This course will
introduce students to basic engine concepts, skills, technology and service of
the automobile.
Students will:
1623.1.1 Interpret and verify complaint; listen to
engine noises; inspect engine assembly for fuel, oil, coolant, and other leaks;
determine needed repairs.
1623.1.2 Diagnose the cause of excessive oil
consumption, unusual engine exhaust color, odor, and sound; determine needed
repairs.
1623.1.3 Perform engine vacuum tests; determine
needed repairs.
1623.1.4 Perform cylinder power balance tests;
cylinder compression tests; cylinder leakage tests; determine needed repairs.
1623.1.5 Remove engine (front-wheel drive); prepare
for disassembly; reinstall engine.
Students will:
1623.2.1 Remove cylinder head(s); inspect cylinder
head(s) for cracks; check gasket surface areas for warpage and leakage; check
passage condition.
1623.2.2 Install cylinder heads and gaskets; tighten
according to manufacturer’s specifications and procedures.
1623.2.3 Inspect and test valve springs for
squareness, pressure, and free height comparison; inspect valve spring
retainers, locks, and valve grooves; replace as needed. Replace valve stem seals.
1623.2.4 Inspect valve guides for wear; check valve
guide height and stem-to-guide clearance; inspect valves; inspect valve seats;
recondition or replace as needed.
1623.2.5 Check valve face-to-seat contact and valve
seat concentricity (run out), service seats and valves as needed.
1623.2.6 Check valve spring assembled height and
valve stem height; service valve and spring assemblies as needed.
1623.2.7 Inspect pushrods, rocker arms, rocker arm
pivots and shaft for wear, bending, cracks, looseness, and blocked oil passages
(orifices); repair or replace.
1623.2.8 Inspect hydraulic or mechanical lifters;
replace as needed. Adjust valves
(mechanical or hydraulic lifters).
1623.2.9 Inspect and replace camshaft drives
(including gear wear and backlash, sprocket and chain wear, overhead cam drive
sprockets, drive belts, belt tension, and tensioners).
1623.2.10 Inspect camshaft for run out, measure
journals and lobes for wear.
1623.2.11 Inspect and measure camshaft bearings for
wear, damage, out-of-round, and alignment; determine needed repairs.
1623.2.12 Verify camshaft(s) timing according to
manufacturer’s specifications and procedure.
Students will:
1623.3.1 Inspect and replace pans, covers, gaskets,
and seals.
1623.3.2 Inspect engine block for cracks, passage
condition, core and gallery plug condition, and surface warpage; determine
needed repairs.
1623.3.3 Inspect internal and external threads;
repair as needed.
1623.3.4 Inspect and measure cylinder walls for
damage and wear; determine needed repairs.
Remove cylinder wall ridges.
Deglaze and clean cylinder walls.
1623.3.5 Inspect crankshaft for surface cracks and
journal damage; check oil passage condition; measure journal wear; determine
needed repairs.
1623.3.6 Inspect and measure main and connecting rod
bearings for damage, clearance, and end play; determine needed repairs
(includes the proper selections of bearings).
1623.3.7 Identify piston and bearing wear patterns
that indicate connecting rod alignment and main bearing bore problems; inspect
rod alignment and bearing bore condition.
1623.3.8 Inspect, measure, service or replace
pistons. Inspect, measure, and install
piston rings.
1623.3.9 Inspect, repair or replace crankshaft
vibrations damper (harmonic balancer).
1623.3.10 Inspect flywheel or flex plate and ring gear
for cracks and wear; measure run out and determine needed repairs.
1623.3.11 Inspect, remove, and replace crankshaft pilot
bearing or bushing (as applicable).
1623.3.12 Reassemble engine components using correct
gaskets and sealants.
1623.3.13 Inspect auxiliary (balance, intermediate,
idler, counterbalance or silencer) shaft(s); inspect shaft(s) and support
bearings for damage and wear; determine needed repairs; reinstall and time.
1623.3.14 Prime engine lubrication system.
Students will:
1623.4.1 Perform oil pressure tests; inspect oil pump
ears or rotors, housing, pressure relief devices, and pump drive; replace as
needed.
1623.4.2 Perform cooling system tests (pressure,
combustion leakage, and temperature) determine needed repairs.
1623.4.3 Inspect, replace, and adjust drive belts and
pulleys.
1623.4.4 Inspect and replace engine cooling and
heater system hoses.
1623.4.5 Inspect, test, and replace thermostat and
housing.
1623.4.6 Inspect coolant; drain, flush, and refill
cooling system with recommended coolant and bleed air as required.
1623.4.7 Inspect, test, remove, and replace water
pump.
1623.4.8 Inspect and test radiator, pressure cap, and
coolant recovery system; remove and replace radiator.
1623.4.9 Clean, inspect, and test fan(s) (electrical
or mechanical), inspect and test electrical fan control system and circuits,
fan clutch, fan shroud and air dams.
1623.4.10 Inspect, test, and replace oil temperature
and pressure switches and sensors.
Inspect auxiliary oil coolers; replace as needed.
1623.4.11 Perform oil and filter change.
