DSL 163 - Engine Repair

Credits: 3
Lecture Hours: 2
Lab Hours: 2
Practicum Hours: 0
Work Experience: 0
Course Type: Voc/Tech

1. Apply work area safety skills
2. Demonstrate personal safety working habits
3. Practice tool and equipment safety use
4. Follow manufactures repair procedures
5. Follow manufactures warnings and government regulations.

2. Explain the fundamentals of basic diesel, gasoline, and liquid propane engine design and operation

1. Describe basic engine operation
2. Describe the basic laws of physics involved with engine operation
3. Classify engines according to the number of cycles, the number of cylinders, cylinder arrangement, and valvetrain type
4. Define the four-stroke cycle theory
5. Describe the different cylinder arrangements and the advantages of each
6. Describe the different valvetrains used in modern engines.
7. Define engine measurement terms such as bore and stroke, displacement, compression ration, engine efficiency, horsepower and torque, horsepower losses, mechanical efficiency, and thermal efficiency
8. Describe the basic operation of alternative engine designs, including diesel, Miller-cycle, and stratified charge
9. Identify engine using vehicle identification number.
10. Acquire pertinent service information for specific repair procedures.

3. Diagnosis and repair cylinder head and valve train.

1. Visually inspect cylinder head(s) for cracks; check gasket surface areas for warpage and leakage; check passage condition
2. Remove and reinstall cylinder heads and gaskets; tighten according to manufacturer’s specifications and procedures
3. Inspect valve springs for squareness and free height comparison; determine necessary action
4. Inspect valve guides for wear; check valve stem-to-guide clearance; determine necessary action
5. Inspect valves and valve seats; determine necessary action.
6. Check valve face-to-seat contact and valve seat concentricity (runout); determine necessary action
7. Check valve spring assembled height and valve stem height; determine necessary action
8. Inspect pushrods, rocker arms, rocker arm pivots and shafts for wear, bending, cracks, looseness, and blocked oil passages (orifices); determine necessary action.
9. Inspect hydraulic or mechanical lifters; determine necessary action.
10. Adjust valves (mechanical or hydraulic lifters)

4. Evaluate Camshaft

1. Inspect camshaft drives (including gear wear and backlash, sprocket and chain wear); determine necessary action
2. Inspect and replace timing belts (chains), overhead camdrive sprockets, and tensioners; check belt/chain; adjust as necessary
3. Inspect camshaft for runout, journal wear and lobe wear.
4. Inspect camshaft bearing surface for wear, damage, out-of-round, and alignment; determine necessary action
5. Establish camshaft(s) timing and cam sensor indexing according to manufacturer’s specifications and procedures

5. Diagnosis and repair diesel, gasoline, and liquid propane engine block assembly

1. Disassemble diesel, gasoline, and liquid propane engine block; clean and prepare components for inspection and reassembly
2. Inspect diesel, gasoline, and liquid propane engine block for visible cracks, passage condition, core and gallery plug condition, and surface warpage; determine necessary action
3. Inspect and measure cylinder walls/sleeves for damage, wear and ridges; determine necessary action
4. Deglaze and clean cylinder walls
5. Inspect and measure camshaft bearings for wear, damage, out-of-round, and alignment; determine necessary action
6. 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 applicable)

6. Inspect main and connecting rod bearings for damage and wear; determine necessary action

1. Identify piston and bearing wear patterns that indicate connecting rod alignment and main bearing bore problems; determine necessary action.
2. Inspect and measure pistons; determine necessary action.
3. Remove and replace piston pin
4. Inspect, measure, and install piston rings
5. 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
6. Inspect or replace crankshaft vibration damper (harmonic balancer).
7. Assemble diesel, gasoline, and liquid propane engine block assembly
8. Install diesel, gasoline, and liquid propane engine covers using gaskets, seals and sealers as required.

 
Competencies Revised Date: AY2022