Multi-Sensor Experimental Investigation of Thermal Runaway and Emissions in a High-Mileage Gasoline Engine Operating at Idle Without Forced Cooling

This study presents a single-case multi-sensor experimental study of thermal loading and emission variation in a high-mileage gasoline engine operating at idle under deliberately impaired cooling until mechanical failure. A production vehicle equipped with a naturally aspirated gasoline engine with a displacement of 1600 cc was operated under relatively steady-state conditions at idle, while gaseous emissions (CO, CO2, HC, NOx, and O2), air–fuel ratio λ, particle number (PN), oil temperature, infrared thermal indicators, and acoustic performance variation were continuously monitored. The results are interpreted primarily in terms of their dependence on the engine oil temperature. They show that despite stable conditions of the air–fuel ratio and an almost constant amount of residual oxygen in the exhaust gases, progressive thermal loading leads to pronounced changes in the behavior of the emissions emitted by the engine during its operation. Hydrocarbon emissions show increased variability and escalation at elevated engine oil temperatures, while nitrogen oxides show a strong temperature-dependent increase, consistent with thermally driven formation mechanisms. The most significant response is observed in the particle number (PN) emissions, which go from low and stable levels to a rapid, multi-step increase in a narrow temperature range preceding mechanical failure. Under the tested cooling impairment scenario, emission behavior was dominated by cumulative thermal stress rather than mixture composition effects. In the investigated case, particle number emissions emerged as a sensitive indicator of system-level thermal instability. The findings provide experimentally documented insight into the system-level progression toward thermal runaway under impaired cooling conditions and its measurable impact on emission behavior in the tested engine.