AUTO-1300: Automotive Engines

AUTO-1300: Automotive Engines 1

AUTO-1300: AUTOMOTIVE ENGINESCuyahoga Community CollegeViewing: AUTO-1300 : Automotive EnginesBoard of Trustees:2017-03-30

Academic Term:2017-08-24

Subject CodeAUTO - Automotive Technology

Course Number:1300

Title:Automotive Engines

Catalog Description:Operation of internal combustion gasoline engine including enginefundamentals and removal, lubrication and cooling system operation, andcylinder head and engine block diagnosis. Engine disassembly, measurementsfor correctness, proper assembly techniques, and gasket and sealing informationincluded.

Credit Hour(s):3

Lecture Hour(s):1Lab Hour(s):6

Other Hour(s):0

RequisitesPrerequisite and CorequisiteNone.

OutcomesCourse Outcome(s):Diagnose, repair, and maintain the vehicles powertrain components.

Essential Learning Outcome Mapping:Critical/Creative Thinking: Analyze, evaluate, and synthesize information in order to consider problems/ideas and transform them ininnovative or imaginative ways.

Objective(s):1. Complete work order to include customer information, vehicle identifying information, customer concern, related service history,cause, and correction.2. Research applicable vehicle and service information, such as internal engine operation, vehicle service history, service precautions,and technical service bulletins.3. Inspect engine assembly for fuel, oil, coolant, and other leaks; determine necessary action.4. Install engine covers using gaskets, seals, and sealers as required.5. Remove and replace timing belt; verify correct camshaft timing.6. Perform common fastener and thread repair, to include: remove broken bolt, restore internal and external threads, and repairinternal threads with thread insert.7. Identify hybrid vehicle internal combustion engine service precautions.

2 AUTO-1300: Automotive Engines

Course Outcome(s):Diagnose, repair, and maintain the engines Cylinder Head and Valve Train Components


Objective(s):1. Inspect pushrods, rocker arms, rocker arm pivots and shafts for wear, bending, cracks, looseness, and blocked oil passages(orifices); determine necessary action.2. Adjust valves (mechanical or hydraulic lifters).3. Inspect and replace camshaft and drive belt/chain; includes checking drive gear wear and backlash, end play, sprocket and chainwear, overhead cam drive sprocket(s), drive belt(s), belt tension, tensioners, camshaft reluctor ring/tone-wheel, and valve timingcomponents; verify correct camshaft timing.4. Establish camshaft position sensor indexing5. Inspect valve springs for squareness and free height comparison; determine necessary action.6. Replace valve stem seals on an assembled engine; inspect valve spring retainers, locks/keepers, and valve lock/keeper grooves;determine necessary action.7. Inspect valve guides for wear; check valve stem-to-guide clearance; determine necessary action.8. Inspect valves and valve seats; determine necessary action.9. Check valve spring assembled height and valve stem height; determine necessary action.10. Inspect valve lifters; determine necessary action.11. Inspect and/or measure camshaft for runout, journal wear and lobe wear.12. Inspect camshaft bearing surface for wear, damage, out-of-round, and alignment; determine necessary action.13. Remove cylinder head; inspect gasket condition; install cylinder head and gasket; tighten according to manufacturer’sspecifications and procedures.14. Clean and visually inspect a cylinder head for cracks; check gasket surface areas for warpage and surface finish; check passagecondition.

Course Outcome(s):Diagnose, repair, and maintain the Engine Block Assembly


Objective(s):1. Remove, inspect, or replace crankshaft vibration damper (harmonic balancer).2. Disassemble engine block; clean and prepare components for inspection and reassembly.3. Inspect engine block for visible cracks, passage condition, core and gallery plug condition, and surface warpage; determinenecessary action.4. Inspect and measure cylinder walls/sleeves for damage, wear, and ridges; determine necessary action.5. Inspect and measure camshaft bearings for wear, damage, out-of-round, and alignment; determine necessary action.6. Inspect crankshaft for straightness, journal damage, keyway damage, thrust flange and sealing surface condition, and visualsurface cracks; check oil passage condition; measure end play and journal wear; check crankshaft position sensor reluctor ring(where applicable); determine necessary action.7. Inspect main and connecting rod bearings for damage and wear; determine necessary action.8. Identify piston and bearing wear patterns that indicate connecting rod alignment and main bearing bore problems; determinenecessary action.9. Inspect and measure piston skirts and ring lands; determine necessary action.10. Determine piston-to-bore clearance.11. Inspect, measure, and install piston rings.12. Inspect auxiliary shaft(s) (balance, intermediate, idler, counterbalance or silencer); inspect shaft(s) and support bearings fordamage and wear; determine necessary action; reinstall and time.13. Assemble engine block.

Course Outcome(s):Diagnose, repair, and maintain the engines Lubrication and Cooling Systems



Objective(s):1. Perform cooling system pressure and dye tests to identify leaks; check coolant condition and level; inspect and test radiator,pressure cap, coolant recovery tank, heater core and galley plugs; determine necessary action.2. Identify causes of engine overheating.3. Inspect, replace, and adjust drive belts, tensioners, and pulleys; check pulley and belt alignment.4. Inspect, remove, and replace water pump.5. Remove, inspect, and replace thermostat and gasket/seal.6. Perform oil pressure tests; determine necessary action.7. Inspect oil pump gears or rotors, housing, pressure relief devices, and pump drive; perform necessary action.

Course Outcome(s):Shop and Personal Safety


Objective(s):1. Identify general shop safety rules and procedures.2. Utilize safe procedures for handling of tools and equipment.3. Identify and use proper placement of floor jacks and jack stands.4. Identify and use proper procedures for safe lift operation.5. Utilize proper ventilation procedures for working within the lab/shop area.6. Identify marked safety areas.7. Identify the location and the types of fire extinguishers and other fire safety equipment; demonstrate knowledge of the proceduresfor using fire extinguishers and other fire safety equipment.8. Identify the location and use of eye wash stations.9. Identify the location of the posted evacuation routes.10. Comply with the required use of safety glasses, ear protection, gloves, and shoes during lab/shop activities.11. Identify and wear appropriate clothing for lab/shop activities.12. Secure hair and jewelry for lab/shop activities.13. Demonstrate awareness of the safety aspects of supplemental restraint systems (SRS), electronic brake control systems, andhybrid vehicle high voltage circuits.14. Demonstrate awareness of the safety aspects of high voltage circuits (such as high intensity discharge (HID) lamps, ignitionsystems, injection systems, etc.).15. Locate and demonstrate knowledge of material safety data sheets (MSDS).

Course Outcome(s):Tools and Equipment


Objective(s):1. Identify tools and their usage in automotive applications.2. Identify standard and metric designation.3. Demonstrate safe handling and use of appropriate tools.4. Demonstrate proper cleaning, storage, and maintenance of tools and equipment.5. Demonstrate proper use of precision measuring tools (i.e. micrometer, dial-indicator, dial-caliper).

Course Outcome(s):Preparing Vehicle for Service


Objective(s):1. Identify information needed and the service requested on a repair order.2. Identify purpose and demonstrate proper use of fender covers, mats.3. Demonstrate use of the three C’s (concern, cause, and correction).


4. Review vehicle service history.5. Complete work order to include customer information, vehicle identifying information, customer concern, related service history,cause, and correction.

Course Outcome(s):Preparing Vehicle for Customer


Objective(s):1. Ensure vehicle is prepared to return to customer per school/company policy (floor mats, steering wheel cover, etc.).

Methods of Evaluation:1. Participation and discussion2. Observation3. Written assignments4. Exams5. Quizzes6. Lab tasks7. Classroom recitations

Course Content Outline:TOPICAL OUTLINE

• a. Engine operationi. Compression and combustion

1. vacuum2. the four-stroke cycle3. reciprocating engine

b. Major engine partsi. Cylinder block

1. crankcase2. crankshaft and connecting rod

a. flywheelb. engine rotation

ii. Cylinder Head1. camshaft2. valves

a. valve arrangementb. valve liftersc. number of valves

c. Cylinder arrangementi. Engine balance

ii. Firing orderd. Engine displacement and compression ratio

i. Engine displacementii. Compression ratio

e. Ignition systemi. Common ignition intervals

ii. Unusual ignition intervalsiii. Spark frequency

1. firing ordera. in-line enginesb. v engines

f. Engine-ignition synchronizationi. Distributor drive

ii. Crankshaft position


iii. EI Ignition systemsiv. Coil on plug systemsv. Burn time

vi. Engine speedg. Initial (base) timing

i. Timing marksii. Adusting Ignition Timimg

iii. Verify proper timingh. Other engine types

i. Two-stroke engineii. Diesel engine

iii. Rotary (Wankel) enginei. Engine torquej. Engine horsepower

i. Torque and horsepower relationships1. brake horsepower2. indicated horsepower and actual horsepower

ii. Airflow requirementsiii. Volumetric efficiency

k. Chemistry and combustioni. Gasoline and combustion

ii. Detonationiii. Preignitioniv. Octane rating

l. Engine operation and air pressurem. Air-fuel ratios

i. Stoichiometric air-fuel ratioii. Engine air-fuel requirements

iii. Power versus economyn. Engine materials

i. Ironii. Cast iron

iii. Steeliv. Steel alloysv. Alloy tool steel

vi. Aluminumvii. Magnesium

viii. Titaniumix. Aluminum-siliconx. Plastics

xi. Ceramicsxii. Other composites

o. Manufacturing operationsi. Casting

ii. Forgingiii. Machiningiv. Stamping

p. Material treatmentsi. Heat treating

ii. Hardeningiii. Temperingiv. Annealingv. Normalizing

vi. Casehardeningvii. Shot-peening

viii. Platingix. Anodizingx. Surface finishes


q. Machining operationsi. Internal machining

ii. Boringiii. Honingiv. Drillingv. Reaming

vi. Tappingvii. Broaching

viii. External machiningix. Millingx. Grinding

xi. Polishingr. Cooling system function

i. Air cooled systemsii. Liquid cooled systems

iii. Achieving proper operating temperature (emissions)iv. Maintaining temperature

s. The development of engine coolanti. Etheyne glycol

ii. Propylene glycoliii. General Motors Dex-cooliv. Organic Acid Technology (OAT)v. G05 - Hybrid Organic Acid Technology (HOAT)

t. Cooling system componentsi. Water pump

ii. Thermostat1. Inlet Thermostat designs2. Outlet Themostat designs3. OBD II Thermostat Monitor

iii. Radiatoriv. Radiator cap

1. system pressure2. system vacuum

v. Coolant recovery tank1. Pressurized Surge Tank2. Non-Pressurized Recovery Tank

vi. Radiator fan1. Mechanically driven clutch fans2. Electronically controlled fans

vii. Radiator hoses and drive beltsviii. Water jackets

ix. Core plugsx. The heater core

u. Engine temperature effects on mechanical wear and emissionsv. The intake system

i. Airflow1. fuel atomization2. fuel vaporization

ii. The intake manifold1. intake manifold design2. unequal distribution and manifold design3. manifold and intake charge heat

iii. Basic intake manifold types1. single-plane manifolds2. dual-plane manifolds

iv. port fuel-injection manifolds1. two-piece manifolds2. one-piece manifolds3. variable induction systems


w. The exhaust systemsi. Exhaust system arrangement

ii. Exhaust system components1. exhaust manifolds

a. high-performance exhaust manifoldsb. exhaust header

2. pipes3. mufflers and resonators4. catalytic converters

x. Purposes of motor oily. Motor oil composition and additives

i. Motor oil additives1. additive precautions

ii. Synthetic motor oilsz. Motor oil designations

i. API service classificationii. SAE viscosity grades

iii. Energy-conserving oilsiv. Engine oil identification

aa. Engine oiling system and pressure requirementsi. Oil reservoir

1. ventilation2. PVC system

ii. Oil pump and pickupiii. Pressure relief valveiv. Filterv. Galleries, lines, and drillways

vi. Indicators1. dipstick2. oil level sensor3. oil pressure warning lamp4. oil pressure gauge5. Oil life systems

bb. Engine lubrication effects on mechanical wearcc. Cylinder block design

i. Cylinder block sizeii. Ribs and webs

iii. The crankcaseiv. Main bearingsv. main bearing number

vi. Cylinders1. siamesed cylinder bores2. cylinder bore taper

vii. Cylinder Sleeves1. types of sleeves2. sleeveless cylinders3. block dimensions4. crankshaft offset5. cylinder offset

dd. Cylinder headsi. Combustion chamber design

1. combustion efficiency and breathing abilitya. squish areab. quench areac. spark plug placementd. surface-to-volume ratioe. valve shroudingf. valve placement


g. valve numberh. auxiliary valves

2. combustion chamber shapea. wedge-shaped combustion chambersb. hemispherical combustion chambersc. modified-wedge chamber designsd. pentroof combustion chamberse. fast-burn combustion chambersf. stratified charge combustion chambers

ii. Intake and exhaust ports1. port design2. port polishing

ee. Valve Designi. valve materials

ii. valve coatingsiii. valve face anglesiv. valve cooling

ff. Springsi. Valve float

ii. Spring materialiii. Spring installations

1. spring retainers2. spring height

iv. Spring design1. dual springs2. dampers3. variable rate spring4. coil bind

v. Valve rotatorsgg. Guides

i. Insert guidesii. Integral guides

iii. Valve guide clearanceshh. Valve guide seals

i. O-ring sealsii. Umbrella seals

iii. Positive sealsii. Valve seats

i. Integral valve seatsii. Induction hardening

iii. Valve seat insertsiv. Valve seal insert materialv. Valve seat angles

jj. Valve, spring, guide, and seat relationshipskk. Camshafts

i. Camshafts in the cylinder blockii. Camshafts in the cylinder head

ll. Camshaft drivesi. Chains

ii. Gearsiii. Beltsiv. Tensioners and guidesv. Accessory drives

vi. Cam thrustmm. Camshaft design

i. Cam lobe constructionii. Camshaft materials

iii. Cam lobe conditioning


iv. Camshaft lubricationv. Camshaft scuffing

nn. Valve timingi. Lift

ii. Durationiii. Overlapiv. Lobe separation anglev. Camshaft installation position

vi. Valve-to-piston interferenceoo. Valve lifters and cam followers

i. Valve liftersii. Valve clearance

iii. Solid liftersiv. Hydraulic lifters

1. hydraulic lifter pump-up2. installing hydraulic lifters

v. Cam and flat tappet wearvi. Followers

pp. Pushrodsi. Pushrods and valve clearance

ii. Pushrod guide platesiii. Pushrod lubrication

qq. Rocker armsi. Shaft-mounted rockers

ii. Stud-mounted rockersiii. Pedestal-mounted rockersiv. Rocker arm ratiov. Rocker arm lubrication

vi. Rocker arm geometryrr. Crankshafts

i. Main bearing journals1. thrust surface2. thrust bearing

ii. Rod bearing journalsiii. Filletsiv. Crankshaft throws and firing impulsesv. Firing order

vi. Counterweightsvii. Keyways and threads

viii. Lubricationix. improved rod journal lubricationx. Cast crankshafts

xi. Forged crankshaftsss. Flywheels

i. Dual mass-flywheelsii. Heavy duty mass flywheel

tt. Flexplatesuu. Vibration dampersvv. Engine balance

ww. Balancing shaftsi. Crankshaft balance

ii. Custom engine balancingiii. Why balance?

xx. Pistonsi. Piston crowns

ii. Piston bossesiii. Ring grooves And landsiv. Piston skirts


v. Piston materials1. hypereutectic cast pistons2. alloy pistons

vi. Piston expansion1. piston clearance2. piston noise

vii. Piston pins1. piston pin attachment2. full floating piston pins

viii. Piston offsetyy. Piston rings

i. Compression rings1. compression ring operation2. compression ring design

a. compression ring widthb. compression ring tension

ii. Oil control rings1. oil ring design2. oil consumption

iii. Ring gap1. ring friction2. ring leakage

iv. Piston ring materials1. ring face coatings2. low tension rings

zz. Connecting rodsi. Connecting rod materials

ii. Powder-forged rodsiii. Cracked connecting rodsiv. The effects of rod length

aaa. Main and connecting rod bearingsi. Plain bearing construction

1. bearing retention2. oil grooves3. thrust bearings4. plain bearing dimensions

ii. Bearing clearance1. undersize bearings2. oversize bearings

bbb. Camshaft bearingsi. Engines without camshaft bearings

ii. Camshaft bearing replacimentccc. Plain bearing operation

i. Fluid frictionii. Oil clearance

iii. Oil film theoryddd. Plain bearing materials

i. Qualitiesii. Main and rod bearing materials

1. babbitt bearings2. multi-layer bearings3. aluminum alloy bearings

eee. Gasketsi. Head gaskets

ii. Sandwich gasketsiii. Multilayer steel gasketsiv. Intake and exhaust manifold gasketsv. Toil pan gaskets and valve and cam cover gaskets

vi. Other gasketsfff. Seals


i. Synthetic rubber seals1. o-ring seal2. square-cut seal3. lip seal

ii. Other types of sealsggg. Sealants and cements

i. Precautionsii. Adhesives

iii. Sealants1. silicone sealants2. anaerobic sealants

iv. Lubricantsv. Cleaners

hhh. Fastenersi. Specifications

1. bolt or screw length2. thread diameter3. thread pitch4. thread depth5. head size and shape

ii. Bolt Torque1. tightening pattern2. torquing bolts

a. torque-to-yield-boltsb. torque angles

iii. Securing fastenersiv. Thread and bolt sizes

1. american sizes2. metric sizes

iii. Engine mountsjjj. Laboratory Topics

kkk. Personal safetyi. First-aid response

ii. Eye protectioniii. Work area

lll. Know your shopmmm. Fire

i. Fire extinguishersii. Fire blankets

nnn. Solvents and chemicalsi. Carbon monoxide asphyxiation

ii. Chemical exposureooo. Vehicle and underhood safety

i. Jump start safetyii. Battery safety

ppp. Engine repair and rebuilding safetyi. Hand tool safety

ii. Hoists, floor jacks, and jackingiii. Hydraulic liftsiv. Engine standv. Compressed air and air hose safety

qqq. Power tools and shop equipmenti. Drill motors

ii. Impact wrenchesiii. Air ratchetsiv. Bench grindersv. Rotary, or die grinders

vi. Compressed airrrr. Specialized engine tools


i. Head and valve service tools1. valve spring compressor2. spring tension tester3. valve seat grinder4. valve seat cutter5. valve grinding machine6. valve guide renewing

a. valve guide bore gaugeb. knurlingc. guide insert

7. seat insertion tool or machine8. rocker stud puller9. hydraulic valve lifter remover

10. head surfacing machinesa. milling machinesb. surface grinders

ii. Block service tools and equipment1. camshaft bearing removal tool2. ridge reamer3. cylinder bore gauge4. boring machines5. cylinder hone6. glaze breaker7. line boring equipment8. align honing9. torque plates for boring and honing

10. block surface mill and grinderiii. Crankshaft service tools and equipment

1. harmonic balancer puller2. v-block and dial indicator3. crankshaft grinder4. crankshaft balancing machine5. balancing scale6. crankshaft polisher

iv. Piston, rod, and ring tools and equipment1. ring expander2. piston-pin drift3. ring-groove cleaner4. ring end-gap grinder5. rod honing machine6. rod aligner7. rod cap grinder8. rod heater for pin assembly9. arbor press

10. hydraulic press11. ring compressor

sss. General measurement toolsi. Straightedges

ii. Steel rulesiii. Feeler gauges

1. blade-type2. go-no-go3. feeler gauge stock4. non-magnetic5. round-wire

iv. Calipers1. vernier calipers2. dial calipers


v. Micrometers1. using a micrometer

a. reading a vernier inch micrometerb. reading a vernier metric micrometer

2. digital micrometersvi. Dial indicators

1. dial indicator stands2. dial indicator

ttt. Accessoriesi. Telescoping gauges

ii. Small-hole gaugesuuu. Torque measuring tools

i. Torque beam indicatorsii. Torque click ratchets

iii. Torque-to-yield degree wheelsvvv. Manufacturer''s specifications

i. Identifying the engine1. using vehicle identification number (VIN) codes2. engine and calibration codes3. interpreting casting numbers and casting marks

a. casting marksb. casting numbersc. miscellaneous marks and labels

4. recognizing oversize/undersize codesii. Obtaining specifications

1. manufacturers'' service manuals2. manufacturers'' service bulletins3. aftermarket service manuals4. aftermarket component suppliers5. Online service information

www. Replacement parts, subassemblies, and enginesi. Overhaul versus rebuild

ii. Engine families and interchangeabilityiii. Service replacement engine pros And consiv. Engine kits and gasket setsv. Used engines

xxx. Oil consumptioni. Oil passing the piston rings

1. worn, stuck, or broken rings2. incorrectly installed rings3. oil viscosity too low4. excessive crankcase pressure5. excessive oil on cylinder walls

ii. Oil passing the valve guidesiii. External oil leaksiv. Internal oil leaks

yyy. Engine oil pressurei. Preliminary oil pressure checks

ii. How to use an oil pressure gaugezzz. Basic diagnostic tests

i. What a vacuum gauge can tell youii. how to test the positive crankcase ventilation (PCV) system

1. with a vacuum gauge2. with a manometer

iii. how to spot vacuum leaksiv. how to pinpoint problems with the valvesv. how to spot an exhaust restriction

vi. how to check compression with a vacuum gaugevii. Engine compression testing


1. how to test engine compression2. compression test results

viii. Cylinder leakage testaaaa. Power balance tests

i. Power balance test equipmentii. Power balance test precautions

iii. Performing a cylinder power balance testiv. Interpreting power balance, compression, and leakage test resultsv. Good balance, good compression, poor leakage

vi. Poor balance, good compression, good leakagevii. Poor balance, poor compression, good leakage

bbbb. Engine noisesi. Using a stethoscope

ii. Top or bottom end?1. valve train noises

a. normal top end sounds2. abnormal top end sounds3. bottom end noises

a. crankshaft endplayb. connecting rod bearingsc. piston slapd. wrist pin noisee. main bearingsf. other noises

cccc. Servicing the camshaft drivei. Valve interference

ii. Timing chains and gears1. how to service OHV timing chains and gears

a. removing the OHV timing coverb. inspecting, removing, and reinstalling the OHV timing gearsc. removing, inspecting, and reinstalling the OHV timing chaind. reinstalling the OHV timing cover

2. how to service an overhead cam timing chaina. removing an OHV chain timing coverb. removing, inspecting, and replacing the timing chain

3. how to install the OHC timing coveriii. Timing belts

1. how to service an OHC timing belta. removing the OHC belt timing coverb. inspecting the timing beltc. removing and replacing the timing beltd. installing the belt

dddd. Valve train adjustment and repairi. How to remove and replace the valve cover

ii. Valve clearances1. adjusting mechanical valve clearances

a. adjusting clearances with the engine runningb. adjusting clearances with the engine off

2. adjusting hydraulic valve clearancesa. adjusting clearances with non-adjustable rocker armsb. adjusting clearances with adjustable rocker arms

iii. How to replace the valve springs and sealsiv. How to replace a camshaft

eeee. Removing and replacing the cylinder headffff. Servicing the bottom end

i. How to remove and replace the oil panii. How to replace the rod bearings

iii. How to replace the crankshaft main bearingsiv. Oil pump


gggg. Preparationi. Clean the engine first

ii. Plan aheadiii. Preliminary operations

1. removing wiring and accessories2. air conditioning systems3. relieving fuel system pressure

hhhh. Removing the enginei. hoisting the engine from a RWD chassis

ii. hoisting the engine and transaxle from a FWD chassisiii. hoisting the engine from a FWD chassisiv. dropping the engine and transaxle from a FWD chassis

iiii. Lifting the enginei. Hoists

ii. Lifting slingsiii. Pulling the engine

1. removing the engine with the transmission disconnected2. removing the engine with the transmission attached3. hoisting the engine

jjjj. Inspect as you gokkkk. Top end disassembly and inspection

i. Remove accessories and manifoldsii. Remove the cylinder heads

1. OHV rocker arm disassembly2. cylinder head removal

llll. Bottom end disassembly and inspectioni. Remove the harmonic balancer and flywheel

ii. Remove the camshaft and liftersiii. Remove the oil pan and pumpiv. Remove the crankshaft, rods, and pistons

1. inspecting the rod2. inspecting the main bearings

v. Remove the gallery plugs, core plugs, and camshaft bearings1. inspecting the cylinder block2. inspecting the cylinder head

mmmm. Engine cleaningi. Cleaning methods

1. steam cleaners2. parts washers3. hot tanks4. spray booths5. chemical dip tanks6. bead blasting7. airless shot blasters8. tumblers and shaker units9. cleaning ovens

ii. Toxic waste disposalnnnn. Removing broken fasteners

i. How to avoid broken fasteners1. left-hand threads2. lubrication3. proper tools4. heat

ii. Why did the bolt break?iii. Removing fasteners with damaged headsiv. Using screw extractorsv. Broken taps, drill bits, and screw extractors

oooo. Repairing damaged threads


i. Using taps and dies1. identifying threads2. using a tap to cut new threads3. using a tap to chase old or damaged threads4. using a threading die to cut new threads5. using a threading die to chase worn or damaged threads

ii. Thread chasers, restorers, and thread-cutting filespppp. Internal thread replacement

i. Drilling oversizeii. Helical inserts

iii. Threaded inserts1. self-tapping inserts2. solid-bushing inserts3. key-locking inserts4. reamer-cut spark plug hole inserts

qqqq. Crack detectioni. Magnetic particle inspection

1. dry magnetic particle inspection2. wet magnetic particle inspection

ii. Dye penetrant testingiii. Pressure test inspection and equipment

rrrr. Crack repairi. Welding cracks

ii. Stop-drilling cracksiii. Pinning cracksiv. Sealing cracks with ceramic sealerv. Epoxies or metallic plastics

1. casting repair with epoxies2. thread repair with epoxies

ssss. Tolerances and oil clearancesi. Tolerances

ii. Oil clearancesiii. Calculating oil clearances from specifications

1. housing bore diameter2. insert thickness3. bearing inside diameter

a. maximum bearing inside diameterb. minimum bearing inside diameter

4. journal outside diameter5. calculating oil clearance

a. maximum oil clearanceb. minimum oil clearance

iv. Measuring oil clearances1. housing bore diameter2. insert thickness3. bearing inside diameter4. crankshaft journal outside diameter

tttt. Block inspectioni. Inspecting the main bearing bores

1. main bearing insert wear patterns2. straightedge in the housing bores3. measure with an inside micrometer or telescoping gauge4. measure with a dial bore gauge

a. adjusting the setting fixtureb. setting the dial bore gaugec. measuring a bearing bore with the dial bore gauge

ii. Inspecting the deck surface1. check for flatness2. check for warpage


iii. Inspect the cylinder bores1. check for previous overbore2. check for taper and out-of-round

uuuu. Main bearing bore reconditioningi. Align honing

1. grinding the main caps2. honing the bores

ii. Line boringvvvv. Deck reconditioning

i. Surface and alignment considerationsii. Surface finishes

iii. How much should you cut?1. amount of cylinder head surfacing2. piston clearances3. compression ratio4. intake manifold to cylinder head alignment5. pushrod length6. valve timing changes

iv. Resurfacing the deck surfacewwww. Cylinder reconditioning

i. Deglazing cylindersii. Cylinder boring

1. boring machines2. how much should you bore?3. boring cylinders to oversize

iii. Cylinder honing1. actual piston size2. torque plates3. automatic honing4. hand honing

iv. Reconditioning aluminum cylinder bores1. machining limitations2. refinishing procedures

v. Cylinder sleevingxxxx. Crankshaft service

i. Crankshaft disassemblyii. Inspecting main bearings

iii. Crankshaft inspection1. threads, keys, keyways, and pilots bearings2. cracks3. journal and thrust bearing condition4. straightness, snout, and flange runout

iv. Crankshaft straighteningv. Building up crankshaft journals

vi. Crankshaft grindingvii. Crankshaft polishing

yyyy. Piston and connecting rod servicei. Separating pistons and connecting rods

1. removing free-floating wrist pins2. removing press-fit wrist pins

ii. Reconditioning pistons1. removing piston rings2. cleaning the pistons3. inspecting and measuring the pistons

iii. Evaluating connecting rod condition1. inspect rod bearings

a. bent connecting rodb. improperly assembled offset rodsc. radius ride


2. inspecting rods, caps, boltsa. pin bore condition and diameterb. bend and twistc. big end bore out-of-roundd. cracks, stress risers, and discontinuities

iv. Reconditioning connecting rods1. correcting rod bend and twist2. reconditioning the big-end bore

a. grinding the parting facesb. honing the bearing bore

3. reconditioning the small-end borea. pin fitting - full-floating type

v. Piston and connecting rod reassembly1. final pre-assembly inspection

a. checking bearing clearanceb. checking piston ring end gap

2. installing pistons on rodsa. installing rods with full-floating wrist pinsb. installing rods with press-fit wrist pins

3. piston ring installationa. checking ring side gapb. fitting three-piece ringsc. fitting two-piece oil control ringsd. fitting compression rings

zzzz. Flywheel and flexplate servicei. Flexplate inspection

ii. Flywheel inspection and repair1. ring gear replacement2. flywheel machining

aaaaa. Head reconditioningi. Head disassembly

1. disassembling overhead valve cylinder heads2. disassembling overhead camshaft cylinder heads

ii. Cleaningiii. Inspection

1. head gasket surface2. valve Inspection

a. visual inspectionb. measuring valves

3. valve spring inspection4. valve guide inspection5. valve seat inspection6. camshaft bore and saddle inspection

iv. Valve repair1. oversize valve stems2. valve facing3. grinding the valve stem

v. Valve guide repair1. knurling2. replacing valve guide inserts3. installing thin-wall valve guide liners4. bronze coil inserts5. general valve guide service tips

vi. Valve seat reconditioning1. replacing valve seats2. valve seat grinding

a. checking valve seat concentricity and configurationb. correcting valve seat position and width

3. valve seat cuttingbbbbb. Head resurfacing


i. Straightening warped aluminum heads1. preparing the cylinder head2. heating and cooling the cylinder head

ii. Head resurfacingiii. Overhead camshaft bore alignmentiv. Matching manifold angles

ccccc. Valve testing and assemblyi. Checking valve seat sealing

ii. Installed heightiii. Cylinder head assembly

1. Installing the valves2. Installing overhead camshafts

ddddd. Camshaft servicei. Inspecting and measuring the camshaft

1. surface finish and condition2. wear patterns3. camshaft straightness4. measuring journal diameter5. calculating oil clearance6. lobe configuration

a. calculating valve liftb. base circle runout

ii. Camshaft Straighteningeeeee. Valve lifter and cam follower service

i. Solid liftersii. Hydraulic lifters

iii. Roller liftersiv. Over head cam lifters

1. bucket-type liftersa. mechanical bucket liftersb. hydraulic bucket lifters

2. finger-type cam followersa. remote-pivot hydraulic adjustersb. rocker arm mounted hydraulic adjusters

fffff. Pushrod servicei. Inspecting the pushrods

ii. Cleaning the pushrodsggggg. Rocker arm and shaft service

i. Stud-mounted rocker arms1. disassembling and inspecting2. assembling and adjusting

ii. Shaft-mounted rocker arms1. disassembling and inspecting the rocker shaft

a. inspecting the rocker shaftb. rocker arm inspectionc. spring and spacer inspection

2. rocker shaft assemblyhhhhh. General assembly practices

iiiii. Oil pump servicei. Camshaft driven pumps

ii. Crankshaft driven pumpsiii. Gear-type pumps

jjjjj. Assembly preparationi. Cleaning engine components

ii. Lubricating engine componentskkkkk. Assembling the block and bottom end


i. Installing core and oil gallery plugs1. installing oil galley plugs

a. threaded plugsb. disc-type plugs

2. installing core plugsii. Installing the camshaft bearings and camshaft

1. installing the camshaft bearings2. installing the camshaft3. installing the cam core plug

iii. Installing the crankshaft1. installing a split-type rear main seal2. installing the main bearings3. installing the crankshaft

a. installing the main bearing capsb. measuring oil clearance with Plastigage(r)

4. checking crankshaft end play5. installing a one-piece main seal

iv. Installing pistons, rings, and rods1. installing piston assemblies2. measuring deck clearance

v. Installing valve timing componentslllll. Final bottom end assembly

i. Installing the oil pump1. installing the pickup screen2. checking screen to pan clearance

ii. Installing the oil pan and timing cover1. timing covers2. oil pans

mmmmm. Assembling the top endi. Installing the cylinder heads

ii. Installing the valve trainiii. Installing valve timing components

nnnnn. Final assembly proceduresi. Installing manifolds

1. intake manifold installation2. exhaust manifold installation

ii. Installing flywheels and flexplates1. checkin

ResourcesErjavec, Jack and Rob Thompson. Automotive Technology: A Systems Approach. 6th ed. Boston, MA: Cengage Learning, 2015.

Halderman, James D. Automotive Engines: Theory and Servicing. 8th ed. New York, NY: Pearson, 2015.

Gilles, Tim. Automotive Engines: Diagnosis, Repair and Rebuilding. 7th ed. Boston, MA: Cengage Learning, 2014.

Johanson, Chris, Martin T. Stockel and Martin W. Stockel. Auto Fundamentals. 11th ed. Tinley Park, IL: Goodheart-Willcox, 2015.

Duffy, James E. Auto Engine Repair. 6th ed. Tinley Park, IL: Goodheart-Willcox, 2015.

Hadfield, Chris. Today's Technician: Basic Automotive Service Systems. 5th ed. Boston, MA: Cengage Learning, 2016.

Rehkopf,. Automotive Engines and Engine Performance. New York, NY: Pearson, 2015.

Halderman, James D. Automotive Engine Performance. 5th ed. New York, NY: Pearson, 2017.


Resources Other1. http://engine-repairs.com/ - Car Engine Repair & Troubleshooting2. http://cylinderhead.com/troubleshooting/ - Troubleshooting Cylinder Heads3. http://www.autorepairkey.com/articles/head-gasket/ - Head Gasket Information, Problems & Solutions4. http://salemboysauto.com/faqs/faq-19.htm - Cooling Systems, Overheating, Leaks & Electric Cooling Fans5. http://www.aa1car.com/library/engine_noise.htm - Diagnosing Engine Noise

Top of pageKey: 739

http://engine-repairs.com/

http://cylinderhead.com/troubleshooting/

http://www.autorepairkey.com/articles/head-gasket/

http://salemboysauto.com/faqs/faq-19.htm

http://www.aa1car.com/library/engine_noise.htm

AUTO-1300: Automotive Engines

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Transcript of AUTO-1300: Automotive Engines