Jan 28, 2022  
2021-2022 College Catalog 
    
2021-2022 College Catalog
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AUT 120 - Engine Diagnosis and Repair

3 Credits, 7 Contact Hours
1 lecture period 6 lab periods

Techniques for light line engine service. Includes personal and environmental safety, general engine diagnosis, lubrication system diagnosis and repair, cooling system diagnosis and repair, cylinder head diagnosis and repair, and engine block diagnosis and repair.

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Course Learning Outcomes
  1. Perform the assembly/disassembly of crankshaft, camshaft, timing chain, distributor, pushrods, and rocker arm shaft assembly on a Chrysler Engine.
  2. Perform the assembly/disassembly of pistons, hydraulic lifters, cylinder heads, fuel pump, water pump, and rocker arm shaft assembly and adjustment of valves on a Ford engine.
  3. Perform the assembly/disassembly of pistons, hydraulic lifters, cylinder heads, fuel pump, water pump, and rocker arm shaft assembly and adjustment of valves on a Chevrolet engine.
  4. Perform Engine Measurements and determine needed repairs.
  5. Perform the assembly/disassembly of valve stem seals, core plugs, and harmonic balancer.
  6. Demonstrate the removal/replacement of a timing belt on a dual overhead cam engine.
  7. Identify engine components, operating principles and demonstrate fastener repair.
  8. Perform overhead camshaft valve lash adjustments on a mechanical and shim type heads.
  9. Perform general engine diagnostic tests and determine necessary action.

Outline:
  1. Personal and Environmental Safety
    1. Clothing and personal protection devices
    2. Fire extinguishers: their location and use
    3. Material Safety Data Sheets (MSDS) location and application
  2. General Engine Diagnosis
    1. Interpret and verify complaint and determine necessary action
    2. Inspect engine assembly for fuel, oil, coolant and other leaks, and determine necessary action
    3. Diagnose engine noises and vibrations and determine necessary action
    4. Diagnose the cause of excessive oil consumption, unusual engine exhaust color, odor and sound and determine necessary action
    5. Perform engine vacuum tests and determine necessary action
    6. Perform cylinder power balance tests and determine necessary action
    7. Perform cylinder compression tests and determine necessary action
    8. Perform cylinder leakage tests and determine necessary action
  3. Lubrication System Diagnosis and Repair
    1. Perform oil pressure tests and determine necessary action.
    2. Inspect oil pump gears or rotors, housing, pressure relief valves, pump drive and perform necessary action
    3. Inspect auxiliary oil coolers and replace as needed
    4. Inspect, test, and replace oil temperature and pressure sensors
    5. Perform engine oil and filter change
  4. Cooling System Diagnosis and Repair
    1. Perform cooling system tests (pressure, combustion leakage, and temperature) and determine necessary action
    2. Inspect, replace, adjust drive belts, tensioners and pulleys
    3. Inspect and replace engine cooling and heater systems hoses
    4. Inspect, test and replace thermostat and housing
    5. Test coolant, flush and refill cooling system with recommended coolant and bleed air as required
    6. Inspect, test and replace water pump
    7. Remove and replace radiator
    8. Clean, inspect, and test fans(s) (electrical or mechanical), fan clutch, fan shroud, and air dams
  5. Cylinder Head and Valve Train Diagnosis and Repair        
    1. Remove cylinder head(s), inspect head(s) for cracks, check gasket surface areas for warpage and leakage, and check passage condition.
    2. Install cylinder head(s) and gaskets and tighten according to manufacturer’s specifications and procedures.
    3. Inspect and test valve springs for squareness, pressure, and free height comparison, and replace as needed.
    4. Inspect valve retainers, locks, and valve grooves.
    5. Replace valve stem seals.
    6. Inspect valve guides for wear, check valve guide height and stem to guide clearance, and recondition or replace as necessary.
    7. Resurface valves and perform necessary action.
    8. Resurface valve seats and perform necessary action.
    9. Check valve face to seat contact and valve concentricity (run out) and service seats and valves as necessary.
    10. Check valve spring installed height and valve height and service valve and spring assemblies as needed.
    11. Inspect pushrods, rocker arms, rocker arm pivots and shafts for wear, bending, cracks, looseness, and blocked oil passages (orifices), and perform necessary action.
    12. Inspect hydraulic or mechanical lifter and replace as needed.
    13. Adjust valves (mechanical and hydraulic).
    14. Inspect camshaft drives (including gear wear and backlash, sprocket and chain wear), and replace as necessary.
    15. Inspect and replace timing belt(s) and Chain(s), overhead cam drive sprockets, and tensioners, check belt tension, and adjust as necessary.
    16. Inspect camshaft run-out, journal wear, and lobe wear.
    17. Inspect and measure camshaft bearings for wear, damage, out of round, and alignment, and determine necessary action.
    18. Verify camshaft(s) timing according to manufacturer’s specifications and procedure.
  6. Engine Block Diagnosis and Repair
    1. Inspect and replace pans, covers, gaskets, and seals.
    2. Inspect engine block for cracks, passage condition, core and gallery plug.
    3. Inspect internal and external threads and restore as needed (includes installing thread inserts).
    4. Remove cylinder wall ridges.
    5. Inspect and measure cylinder walls for damage and wear and determine necessary action.
    6. Deglaze and clean cylinder walls.
    7. Inspect and measure camshaft bearings for wear, damage, out of round, and alignment, and determine necessary action.
    8. Inspect crankshaft for surface cracks and journal damage, check oil passage condition, measure journal wear, and determine necessary action.
    9. Inspect and measure main and connecting rod bearings for damage, clearance, and end play and determine needed repairs (includes the proper selection of bearings).
    10. Identify piston and bearing wear patterns that indicate connecting rod alignment and main bearing bore problems and inspect rod alignment and bore condition.
    11. Inspect, measure, service or replace pistons, and determine necessary action.
    12. Inspect, measure, and install piston rings.
    13. Inspect, repair, or replace crankshaft vibration damper (harmonic balancer).
    14. Reassemble engine components using correct gaskets and sealants.
    15. Inspect auxiliary (balance, intermediate, counterbalance, or silencer) shafts(s), inspect shaft(s) and support bearings for damage and wear, determine needed repairs, and reinstall and time.
    16. Prime engine lubrication system.


Effective Term:
Fall 2015



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