Metropolitan Community College COURSE OUTLINE FORM
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1 COURSE TITLE: ENGINE MECHANICAL SERVICE COURSE PREFIX AND NO. AUTT 1710 LEC 3.0 LAB 9.0 CREDIT HOURS 6.0 COURSE DESCRIPTION: This course covers the diagnosis and repair of upper engine components. The major objective of this course is to properly diagnose engine problems, estimate repair costs, and repair the engine as necessary to conform to service specifications. The course includes individualized hands-on laboratory training utilizing live work. COURSE PREREQUISITE (S): AUTT 1210 or instructor approval, valid driver s license, Sp/2 safety course completion for Mechanical Safety and Mechanical Pollution Prevention RATIONALE: This course expands the student s knowledge of four-stroke engine operation. It also provides additional Learning experiences to establish a solid foundation in problem solving techniques for noise diagnosis, disassembly, cleaning, inspecting, repair and reassemble of various in-chassis components. Since most dealerships do not have the necessary equipment to perform major machine shop work in-house, some machine shop descriptions will be included to aid the student in the planning of engine repairs. REQUIRED TEXTBOOK (S) and/or MATERIALS: Title: Automotive Technology (MyAutoLab package w/natef Correlated Task Sheets) Edition: Current Author: Halderman Publisher: Prentice Hall Materials: Tools (list is provided for students) Attached course outline written by: Automotive Faculty Date: February 2003 Reviewed/Revised by: Al Cox Date: October 2012 Effective quarter of course outline: 13/FA Date: Academic Dean Kirk Ahrends Date: Course Objectives, Topical Unit Outlines, and Unit Objectives must be attached to this form. (Page 1 of 4)
2 TITLE: Engine Mechanical Service PREFIX/NO: AUTT 1710 COURSE OBJECTIVES: Upon completion of this course, the student will be able to: 1. Safety course completion for Mechanical and Pollution prevention. 2. Explain Various Engine Classifications and identify internal combustion engine parts by name. 3. Measure various engine parts using measuring instruments common to the automotive trade, both U.S. and Metric 4. Diagnose engine problems and determine proper repair procedures. 5. Disassemble, clean and inspect cylinder heads for wear and damage. 6. Analyze the operation of camshafts and their related parts and inspect for damage or wear. 7. Explain the fundaments of supercharging, it s application in the automotive industry, and identify the different types used. 8. Explain lubrication systems theory and analyze wear and damage to systems parts. 9. Successfully complete NATEF compliant worksheets related to Engine repair TOPICAL UNIT OUTLINE/UNIT OBJECTIVES: 1. Sp/2 Safety course completion for Mechanical and Pollution prevention A. Sp/2 training document number 2. Explain Various Engine Classifications and identify internal combustion engine parts by name. A. Identify basic engine design. B. List various engine cylinder arrangements. C. Differentiate between rotary and reciprocating motions. D. Define meaning of bore and stroke. E. Calculate engine displacement. F. Identify the various valve arrangement designs. G. Differentiate between cylinder block, short block and long block. H. Relate to the various firing orders. I. Recognized the different combustion chamber designs. J. Explain function of crankshaft, flywheel and harmonic balancer. K. Describe two types of cooling systems. 3. Measure various engine parts using measuring instruments common to the automotive trade, both U.S. and Metric A. Measure parts using the metric and English system of measurement. B. Convert measurements from English to metric and metric to English. C. Use the common steel ruler to make approximate measurements. D. Practice use of thickness gauges (feeler gauges). (Page 2 of 4)
3 TOPICAL UNIT OUTLINE/UNIT OBJECTIVES: (Cont d) D. Measure and read a vernier caliper. E. Measure and read micrometers to the nearest 1/10,000 of an inch. F. Outside micrometers G. Inside micrometers H. Depth micrometers I. Measure and read to 1/10,000 of an inch micrometer (micrometer Vernier scale). J. Use telescoping and split ball type measuring tool. K. Set up and read a dial indicator. L. Set up, measure and read a precision dial bore gauge. 4. Diagnose engine problems and determine proper repair procedures A. List possible causes of oil consumption. B. Identify reasons for rough running engine or loss of engine power. C. Locate and identify engine noises. D. Identify engine oil pressure problems. E. Recognize and locate cooling system problems. 5. Disassemble, clean and inspect cylinder heads for wear and damage. A. Correctly disassemble upper components of an engine and remove cylinder head(s). B. Identify type of material head is made of. C. Clean heads before disassembly. D. Disassemble cylinder head(s) and keep parts in the order in which they were removed. E. Clean and inspect all parts. F. Check cylinder head(s) for cracks or warpage. G. Check and measure valve guides. H. Inspect valve seats for damage or wear I. Measure valve stems for wear. J. Measure valve guides for wear K. Distinguish the various parts of a valve. L..Measure seat width and compare its position on the valve face. 6. Analyze the operation of camshafts and their related parts and inspect for damage or wear. A. Identify the various parts associated with camshaft. B. Name the parts of a cam lobe. C. Explain the term cam thrust and what causes it. D. Explain the meaning of valve lash. E. Adjust the valve lash on various types of engines. F. List the types of valve lifters. G. Explain operation of a hydraulic valve lifter. H. Explain hydraulic lifter leak down. I. Explain hydraulic lifter pump-up. J. Disassemble and clean a hydraulic lifter. K. Check valve timing on an engine. L. Calculate valve overlap on a camshaft. M. Measure valve lift. N. Locate true top-dead-center on an engine. (Page 3 of 4)
4 O. Explain rocker arm ratio. P. Identify various parts of a cam drive system. Q. Remove and correctly install the different types of cam drives. R. Time the camshaft to the crankshaft. S. Explain the different design features of intake manifolds T. Multiple Runner manifolds U. Identify different types of exhaust manifolds. 7. Explain the fundaments of supercharging, it s application in the automotive industry, and identify the different types used. A. Explain the fundamentals of supercharging B. Explain the basic principle of supercharging an air intake system. C. Define density. D. Explain the variable of pressure and temperature. E. Explain intercooling. F. Explain how detonation is controlled. G. Describe how the various superchargers are driven. H. Identify the different types of superchargers used in the automotive field. I. Positive displacement superchargers. J. Dynamic superchargers. K. Explain reason for and operation of a waste gate. 8. Explain lubrication systems theory and analyze wear and damage to systems parts. A. Identify ways oil is routed throughout engine. B. Recognize difference between flow and pressure. C. Identify oil service ratings. D. Explain why oil deteriorates. E. Name various additives used in oil. F. Identify the various types of oil pumps. G. Check systems parts for wear. H. Identify the different types of oil filters. I. Explain reasons for crankcase ventilation systems. J. Cooling Systems K. Explain cooling systems theory L. Select and perform repairs to the cooling system 9. Successfully complete NATEF compliant worksheets related to Engine Repair Complete work order to include customer information, vehicle identifying information, customer concern, related service history, cause, and correction Research applicable vehicle and service information, such as internal engine operation, vehicle service history, service precautions, and technical service bulletins Verify operation of the instrument panel engine warning indicators. Inspect engine assembly for fuel, oil, coolant, and other leaks; determine necessary action. Install engine covers using gaskets, seals, and sealers as required. Remove and replace timing belt; verify correct camshaft timing. Inspect, remove and replace engine mounts. Identify hybrid vehicle internal combustion engine service precautions. (Page 4 of 4)
5 Metropolitan Community College Remove cylinder head; inspect gasket condition; install cylinder head and gasket; tighten according to manufacturer s specifications and procedures. Clean and visually inspect a cylinder head for cracks; check gasket surface areas for warpage and surface finish; check passage condition. Inspect pushrods, rocker arms, rocker arm pivots and shafts for wear, bending, cracks, looseness, and blocked oil passages (orifices); determine necessary action. Adjust valves (mechanical or hydraulic lifters). Inspect and replace camshaft and drive belt/chain; includes checking drive gear wear and backlash, end play, sprocket and chain wear, overhead cam drive sprocket(s), drive belt(s), belt tension, tensioners, camshaft reluctor ring/tone-wheel, and valve timing components; verify correct camshaft timing. Establish camshaft position sensor indexing. Remove, inspect, or replace crankshaft vibration damper (harmonic balancer). Perform cooling system pressure and dye tests to identify leaks; check coolant condition and level; inspect and test radiator, pressure cap, coolant recovery tank, and heater core; determine necessary action. Identify causes of engine overheating. Inspect, replace, and adjust drive belts, tensioners, and pulleys; check pulley and belt alignment. Inspect, remove, and replace water pump. Remove and replace radiator. Remove, inspect, and replace thermostat and gasket/seal. Inspect and test fan(s) (electrical or mechanical), fan clutch, fan shroud, and air dams. Perform oil pressure tests; determine necessary action. Inspect auxiliary coolers; determine necessary action. Inspect, test, and replace oil temperature and pressure switches and sensors. COURSE REQUIREMENTS/EVALUATION: COURSE OBJECTIVES/ASSESSMENT MEASURES COURSE OBJECTIVES 1. Safety course completion for Mechanical and Pollution prevention 2. Explain Various Engine Classifications and identify internal combustion engine parts by name. 3. Measure various engine parts using measuring instruments common to the automotive trade, both U.S. and Metric ASSESSMENT MEASURES 1. Sp/2 completion on record. 2. Written/LMS exam and hands on evaluation. 3. Written/LMS exam and hands on evaluation. 4. Diagnose engine problems and determine proper 4. Written/LMS exam and hands on evaluation. (Page 5 of 4)
6 repair procedures. Metropolitan Community College 5. Disassemble, clean and inspect cylinder heads for wear and damage. 6. Analyze the operation of camshafts and their related parts and inspect for damage or wear. 7. Explain the fundaments of supercharging, it s application in the automotive industry, and identify the different types used. 8. Explain lubrication systems theory and analyze wear and damage to systems parts. 9. Successfully complete NATEF compliant worksheets related to Engine Repair 5. Written/LMS exam and hands on evaluation. 6. Written/LMS exam and hands on evaluation. 7. Written/LMS exam and hands on evaluation. 8. Written/LMS exam and hands on evaluation. 9. Written/LMS exam and hands on evaluation. (Page 6 of 4)
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