intermediate pipes
o Catalytic converter(s)
o Muffler and resonator
o Tail-pipe
o Heat shields
o Clamps, gaskets, and hangers.

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 Figur
e 7. A typical exhaust system of a vehicle.

Emission Control System

Various emission control systems are used to reduce the amount of toxic (poisonous) substances
produced by an engine. Some systems prevent fuel vapors from entering the atmosphere (air
surrounding the earth). While other emission systems remove unburned and partially burned
fuel from the engine exhaust.
The pollutants that have been drastically reduced are hydrocarbons (HC), carbon monoxide
(CO), and oxides of nitrogen (NOX). A list of the most common pollution control devices are
outlined as follows:

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 o Positive crankcase ventilation (PCV) system.
This system reduces HC emissions by drawing fuel and oil vapors from the crankcase
and sends them into the intake manifold where they are delivered to and burned in the
cylinders. This system prevents the pressurized vapors from escaping the engine and
entering into the atmosphere.

o Evaporative emission control system.

This system reduces HC emissions by drawing fuel vapors from the fuel system and
releases them into the intake air to be burned. This system stops these vapors from
leaking into the atmosphere.

o Exhaust gas recirculation (EGR) system.

This system introduces exhaust gases into the intake air to reduce the temperatures
reached during combustion. This reduces the chances of forming NOX during
combustion.

o Catalytic converter.
Located in the exhaust system it allows for the burning or converting of HC, CO, and
NOX into harmless substances, such as water.

o Air injection system.

This system reduces HC emissions by introducing fresh air into the exhaust stream to
cause minor combustion of the HC in the engine’s exhaust.

Ignition System
An ignition system is required on a gasoline engine to ignite the air-fuel mixture. It produces an
extremely high voltage surge, which operates the spark plugs. After the air-fuel mixture has
been delivered to the cylinder and compressed by the piston, a very hot electric arc jumps
across the tip of each spark plug at the correct time to ignite the mixture. A gasoline engine uses
an electrical spark to ignite the mixture. This causes the air-fuel mixture to burn, expand and
produce power required to operate an engine.
Generating this spark is the role of the ignition system. With the ignition switch on and the
engine running, the system uses sensors to monitor engine speed and other operating variables.
The control module then modifies and amplifies (increase) these signals into on-off current
pulses that activate the ignition coil.
The ignition coil generates the electricity that creates this spark. The coil transforms the low
voltage of the battery into a burst of 30,000 to 100,000 volts. This burst is what ignites the
mixture. The mixture must be ignited at the proper time in order for complete combustion to

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occur. Although the exact proper time varies with engine design, ignition must occur at a point
before the piston has completed its compression stroke.
When the ignition switch (key) is turned off, the coil stops functioning and the spark-ignition
engine stops running
On most engines, the motion of the piston and the rotation of the crankshaft are monitored by a
crankshaft position sensor. The sensor electronically tracks the position of the crankshaft and
relays that information to an ignition control module. Based on input from the crankshaft
position sensor, and, in some systems, the electronic engine control computer, the ignition
control module then turns the battery current to the coil on and off at just the precise time so
that the voltage surge arrives at the cylinder at the right time.

Figure 8. A typical ignition system used on a gasoline engine.

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ASSIGNMENT
1. List two merits of gasoline injection system over carburetor fuel system.
2. Differentiate Emission Control System from Exhaust System.
3. Explain the importance of cleaning the outside air entering the combustion chamber.

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