May 17, 2022
AUT 163 - Automotive Engine Repair Credits: 3
Lecture Hours: 2
Lab Hours: 2
Practicum Hours: 0
Work Experience: 0
Course Type: Voc/Tech
Course will provide instruction in the theory and operation of 4-stroke cycle engines. Emphasis will be placed on both design and proper disassembly/ reassembly procedures.
Prerequisite: AUT 114 or AUT 111
- Perform proper shop safety procedures
- Apply work area safety skills
- Demonstrate personal safety working habits
- Practice tool and equipment safety use
- Follow manufactures repair procedures
- Follow manufactures warnings and government regulations.
- Explain the fundamentals of basic engine design and operation
- Describe basic engine operation
- Describe the basic laws of physics involved with engine operation
- Classify engines according to the number of cycles, the number of cylinders, cylinder arrangement, and valvetrain type
- Define the four-stroke cycle theory
- Describe the different cylinder arrangements and the advantages of each
- Describe the different valvetrains used in modern engines.
- Define engine measurement terms such as bore and stroke, displacement, compression ration, engine efficiency, horsepower and torque, horsepower losses, mechanical efficiency, and thermal efficiency
- Describe the basic operation of alternative engine designs, including diesel, Miller-cycle, and stratified charge
- Identify engine using vehicle identification number.
- Acquire pertinent service information for specific repair procedures.
- Diagnosis and repair cylinder head and valve train.
- Visually inspect cylinder head(s) for cracks; check gasket surface areas for warpage and leakage; check passage condition
- Remove and reinstall cylinder heads and gaskets; tighten according to manufacturer’s specifications and procedures
- Inspect valve springs for squareness and free height comparison; determine necessary action
- Inspect valve guides for wear; check valve stem-to-guide clearance; determine necessary action
- Inspect valves and valve seats; determine necessary action.
- Check valve face-to-seat contact and valve seat concentricity (runout); determine necessary action
- Check valve spring assembled height and valve stem height; determine necessary action
- Inspect pushrods, rocker arms, rocker arm pivots and shafts for wear, bending, cracks, looseness, and blocked oil passages (orifices); determine necessary action.
- Inspect hydraulic or mechanical lifters; determine necessary action.
- Adjust valves (mechanical or hydraulic lifters).
- Inspect camshaft drives (including gear wear and backlash, sprocket and chain wear); determine necessary action
- Inspect and replace timing belts (chains), overhead camdrive sprockets, and tensioners; check belt/chain; adjust as necessary
- Inspect camshaft for runout, journal wear and lobe wear.
- Inspect camshaft bearing surface for wear, damage, out-of-round, and alignment; determine necessary action
- Establish camshaft(s) timing and cam sensor indexing according to manufacturer’s specifications and procedures
- Diagnosis and repair engine block assembly
- Disassemble engine block; clean and prepare components for inspection and reassembly
- Inspect engine block for visible cracks, passage condition, core and gallery plug condition, and surface warpage; determine necessary action
- Inspect and measure cylinder walls/sleeves for damage, wear and ridges; determine necessary action
- Deglaze and clean cylinder walls
- Inspect and measure camshaft bearings for wear, damage, out-of-round, and alignment; determine necessary action
- Inspect crankshaft for end play, straightness, journal damage, keyway damage, thrust flange and sealing surface condition, and visual surface cracks; check oil passage condition; measure journal wear; check crankshaft sensor reluctor ring (where applicabl
- Inspect main and connecting rod bearings for damage and wear; determine necessary action
- Identify piston and bearing wear patterns that indicate connecting rod alignment and main bearing bore problems; determine necessary action.
- Inspect and measure pistons; determine necessary action.
- Remove and replace piston pin
- Inspect, measure, and install piston rings
- Inspect auxiliary (balance, intermediate, idler, counterbalance or silencer) shaft(s); inspect shaft(s) and support bearings for damage and wear; determine necessary action; reinstall and time
- Inspect or replace crankshaft vibration damper (harmonic balancer).
- Assemble engine block assembly
- Install engine covers using gaskets, seals and sealers as required.
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