SYLLABUS ENGINE REBUILDING AUTO WESTERN NEBRASKA COMMUNITY COLLEGE DIVISION

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					             SYLLABUS
        ENGINE REBUILDING 2
             AUTO-2010




               2007




WESTERN NEBRASKA COMMUNITY COLLEGE
   DIVISION OF APPLIED TECHNOLOGY
I.     CATALOG DESCRIPTION:

       AUTO-2010
       Engine Rebuilding 2
       Prerequisite: AUTO-1160

       This course covers engine components, their function, measuring for wear,
       diagnosis of engine problems, and complete reassembly procedures for engine
       overhaul. Students will learn how to perform all engine related machine work,
       such as valve grinding, cylinder honing, piston knurling, and cam bearing
       installation. Students may supply shop projects, but it is not mandatory.
       Offered spring semester only.

       (6/60/90/0/0/10)

II.    GENERAL OBJECTIVES:
       A. To develop in each student safe, clean work habits, attitudes and skills

       B. Provide information concerning the vocational opportunities offered by this
          area of technological development

       C. Provide the student the opportunity to learn by doing under high quality
          conditions similar to those found in advanced automotive industry settings

       D. To assist the student to learn to work effectively with others

       E. Develop in each student knowledge of correct lab techniques and equipment
          usage, resulting in an intelligent and effective application of these skills in the
          performance of his/her assigned duties

       F. Develop in each student the technical and academic knowledge necessary to
          expand on life-long learning as the automotive industry continually updates

III.   INSTRUCTIONAL MATERIALS:
       A. Text

              1. Halderman and Ellinger. Automotive Engines. Current Edition.

       B. Required References
                                                            ENGINE REBUILDING 2
                                                                     AUTO-2010
            1. Motor Repair Manual

            2. Chilton Repair Manual

            3. Mitchell Manual

            4. Manufacturers Shop Manuals

            5. Mitchell On-Demand CD Systems

            6. AllData CD System

      C. Audio-Visual Aides

            1. Films, filmstrips, video tapes, CD, DVD

            2. Demonstrations by instructor

            3. Field trips to industry

            4. Charts

IV.   COURSE OUTLINE:
      A. Approximate Breakdown

            1. Engine fundamentals

                   a) Cylinder preparation

            2. Internal Components (checking, removing, and installing)

                   a) Pistons

                   b) Piston rings and pins

                   c) Connecting rods

                   d) Engine bearings

                   e) Crankshaft

                   f) Camshaft

            3. Cylinder heads and valves

                   a) Combustion chamber (and effects of design)

                   b) Guide repair



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                   c) Grinding valves

                   d) Grinding seats

                   e) Magnafluxing

                   f) Cooling systems

                   g) Radiators

                   h) Thermostats

            4. Lubrication systems

                   a) Oil pumps

                   b) Modern oils, viscosity ratings, classifications

            5. Engine installation, set up, and break-in

            6. In-chassis engine repair procedures

V.    METHOD OF PRESENTATION:
      A. Methods of presentation include both individual and group demonstrations

      B. Work in the classroom and shop is closely correlated. The student is first told
         and shown why and how a mechanism works. Next the student goes into the
         shop and actually handles the mechanism himself/herself verifying what
         he/she has just seen or heard. All repair, overhaul and other service work is
         preceded by classroom instruction and demonstration. Since there is little
         time lapse between classroom presentation and the related shop work, the
         student applies the theory while it is still fresh in his/her mind.

VI.   METHOD OF EVALUATION:
      A. Attendance

      B. Quality of Work

      C. Quantity of Work

      D. Effort and Attitude to include:

            1. Cooperation with group and instructor

            2. Care and use of equipment

            3. Organization and pride in work


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             4. General courtesy and respect for rules and general situation in shop

             5. Observation of safety factors

             6. Thriftiness of use of materials and equipment

       E. Tests

             1. Written

             2. Practical

       F. Final grade will be determined approximately by the following criteria:

             1. Attendance, quality and quantity of work

             2. Effort and attitude

             3. Test portion

VII.   SPECIFIC UNIT OBJECTIVES:
       A. Engine Fundamentals

             1. Cylinder preparation

                    a) Cylinder ridge removal

                    b) Deglazing cylinder

                    c) Checking and analyzing cylinder wear

                    d) Cleaning of cylinder after deglazing

       B. Internal Components

             1. Pistons

                    a) Measuring

                    b) Service and repair

       C. Piston Rings and Pins

                    a) Types

                    b) Removing and installing procedures

                    c) Measuring



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2. Connecting Rods

      a) Marking

      b) Care and maintenance

      c) Alignment

      d) Measuring

3. Engine Bearings

      a) Analyzing wear

      b) Installation

4. Crankshaft

      a) Cleaning

      b) Care and maintenance

      c) Measuring

5. Camshaft

      a) Characteristics

      b) Care and maintenance

      c) Measuring

      d) Timing and degreeing

      e) Bearings

6. Cylinder Heads

      a) Design

      b) Combustion chambers

      c) Checking

              (1) Magnafluxing

              (2) Measuring and knurling guides

      d) Valves



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                                                  ENGINE REBUILDING 2
                                                           AUTO-2010
                       (1) Cleaning

                       (2) Measuring

                       (3) Valve refacing

                       (4) Valve seat refacing

                       (5) Valve spring testing

D. Cooling Systems

      1. Radiators

             a) Repair

             b) Cleaning

      2. Thermostats

             a) Checking

             b) Replacing

E. Lubrication

      1. Oil pumps

             a) Checking

             b) Repair

      2. Oil filters

             a) Check valves

      3. Oil properties

             a) Viscosity

             b) Additives

             c) Classifications

F. Engine Installation

      1. Set-up

      2. Break-in



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G. In-Chassis Repairs

H. Performance Objectives

      1. Short block assembly

            a) Install cam bearings and camshaft

            b) Install crankshaft and plastigauge bearings

            c) Measure crankshaft end-play

            d) Measure cam thrust plate clearance (if equipped)

            e) Install timing chain and/or gears, measure camshaft timing

            f) Install pistons and rings, demonstrating proper measurements
               and procedures

            g) Plastigauge rod bearings and measure connecting rod side
               clearance

            h) Inspect flywheel and ring gear for cracks, wear and runout,
               determine needed repairs

            i) Inspect, remove and replace crankshaft pilot bearing (if
               applicable)

      2. Cylinder head and valve train diagnosis and repair
                    a) Remove cylinder head(s), visually inspect             P-2
                       cylinder head(s) for cracks, check gasket
                       surface areas for warpage and leakage;
                       check passage condition.
                    b) Install cylinder heads and gaskets, tighten           P-1
                       according to manufacturer’s specifications
                       and procedures.
                    c) *Inspect valve springs for squareness and             P-2
                       free height comparison, determine
                       necessary action.
                    d) Replace valve stem seals on an assembled              P-2
                       engine; inspect valve spring retainers,
                       locks, and valve grooves, determine
                       necessary action.
                    e) Inspect valve guides for wear, check valve            P-3
                       stem-to-guide clearance, determine
                       necessary action.
                    f) Inspect valves and valve seats, determine             P-3
                       necessary action.


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                                                 ENGINE REBUILDING 2
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              g) Check valve face-to-seat contact and valve      P-3
                 seat concentricity (runout), determine
                 necessary action.
              h) Check valve spring assembled height and         P-3
                 valve stem height, determine necessary
                 action.
              i) *Inspect pushrods, rocker arms, rocker arm      P-2
                 pivots and shafts for wear, bending, cracks,
                 looseness and blocked oil passages
                 (orifices), determine necessary action.
              j) *Inspect hydraulic or mechanical lifters,       P-2
                 determine necessary action.
              k) *Adjust valves (mechanical or hydraulic         P-1
                 lifters).
              l) *Inspect camshaft drives (including gear        P-2
                 wear and backlash, sprocket and chain
                 wear); determine necessary action.
              m) *Inspect and replace timing belts (chains),     P-1
                 overhead camdrive sprockets, and
                 tensioners; check belt/chain tension; adjust
                 as necessary.
              n) Inspect camshaft for runout, journal wear       P-2
                 and lobe wear.
              o) Inspect camshaft bearing surface for wear,      P-3
                 damage out-of-round, and alignment;
                 determine necessary action.
              p) *Establish camshaft(s) timing and cam           P-1
                 sensor indexing according to
                 manufacturer’s specifications and
                 procedures.

3. Lubrication and cooling systems diagnosis and repair

              a) *Perform oil pressure tests: determine          P-1
                 necessary action.
              b) Inspect oil pump gears or rotors, housing,      P-2
                 pressure relief devices, and pump drive;
                 perform necessary action.
              c) *Perform cooling system, cap, and recovery      P-1
                 system tests (pressure, combustion
                 leakage, and temperature); determine
                 necessary action.
              d) *Inspect, replace, and adjust drive belts,      P-1
                 tensioners, and pulleys; check pulley and
                 belt alignment.
              e) *Inspect and replace engine cooling and         P-1



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                                                                ENGINE REBUILDING 2
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                                heater system hoses.
                           f)   *Inspect, test and replace thermostat and             P-2
                                housing.
                           g)   *Test coolant; drain and recover coolant;             P-1
                                flush and refill cooling system with
                                recommended coolant; bleed air as
                                required.
                           h)   *Inspect, test, remove, and replace water             P-1
                                pump
                           i)   *Remove and replace radiator                          P-2
                           j)   *Inspect and test fan(s) (Electrical or               P-2
                                mechanical), fan clutch, fan stroud, and air
                                dams.
                           k)   *Inspect auxiliary oil coolers; determine             P-3
                                necessary action.
                           l)   *Inspect, test and replace oil temperature            P-2
                                and pressure switches and sensors.
                           m)   *Perform oil and filter change.                       P-2

             4. In-chassis engine repairs
      (*) Denotes repair procedures that will be covered during the in-chassis engine
      repair section, as well as during the engine rebuilding procedures

VIII. ACADEMIC INTEGRITY:
      Academic integrity represents a fundamental bond of trust between colleagues,
      peers, teachers, and students; academic integrity influences and often controls a
      learner’s individual odyssey. At Western Nebraska Community College, there is
      no tolerance for plagiarism or any form of academic dishonesty, including
      unacknowledged "borrowing" of proprietary material, copying answers or papers,
      or passing off another’s work as one's own. Such acts are reported to the
      appropriate authorities.

      A breach of ethics or act of dishonesty can result in:
         • failure of a paper or exam within a course
         • failure of an entire course (blatant plagiarism, cheating on a test or quiz)
         • academic suspension or expulsion from the college

IX.   EQUAL ACCESS STATEMENT:
      Western Nebraska Community College is committed to providing reasonable
      accommodation to persons with disabilities. If you qualify under the Americans
      with Disabilities Act (ADA), please notify the Director of Counseling, 308-635-
      6090, as soon as possible to begin the process of documentation review and
      determination of appropriate accommodation or adaptive strategies.

      11-21-07



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