ChabotCollege

Course Outline for Automotive Technology 63A, Page 1

Fall 2012

Chabot CollegeFall 2012

Course Outline for Automotive Technology 63A

INTRODUCTION TO ENGINES AND MACHINING PROCESSES

Catalog Description:

63A - Introduction to Engines and Machining Processes3 units

Diagnosis, inspection and repair of various engine types; machining operations, use of instruments and automotive machinist equipment in repairing engines, valve train assemblies and cylinder head reconditioning, cooling and lubrication system fundamentals. Prerequisite: Automotive Technology 50 (may be taken concurrently) or equivalent. Strongly recommended: Industrial Technology 74. 1.5 hours lecture, 5 hours laboratory.

[Typical contact hours: lecture 26.25, laboratory 87.5]

Prerequisite Skills:

Before entering the course, the student should be able to:

  1. demonstrate safe working conditions and practices;
  2. use common automotive shop equipment safely;
  3. identify and recognize common automotive tools and equipment;
  4. identify fasteners;
  5. discuss automotive engine fundamentals;
  6. perform vehicle fluid services;
  7. access and use service information;
  8. demonstrate proper use of metric and standard micrometers;
  9. demonstrate proper use of a volt/ohmmeters;
  10. select the appropriate automotive fluid for the selected application;
  11. use appropriate methods for hazardous waste handling and disposal;
  12. identify potential areas of employment in the automotive industry;
  13. describe basic electricity;
  14. complete work orders to meet industry and Bureau of Automotive Repair standards;
  15. perform basic vehicle maintenance.

Expected Outcomes for Students:

Upon completion of the course the student should be able to:

  1. verify and interpret engine concerns, and determine necessary action;
  2. inspect an engine assembly for fuel, oil, coolant, and other leaks, and determine necessary action;
  3. perform cooling system, cap, recovery system tests (pressure, combustion leakage, and temperature), and determine necessary action;
  4. inspect, replace, and adjust drive belts, tensioners, and pulleys;
  5. test coolant; drain and recover coolant; flush and refill cooling system with recommended coolant; bleed air as required;
  6. inspect, test, remove, and replace engine cooling and heater system hoses, radiator, thermostat and housing, and water pump;
  7. inspect, and test fans(s) (electrical or mechanical), fan clutch, fan shroud, and air dams;
  8. inspect, test, and replace oil temperature and pressure switches and sensors;
  9. Inspect oil pump gears or rotors, housing, pressure relief devices, and pump drive; perform necessary action;
  10. perform cylinder power balance tests, and determine necessary action;
  11. diagnose engine noises and vibrations, and the cause of excessive oil consumption, unusual engine exhaust color, odor, and sound; determine necessary action;
  12. visually inspect cylinder head(s) for cracks, check gasket surface areas for warpage and leakage;
  13. install cylinder heads and gaskets, and tighten according to manufacturers specifications and procedures;
  14. inspect and test valve springs for squareness, pressure, free-height comparison, valve spring retainers, locks, and valve grooves and replace as needed;
  15. inspect valve guides for wear, check valve guide height, and stemtoguide clearance, recondition or replace as needed;
  16. resurface valves, valve seats and perform necessary action;
  17. check valve spring assembled height and valve stem height; service valve and spring assemblies as needed;
  18. inspect pushrods, rocker arms, rocker arm pivots and shafts for wear, bending, cracks, looseness, and blocked oil passages (orifices), and perform necessary action;
  19. adjust valves (mechanical or hydraulic lifters);
  20. inspect and replace timing belt(s), overhead cam drive sprockets, and tensioners, check belt tension, and adjust as necessary;
  21. verify camshaft(s) timing according to manufacturer’s specifications and procedures;
  22. inspect camshaft drives (including gear wear and backlash, sprocket and chain wear); replace as necessary.

Course Content (Lecture):

  1. Automotive safety and shop practice
  2. Proper care and manipulation of basic hand tools
  3. Engine fundamentals, types, construction, operation and identification
  4. Four stroke cycle
  5. Flathead, OHV, SOHC, DOHC
  6. Valve timing relationship
  7. Ignition timing
  8. Cooling system operation
  9. Lubrication system
  10. Engine condition diagnosis, inspection and repair
  11. Compression tests
  12. Cylinder leakage tests
  13. Engine vacuum tests
  14. Oil pressure tests
  15. Engine combustion four-gas analysis
  16. Engine precision measurement, proper care, and operation of precision measurement tools
  17. Engine disassembly, cleaning techniques and procedures
  18. Cylinder head diagnosis, disassembly, testing, and inspection
  19. Valve guide, valve and valve seat inspection, and servicing
  20. Cylinder head reconditioning, reassembly and inspection
  21. Camshaft, timing belts, timing chains and valve train service
  22. Hazardous waste handling

Course Content (Laboratory):

Each of the lecture content items is accompanied by a required NATEF (National Automotive Technical Education Foundation) lab “task sheet” with required levels of exposure (general knowledge, demonstration, basic skill level, advanced skill level.

Examples include:

  1. Demonstrated use and care of basic shop tools
  2. Performance of engine compression test
  3. Diagnosis of engine problems as a result of conducting engine test
  4. Compression tests
  5. Cylinder leakage tests
  6. Engine vacuum tests
  7. Oil pressure tests
  8. Engine combustion four-gas analysis

Methods of Presentation:

  1. Lecture/discussion
  2. Laboratory
  3. Guest speakers
  4. Field trips

Assignments and Methods of Evaluating Student Progress:

  1. Typical Assignments
  2. Read Chapter titled “Engine Condition Diagnosis”
  3. Perform cylinder leakage test worksheet following directions listed and the class lecture/discussion
  1. Methods of Evaluating Student Progress
  2. Class participation
  3. Performance of laboratory task lists and projects
  4. Homework assignments
  5. Quizzes
  6. Midterm exam
  7. Final exam

Textbook(s) (Typical):

Engines: Diagnosis, Repair and Rebuilding, Author-Gilles, Publisher-Prentice Hall, 2011

Special Student Materials:

  1. Safety glasses
  2. Shop/safety clothing

KWS09282011

ATEC 63A course outline.doc