ChabotCollegeFall 2005

Replaced Fall 2010

Course Outline for Automotive Technology 63A

INTRODUCTION TO ENGINES AND MACHINING PROCESSES

Catalog Description:

63A - Introduction to Engines and Machining Processes 3 units

May be repeated three times

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. recognize unsafe working conditions and practices;
  2. use common automotive shop equipment safely;
  3. identify and recognize common automotive tools and equipment;
  4. identify fasteners;
  5. demonstrate proper procedures to repair a broken fastener and/or repair threads;
  6. discuss automotive engine fundamentals;
  7. perform engine vacuum tests;
  8. perform cylinder compression tests;
  9. perform cylinder leakage tests;
  10. perform oil pressure tests;
  11. perform oil and filter change;
  12. assess and use service information;
  13. demonstrate proper use of metric and standard micrometers;
  14. demonstrate proper use of an analog or digital volt/ohmmeter;
  15. select the appropriate automotive fluid for the selected application;
  16. use appropriate methods for hazardous waste handling and disposal;
  17. discuss potential areas of employment in the automotive industry.

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;
  1. inspect an engine assembly for fuel, oil, coolant, and other leaks, and determine necessary action;
  2. perform cooling system, cap, recovery system tests (pressure, combustion leakage, and temperature), and determine necessary action;
  3. inspect, replace, and adjust drive belts, tensioners, and pulleys;
  4. test coolant; drain and recover coolant; flush and refill cooling system with recommended coolant; bleed air as required;
  5. inspect, test, remove, and replace engine cooling and heater system hoses, radiator, thermostat and housing, and water pump;
  6. inspect, and test fans(s) (electrical or mechanical), fan clutch, fan shroud, and air dams;
  7. inspect, test, and replace oil temperature and pressure switches and sensors;

ChabotCollege

Course Outline for Automotive Technology 63A, Page 2

Fall 2005

  1. Inspect oil pump gears or rotors, housing, pressure relief devices, and pump drive; perform necessary action;
  2. perform cylinder power balance tests, and determine necessary action;
  3. diagnose engine noises and vibrations, and the cause of excessive oil consumption, unusual engine exhaust color, odor, and sound; determine necessary action;
  4. visually inspect cylinder head(s) for cracks, check gasket surface areas for warpage and leakage;
  5. install cylinder heads and gaskets, and tighten according to manufacturers specifications and procedures;
  6. inspect and test valve springs for squareness, pressure, free-height comparison, valve spring retainers, locks, and valve grooves and replace as needed;
  7. inspect valve guides for wear, check valve guide height, and stemtoguide clearance, recondition or replace as needed;
  8. resurface valves, valve seats and perform necessary action;
  9. check valve spring assembled height and valve stem height; service valve and spring assemblies as needed;
  10. inspect pushrods, rocker arms, rocker arm pivots and shafts for wear, bending, cracks, looseness, and blocked oil passages (orifices), and perform necessary action;
  11. adjust valves (mechanical or hydraulic lifters);
  12. inspect and replace timing belt(s), overhead cam drive sprockets, and tensioners, check belt tension, and adjust as necessary;
  13. verify camshaft(s) timing according to manufacturer’s specifications and procedures;
  14. inspect camshaft drives (including gear wear and backlash, sprocket and chain wear); replace as necessary.

Course Content:

1.Automotive safety and shop practice

2.Proper care and manipulation of basic hand tools

  1. Engine fundamentals, types, construction, operation and identification
  2. Four stroke cycle
  3. Flathead, OHV, SOHC, DOHC
  4. Valve timing relationship
  5. Ignition timing
  6. Cooling system operation
  7. Lubrication system
  8. Engine condition diagnosis, inspection and repair
  9. compression tests
  10. cylinder leakage tests
  11. engine vacuum tests
  12. oil pressure tests

e. engine combustion four-gas analysis

5.Engine precision measurement, proper care, and operation of precision measurement tools

6.Engine disassembly, cleaning techniques and procedures

7.Cylinder head diagnosis, disassembly, testing, and inspection

8.Valve guide, valve and valve seat inspection, and servicing

9.Cylinder head reconditioning, reassembly and inspection

10.Camshaft, timing belts, timing chains and valve train service

11.Hazardous waste handling

ChabotCollege

Course Outline for Automotive Technology 63A, Page 3

Fall 2005

Methods of Presentation:

1. Lecture/discussion

2. Laboratory

3. Guest speakers

4. Field trips

Assignments and Methods of Evaluating Student Progress:

1. Typical Assignments

a. Read Chapter titled “Engine Condition Diagnosis”

b. Perform cylinder leakage test worksheet following directions listed and the class lecture/discussion

2. Methods of Evaluating Student Progress

a. Class participation

b. Performance of laboratory task lists and projects

c. Homework assignments

d. Quizzes

e. Midterm exam

f. Final exam

Textbook(s) Typical:

Automotive Engines, Theory and Servicing, James D. Halderman, Chase D. Mitchell, Jr., Prentice Hall Publishers, 2001

Special Student Materials:

1. Safety glasses

2. Shop/safety clothing

RJ 09/2004

AT63A course outline.doc