AFM 111 - Internal Combustion Engines

1. Appraise automotive precision measuring tool readings.
2. Explain internal combustion engine theory and fundamental operation.
3. Describe internal combustion engine components and subsystem’s purpose and function.
4. Contrast gasoline and diesel engine design variants, functions, strengths, and weaknesses.
5. Appraise gasoline and diesel engine malfunctions and repair methods.
6. Diagnose and repair internal combustion engine-related malfunctions.

1. Engine Fundamentals and Operation
   1. Engine Operation
      1. 4 stroke cycle
      2. 2 stroke cycle
   2. Engine Bottom End
      1. Block
      2. Crankshaft
         1. Main bearings
         2. Oil seals
      3. Flywheel
      4. Connecting Rod
         1. Rod bearings
      5. Piston
         1. Pin
         2. Rings
      6. Lubrication
         1. Pump operation and design variants
   3. Engine Top End
      1. Cylinder head 
      2. Valvetrain and componentry
      3. Intake manifold(s)
      4. Exhaust manifold(s)
      5. Valve cover(s)
   4. Valve actuation
      1. Camshaft in block / Overhead valve (OHV)
      2. Camshaft in head / Overhead Cam (OHC)
2. Engine Classifications
   1. Cylinder arrangements 
   2. Number of cylinders
   3. Displacement
   4. Fuel types
   5. Ignition types
   6. Camshaft configurations
   7. Combustion chamber design variants
3. Engine Top End Construction
   1. Head design variants
      1. Camshafts
      2. Valves
      3. Guides
      4. Actuation variants
      5. Lubrication
      6. Cooling
      7. Fluid sealing
4. Bottom End Construction
   1. Block design variants
      1. Cylinders
      2. Structural components
      3. Pistons
      4. Rods
      5. Crankshafts
      6. Lubrication systems
      7. Cooling
      8. Fluid sealing
5. Front and Back End Construction
   1. Valve Timing Drive design variants
      1. Chain drive systems
         1. Primary chains
         2. Secondary chains
         3. Tensioners, guides, and lubrication
         4. Timing
      2. Belt drive systems
         1. Tensioners, idlers, and guides
         2. Timing
      3. Gear drive systems
         1. Timing
      4. Balancing systems
         1. Internal
         2. External
6. Cooling System Technology
   1. Functions
      1. Removing heat
      2. Reaching ideal operating temperature quickly
      3. Maintaining operating temperature
   2. Components
      1. Pumps
      2. Thermostats
      3. Heat exchangers
      4. Fans
      5. Hoses, belts and flow sequence
      6. Coolants
7. Cooling System Testing, Maintenance, and Repair
   1. Troubleshooting
      1. Inspections
      2. Symptom verification
      3. On-board diagnostic methods
   2. Common malfunctions
      1. Leaks, coolant loss
      2. Overcooling
      3. Overheating
   3. Coolant pump service
      1. Checks
      2. Removal and installation
   4. Thermostat service
      1. Checks
      2. Removal and installation
   5. Hose and belt service
      1. Inspection
      2. Removal and installation
   6. Heat exchanger service
      1. Inspection
      2. Cap and pressure testing
      3. Leak testing
      4. Removal and installation
   7. Fan service – electrical and mechanical
      1. Inspection
      2. Diagnostics
      3. Removal and installation
   8. Coolant service
      1. Inspection
      2. Testing
         1. Chemical
         2. Electrolysis
         3. Hydrometer
      3. Draining, filling, and flushing
         1. Air purging
8. Lubrication system fundamentals
   1. Components
      1. Engine oil
         1. Ratings, chemistry, and additives
      2. Wet sump systems
      3. Dry sump systems
      4. Pickups and screens
      5. Pumps and drive mechanisms
      6. Filtration
      7. Cooling
      8. Galleries and flow cycles
      9. Sensors and electronic controls
9. Lubrication system diagnostics, testing and service
   1. Malfunctions
   2. Sludging
   3. Contamination
      1. Water
      2. Fuel
      3. Other fluids
   4. Consumption and fluid loss
   5. Low pressure
   6. High pressure
   7. Pump service
10. Base engine malfunction testing, diagnosis and repair methods
    1. Noise isolation
       1. Subassembly isolation
    2. Performance
       1. Visual and audible inspection
       2. Compression testing
          1. Static
          2. Running
       3. Leakdown testing 
    3. Root cause failure analysis
    4. Cylinder head repair procedures
    5. Block repair procedures
    6. Setting valve timing
    7. Installation and final assembly