Servicing Lubricating System

COMPETENCY BASED LEARNING MATERIAL

Sector:

AUTOMOTIVE

Qualification:

Automotive Servicing NC II

Unit of Competency:

Service Engine Mechanical System

Module Title:

SERVICING LUBRICATING SYSTEM

Technical Education and Skills Development Authority

East Service Road, South Superhighway, Taguig City, Metro Manila

NATIONAL CERTIFICATE LEVEL 2

QUALIFICATION LEVEL

COMPETENCY-BASED LEARNING MATERIALS

No. Unit of Competency Module Title Code

1. Service Starting System • Servicing Starting System ALT723307

2. Service Charging System • Servicing Charging System ALT723308

3. Service Engine Mechanical • Servicing Cooling System ALT723309a

System • Servicing Lubricating ALT723309b

System

• Servicing Gasoline Fuel System ALT723309c

• Servicing Air Induction System ALT723309d

• Servicing Diesel Fuel Injector ALT723309e

4. Service Clutch System • Servicing Clutch System ALT723310

5. Service Differential and Front • Servicing Differential and Front ALT723311

Axle Axle

6. Service Manual Steering System • Servicing Manual Steering ALT723312

System

7. Overhaul Manual Transmission • Pulling-out, Disassembling and ALT723313a

Checking Manual Transmission

• Assembling and Testing ALT723313b

Manual Transmission

8. Service Brake System • Identifying and Explaining ALT723314a

Hydraulic Brake System

Operations and Functions

• Servicing Brakes ALT723314b

• Overhauling Brake Systems ALT723314c

9. Service Suspension System • Servicing Suspension System ALT723315

HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL

Welcome to the module “Servicing Lubricating System”. This module contains training
materials and activities for you to complete.

The unit of competency “Service Engine Mechanical System” contains knowledge,
skills and attitudes required for Automotive Servicing. It is one of the Core Modules at
National Certificate Level II (NC II).

You are required to go through a series of learning activities in order to complete each
learning outcome of the module. In each learning outcome there are Information Sheets,
Resource Sheets and reference materials for further reading to help you better understand the
required activities. Follow these activities on your own and answer the self-check at the end of
each learning outcome and compare your answer with the feedback provided. Check your work
honestly. If you have questions, please don’t hesitate to ask your facilitator for assistance.

Recognition of Prior Learning (RPL)

You may already have some or most of the knowledge and skills covered in this module
because you have:

• been working for sometime
• already completed training in this area

If you can demonstrate to your trainer that you are competent in a particular skill or skills,
talk to him/her about having them formally recognized so you don’t have to do the same training
again. If you have qualifications or Certificates of Competency from previous trainings, show
them to your trainer. If the skills you acquired are still relevant to this module, they may become
part of the evidence you can present for RPL.

At the end of this learning material is a Learner’s Diary, use this diary to record important
dates, jobs undertaken and other workplace events that will assist you in providing further
details to your trainer or assessors. A Record of Achievement is also provided for your trainer to
complete once you completed the module.

This learning material was prepared to help you achieve the required competency in
Servicing Lubricating System. This will be the source of information for you to acquire the
knowledge and skills in this particular trade independently and at your own pace with minimum
supervision or help from your instructor.

In doing the activities to complete the requirements of this module, please be guided by
the following:

• Talk to your trainer and agree on how you will both organize the training under this
module. Read through the module carefully. It is divided into sections which cover all the
skills and knowledge you need to successfully complete.

• Work through all information and complete the activities in each section. Read the
information sheets and complete the self-checks provided. Suggested references are
included to supplement the materials provided in this module.

• Most probably your trainer will also be your supervisor or manager. He/she is there to
support you and show you the correct way to do things. Ask for help.

• Your trainer will tell you about the important things you need to consider when you are
completing the activities and it is important that you listen and take notes.

• You will be given plenty of opportunities to ask questions and practice on the job. Make
sure you practice your new skills during regular work shifts. This way you will improve
both your speed and memory and also your confidence.

• Talk to more experienced work mates and ask for their guidance.

• Use self-check questions at the end of each section to test your own progress.

• When you are ready, ask your trainer to watch you perform the activities outlined in this
module.

• As you work through the activities, ask for written feedback on your progress. Your
trainer keeps feedback/pre-assessment reports for this reason. When you have
completed this learning material and feel confident that you had sufficient knowledge and
skills, your trainer will arrange an appointment with a registered assessor to assess you.
The results of the assessment will be recorded in your Competency Achievement
Record.

QUALIFICATION : Automotive Servicing NC II

UNIT OF COMPETENCY : Service Engine Mechanical System

MODULE TITLE : Servicing Lubricating System

INTRODUCTION:

This module contains information and practices in servicing lubricating system. It
includes information about lubricating system, procedure in overhauling, inspecting oil pump,
and charging oil and oil filter.

You need to complete this module before going to the actual servicing of the lubricating
system. Procedures in this module will help you to become competent in overhauling,
inspecting and changing oil and oil filter.

This module consists of three learning outcome, each outcome contains learning
activities for both knowledge and skills, supported with information sheets, self–checks and
operation sheets gathered from different resources. Before you perform the manual exercises,
read the information/operation sheet and answer the self – check provided to confirm to yourself
and to your instructor that you are equipped with knowledge necessary to perform the skill
portion of the particular learning outcomes.

Upon completion of this module you have to ask your instructor for assessment. You will
be given a certificate of completion as a proof that you met the standard requirements
(knowledge and skills) for this module. The assessment could be made in different methods, as
prescribed in competency standard.

LEARNING OUTCOMES:

At the end of this module you must be able to:

1. Explain oil cycle within the engine.

2. Identify type, classification and application of engine oil.

3. Overhaul oil pump, replace oil filter and change oil.

ASSESSMENT CRITERIA:

1. Component / parts of the lubricating system identified.
2. Function of each part explained.
3. Oil cycle in the lubricating system discussed.
4. Different types and classifications of engine oil identified.
5. Application/uses of engine oil explained.
6. Appropriate tools are selected and used.
7. Proper procedure is followed in overhauling oil pump, replacing oil filter and changing

oil.
8. Personal safety during the performance of the job is observed.

Code No. Servicing Lubricating System Date Developed Date Revised Page #
Nov. 28, 2003 April 28, 2005
ALT723309 1

UALIFICATION : Automotive Servicing NC II
Servicing Lubricating System
MODULE TITLE : Explain oil cycle within the engine

LEARNING OUTCOME 1 :

ASSESSMENT CRITERIA :
1.) Components/parts of the lubricating system identified.
2.) Function of each part explained.
3.) Oil cycle in the lubricating system discussed.

RESOURCES:
1.) Automotive Mechanics, 10th edition by: Crouse and Anglin
2.) Automotive Mechanics: Theory and Service by: De Kryger, Kovacik, Bono
3.) Diesel Fundamentals, Service, Repair by: William Toboldt
4.) University Physics, 9th edition by: Young and Freedman
5.) Automotive Excellence for Applied Science and Applied Mathematics

Code No. Servicing Lubricating System Date Developed Date Revised Page #
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LO1: Explain oil cycle within the engine SPECIAL INSTRUCTIONS
LEARNING ACTIVITIES

♦ Are you ready to perform the activities?

♦ If ready, observe safety precautions and
Personal Protective Equipment and always
perform 5’S.

1. In the training workshop, using different types ♦ View VHS / CD

of engine, and guided by an instructional ♦ Read: Information sheet LO1-1

materials, identify the components/parts of the ♦ After viewing VHS/CD and reading

lubricating system and explain the function of the attached Information Sheet LO1-

each part. 1, answer self-check LO1-1 and

compare your answers to the answer

key.

2. Using different types of engine and guided by ♦ View VHS/CD

an instructional materials, discuss the oil cycle ♦ Read: Information Sheet LO1-2

in the engine lubricating system. Do it in the ♦ After viewing VHS/CD and reading
training workshop.
the attached Information Sheet LO1-

2, answer the self-check LO1-2 and

compare your answers to the answer

key.

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INFORMATION SHEET LO1-1

Purpose of Lubricating System
The lubricating system supplies lubricating oil to all moving parts in the engine. Figure 1-

1 shows the lubricating system for a four – cylinder OHC spark – ignition engine.

Figure 1-1. Lubricating system for a four-cylinder OHC spark-ignition engine, which also has a
turbocharger and oil cooler. (Mazda Motors of America, Inc.)

Figure 1-2 shows an in–line six-cylinder engine. Oil flows up through the hollow pushrods
to lubricate the rocker arm and valve stems. Some of the oil thrown off the connecting-rod
bearings land on the cylinder wall. In a V – type engine, the oil splashes on the cylinder wall of
the opposing cylinder in the other cylinder bank. This lubricates the pistons, piston rings, and
piston pins.

Many engines have small matching grooves or an oil-spurt hole (Figs, 1-3) in each
connecting rod. The opening provides additional piston and cylinder-wall lubrication. A spurt of
oil sprays out when the hole in the rod aligns with the crankshaft – journal oil hole once each
revolution.

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Figure 1-2 Lubricating system for an inline OHV Figure 1-3. When a hole in the connecting rod
engine. Arrows show the flow of oil to the moving aligns with a hole in the crankshaft journal, a
spurt of oil sprays onto the cylinder walls to
parts in the engine. (Buick Division of General
Motors Corporation) lubricate the piston and rings. (Ford Motor
Company)

TYPES OF LUBRICATING SYSTEM

1. The full flow system is found in most new designs. In this system, the filter elements
are designed with high flow rate permitting the entire pump delivery to pass through the
filters. A bypass valve is provided in case the flow of oil through the filters is obstructed. If
so, the filter will be bypassed.

2. In the shunt type filtering system, the pressure pump discharges the oil through the
filters, then through a cooler to the engine. In order that an adequate flow of oil will be
delivered under all conditions, the pump is designed for excess capacity and the filters
are provided with a bypass through which a portion of the oil flows. If the filter becomes
clogged, or if the oil is cold, a relatively large portion of the lubricating oil is shunted
through the bypass.

3. The sump filtering system is similar to the shunt system, except that the filter is placed
in a separate circulating system including a separate motor driven pump. The sump
system permits the lubricating oil to circulate through the filter, even when the engine is
not operating. Oil to be filter is taken from the sump by the motor driven pump, forced
through the filter and then discharged back to the sump. Oil to the engine is taken from
the sump by the engine driven pump and forced through the cooler and filter to the
engine.

4. The bypass lubricating system is similar to the shunt system, except that a portion of
the oil is continuously bypassed back to the sump through the filters. In order that

Code No. Servicing Lubricating System Date Developed Date Revised Page #
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sufficient oil will be supplied to the engine, the amount of oil permitted to flow through the
filter is limited by the size of the piping or an orifice. The complete system consists of an
oil pump, oil cooler, a full flow oil filter with bypass valve, together with a suitable relief
valve to the pump a bypass valve to the oil cooler and a pressure regulator valve in the
cylinder block oil gallery. A bypass oil filter is also included in some engines. Oil for
lubrication of the connection rod bearings, piston pins, and for cooling the piston head is
provided through the drilled crankshaft from the adjacent forward main bearing. The gear
train is lubricated by the overflow oil from the camshaft pocket through a communicating
passage into the flywheel housing. A certain amount of oil spills into the flywheel housing
from the camshaft, balancer shaft and idler gear bearings. The blower drive gear veering
is lubricated through an external pipe from the rear horizontal oil passage of the cylinder
block.

LUBRICATING – SYSTEM COMPONENTS

1.) OIL PUMP

The gear–type (fig.1-4) pump has a pair of
meshing gears. As the gears unmeshed, the
spaces between the teeth fill with oil from the
pump inlet. The gears mesh and force the oil
out through the pump outlet.

Figure 1-4. Disassembled gear-type oil pump.
(Chevrolet Division of General Motors Corporation)

The rotor–type oil pump (fig.1-5) uses an inner
rotor and an outer rotor. The inner rotor is
driven and drives the outer rotor. As the rotors
turn, the spaces between the lobes fill with oil.
When the lobes of the inner rotor move into
the spaces in the outer rotor, oil is forced out
through the pump outlet.

Figure 1-5. Disassembled rotor-type oil pump.
(Chrysler Corporation)

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Various arrangements are used to drive the oil pump. In camshaft – in – block engines,
the camshaft spiral gear that drives the ignition distributor usually drives the oil pump. Some
engines drive the distributor directly from the end of an overhead camshaft. The oil pump on
these engines may be driven by a separate drive shaft or jackshaft. An engine with distributor
less ignition may have a crankshaft – driven oil pump. Other engines have a crankshaft – driven
rotor – type.

An oil pump, consists of the following parts:

ƒ Pickup and screen ƒ Gears or rotors
ƒ Housing and cover ƒ Oil pressure relief valve

Pickup and Screen

The oil pickup is a hollow, flat cup mounted at the end of a tube. Mounted over the cup is
a screen to prevent large particles from entering the pump and damaging the gears and
housing. The pickup tube leads to the intake, or low pressure, side of the pump.

Housing and cover
The housing encloses the gears or rotors and contains a drive shaft for one of the gears.

Gears or rotors

Two gears or rotors are meshed in the housing. One of the gears is driven, in most cases
by a shaft from the distributor drive gear. At the point where the oil pump gears unmeshed, or
separate, a low pressure area is created. Atmospheric pressure forces the oil up through the
pickup to the low pressure area. The oil is then carried around the outside of the gear, in the
chambers formed between the teeth, housing, and side plates. As the oil reaches the outlet
port, it is forced out, under pressure, as the teeth go back into mech. Thus, oil is forced out of
the pump under pressure to the oil filter.

Oil pressure relief valve

To prevent excess pressure from developing, a relief valve is used. A spring holds a
check valve or ball on a seat in the oil outlet. When oil pressure develops more force against
the check valve than the spring, the valve is pushed open. This action uncovers a relief
passage that allows oil to be redirected to the inlet side of the oil pump. In action, the valve acts
as a controlled leak and allows only enough oil out to maintain a controlled pressure.

Code No. Servicing Lubricating System Date Developed Date Revised Page #
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2.) OIL COOLER

It prevents the oil from getting too hot. In the
oil cooler (fig.1-6), engine coolant flows past
tubes carrying the hot oil. The coolant picks up
the excess heat and carries it back to the
engine radiator. Outside air passing through
the radiator carries away the heat.

Another arrangement that transfers heat to the
engine coolant. A hose from the oil filter
carries engine oil to oil–cooler tube in the side
tank of the radiator. As the oil flows down the
tube, the oil loses heat to the coolant. The
cooled oil then flows back to the oil filter and to
the engine. A similar arrangement cools the
fluid in automatic transmission and transaxles.

Engines in severe service such as those in Figure 1-6. Reassembly steps:
taxis and police cars use a radiator–like oil 1. Oil Filter Body
cooler that mounts in front of the engine
radiator. The excess heat transfers from the oil 2. Relief valve
to the outside air passing through the oil 3. Safety valve (oil cooler)
cooler. A similar system cools automatic– 4. O-ring
transmission fluid.
5. Oil cooler
6. Oil filter cartridge
7. Drain plug

3.) OIL FILTERS

All automotive engine lubricating systems
have an oil filter (Fig.1-7). The oil from the
pump flows through the filter before reaching
the engine bearings. The filter has a pleated –
paper filtering element. It allows the oil to pass
through while trapping particles of dirt and
carbon.

The filter has a spring–loaded particles Figure 1-7. Connection to engine oil cooler, located
bypass valve. It opens to protect the engine in the left radiator tank. (Chevrolet Division of
from oil starvation if the filter becomes General Motors Corporation)
clogged. Then unfiltered oil bypasses the filter
and goes directly to the engine. However, the
filter should be changed before this happens.

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Some oil filters have an anti–drain back valve.
It helps prevent oil from draining out of the
filter while the engine is off. A full supplies oil
quickly on starting. This reduces wear and
possible damage. They attach to the outside of
the engine. Some engines have an internal oil
filter. It mounts inside the pan and attaches
directly to the oil pump. Removing a large
drain plug allows the filter to be changed.

Oil filter, cutaway to show the built-in bypass valve.
(Chrysler Corporation)

4.) OIL PAN

The oil pan (fig.1-8), bolted to the engine
crankcase area, serves as a reservoir for oil. A
drain plug can be removed to allow the engine
oil to drain out during oil changes. An oil pump
and pickup are mounted on the crankcase
inside the oil pan.

Figure 1-8. Internal oil filter, which attaches to the
oil pump inside the oil pan. (Pontiac Division of
General Motors Corporation)

LUBRICATING – SYSTEM INDICATORS

5.) OIL – PRESSURE INDICATORS

An oil–pressure indicator in the instrument
panel warns the driver if engine oil pressure is
too low. There are six types of oil – pressure
indicators.

1. Indicator Light. The light connects in

series with the battery, the ignition switch,

and an oil-pressure switch on the engine

(Fig.1-9). The oil pressure switch is closed

when the engine is not running. When the

ignition key is turned to ON, the indicator

light glows. Figure 1-9. Electric circuit of an oil-indicator lamp.

As soon as the engine starts, pressure builds up in the lubricating system. This opens the oil–

pressure switch and the light goes out. Anytime engine oil pressure falls below a preset

minimum, the pressure switch closes and the light comes on.

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2. Electric Gauge- Fig.1-10 shows analog oil Figure 1-10. Electric circuit of an oil-pressure
– pressure gauge. The operation is similar gauge.
to the fuel gauge. The oil–pressure gauge
may be a magnetic gauge or a thermal Figure 11. ELECTRONIC FUEL-LEVEL DISPLAY
gauge. In the magnetic oil–pressure Fuel Level indicators. (Ford Motor Company)
gauge the engine unit has a diaphragm
connected to a sliding contact. Engine oil
pressure pushes the diaphragm up. This
moves the sliding contact along the
resistance. An increase in oil pressure
causes the sliding contact to increase the
resistance in the circuit. The amount of
current flowing decreases. This allows the
right coil to pull the pointer to the right,
indicating the increased oil pressure.

3. Electronic Gauge (fig.1-11). Many cars
have an electronic instrument cluster. Part
of the cluster is electronic oil–pressure
gauge. It usually is a bar–graph display
made up of a series of segments. The
gauge is similar to the electronic fuel – level
display. The more segments displayed, the
higher the oil pressure. High or low oil
pressure causes the bar graph to flash.

4. Digital Gauge. Some cars with an electronics instrument cluster have digital oil–pressure
gauge (fig.1-12). The number displayed tells the oil pressure in pounds per square inch (psi)
or kilopascals [kPa].

Figure 1-12. An electronic instrument cluster that displays fuel-level and / or driver information.
Ford Motor Company)

Code No. Servicing Lubricating System Date Developed Date Revised Page #
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5. Oil–Level Indicators. An oil–level indicator
or dipstick (fig.1-13) is used to measure the
crankcase oil level. The dipstick extends
down into the oil. To determine the oil level,
pull out the dipstick and see how high the
oil reaches on the dipstick. Markings
usually indicate FULL or ADD OIL. The
dipstick tube seals at the top when the
dipstick is in place. This prevents unfiltered
air from entering the crankcase and
crankcase gases from escaping. Some
vehicles have a low oil–level indicator light.

Figure 1-13. Lubrication system for an inline OHV
engine. Arrows show the flow of oil to the moving

parts in the engine. (Buick Division of General
Motors Corporation)

An oil – level sensor (fig.1-14) in the oil pan
connects to a CHECK OIL LEVEL light in
the instrument panel. Turning the ignition
key to CRANK or START causes the
sensor to check the oil level in the pan. If
the oil is not low, the light goes out when
the ignition key returns to RUN. If the
engine needs a quart [liter] or more of oil,
the sensor turns on the CHECK OIL
LEVEL light.

Figure 1-14. Location of the low oil-level sensor in
the oil pan. (Ford Motor Company)

6. Oil–Change Indicator. The instrument panel of some cars includes oil–change indicator
light. The body–control module (BCM) monitors the coolant–temperature sensor, engine-
speed sensor, and vehicle–speed sensor. Then the BCM calculates the remaining useful life
of the oil. This is based on the actual driving conditions of the car. When the remaining
useful life is zero, the BCM turns on the CHANGE OIL SOON light. Cars with an electronic
instrument cluster may display the message CHANGE OIL.

Code No. Servicing Lubricating System Date Developed Date Revised Page #
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SELF – CHECK LO1-1

A. Label the following:
1. Parts of lubricating system

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2. Parts of oil pump
a. Gear type

b. Rotor type

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B. Explain briefly the function of the following:
1. oil pump
2. oil filter
3. oil cooler
4. oil level indicator
5. pressure–relief valve

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ANSWER KEY LO1-1

A.
1.) Parts of lubricating system

2.) Oil pump b. Rotor type
a. Gear type

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B. Functions of the lubricating system components / sub-component

1.) Oil Pump

The gear-type pump has a pair of meshing gears. As the gears unmeshed, the spaces
between the teeth fill with oil from the pump inlet. The gears mesh and force the oil out
through the pump outlet.

The rotor-type oil pump uses an inner rotor and an outer rotor. The inner rotor is driven
and drives the outer rotor. As the rotors turn, the spaces between the lobes fill with oil.
When the lobes of the inner rotor move into the spaces in the outer rotor, oil is forced out
through the pump outlet.

Various arrangements are used to drive the oil pump. In camshaft-in-block engines, the
camshaft spiral gear that drives the ignition distributor usually drives the oil pump.

2.) Oil Filter

All automotive engine lubricating systems have an oil filter. The oil from the pump flows
through the filter before reaching the engine bearings. The filter has a pleated-paper filtering
element. It allows the oil to pass through while trapping particles of dirt and carbon.

The filter has a spring-loaded bass valve. It opens to protect the engine from oil
starvation if the filter becomes clogged. Then unfiltered oil bypasses the filter and goes
directly to the engine. However, the filter should be changed before this happens.

Some oil filters have an anti-drain back valve. It helps prevent oil from draining out of the
filter while the engine is off. A full filter supplies oil quickly on starting. This reduces wear
and possible damage.

3.) Oil Cooler

It prevents the oil from getting too hot. In the oil cooler, engine coolant flows past tubes
carrying the hot oil. The coolant picks up the excess heat and carries it back to the engine
radiator. Outside air passing through the radiator carries away the heat.

4.) Oil – Level Indicators

An oil–level indicator or dipstick is used to measure the crankcase oil level. The dipstick
extends down into the oil. To determine the oil level, pull out the dipstick and see how high
the oil reaches on the dipstick. Markings usually indicate FULL or ADD OIL. The dipstick
tube seals at the top when the dipstick is in place. This prevents unfiltered air from entering
the crankcase and crankcase gases from escaping.

5.) Pressure – Relief Valve

To prevent excessive oil pressure, the lubricating system has a pressure regulator valve
or relief valve. It is a spring–loaded ball or plunger. When the pressure reaches the preset
value, the ball or plunger compresses the spring. This opens a port through which oil flows
back into the oil pan. Enough oil flows past the relief valve to prevent excessive pressure.
The oil pump can normally deliver much more oil than the engine requires.

Code No. Servicing Lubricating System Date Developed Date Revised Page #
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INFORMATION SHEET LO1-2

OIL CYCLE IN LUBRICATING SYSTEM

The oil pump picks up oil from the oil pan (fig1-15 & 16). The pump sends the oil through the
oil filter and then galleries (passages) to the main bearings that support the crankshaft. Some
oil flows from the main bearings through oil holes drilled in the crankshaft to the rod bearings.
The oil flows through the bearing oil clearance and then is thrown off the moving parts.

At the same time, oil flows through an oil gallery to the cylinder head. There the oil flows
through an oil gallery to lubricate the camshaft bearings and valve – train parts. After the oil
circulates to all engine parts, it drops back down into the oil pan.

Figure 1-15. Lubricating system for a four-cylinder OHC spark-ignition engine, which also has a
turbocharger and oil cooler. (Mazda Motors of America, Inc.)

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Fig.1-16 Oil flows as shown below in a fully-pressurized lubrication system:

PISTONS & CAMSHAFT DRIVE
CYLINDERS GEAR AND
DRIVEN GEAR

VALVE LIFTERS &
VALVE STEMS

CAMS

CONNECTING RODS CAMSHAFT JOURNALS

CRANKSHAFT CYLINDER HEAD

OPENING PRESSURE
1.0 kg/cm2

VALVE OPENING PRESSURE OIL FILTER BY-PASS VALVE
4.0 kg/cm2

RELIEF VALVE

OIL PUMP

OIL STRAINER

OIL PAN

OIL FLOW IN FULLY-PRESSURIZED LUBRICATING SYSTEM

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SELF-CHECK LO1-2

Explain in your own words:
1. Oil cycle in the lubricating system

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ANSWER KEY LO1-2

1.) Oil cycle in the lubricating system
The lubricating system supplies lubricating oil to all moving parts in the engine. The oil

pump picks up oil from the oil pan. The pump sends the oil through the oil filter and then
galleries (passages) to the main bearings that support the crankshaft. Some oil flows from
the main bearings through oil holes drilled in the crankshaft to the rod bearings. The oil
flows through the bearing oil clearance and then is thrown off the moving parts.

At the same time, oil flows through an oil gallery to the cylinder head. There the oil flows
through an oil gallery to lubricate the camshaft bearings and valve-train parts. After the oil
circulates to all engine parts, it drops back down into the oil pan.

Code No. Servicing Lubricating System Date Developed Date Revised Page #
Nov. 28, 2003 April 28, 2005
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QUALIFICATION : Automotive Servicing NC II

MODULE TITLE : Servicing Lubricating System

LEARNING OUTCOME 2 : Identify type, classification and application of engine oil

ASSESSMENT CRITERIA :

1.) Different types and classification of engine oil.

2.) Application / uses of engine oil explained.

RESOURCES:
1.) Automotive Mechanics, 10th edition by: Crouse and Anglin
2.) Automotive Mechanics: Theory and Service by: De Kryger, Kovacik, Bono
3.) Grolier International Encyclopedia
4.) Encyclopedia Americana, Volume 17
5.) University Physics, 9th edition by: Hugh D. Young and Roger Freedman
6.) Isuzu Workshop Manual
7.) Mitsubishi L300 1980 Workshop manual Maintenance

Code No. Servicing Lubricating System Date Developed Date Revised Page #
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ALT723309 21

LO #2: Identify type, classification and application of engine oil

LEARNING ACTIVITIES SPECIAL INSTRUCTION

1. In the contextual learning laboratory, using the ♦ View VHS/CD
different type of engine oil, and with the help of ♦ Read: Information sheet LO2-1
the contextual learning instructor, identify/ ♦ After viewing VHS/CD and
classify the different types of engine oil.
reading information sheet LO2-1,
answer self check LO2-1 and
compare your answer to the
answer key.

2. In the contextual learning laboratory, using ♦ View VHS/CD
different types of engine oil, with the aid of the ♦ Read: Information sheet LO2-2
contextual learning instructor, explain the ♦ After viewing VHS/CD and
properties and viscosity rating of lubricating oil.
reading information sheet LO2-2,
3. In the training workshop, using different type of answer self check LO2-2 and
engine and engine oil, explain the correct compare your answer to the
application/use of engine oil. answer key.

♦ View VHS/CD
♦ Read: Information sheet LO2-3
♦ After viewing VHS/CD and

reading information sheet LO2-3,
answer self check LO2-3 and
compare your answer to the
answer key.

Code No. Servicing Lubricating System Date Developed Date Revised Page #
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INFORMATION SHEET LO2-1

Types / Classification of Engine Oil

Engine oil is rated by viscosity number and by its servicing ratings. Service rating of oil is its
ability to perform under a variety of engine conditions. The designation by American Petroleum
Institute (API) indicates the service for which the oil is best suited.

A. System for Automotive gasoline engines (spark – ignition) services
“S” – service oils
1. SA – are non-detergent oils (straight mineral oil). It is used in some light – duty,
non automotive engines.

2. SB – are non-detergent oils (straight mineral oil, plus antioxidant and anti-scuff
properties). It is used in medium duty gasoline engine.

3. SC used for heavy – duty engine, model: 1964 (SC), 1969 (SD).
4. SD This oil must meet automobile manufacturer’s warranty
requirements.

5. SE – for heavy duty engine in passenger cars and some trucks beginning with
1972 – 1979 models operating under engine manufacturer’s warranties. Oils
designed for this service provide more protection against oil oxidation, high
temperature engine deposits, rust and corrosion in gasoline engines.

6. SF – for heavy – duty engine in passenger cars and some trucks beginning with
1980 through 1988 model years operating under engine manufacturer’s
recommended maintenance procedures. Oils developed for this service provide
increased oxidation stability and improved antiwear performance. These oils also
provide more protection against engine deposits, rust and corrosion.

7. SG – denotes service typical of gasoline engines in passenger cars, vans and
light trucks beginning with 1988 through 1993 model years operating under
manufacturer’s recommended maintenance procedures. It provides better control
of engine deposits, oil oxidation, engine wear, rust and corrosion than SF oil.

8. SH – denotes service typical of gasoline engines in 1993 through 1996 passenger
car, van and light trucks operating under vehicle manufacturer’s recommended
operating procedures.

9. SJ – was adopted for use in describing engine oils available in 1996. These oil are
for use in service typical of gasoline engines in current and earlier passenger –
car, sport utility vehicle, van and light truck operations under vehicle
manufacturer’s recommended maintenance procedures.

NOTE: The ratings SA through SF are no longer recommended for use in new automotive
engines. They are obsolete.

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B. System for Commercial Diesel Engines (compression – ignition) Services

“C” – Commercial [fleets, contractors, farmers, etc.]

1. CA – for light duty engine.

2. CB – for light duty to medium duty engine

3. CC – for medium duty to heavy duty engine

4. CD – for heavy duty engine. Oils designed for this service provide protection from
bearing corrosion and from high temperature deposits in the diesel engine.

a. CD.11 – for severe duty two – stroke cycle diesel engines requiring highly
effective control over wear and deposits.

5. CE – for turbo charged or supercharged heavy – duty engines manufactured since
1983 and operated under both low – speed, high load and high speed, high load
conditions. This oil must meet automobile manufacturer’s warranty requirements.

6.
a. CF – denotes service typical of indirect injected diesel engines and other
diesel engines which use a broad range of fuel types including those
using fuel with higher sulfur content. OIL designated for this service may
also be used when API service category CD is recommended.

b. CF – 2 – denotes typical of two – stroke cycle engines requiring highly
effective control over diesel cylinder and ring face scuffing and deposits.
Oil designated for this service maybe used when API Service Category
CD – II is recommended. These oils do not necessarily meet the
requirements of CF or CF – 4 unless passing test requirements for these
categories.

c. CF – 4 – describes oils for use in high speed, four – stroke cycle, diesel
engines. They are particularly suited for on-highway, heavy – duty truck
applications. These oils should be used in place of CE oils.

7. CG – 4 – describes oils for use in high speed four – stroke cycle diesel engines
used in highway and off-road applications where the fuel sulfur may vary from less
than 0.05% by weights – 0.5% by weight. These oil provide effective control over
high temperature piston deposits, wear, corrosion, foaming, oxidation stability and
soot accumulation. These oils are especially effective in engines designated to
meet 1994 exhaust emission standards.

NOTE: The CA, CB and CC ratings are obsolete. The CD, CF, CE and CC ratings indicate oils
for severe operating conditions. Use the oil recommended in the owner’s manual. The
recommended oil may have a combined rating, such as SC/CE or SG/CF. An oil that does not
have the recommended combined designation may cause engine damage.

Code No. Servicing Lubricating System Date Developed Date Revised Page #
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ALT723309 24

SELF-CHECK LO2-1

1. Give at least 3 types of engine oil used for gasoline engine and 3 types for diesel engine.
GASOLINE ENGINE
1.
2.
3.
DIESEL ENGINE
1.
2.
3.

Code No. Servicing Lubricating System Date Developed Date Revised Page #
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ALT723309 25

ANSWER KEY LO2-1

For Gasoline Engine:
1. SG
2. SF
3. SH

For Diesel Engine:
1. CC
2. CD
3. CE

Code No. Servicing Lubricating System Date Developed Date Revised Page #
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INFORMATION SHEET LO2-2

Properties of Lubricating Oil

1.) Proper viscosity

Viscosity is a measure of oil’s resistance to flow. A low – viscosity oil is thin and
flows easily. It reduces the ability of oil to stay in place between moving engine parts
which results to rapid wear. A high viscosity oil is thicker and flows more slowly to
engine parts, especially when the engine and oil is cold, which causes rapid engine
wear. In cold weather also, a high viscosity oil may be so thick that it prevents normal
cranking and starting.

2.) Viscosity Index

This is a measure of how much the viscosity of an oil changes with temperature. A
single viscosity oil could be too thick at low temperatures and very thin at high engine
temperatures. Multi – viscosity oils are oils that have been chemically modified to
stabilize the rate of viscosity change. Viscosity index improvers are added to engine
oil so its viscosity stays nearly the same, hot or cold. A multi – viscosity oil graded
SAE 5W – 30 has the viscosity of SAE 5W when cold and a SAE 30 when hot.
Automotive manufacturers recommend multi – viscosity oil for most driving
conditions.

3.) Viscosity Numbers

There are several grades of single viscosity oils. They are rated for winter or for
other than winter. Winter – grade oils are SAE 0W, SAE 5W, SAE 10W, SAE 15W,
SAE 20W and SAE 25W. SAE stands for the Society of Automotive Engineers, which
developed the grading system, W stands for winter. For other than winter use, single
viscosity oil, grades are SAE 20, SAE 30, SAE 40, and SAE 50. The higher the
number the thicker the oil.

A multiple viscosity oil graded SAE 5W – 30, SAE 20W – 40, SAE 20W – 50, SAE
15W – 40, SAE 10W – 30 and SAE 10W – 40.

4.) Resistance to carbon formation and oil oxidation.

When oil is refined, chemicals are added to fight carbon formation and oxidation.
Detergent – dispersants are added to keep particles of carbon and other
contaminants suspended within the oil. These additives are similar in action to soap.
They loosen and detach particles of carbon and gilt from engine parts. The circulating
oil carries the particle to the oil fan. Detergent additives are usually oil – soluble metal
soaps, salts of naphthenic acids and salts of sulfonic acids. Dispersant additives are
generally polypolar polymers. Oxidation inhibitors help prevent oil oxidation, the
chemical breakdown of oil. The organic chemicals used include sulfur and
phosphorus compounds, amines and phenolic derivatives.

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ALT723309 27

5.) Corrosion and rust inhibitions

Corrosion inhibitors help prevent the formation of acids in the oil that can damage
metal part in the engine. Additives are put in the oil to help fight corrosion and rust in
the engine. These additives displace water from metal surfaces so oil coats them.
The chemical used include the earth – metal salts of sulfonates.

6.) Foaming resistance

The churning action of the crankshaft causes the oil to foam or aerate. This
reduces the lubricating effectiveness of the oil. Foaming can cause the oil to overflow
and pass through the crankcase – ventilating system into the intake manifold and air
cleaner. The additives help prevent foaming.

7.) Extreme – pressure resistance

Additives put into the oil improve the resistance of the oil film to penetration.
Engine subject the oil to very high pressures in the bearings and valve train. The
extreme – pressure additives react chemically with the metal surfaces The result is a
strong, slippery film that resist penetration and being squeezed out.

8.) Energy – conserving

Energy – conserving oils reduce fuel consumption when compared to engine
operation with specified test oil. There are two categories of energy – conserving
(EC) engine oils EC 1 and EC II. Oil labeled EC II provides a better fuel – economy
improvement than an EC I oil. These oils have special additive (friction modifiers)
which change some characteristics of the oil. There are two types of modifiers. One is
a chemical that dissolves completely in the oil. The other used powdered graphite or
molybdenum held in a suspension in the oil.

Code No. Servicing Lubricating System Date Developed Date Revised Page #
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ALT723309 28

Viscosity Rating of Lubricating Oil

The viscosity rating of engine oils are established through tests. A specified quality of oil
at a specific temperature is passed through a calibrated hole. The time required for the oil to
pass through this hole establishes its viscosity rating number.

Single–viscosity oils commonly used for automobiles include SAE 10, 20, 30, 40 and 50,
for other than winter use. Winter grade oils are SAE 0W, SAE 5W, SAE 10W, SAE 15W, SAE
20W and SAE 25W. The higher viscosity index number, the thicker the oil remains when
heated. Oils with higher viscosity numbers can withstand conditions of extreme heat, such as
high speed driving in dessert conditions. Oils with lower viscosity ratings are used in moderate
temperature conditions.

Multi– viscosity oils are oils that have been chemically modified to stabilize the rate
viscosity change. Thus, these oils have low viscosity when cold, yet sufficient viscosity when
hot to provide adequate engine protection. A multi–viscosity oil can have a rating such as SAE
20W–50 as shown in Figure 2.

The “W” indicates winter, or cold weather, test conditions. “20W” indicates that the oil has
been checked for viscosity at 0 degrees F [ -18 degrees C]. At that temperature, the oil has the
viscosity of SAE 20 oil at 212 degrees F [100 degrees C]. “50” indicates that the oil also has
been checked for viscosity at 212 degrees F [100 degrees C] and found to have a viscosity
equivalent to SAE 50. Such a multi–viscosity oil can flow easily at low temperatures and allow
the engine to start and run well under cold conditions. The same oil also will protect engine
parts from wear even in extremely hot conditions.

The choice of a proper viscosity engine oil depends on the vehicle manufacturer’s
recommendations and the outside temperatures to be encountered, as shown in Figure 2-1.

Figure 2-1. A multi-viscosity engine oil changes viscosity when it is cold and when it is hot.

Code No. Servicing Lubricating System Date Developed Date Revised Page #
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ALT723309 29

SELF-CHECK LO2-2

Explain the following briefly:
1. Viscosity number

2. Multiple viscosity

3. Detergent dispersants

4. Differentiate single viscosity oil from multi-viscosity oil.

Code No. Servicing Lubricating System Date Developed Date Revised Page #
Nov. 28, 2003 April 28, 2005
ALT723309 30

ANSWER KEY LO2-2

1. Viscosity number

There are several grades of single viscosity oils. They are rated for winter or for other
than winter. Winter–grade oils are SAE 0W, SAE 5W, SAE 10W, SAE 15W, SAE 20W
and SAE 25W. SAE stands for the Society of Automotive Engineers, which developed
the grading system, W stands for winter. For other than winter use, single viscosity oil,
grades are SAE 20, SAE 30, SAE 40, and SAE 50. The higher the number, the thicker
the oil.

2. Multiple viscosity oil are oils that have been chemically modified to stabilize the rate of
viscosity change. Viscosity index improvers are added to engine oil so its viscosity stays
nearly the same, hot or cold. A multi–viscosity oil graded SAE 5W–30 has the viscosity of
SAE 5W when cold and a SAE 30 when hot. Automotive manufacturers recommend
multi – viscosity oil for most driving conditions.

3. Detergent–dispersants are added to keep particles of carbon and other contaminants
suspended within the oil. These additives are similar in action to soap. They loosen and
detach particles of carbon and gilt from engine parts. The circulating oil carries the
particle to the oil fan. Detergent additives are usually oil–soluble metal soaps, salts of
naphthenic acids and salts of sulfonic acids. Dispersant additives are generally polypolar
polymers. Oxidation inhibitors help prevent oil oxidation, the chemical breakdown of oil.
The organic chemical used includes sulfur and phosphorus compounds, amines and
phenolic derivatives.

4. Single viscosity oils commonly used for automobiles include SAE 10, 20, 30, 40 and 50.
The higher the viscosity index number, the thicker the oil remains when heated. Multi–
viscosity oils are oils that have been chemically modified to stabilize the rate of viscosity
change. Thus, their oils have low viscosity when cold, yet sufficient viscosity when hot to
provide adequate engine protection.

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ALT723309 31

INFORMATION SHEET LO2-3

APPLICATION / USE OF LUBRICATING OIL

Lubricants should be carefully selected according to the lubrication chart (fig. 2-2&2-3). It
is also important to select viscosity of lubricants according to the following table.

Fig.2-2

Code No. Servicing Lubricating System Date Developed Date Revised Page #
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ALT723309 32

RECOMMENDED LUBRICANT

Description Engine Oil Transmission Gear Multi-purpose Grease Brake fluid
HP SAE classification Oil SAE J1703
SAE J31Ce
CASTROL SO, SE API classification GL- [equivalent to NLG1-2] -
- 4, GL-5 SAE#80
Duckham -
Esso Castrol GTX HP Hypogear HP Eneregrease
Castrol GTX2
Getty Castrolite HO EP L2 Multi-ourpose
Castrol GTZ
Shell Castrol GTZ Castrol Hypov Castrol
Total
O Motor Oil Light 80 LM Grease
UNIFLO
Extra Motor Oil Castrol Hypov L810 -
880 Esso -
Veedol Hypoid R1 Multi-purpose
Esso Gear Oil Grease -
Super Motor Oil GX 80 RONEX MP
Veedol Shell Dohan
Total Super Veedlo Multigear All-purpose B
Total Antigrade B Lubricant Grease “Brake and
GTS 80-90 Clutch Fluid
Veedol Multigear Shell Retarvax A Total HBF
Lubricant 80 Total Fluid
Shell Spirax SY

Total Extreme Total Multix
Pression

Fig. 2-3

Code No. Servicing Lubricating System Date Developed Date Revised Page #
Nov. 28, 2003 April 28, 2005
ALT723309 33

SELF-CHECK LO2-3

Give the recommended engine oil for the temperature:
1. – 250C – 00C
2. – 150C – 150C
3. 00C - 300C
4. 250C and above

Code No. Servicing Lubricating System Date Developed Date Revised Page #
Nov. 28, 2003 April 28, 2005
ALT723309 34

ANSWER KEY LO2-3

1. SAE 10W
2. SAE 20, 20W
3. SAE 20
4. SAE 40, 50

Code No. Servicing Lubricating System Date Developed Date Revised Page #
Nov. 28, 2003 April 28, 2005
ALT723309 35

QUALIFICATION : Automotive Servicing NC II

MODULE TITLE : Servicing Lubricating System

LEARNING OUTCOME 3 : Overhaul oil pump, replace oil filter and change oil

ASSESSMENT CRITERIA :

1.) Appropriate tools are selected and used.

2.) Proper procedure is followed in overhauling oil pump, replacing oil filter and

changing oil.

3.) Personal safety during the performance of the job is observed.

RESOURCES:
1.) Corolla Service and Repair Manual, Models: Sedan and Nagon 1970 / 1978.
2.) Lancer Service and Repair Manual, Models: Sedan 1974 – 1979.
3.) Auto Mechanics: Theory and Service by: Dekryger, Kovacik, Bono.

Code No. Servicing Lubricating System Date Developed Date Revised Page #
Nov. 28, 2003 April 28, 2005
ALT723309 36

LO3: Overhaul oil pump, replace oil filter and change oil

LEARNING ACTIVITIES SPECIAL INSTRUCTIONS

1. In the contextual learning laboratory, using ♦ Read: Information sheet LO3- 1
laboratory manuals, liquids, needed supplies ♦ After reading the information
and materials, study the concept of volume.
sheet LO3-1, answer self check
LO3-1, then compare your answer
to the answer key.

2. In the training workshop, using different types of ♦ View VHS/CD
engine and guided by an instructional materials ♦ Perform: Operation sheet LO3- 2
and service manuals, overhaul oil pump. ♦ After viewing and performing the

3. In the training workshop, using different types of operation sheet, answer self
engine and guided by an instructional materials check LO3-2, and compare your
and service manuals, change engine oil and answer to the answer key.
replace oil filter.
♦ View VHS/CD
♦ Perform: Job sheet LO3- 3
♦ After viewing and performing the

job sheet, answer self check LO3-
3, and compare your answer to
the answer key.

Code No. Servicing Lubricating System Date Developed Date Revised Page #
Nov. 28, 2003 April 28, 2005
ALT723309 37

INFORMATION SHEET LO3-1

VOLUME

Volume is defined as the amount of space occupied by any object or substance. It can
be a solid, gas, or liquid. Engine oil like any other substances occupies space and can be
described as to how much space it occupies in the oil pan. IN describing volume several units
have been used and we give conversion factors to make conversion easier.

1 liter (L) = 1000 cubic centimeter (cm3 or cc)
= 0.001 cubic meter (m3)
= 0.03531 cubic foot (ft3)
= 61.02 cubic inches (in3)

1 gallon (gal) = 3.788 liters (L)
= 4 quarts (qt.)

1 quart (qt.) = 0.947 liters (L)
1 liter (L) = 1.056 qt.

Let us try these examples:

1) 5 quarts is needed to fill a tank of fuel. Convert this to liters.

Solution: 5 qt. = 5 (0.947) = 4.735 L

2) Sump refill capacity of an engine is 3.5 liters. How many quarts is this?

Solution: 3.5 L = 3.5 (1.056) = 3.696 qt.

Code No. Servicing Lubricating System Date Developed Date Revised Page #
Nov. 28, 2003 April 28, 2005
ALT723309 38

SELF-CHECK LO3-1

Convert the following:

1. 5.3 liters to quarts

a. 5.497 qt. b. 5.597 qt. c. 5.957 qt. d. 5.795 qt
c. 12.472 qt. d. 12.572 qt.
2. 12 liters to quarts c. 4.654 L d. 4.564 L
c. 5.403 L d. 5.493 L
a. 12.672 qt. b. 12.172 qt c. 1.431 L d. 1.341 L

3. 4.8 qt to liters

a. 4.546 L b. 4.456 L

4. 5.8 qt to liters

a. 5.394 L b. 5.439 L

5. 1.5 qt to liters

a. 1.412 L b. 1.421 L

Code No. Servicing Lubricating System Date Developed Date Revised Page #
Nov. 28, 2003 April 28, 2005
ALT723309 39

ANSWER KEY LO3-1

1. B
2. A
3. A
4. D
5. B

Code No. Servicing Lubricating System Date Developed Date Revised Page #
Nov. 28, 2003 April 28, 2005
ALT723309 40

OPERATION SHEET LO3-2

OPERATION TITLE : OVERHAULING OIL PUMP
: To carry out checking/inspecting procedure of the parts of
PURPOSE
oil pump
CONDITIONS OR
SITUATIONS FOR : Oil pump should be removed from the engine before
OPERATION performing the overhauling procedure.

EQUIPMENT, TOOLS &

MATERIALS : Philip screw driver, combination wrench oil pump

PROCEDURE:

To Dismantle :( see fig. 3-1)

1. Remove the flange nuts and lock
washers securing the oil strainer to
the pump and remove the strainer
and gasket.

2. Remove the oil pump cover
retaining bolts and remove the
cover.

NOTE: Using a suitable punch mark both
rotors to ensure correct installation.

3. Remove the oil pump drive rotor
and shaft and the driven rotor.

Undo the relief valve plug and remove the
gasket, spring, and relief valve.

Fig. 3-1

Code No. Servicing Lubricating System Date Developed Date Revised Page #
Nov. 28, 2003 April 28, 2005
ALT723309 41

TO CHECK AND INSPECT: ( see fig. 3-2, 3-3&3-4)

1. Inspect the pump shaft for excessive wear and scoring. Replace the rotors as a set if
wear is excessive.

2. Check the following according to
the specifications:

a. The tip clearance of the drive
rotor with the driven rotor. If
beyond the specified limit
replace the rotors as a set.

b. The side clearance between the
drive rotor and the driven rotor
with the pump cover. If beyond
the specified limit replace the
body cover or rotor set.

c. The clearance between the body Fig. 3-2
and the driven rotor. If beyond
the specified limit replace the
pump body or rotor set.

d. Measure the oil pump outer rotor diameter and the timing base bore inner
diameter and compare the difference in the two readings to specifications.
(Clearance between outer rotor and timing case).

3. Clean all components thoroughly in solvent and check the relief valve for
serviceability and inspect the oil passages and the sliding surfaces for wear or
damage. If defective replace the relief valve or pump body as necessary.

4.

Code No. Fig. 3-3 Date Developed Date Revised Page #
Servicing Lubricating System Nov. 28, 2003 April 28, 2005
ALT723309 42

Fig. 3-4

To Assemble:

Carry out the dismantling procedure in reverse paying attention to the following:

1. Assemble the drive rotor and the driven rotor with the punch marks facing the pump
cover side.

2. Check the rotor for free movement after assembly.

3. Prime the pump, immerse the strainer in engine oil and rotate the shaft to ascertain
that oil flows out of the delivery port.

4. Install the pump as described in TO INSTALL.

Precautions: Exercise extreme caution when performing oil pump overhauling to
Quality Criteria: avoid damage of parts.

1. Oil pump is overhauled without damaging the parts.
2. Procedure in dismantling is observed.
3. Procedure in assembling is observed.
4. 5’S is observed.

Code No. Servicing Lubricating System Date Developed Date Revised Page #
Nov. 28, 2003 April 28, 2005
ALT723309 43

SELF-CHECK LO3-2

1. Enumerate the procedures in dismantling oil pump.

2. Enumerate the procedure in inspecting oil pump.

3. Enumerate the procedures in assembling oil pump.

Code No. Servicing Lubricating System Date Developed Date Revised Page #
Nov. 28, 2003 April 28, 2005
ALT723309 44

ANSWER KEY LO3-2

To Dismantle:

1. Remove the flange nuts and lock washers securing the oil strainer to the pump
and remove the strainer and gasket.

2. Remove the oil pump cover retaining bolts and remove the cover.

NOTE: Using a suitable punch mark both rotors to ensure correct installation.

3. Remove the oil pump drive rotor and shaft and the driven rotor.

4. Undo the relief valve plug and remove the gasket, spring, and relief valve.

To Check and Inspect:

1. Inspect the pump shaft for excessive wear and scoring. Replace the rotors as a set if
wear is excessive.

2. Check the following according to the specifications:

a. The tip clearance of the drive rotor with the driven rotor. If beyond the
specified limit replace the rotors as a set.

b. The side clearance between the drive rotor and the driven rotor with the pump
cover. If beyond the specified limit replace the body cover or rotor set.

c. The clearance between the body and the driven rotor. If beyond the specified
limit replace the pump body or rotor set.

3. Measure the oil pump outer rotor diameter and the timing base bore inner diameter
and compare the difference in the two readings to specifications. (Clearance
between outer rotor and timing case).

Clean all components thoroughly in solvent and check the relief valve for serviceability and
inspect the oil passages and the sliding surfaces for wear or damage. If defective replace the
relief valve or pump body as necessary.

To Assemble:

Carry out the dismantling procedure in reverse paying attention to the following:

1. Assemble the drive rotor and the driven rotor with the punch marks facing the pump
cover side.

2. Check the rotor for free movement after assembly.
3. Prime the pump, immerse the strainer in engine oil and rotate the shaft to ascertain

that oil flows out of the delivery port.
4. Install the pump as described in TO INSTALL.

Code No. Servicing Lubricating System Date Developed Date Revised Page #
Nov. 28, 2003 April 28, 2005
ALT723309 45

JOB SHEET LO3-3

LO3: OVERHAUL OIL PUMP, REPLACE OIL FILTER, AND CHANGE OIL.

TITLE: ENGINE OIL AND FILTER CHANGE

PUROSE:
To carry out procedure in changing engine oil, and replace oil filter.

Vehicle Make Model Year
Time Started Time Finished
Job Completion Time Flat Rate Time

Safety Items and Special Equipment

♦ Safety glasses or goggles
♦ Oil filter wrench
♦ Oil catch pan

References

Manufacturer’s Service Manual
Repair Manual
Service Bulletin
Procedure

1. Start engine in a well-ventilated area and allow it to reach normal operating temperature.
Shut off the engine.

2. Safely raise vehicle on a hoist or support vehicle on jack stands.

SAFETY CAUTION: When hot, exhaust system parts, can cause severe burns. Avoid
touching exhaust system parts. In addition, drain plugs and oil are hot enough to cause
pain and minor burns. Use a shop towel to hold the drain plug as it is unscrewed, and
avoid getting oil on yourself during draining.

3. Loosen drain plug with a wrench. Do not unscrew plug.

4. Position an oil catch pan under oil pan drain pug.

5. Unscrew and remove drain plug by hand. Allow hot oil to drain into the catch pan for at
least five minutes.

6. Clean drain plug and mounting hole with a shop towel. Thread plug in by hand, and then
tighten as recommended by vehicle manufacturer.

7. Position oil catch pan under oil filter.

Code No. Servicing Lubricating System Date Developed Date Revised Page #
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ALT723309 46