JEFFERSON COLLEGE COURSE SYLLABUS

JEFFERSON COLLEGE COURSE SYLLABUS AUT101 POWER PLANTS 9 Credit Hours Prepared by Richard Slinkard Revision Date: April 2004 by Gerard Uhls CAREER & TECHNICAL EDUCATION Alan C. Foster, Associate Dean

AUT101 Power Plants I. CATALOG DESCRIPTION Prerequisite: Demonstrate proficiency on the ASSET 9 semester hours credit Power Plants is the study of design and construction of automotive engines. The emphasis is on design and fundamentals of general engine diagnosis and repair. Mastery of the fundamentals is necessary for passing the National Institute for Automotive Service Excellence (ASE) engine repair test. (F) II. GENERAL COURSE OBJECTIVES Upon completion of this course the student will: A. Diagnose engine problems related to wear and parts failure. B. Determine engine condition using various methods and testing equipment. C. Repair and/or repair defective parts. D. Identify engine components and their relationship to the engine. E. Recognize safety hazards and cautions in the automotive shop. F. Identify and recognize the use of common hand tools and equipment. III. COURSE OUTLINE (lecture) A. Engine Operation and Construction 1. 4-stroke cycle 2. Major components 3. Engine configuration 4. Engine displacement and compression ratio 5. Ignition system B. Engine Physics and Chemistry 1. Principles of chemistry and physics (applied in an internal combustion engine). 2. Air pollution 3. Alternative engines a. Past engines b. Future engines 4. Engine torque and horsepower 5. Air flow requirements

C. Engine Materials and Manufacture 1. Science and properties of metals 2. Alloy metals 3. Metal treating processes 4. Man-made materials 5. Machining operations a. Internal b. External D. Cooling and Exhaust Systems 1. Effects of heat on engine components 2. Controlling temperatures 3. Relationship to performance, economy, and emission control and wear E. Intake and Exhaust Systems 1. Venturi principle and carburetor operation 2. Throttle body and port fuel 3. Air-fuel mixture control 4. Manifold design 5. Exhaust systems F. Engine Lubrication and Ventilation 1. Purpose of motor oil 2. Motor oil composition and additives 3. Motor oil designations a. API service classification b. SAE viscosity grades 4. Energy conserving oils 5. Synthetic motor oils 6. Engine oiling systems and pressure requirements - reservoir and ventilation a. Road draft tube b. PCV system 7. Oil pump and pickup a. Gear type pump b. Rotor type pump 8. Pressure relief valve 9. Filter 10. Galleries and lines 11. Indicators a. Dipstick b. Oil pressure lamp c. Oil pressure gauge

12. Lubrication effects on performance, economy, and emission control a. Performance b. Economy c. Emission control G. Engine Construction 1. Materials of construction 2. Cylinder block design 3. Cylinder head design 4. Miscellaneous engine covers H. Valves, Springs, Guides, and Seats 1. Poppet valves a. Intake b. Exhaust 2. Valve guides a. Integral b. Insert 3. Seats a. Hardening b. Angles I. Camshafts, Lifters, Pushrods, and Rocker Arms 1. Camshafts, and locations a. Lift b. Duration c. Overlap d. Timing 2. Lifters (followers) a. Solid b. Hydraulic c. Mushroom 3. Pushrods 4. Rocker arms - rocker arm ratios J. Crankshafts, Flywheels, Vibration Dampers, Pistons, and Rods 1. Crankshafts a. Main bearings b. Crankshaft offset c. Counterweights d. Crankshaft throws and firing impulses e. Firing order f. Materials g. Lubrication 2. Flywheels and flexplates

3. Vibration dampers a. Harmonic balancer b. Tortional vibration 4. Connecting rods a. Babbit b. Insert bearing c. Full floating pins d. Press fit pins e. Effect of rod length f. Materials and construction - shot-peening 5. Pistons a. Construction and material b. Piston finish c. Piston expansion d. Piston speed e. Piston offset (1) Major thrust (2) Minor thrust f. Piston crown shape g. Clearance 6. Piston rings - construction, purpose K. Engine Bearings 1. Friction and bearings 2. Types 3. Main, rod, and cam bearings 4. Operation and materials L. Gaskets, Sealants, Fasteners, and Engine Mounts 1. Gaskets and seals 2. Adhesives, sealants, lubricants, and cleaners 3. Fasteners 4. Engine mounts M. Tools and Precision Measuring Instruments and Test Equipment 1. Hand tools 2. Precision measuring instruments 3. Power tools 4. Engine condition diagnosis 5. Power balance test 6. Compression test a. Compression specs b. Dry compression test c. Wet compression test d. Running compression test 7. Cylinder leakage test 8. Vacuum gauge 9. Stethoscope 10. Tachometer and Dwellmeter - fan strobe tach 11. Bearing leakage tester and engine prelubrication

12. Oil pressure gauge 13. Engine temperature gauges a. Top tank thermometer b. Sensing patches and crayons N. Cleaning and Inspecting Equipment 1. Cleaning equipment a. Chemical dip tanks b. Hot tanks and sprays c. Blasting chambers d. Steam and high pressure water cleaners 2. Inspecting equipment a. Magnetic particle b. Nonmagnetic inspection equipment c. Pressure test equipment O. Head and Valve Service Equipment 1. Valve seat grinders 2. Valve seat cutters 3. Valve guide renewing a. Knurling b. Guide inserts 4. Rocker stud pullers 5. Head surfacing machines a. Mills b. Grinders c. Planers 6. Spring tension tester P. Block, Crankshaft, Piston, and Rod Service Equipment 1. Block service equipment a. Boring bars b. Hones c. Glaze breakers d. Line boring equipment e. Torque plates f. Surface mills and grinders. 2. Crankshaft service equipment a. V-blocks and dial indicators b. Crankshaft grinders c. Hand grinders d. Balancing machines e. Crank polisher

3. Piston and rod service equipment a. Rod honing machine b. Arbor press c. Rod cap grinder d. Hydraulic press e. Rod heater for pin assembly f. Balancing scales g. Rod aligner h. Piston knurler 4. Flywheel service equipment IV. COURSE OUTLINE (LABORATORY) A. Engine Testing and Diagnosis 1. Oil leaks 2. PCV testing 3. Internal oil leaks 4. Coolant leaks 5. General engine condition 6. Oil consumption 7. Vacuum tests 8. Compression tests 9. Cylinder leakage test 10. Test results 11. Valve train noises B. Engine Repair in the Vehicle 1. Front timing cover removal 2. Timing chain and belt service 3. Timing cover installation 4. Valve cover removal and replacement 5. Upper valve train repair 6. Cylinder head replacement 7. Oil pan removal and replacement C. Engine Removal 1. Top side removal 2. Removal under the vehicle 3. Lifting the engine D. Engine Disassembly and Cleaning 1. Engine disassembly 2. Cleaning and Preliminary inspection E. Measuring and Inspection 1. Crankshaft measuring and inspection 2. Measuring main bearing bores 3. Determining Bearing oil clearance 4. Measuring connecting rod bores

5. Measuring piston bores 6. Measuring cylinders F. Repairing Cracks and Threads 1. Repairing damaged threads 2. Replacing threads 3. Removing broken fasteners 4. Crack detection and repair G. Servicing Cylinder Heads and Manifolds 1. Head reconditioning 2. Head disassembly, inspection, and cleaning 3. Valve guide repair 4. Valve seats 5. Valve lapping 6. Valve testing and assembly 7. Head resurfacing 8. Checking heads for out-of-flat H. Servicing Camshafts, Lifters, Pushrods, and Rocker Arms 1. Camshafts and lifters 2. Replacement procedures 3. Pushrods and rocker arms I. Servicing Blocks 1. Cylinder deglazing 2. Cylinder boring 3. Cylinder sleeving 4. Cylinder honing 5. Block resurfacing J. Servicing Crankshafts, Flywheels, Pistons, and Rods 1. Crankshaft service 2. Preparing and inspecting crankshafts for grinding 3. Flywheel service 4. Rod service K. Engine Balancing 1. Out of balance conditions 2. Balancing reciprocating weight 3. Balancing rotating weight L. Lubrication System Service 1. Rotor pump 2. Gear-type pumps

M. Engine Assembly 1. Assembly preparation 2. Installing core plugs 3. Installing main bearings, crankshaft, and the rear main bearing seal 4. Installing the camshaft 5. Installing pistons, rings, and rods 6. Oil pump installation 7. Lifter installation 8. Timing cover installation 9. Cylinder head installation 10. Intake manifold installation 11. Overhead cam engines 12. General practices N. Engine Installation, Preoiling and Break-In 1. Installing accessories and external engine parts 2. Engine preoiling 3. Attaching the transmission to the engine 4. Engine mounts and exhaust manifold installation 5. Engine installation 6. Static timing the engine 7. Cycling the engine V. UNIT OBJECTIVES (Lectures) A. Engine Operation and Construction 1. Explain the 4-stroke cycle 2. List the major components of a reciprocating engine 3. Describe the three ways in which cylinders are arranged 4. Describe the three ways in which valves are positioned in relation to the cylinder 5. Explain the operation of a typical engine valve mechanism 6. Define the terms "displacement" and "compression ratio" 7. List the parts of the fuel delivery system 8. Compute the ignition interval of multi-cylinder, 4-stroke engine 9. Describe the various way cylinders are numbered 10. Explain the relationship between cylinder numbering and firing order 11. Define the terms "top dead center", "bottom dead center", advanced spark", "retarded spark", "basic or initial timing", and "timing marks" 12. Explain the need for ignition spark advance B. Engine Physics and Chemistry-Alternative Engines 1. Define the terms: "energy", "force", "work", "torque", "power", "inertia", and "momentum", and explain their use in reference to the automotive engine. 2. List the advantages of gasoline as a fuel and explain the relationship between detonation and octane rating 3. Explain the terms: "torque" and "horsepower", and their U.S. and metric

system of measurement 4. Define and explain the term "vacuum" 5. Explain the principle of pressure differential 6. Explain the venturi principle and its use in carburetors 7. List the factors that determine an engine's airflow requirement 8. Define the term "volumetric efficiency" 9. Define and explain the terms "air-fuel ratio" and the concept of a stoichiometric ratio 10. Describe the factors and forces which affect an engine's air-fuel ratio requirement 11. List the three types of pollutants emitted by automobiles and describe the control system(s) used to limit each type 12. List the three sources of automotive HC emissions 13. Describe the formation of CO in the combustion chamber 14. Describe the formation of NO x in the combustion chamber 15. Describe the effect of basic engine design of the three major pollutants C. Basic Metallurgy and Machine Processes 1. Name the three main metals used in engine construction and describe the advantages and disadvantages of each. 2. List the four main factors that affect the selection of bearing alloys and explain their importance. 3. Explain the piston and cylinder wall construction of an aluminum-silicon alloy engine and how it differs from a conventional cast iron engine. 4. Define the term "composite" and give examples of some composite materials, their specific applications, and the incentive for their use. 5. List the four major processes used in manufacturing engine components (casting, forging, stamping, machining from billet steel), give examples of the type of parts usually produced by each, and list the strengths and weaknesses of each process. 6. Describe and explain the heat-treating process used to alter the hardness of steel (hardening, tempering, annealing). 7. Explain electroplating and anodizing and list the reasons for their use. 8. Explain the function of a surface analyzer and its bearing on engine construction. 9. List and explain the internal machining processes of boring, honing, drilling, reaming, and broaching and their common applications in engine construction and rebuilding. 10. List and explain the external machining processes of milling, grinding, polishing, and lapping and their common application in engine construction and rebuilding. D. Cooling and Exhaust Systems 1. Describe the two patterns of coolant circulation. 2. Explain the need for cooling system pressurization. 3. List the properties of modern antifreeze mixtures. 4. Explain the need for a thermostat-controlled bypass. 5. Describe radiator construction. 6. Explain how a water pump causes coolant circulation. 7. Explain the job done by the radiator fan.

8. List and describe the three methods used to avoid wasting fan-drive energy. 9. Describe the operation of a wax-actuated thermostat. 10. Explain the need for both a pressure valve and a vacuum valve in the radiator cap. 11. Describe the operation of a coolant recovery system. 12. List the effects of too-hot operation of an engine. 13. List the effects of too-cold operation of an engine. 14. Identify the three basic exhaust system designs. 15. Explain how mufflers and resonators quiet exhaust flow. 16. List the two types of catalytic converters and where they may be located in the exhaust system. 17. Define the term "exhaust back-pressure" and describe its effect on an engine. E. Engine Construction and Operation 1. Describe the basic layout of a cylinder block and the relationships of its major parts and openings. 2. Explain the flow pattern of coolant through a V-8 engine. 3. List the three types of sleeves and explain their construction, application, and installation. 4. Discuss main bearing location and number in relation to engine durability and strength. 5. Explain the relative accuracy of the different means of locating boring and surfacing machines in relation to the block. 6. List the factors which influence the size and weight of the cylinder block. 7. Describe the two main combustion chamber shapes and the advantages and disadvantages of each. 8. Define the terms "quench" and "squish" and explain their effect on the combustion process. 9. Explain the construction and advantages of a crossflow head. 10. Explain the affect of valve location in the combustion chamber on breathing efficiency. 11. Explain the advantages and disadvantages of smaller versus larger port sizes. 12. Describe design and assembly elements which affect the mating of the head to the block. 13. Explain how resurfacing cylinder heads can affect rocker arm geometry, camshaft timing, and intake manifold fit and alignment. 14. Explain the need for intake manifold preheating and describe the two common methods of achieving it. 15. Define the term "siamesed ports". 16. Explain the relative advantages and disadvantages of single plane versus 2- plane intake manifolds. 17. Define the term "scavenging". 18. Discuss the cost and clearance factors which affect exhaust manifold design. 19. Explain the operation of the manifold heat control valve and its effect on engine efficiency. 20. Describe the major engine covers and list any jobs they may perform in addition to keeping the oil in and the dirt out.

F. Valves, Springs, Guides, and Seats 1. Explain the relative advantages and disadvantages of two valves per cylinder versus four valves per cylinder. 2. Define the term "interference angle" and "included angle" and explain their relation to the valve-grinding process. 3. Name the two main paths of heat removal from the valves. 4. Describe the construction of a sodium-cooled valve and explain how it aids in the valve-coding process. 5. List the three main configurations of valve trains and explain the advantages and disadvantages of each. 6. Explain the operation of a hydraulic valve lifter. 7. Describe the lubrication of valve stems and guides. 8. Describe the construction of intake and exhaust valves, the materials used for each, and any additional treatments that may be used to extend their working lives. 9. Define the term "stellite" and "stress riser". 10. Define the terms "valve float and "lifter pump-up" and explain how they are related. 11. List the main types or combinations of valve springs in common use and the methods used to control harmonic vibrations in them. 12. Define the term "coil bind". 13. Explain the basic method of mounting valve springs and the importance of checking spring height. 14. List the two types of valve rotators and describe their operation. 15. List the two types of valve guides, their common applications, and the means by which they may be repaired. 16. List the negative effects of excess oil traveling through the valve guides and explain the various types of seals used to prevent it. 17. Describe the two types of valve seats and explain the factors affecting their durability. 18. Define the term "induction hardening". 19. Explain the relationship of the valve seat to the port, and its effect on gas flow into and out of the engine. 20. Give examples of how one problem in the valve train may be indicative of other worn or broken components. G. Camshafts, Lifters or Followers, Pushrods, and Rocker Arms 1. List the possible locations for the camshaft and give advantages and disadvantage of each. 2. Describe the three forms of camshaft drives and give advantages and disadvantages of each. 3. Explain the difference in the use of tensioners on timing chains versus belts. 4. List common engine accessories driven off the camshaft, and the type of drive used for each. 5. Describe the different materials and manufacturing processes used in making camshafts, and give advantages and disadvantages of each. 6. List the various processes used to prevent camshaft scuffing during initial break-in and reduce long-term wear. 7. Define the terms "valve timing", "duration", and "overlap". 8. Explain why camshaft duration specifications are not always comparable

between manufacturers. 9. Define the terms "valve lift", "lobe lift", and "rocker arm ratio", and describe the relationship between them. 10. State, in general terms, the optimum opening and closing points for the intake and exhaust valves. 11. Describe the effect of engine design speed and emission control requirements on valve timing. 12. Define the term "cam thrust" and list some of the methods used to control it. 13. Describe the lubrication of each part in the valve train and the overall lubrication of the entire valve system. 14. List the major types of valve lifters, tappets, and cam followers, their common applications, their means of adjustment, and the advantages and disadvantages of each. 15. Explain, in detail, the operation of a hydraulic lifter. 16. Describe basic lifter construction and how they are made to rotate for even wear. 17. Explain the use of pushrods and their relation to valve adjustment. 18. Describe the two main methods of rocker arm mounting and give the advantages and disadvantages of each. 19. Explain the concept of engine balancing shafts and describe their basic operation. H. Crankshafts, Flywheels, Vibration Dampers, Pistons, and Rods 1. Define the term "insert-type bearing", list their two primary uses in an engine, and describe the means used to retain them in their bores. 2. Explain the concept of crankshaft or cylinder offset and why it is used in engine construction. 3. Explain the relationship between number of cylinders, crankshaft throw spacing, angle between the cylinder banks on V-type engines, and the intervals of the engine's firing impulses. 4. Describe how cylinder numbering and crankshaft throw arrangement produce firing orders. 5. List common crankshaft materials and methods of construction, and give advantages and disadvantages of each. 6. Name the three processes used to harden crank bearing journals and give advantages and disadvantages of each. 7. List the similarities and differences between the jobs performed by flywheels and flexplates. 8. Explain the need for vibration dampers, describe their construction, and list the types of engines that commonly use them. 9. Describe the materials and methods used in connecting rod construction. 10. Explain the effect of rod length on piston movement. 11. List the two types of pin fit at the small end of the rod. 12. Name the various parts of the piston. 13. Describe the types of piston finishes used to help prevent scuffing. 14. Describe the various methods used to control piston expansion. 15. Define the term "piston speed" and its relationship to maximum piston velocity. 16. Define the term "major thrust face" as it applies to pistons. 17. Explain the use of piston pin offset to control piston slap. 18. List the normal range of piston to cylinder clearance and explain how proper clearance is obtained at the factory and when rebuilding an engine. 19. Describe the various means used to prevent the piston pins from coming into contact with the cylinder walls. 20. Explain the need for piston rings and name the two types. 21. Describe the operation of compression rings and list the advantages and

disadvantages of the types available. 22. Describe the construction and operation of oil control rings. 23. Define the term "ring flutter". 24. Explain he difference between factory and precision balancing, and describe the method used to balance the individual parts of the reciprocating assembly. 25. Explain the lubrication of every component within the cylinder block. I. Engine Bearings 1. Explain the difference in the operating principle of friction and antifriction bearings, list the advantages and disadvantages of each, and give examples of their common applications. 2. Define the term 'crankshaft endplay" and explain how it is controlled. 3. List and define the four main properties required of friction bearings. 4. Summarize the uses and advantages of tin base babbit, lead base babbit, copper alloys, aluminum alloys, and multilayer bearings. 5. Determine the optimum number of main bearings for any engine configuration, taking into account the common layout of the rod journals for the engine. 6. Define the term "web" and "bearing saddle" as they apply to main bearing support. 7. Describe the various means used to locate the bearing halves in their bores and prevent them from moving. 8. Describe the path of lubricating oil from the oil galley to the rod bearing. 9. Define the terms "bearing spread" and "bearing crush". 10. Explain the relationship between journal size, bearing material, and oil clearance. 11. Describe how an oil film prevents contact between the shaft and the bearing except under certain circumstances, and list those circumstances. 12. Explain the relationship between oil pressure, oil clearance, oil consumption, and bearing life. 13. Define the term "oversize bearing" and "undersize bearing", and explain their applications in engine rebuilding. 14. List the reasons that camshaft bearings should always be replaced when overhauling an engine. J. Engine Lubrication and Ventilation 1. Describe the jobs done by engine oil. 2. List the purposes of common oil additives. 3. Explain the API rating systems used for gasoline and for diesel engines. 4. Describe how an oil is tested by API. 5. Explain the SAE viscosity rating system. 6. Define the terms "single-grade oil" and "multi-grade" oil. 7. Describe the differences between conventional and synthetic motor oils. 8. Explain the need for crankcase ventilation. 9. Describe the lubrication system's effect on performance, economy, and exhaust emissions.

K. Gaskets, Fasteners, Seals, and Sealants 1. List the two major types of gaskets, describe the materials and construction of each, and give examples of their common applications. 2. Explain three common problems that may result in a gasket leaking once it is installed. 3. Define the purpose of a seal, list the three common neoprene seals describing their construction and applications, and give examples of other types of seals used in automotive engines. 4. Explain the difference between gaskets cements and sealants. 5. Explain the difference between aerobic and anaerobic sealants, and give examples of the applications of each. 6. List a wide variety of nuts and washers designed to prevent loosening. 7. Define the terms "bolt", "capscrew", and "machine screw". 8. Describe the methods of measuring diameter, thread pitch, and length for any U.S. or metric bolt. 9. Describe the American Standard Pipe thread system. 10. Explain the relationship between wrench length, bolt head size, and torque. 11. Determine the strength of a fastener using a U.S. customary nut or bolt grade table and explain the importance of fastener strength in engine assembly. 12. List the two reasons for using engine mounts. 13. Describe the function of an engine shock absorber. L. Tools and Precision Measuring Instruments 1. Describe the types of wrenches available and describe the uses of each. 2. Explain why a slot-type screwdriver should be carefully matched to the size of the screw slot. 3. List a number of recessed-head screw designs and explain why each requires a special screwdriver. 4. List a wide variety of uses for pliers. 5. List the common hammers used in auto repair and describe the construction and uses of each. 6. List the variety of sockets, handles, extensions, and adaptors used with socket wrenches and explain how each contributes to the overall versatility of the socket wrench system. 7. Explain the need for torque wrenches, list the three types available, and describe how various extensions affect the actual torque applied to a fastener. 8. List the three main tools used for servicing piston rings and grooves, and explain the need for each. 9. Explain the necessity of using a special puller to remove harmonic dampers. 10. Describe the rules used to prevent a misleading appearance of accuracy when converting between U.S. and metric measurement. 11. Identify the parts of a micrometer and explain the procedure for reading a measurement to four decimal places (three decimal places in the case of a metric micrometer). 12. Describe the two types of cylinder bore gauges and give the advantages and disadvantages of each. 13. Describe, and explain the use of, snap gauges, feeler gauges, dial indicators, straightedges, and valve guide bore gauges. 14. Explain the advantages and disadvantages of vernier calipers compared to micrometers.

15. Describe the respective uses of drill motors and drill pressers. 16. List the two types of impact wrenches and explain the need for using special sockets with these wrenches. 17. Explain the respective uses of bench grinders and rotary grinders. 18. List the important points of air compressor maintenance. M. Engine Test Equipment 1. Describe the two methods of expressing compression specifications. 2. List the components evaluated by a compression test. 3. Describe the procedures for conducting both wet and dry compression tests, and explain how the results of each are interpreted. 4. Describe the uses of a vacuum gauge and list the factors which affect manifold vacuum. 5. Describe the use of a stethoscope in automotive engine work. 6. Describe the use of a fan strobe tachometer, engine prelubricator, and oil pressure gauge in engine diagnosis. 7. List the various factors which affect CO and HC emissions. 8. Describe the procedure for testing thermostat opening temperature. N. Cleaning and Inspection Equipment 1. Describe the construction of a parts washer tank, chemical cleaning dip tank, hot tank, and spray tank; explain how each provides its cleaning action; and list the types of metal that can, and cannot, be cleaned in each. 2. Describe the construction of a blasting chamber, explain its primary use, and list at least three materials that are used as abrasives. 3. Describe the construction of a steam cleaner, high-pressure water cleaner, and engine cleaner gun; and give examples of where they may or may not be used. 4. Explain the use of an air gun and list some of the safety precautions that should be followed in its use. 5. Describe the crack detection methods and procedures used on parts that cannot be magnetized. O. Head and Valve Service Equipment 1. Describe the three methods of reconditioning valve seats and list the advantages and disadvantages. 2. Describe the operation of a valve grinding machine and list any additional operations that may be performed on one. 3. List the methods used to recondition and repair worn valve guides and explain the repair procedure used for each. 4. Explain the use of reamers and hones in valve guide reconditioning. 5. Describe the process of installing or replacing hard seat inserts in a cylinder head. 6. Explain "swaging" and "staking" operations and their application in cylinder head reconditioning. 7. Describe the removal of both broken and worn rocker arm studs. 8. Explain the operation of head resurfacing machines. 9. Describe valve spring testers and their use. 10. Describe how to measure a cylinder head for out-of-flat.

P. Block, Crankshaft, Piston and Rod Service Equipment 1. List the various types of hones that are available and explain the uses of each. 2. Explain the need for line boring and list the negative effects it can have if performed improperly. 3. Explain the need rom, and uses of, torque plates. 4. Describe the procedure for checking a crankshaft using V-blocks and a dial indicator. 5. Describe the two methods of straightening crankshafts. 6. Describe a crankshaft grinder and explain how the crank is mounted for grinding rod and main journals. 7. Explain the basic procedure for balancing a crankshaft. 8. Explain the effect and purpose of crankshaft polishing. 9. Explain the use of piston knurlers and rod aligners. VI. UNIT OBJECTIVES (Laboratory) A. Engine Testing and Diagnosis 1. Locate the source and cause of engine oil leaks. 2. Test a PCV system for proper operation. 3. Recognize the symptoms that may indicate an internal oil leak. 4. Pressure test cooling systems and radiator caps. 5. Describe and perform a number of tests used to diagnose suspected internal coolant leaks. 6. Explain the difference between overhauling and rebuilding an engine. 7. List the factors that should be taken into account when trying to determine an engine's oil consumption. 8. Perform vacuum leak, valve action, and piston ring tests using a vacuum gauge. 9. Perform wet and dry compression tests, a cylinder leakage test, and interpret their results to identify specific combustion chamber sealing problems. 10. Locate and identify engine and valve train noises. B. Engine Repair in the Vehicle 1. Remove and replace the front timing cover on belt, gear, and chain-drive push-rod and OHC engines. 2. Replace timing belts, gears, and chains. 3. Remove and replace engine valve covers. 4. Explain the importance of determining total engine condition before beginning any upper valve train repairs. 5. Describe and perform the three basic valve adjustment procedures. 6. Adjust valves with the engine running.

7. Explain and demonstrate the procedure for determining when a cylinder is at top dead center on the compression stroke. 8. Remove and correctly replace rocker arms, shafts, and pushrods. 9. Replace valve springs and stem seals with the heads on the engine. 10. Remove and replace a cylinder head. 11. Remove and replace an oil pan. 12. Remove and replace crankshaft main bearings. C. Engine Removal Upon completion of this course the student should be able to remove the engine from a car. D. Engine Disassembly and Cleaning Upon completion of this course the student should be able to disassemble an engine. E. Measuring and Inspection 1. Check a crankshaft for straightness. 2. Visually inspect crankshaft journals and check them for size, taper, and out-ofroundness using an outside micrometer. 3. Check main bearing bores for elongation and out-of-roundness using either an inside micrometer or dial bore gauge. 4. Determine bearing oil clearance by measurement and computation. 5. Measure rod bores for size, roundness, and bell mouthing using a telescoping gauge, inside micrometer, or rod gauge. 6. Check piston pin bores with a rod gauge and explain why telescoping gauges cannot be used for this operation. 7. Measure cylinder bores for size, taper, and out-of-roundness using an inside micrometer, dial indicator, or dial bore gauge. 8. Explain where the maximum cylinder wear is normally located and why. F. Repairing Cracks and Threads 1. Clean and repair internal and external threads. 2. Remove broken fasteners. 3. Check engine components for cracks using the three basic inspection methods. 4. List crack repair methods and where they might be used. G. Servicing Cylinder Heads and Manifolds 1. Disassemble and clean a cylinder head and inspect its component parts for wear and damage. 2. List a number of methods used to repair valve guides and explain the procedure used for each. 3. List a number of methods for correcting valve spring height. 4. Remove and replace insert-type valve guides in a cylinder head. 5. Explain the concept of interference fit, and demonstrate how it is determined for

valve guides and seats. 6. Reface valves on a valve grinding machine. 7. Replace and install valve seat inserts 8. Grind and cut new valve seats using appropriate tools. 9. Demonstrate how a valve seat is narrowed and how its position on the valve face is adjusted. 10. Explain the past and present uses of valve lapping. 11. Assemble a cylinder head and check it for proper valve sealing. 12. Explain the relationship between head resurfacing and intake manifold fit, and describe how to compensate for mismatches between the two. H. Servicing Camshafts, Lifters, Pushrods, and Rocker Arms 1. Determine the condition of camshafts and lifters by visual inspection. 2. Recognize both normal and abnormal cam wear patterns and explain the causes of each. 3. Leak test hydraulic valve lifters. 4. Discuss the difference and similarities between new and reground camshafts. 5. Measure cam bearing clearance in an engine. 6. Install a camshaft taking proper precautions to prevent scuffing during initial break in. 7. Explain the procedure for resurfacing a warped OHC cylinder head. 8. Check pushrods for straightness and wear. 9. Recondition rocker arms. 10. Install and adjust rocker arms for proper lifter operation. I. Servicing Blocks 1. Deglaze cylinders and explain why only cast iron rings should be used after deglazing. 2. Bore the cylinders of an engine using a portable boring bar. 3. Hone a cylinder using a power honing machine. 4. Align hone the main bearing bores of an engine. 5. Resurface a cylinder block. J. Servicing Crankshafts, Flywheels, Pistons and Rods 1. Inspect and prepare a crankshaft for grinding. 2. Explain the basic operational sequence of grinding a crankshaft. 3. Resurface flywheels. 4. Fit stationary and full-floating piston pins. 5. Install pistons on connecting rods. 6. Align connecting rods. 7. Measure pistons to determine diameter and ring groove wear.

K. Engine Balancing 1. Explain he difference between static and dynamic balance and identify which type is required for each engine part. 2. Explain why engine components should be balanced when rebuilding an engine. 3. Balance connecting rods and pistons and explain where the weight is removed from each. L. Lubrication System Service 1. Determine the condition of an oil pump drive system by visual inspection. 2. Disassemble and reassemble an oil pump. 3. Check both rotor-type and gear-type oil pumps for wear. M. Engine Assembly 1. List the steps that should be taken to prepare the cylinder block for engine assembly. 2. Install core plugs, oil galley plugs, and cam bearings. 3. Install crankshafts and camshafts. 4. Check piston ring end gaps and install the rings on the pistons. 5. Install piston and connecting rod assemblies in the cylinder block. 6. Install oil pumps and pans, valve lifters, and front timing covers. 7. Install cylinder heads and torque the bolts in the proper sequence. 8. Install intake manifolds on V-type engine manifolds taking proper precautions to ensure gasket sealing. 9. List general assembly practices that are applicable to all engine work. N. Engine Installation, Preoiling, and Break-In 1. Preoil an engine. 2. Attach a manual or automatic transmission to an engine. 3. Install an engine in a vehicle and reconnect its ancillary systems. 4. Static time an ignition system and properly start a rebuilt engine. 5. Describe the process of cycling an engine and explain the precautions that should be observed during the first few hundred miles of engine use. VII. METHOD(S) OF INSTRUCTION A. Lecture B. Demonstration C. Laboratory

VIII. REQUIRED TEXTBOOKS Automatic Engine Repair and Rebuilding, 2nd Edition, Chek-Chart Harper and Row Publishers, Classroom and Shop Manual IX. REQUIRED MATERIALS Safety Glasses X. SUPPLEMENTAL REFERENCES Automotive Engine Fundamentals, Reston Publishing Company, Inc. Automotive Engines, Prentice Hall Automotive Engines Diagnosis-Repair-Rebuilding, Delmar Publishers, Inc. Engine Repair Head Assembly and Valve Gear, McKnight Career Publications Automotive Engines, Theory and Servicing, by Ellinger Halderman, Prentice Hall Publishing XI. METHOD(S) OF EVALUATION A. Tests B. Quizzes C. Laboratory Performance D. Comprehensive Final Exam