ATC 335 - Service/Repair Chrysler Engine

1. Develop safe working habits
   1. Use proper eye protection
   2. Select proper tools to work in a safe manner
   3. Demonstrate a concern for the safety of fellow workers
2. Explain the fundamentals of Basic Gas Engine Design
   1. Describe sequence of 4 stroke cycle
   2. Determine valve position on each stroke of 4 stroke cycle
   3. Determine piston position on each stroke of 4 stroke cycle
   4. Determine ignition system performance on each stroke of 4 stroke cycle
   5. Determine fuel system performance of each stroke of 4 stroke cycle
   6. Explain efficiency of engine performance as it pertains to thermal and mechanical conditions
3. Explain Engine Identification and Component Nomenclature
   1. Identify Chrysler engines
   2. Locate Service Information
   3. Identify engine components
   4. Discuss personal and vehicle safety repair procedures
4. Service cooling system
   1. Inspect water pump
   2. Perform cooling system pressure test
   3. Test thermostat
   4. Inspect radiator, radiator cap, and radiator hoses
   5. Evaluate coolant
   6. Troubleshoot cooling fan, fan clutch, and shrouds
5. Service engine lubrication system
   1. Perform engine oil pressure test
   2. Diagnose the cause of excessive oil consumption
   3. Explain engine oil classifications and categories
6. Evaluate engine performance
   1. Perform engine vacuum test
   2. Conduct cylinder power balance test
   3. Analyze engine fluid leaks
   4. Perform engine compression test
   5. Diagnose engine noises
   6. Evaluate engine performance during a road test
   7. Perform cylinder leakage test
7. Analyze engines during disassembly
   1. Describe oil consumption causes
   2. Identify coolant leak locations
   3. Locate engine noises
   4. Diagnose low oil pressure concerns
   5. Locate oil leaks
   6. Determine low compression causes
8. Explain valve train reconditioning techniques
   1. Identify valve train designs
   2. Identify valve train component nomenclature
   3. Disassemble valve train components
   4. Evaluate valve train component wear patterns
   5. Measure valve train wear
   6. Check for cracks in cylinder heads or block area using magnetic and dye crack detection
   7. Check for warpage of cylinder heads and block area
   8. Knurl valve guides
   9. Ream valve guides to 0/size
   10. Machine valve seats
   11. Reface valves
   12. Check valve spring tension
   13. Measure and correct valve spring assembled height
   14. Use manufacturers specifications and recommended repair techniques
   15. Check camshaft
   16. Check valve lifters
   17. Discuss rocker arm ratio
   18. Check valve timing of engine
   19. Determine need for timing gear and belt replacement
9. Recondition engine block assembly
   1. Clean engine components
   2. Perform all necessary measurements
   3. Inspect components for wear
   4. Determine necessary operations to restore engine to manufacturer’s recommendations
   5. Perform pre-determined operations
   6. Reassemble engine block following all service manual special procedures
10. Replace cylinder head assemblies
    1. Clean all mounting surfaces and components
    2. Check surfaces for sealing quality
    3. Torque cylinder heads using manufacturer’s recommended procedures
    4. Reassemble valve trains
    5. Use manufacturer’s specifications and installation recommendations
11. Replace engine
    1. Remove engine assembly
    2. Reseal engine
    3. Reinstall engine
12. Perform engine start-up after valve train repair
    1. Set static timing of engine to manufacturers specifications
    2. Reconnect all fuel and electrical accessories
    3. Refill cooling system
    4. Adjust valve train clearances
    5. Start engine and adjust ignition timing
    6. Adjust engine idle speed if required