AUTOMOTIVE TECHNOLOGY SYLLABUS (rev. Fall 2012) AUMT 1319: AUTOMOTIVE ENGINE REPAIR SEMESTER HOURS: 3 TEXTBOOK Chek-Chart: Automotive Engine Repair And Rebuilding COURSE DESCRIPTION; Fundamentals of engine operation, diagnosis and repair including lubrication and cooling systems. Emphasis on overhaul of selected engines, identification and inspection, measurements, and disassembly, repair, and reassembly of the engine. COURSE LEARNING OUTCOMES; Utilizing appropriate safety procedures, the student will demonstrate engine diagnostic procedures. The student will perform cylinder head valve train, engine block, and lubrication and cooling systems diagnosis and repair. PERFORMANCE OBJECTIVES; By the end of the course, the student will develop entry level skills and knowledge necessary to perform the following tasks. 1. Demonstrate knowledge of correct safety procedures in the automotive lab in accordance with shop safety and dress code standards. 2. Demonstrate knowledge of proper procedures involving the operation and cleaning of the automotive lab and tool room according to the standards of the instructor and the Industrial Division. 3. Acquire acceptable work skills and attitudes according to Industrial Division standards which will increase the students chances of securing gainful employment in the field. 4. Identify all hand and power tools used by craftsmen of the field that are needed to properly perform repairs on automotive and light duty diesel engines using shop manual procedures. 5. Accurately describe the gasoline and light duty diesel four stroke cycle and correctly relate each stroke's function. 6. Identify, diagnose, and accurately repair problems in the crank, rod, and piston assembly of gasoline and light duty diesel engines using shop manual procedures, manufacturer's specifications, and allowable tolerances. 1 7. Identify and accurately implement automotive nomenclature and trade terms that are used by automotive manufacturers and craftsmen in the field. 8. Show the ability to accurately solve mathematical problems in the automotive trade that are encountered by craftsmen in the field. 9. Accurately measure tolerances to compare with manufacturer's recommended specifications using various measuring devices. 10. Properly road test an automobile according to the standard set forth by the instructor. COURSE OUTLINE: Automotive Engines I. Engine Construction II. Engine Classification A. Operational Cycles 1. Four- stroke cycle 2. Two-stroke cycle B. Number of Cylinders C. Cylinder Arrangement D. Valve Train Type 1. OHC 2. OHV 3. DOHV E. Ignition Type F. Cooling System Type G. Fuel type III. Four-Stroke Gasoline Engines A. Intake Stroke B. Compression Stroke C. Power Stroke D. Exhaust Stroke IV . Two-Stroke Gasoline Engines V. Characteristics of Four-Stroke Engines A. In-Line Engines B. V-Type Engines C. Slant Cylinder Engines D. Opposed Cylinder Engines E. Valve and Camshaft Placement 1. Overhead valve 2. Overhead cam F. Valve Arrangement G. Valve and Camshaft Operation H. Engine Location 1. Front engine longitudinal 2. Front engine traverse 3. Mid-engine transverse 2 4. Rear engine VI. Gasoline Engine Systems A. Air/Fuel Systems B. Ignition Systems C. Lubrication Systems D. Cooling Systems E. Exhaust Systems F. Emission Control Systems VII. Engine Measurement and Performance A. Bore and Stroke B. Displacement C. Compression Ratio D. Engine Efficiency E. Torque and Horsepower VIII. Engine Identification IX. Engine Diagnosis A. Engine Temperature Tests B. Oil Pressure testing X. Evaluating the Engine’s Condition A. Noise Diagnosis 1. Using a stethoscope 2. Common noises a. Ring noise b. Piston slap c. Piston pin knock d. Ridge noise e. Rod-bearing noise f. Main or thrust bearing noise g. Tappet noise h. Abnormal combustion noise XI. Other Engine Designs A. Diesel Engine B. Rotary Engine C. Stratified Charge Engine D. Miller-Cycle Engine E. Electric Engine H. Hybrid Vehicles Engine Disassembly I. Preparing the Engine for Removal II. Lifting an Engine III. Engine Disassembly and Inspection A. Cylinder Head Removal B. Cylinder Head Disassembly C. Cylinder Block Disassembly IV. Cleaning Engine Parts A. Types of Soil Contaminants 1. Water-soluble soils 3 2. Organic soils a. Petroleum byproducts b. Combustion byproducts c. Coatings 3. Rust 4. Scale B. Cleaning with Chemicals 1. Parts washers 2. Soak tanks 3. Hot spray tanks C. Thermal Cleaning D. Abrasive Cleaners 1. Abrasive blaster 2. Parts tumbler 3. Vibratory cleaning 4. Cleaning by hand E. Alternative Cleaning Methods 1. Ultrasonic cleaning 2. Citrus chemicals 3. Salt bath V. Crack Repair A. Crack Detection Methods B. Furnace Welding Crack Repairs C. Repairing Aluminum Heads 1. Cracks in the aluminum between the valve seat rings 2. Cracks coming from the cooling passages 3. Cracks across the main oil gallery 4. Detonation damage 5. Meltdown damage 6. Coolant-related metal erosion Short Block I. Cylinder Blocks A. Lubricating and Cooling B. Core Plugs C. Cylinder Sleeves II. Cylinder Block Reconditioning A. Deck Flatness B. Cylinder Walls C. Cylinder Bore Inspection 1. Taper 2. Out of roundness D. Cylinder bore Surface Finish 1. Cylinder deglazing 2. Cylinder boring 3. Cylinder honing E. Installing core Plugs 1. Disc- or dished- type 2. Cup-type 4 3. Expansion type III. Crankshaft A. Vibration dampner B. Flywheel C. Balance shafts IV. Crankshaft Inspection and Rebuilding A. Checking Crankshaft Saddle Alignment B. Checking Crankshaft Straightness C. Checking Crankshaft Clearance and End Play D. Flywheel Inspection E. Crankshaft Bearings F. Bearing Spread G. Bearing Crush H. Bearing Locating groves I. Oil Grooves J. Oil Holes K. Oil Clearance L. Bearing failure and Inspection V. Installing Main Bearings and Crankshaft A. Plastigauge B. Crankshaft End Play C. Connecting Rod VI. Pistons and Piston Rings A. Pistons 1. Head or dome 2. Ring lands 3. Piston pin B. Piston Rings 1. Compression rings 2. Oil control rings VII. Installing Pistons and Connecting Rods Cylinder heads and valves I. Cylinder head II. Combustion Chamber A. Wedge chamber B. Hemispherical chamber C. Swirl chamber D. Chamber-in-piston E. Fast-burn combustion chamber III. Intake and exhaust valves A. Poppet Design B. Vavle Face C. Margin D. Valve Guides E. Valve Springs, Retainers, and Seals F. Valve Rotaters G. Multi-valve engines 5 IV. Aluminum Cylinder Heads A. Reconditioning Aluminum Cylinder Heads V. Resurfacing Cylinder Heads A. Surface Finish B. Belt Finishers C. Milling Machines D. Broaching Machines E. Surface Grinders F. Stock Removal Guidelines 1. Combustion chamber volumes a. Compression ratio b. Piston/valve interference and misalignment VI. Grinding Valves VII. Valve Guide Reconditioning A. Knurling B. Reaming and Oversize Valves C. Thin-walled Guide Liners D. Valve Guide Replacement 1. Integral guides 2. Insert guides VIII. Reconditioning Valve Seats A. Installing Valve Seat Inserts B. Reconditioning Integral Seats C. Grinding Valve Seats D. Cutting Valve Seats E. Machining Valve Seats IX. Valve Stems Seals A. Installing Positive Valve Seals B. Installing Umbrella-Type Valve seals C. Installing O-Rings D. Valve Spring 1. Freestanding height test 2. Spring squareness test 3. Open/close spring pressure test E. valve Spring Rotaters and Keepers 1. Valve rotaters X. Assembling the Cylinder Head Camshaft and Valve Trains I. Camshaft A. Camshaft bearings B. Valve lifters 1. Operation of hydraulic lifters C. Pushrods D. Pushrod Guide Plates E. Rocker Arms E. Timing Mechanism 1. Gear drive 2. Chain drive 7 3. Belt drive 4. Timing belt and chain tensioners 5. Timing marks 6. Auxiliary camshaft functions F. Variable Valve Timing II. Camshaft and Valve Train Inspection A. camshaft B. Valve Lifters C. Pushrods D. Rocker Arms E. Timing Components 1. Timing gear backlash 2. Timing belt 3. Camshaft/crankshaft timing III. Installing the Camshaft A. Camshaft End Play IV. Installing the Cylinder Head and Valve train A. Adjusting Valves B. valve Lash V. Installing the Timing Components LUBRICATING AND COOLING SYSTEMS I. Lubrication A. Oil Types B. Oil Consumption II. Lubricating Systems A. Oil Pumps B. Oil Pump Pickup C. Oil Pan or Sump D. Pressure Relief Valve E. Oil Filter F. Engine Oil Passages or Galleries G. Engine Bearings H. Oil Pressure Indicator I. Oil Seals and Gaskets J. Dipstick K. Oil Cooler III. Oil Pump A. Types of Oil Pumps 1. Rotor types 2. Gear type B. Pressure regulation C. Measuring Oil Pressure D. Oil Pressure Indicators E. Oil Filters IV. Oil Pump Inspection and Service V. Installing the Oil Pump VI. Cooling Systems A. Liquid Cooled System 8 1. Coolant a. Expansion or recovery tank 2. Water pump 3. Radiator 4. Radiator pressure caps 5. Water outlet 6. Hoses 7. Thermostat 8. Belt drives 9. Fans and fan clutches 10. Water jackets 11. Temperature indicator 12. Heater system 13. Oil cooler B. Air-Cooled system VII. Cooling System Testing A. Testing the Cooling System for Leaks B. Repairing Radiators C. Testing the Radiator Cap D. Testing the Thermostat E. Checking and Replacing Hoses F. Water Pump Service G. Checking Fans and Fan Clutches H. Checking Belts I. Flushing Cooling Systems J. Refilling and Bleeding INTAKE AND EXHAUST SYSTEMS I. Air Induction System A. Air Intake Ductwork 1. Air cleaner/filter a. Air filter design b. Air filter service c. Thermostatic air cleaners 2. Intake manifold a. Servicing an intake manifold B. Vacuum Systems 1. Vacuum basics 2. Vacuum controls 3. Vacuum schematic 4. Diagnosis and troubleshooting 5. Vacuum test equipment II. Exhaust System components A. Exhaust Manifold B. Exhaust Pipe and Seal C. Catalytic Converters D. Mufflers E. Resonator F. Tail pipe 9 G. Heat Shields H. Clamps, Brackets, and Hangers III. Exhaust System service A. Exhaust System Inspection B. Exhaust Restriction Test C. Exhaust Manifold and Exhaust Pipe Servicing D. Replacing Exhaust System Components 1. Replacing leaking gaskets and seals IV. Turbochargers and Superchargers A. Turbocharger Operation 1. Turbocharger system 2. Waste gate valve 3. Intercooler 4. Lubricating system 5. Spark-retard system 6. Computer-controlled systems B. Turbocharger Inspection C. Waste Gate Service D. Common Turbocharger Problems 1.