AUTOMOTIVE ENGINE DIAGNOSIS, REPAIR AND REBUILDING 9TH EDITION BY TIMS GRILLES, TIM LEVAN (CHAPTER 1 by QuentinAxel

TEST BANK

Instructor Manual: Automotive Engines Diagnosis, Repair, and Rebuilding 9th Edition Tim Gilles, Tim LeVan

AUTOMOTIVE ENGINE DIAGNOSIS, REPAIR AND REBUILDING 9TH EDITION BY TIMS GRILLES, TIM LEVAN (CHAPTER 1_19) SOLUTIONS MANUAL Chapter 1-19 Chapter 1: Engine Operation

TABLE OF CONTENTS Purpose and Perspective of the Chapter ................................................................................................... 2 Chapter Objectives ...................................................................................................................................... 2 Complete List of Chapter Activities and Assessments ............................................................................. 2 Key Terms .................................................................................................................................................... 3 What’s New in This Chapter ...................................................................................................................... 3 Chapter Outline ........................................................................................................................................... 3 Lesson Hints................................................................................................................................................. 5 Reading Assignment .................................................................................................................................... 5 Written Assignments ................................................................................................................................... 5 Chapter 1 Answers To Study Questions ..................................................................................................... 5 Chapter 1 Answers To ASE-Style Review Questions ................................................................................... 6

Instructor Manual: Chapter 1: Engine Operation

PURPOSE AND PERSPECTIVE OF THE CHAPTER The purpose of this chapter is to introduce students to the basic construction and operation of an internal combustion engine. It describes the many engine components and how to identify the various pieces. Also explained are the different engine classifications along with the different systems and how they work together to keep the engine operating effectively.

CHAPTER OBJECTIVES Upon completion of this chapter, the student should be able to:   

Explain the principles of internal combustion engine operation. Identify internal combustion engine parts by name. Explain various engine classifications and systems.

COMPLETE LIST OF CHAPTER ACTIVITIES AND ASSESSMENTS For additional guidance, refer to the Teaching Online Guide. Chapter Objective Explain the principles of internal combustion engine operation.

Activity/Assessment

Duration

Icebreaker

Source (i.e., PPT slide, Workbook) PPT slide 2

Identify internal combustion engine parts by name.

Activity

PPT slide 27

10–20 minutes

Explain various engine classifications and systems.

Self-Assessment

PPT slide 29

5–10 minutes

10–15 mins

[return to top]

Instructor Manual: Chapter 1: Engine Operation

KEY TERMS BDC: Bottom Dead Center, referring to the location of the piston at the bottom of the stroke bimetal engine: Engines composed of cast iron block and aluminum heads blowby: Gasses that escape past piston rings companion cylinders: term given to pairs of cylinders found in engines with even number of cylinders compression ratio: the ratio at which the air fuel gas mixture is compressed displacement: refers to the volume that the piston displaces in the cylinder firing order: The sequence in which the spark plugs fire in each cylinder lower end: Refers to the location at the bottom of the block where the crankshaft and bearings are located TDC: Top Dead Center, referring to the location of the piston at the top of the stroke transverse engine: term given to the engines in front wheel drive vehicles [return to top]

WHAT’S NEW IN THIS CHAPTER [Information to be added later by author]

The following elements are improvements in this chapter from the previous edition:

[return to top]

CHAPTER OUTLINE 

In a simple one-cylinder engine, the reciprocating (up-and-down) motion of the piston is changed to usable rotary motion by the connecting rod and crankshaft. A flywheel gives momentum to the crankshaft between power strokes. Valves control the engine’s intake and exhaust. (PPT Slide 4)



During one four-stroke cycle, the intake, compression, power, and exhaust strokes are completed. This action takes 720° , or two crankshaft revolutions. (PPT Slide 5)

Instructor Manual: Chapter 1: Engine Operation



The compression ratio is how the engine makes the most efficient use of the combustion event in each cylinder. The higher the compression ratio the more potential output a cylinder has. (PPT Slide 6)



Cylinders are arranged in-line, in a V-type, or opposed to each other. The most popular automotive engines have four, six, or eight cylinders. (PPT Slide 7)



The camshaft controls the opening and closing of the valves and, thus, the way that the engine breathes. Different cam grinds provide better low-speed or better high-speed operation. (PPT Slides 8, 9)



The camshaft is driven by a chain, a belt, or gears. (PPT Slide 8)



Camshafts are driven by a timing chain or a timing belt. (PPT Slides 8, 9)



Cylinder rows, called banks, are determined from the flywheel end of the engine. A complete engine assembly including the heads is called a long block; without heads it is called a short block. (PPT Slide 12, 13)



The crankcase houses the crankshaft and bearings. It is enclosed by the oil pan. The crankshaft has a flywheel on one end and a vibration damper or pulley on the other end. The part that the bearing rides against is called the main or rod bearing journal. Crankpins on four cylinders are offset from each other by 180° , in-line six cylinders by 120° , and V8s by 90° . (PPT Slides 14)



Engine sizes are described by their cylinder displacement, usually in liters. Engine breathing determines the power that the engine develops. (PPT Slide 15)



The location of the camshaft depends on the engine design and the type of vehicle the engine is being put in. Cam-In Block engines have the camshaft in the cylinder block. Overhead cam engines have the camshaft in the cylinder head. (PPT Slide 17)



Engine cylinders are fired in one of several firing orders. (PPT Slide 21)



Pairs of pistons that go up and down together but fire 360° from each other are called companions. (PPT Slide 19)



Most engines have liquid cooling systems that use coolant to prevent rust and corrosion and provide additional protection against freezing and boiling. (PPT Slides 23–25)



Spark ignition engines utilize a spark plug to start the ignition event. (PPT Slide 26)



Compression engines utilize heat and pressure to start the ignition event in the cylinder (PPT Slide 27)

Instructor Manual: Chapter 1: Engine Operation



Gasoline Direct Injection utilizes a spark plug, has a high compression similar to a compression engine and gasoline to complete the combustion event. (PPT Slide 28)



Two Stroke cycle is utilized in applications where there needs to be a power stroke every rotation. They are very quick but require the oil to be injected/mixed with the fuel. (PPT Slide 29)

[return to top]

LESSON HINTS Use a model and diagrams to discuss the four-stroke cycle. Have students write down events that occur during each of the four strokes. Show engine parts and discuss basic engine operation. Discuss companion cylinders and firing orders. Have students fill in part names on a handout. [return to top]

READING ASSIGNMENT Read pages 2 through 24 in Automotive Engines: Diagnosis, Repair, and Rebuilding, 9th edition. [return to top]

WRITTEN ASSIGNMENTS Complete Chapter 1 Study Questions (found on p. 23 in Automotive Engines: Diagnosis, Repair, and Rebuilding, 9th edition). Complete Chapter 1 ASE-Style Review Questions (found on p. 24 in Automotive Engines: Diagnosis, Repair, and Rebuilding, 9th edition). [return to top]

CHAPTER 1 ANSWERS TO STUDY QUESTIONS 1. a stroke 2. compression ratioVa 3. B (twice as fast) 4. in lawnmowers generators, and other industrial engines 5. overhead cam

Instructor Manual: Chapter 1: Engine Operation

6. 50 times 7. Welsh plug, expansion plug, core plug, freeze plug, soft plug, water jacket plug 8. a long block 9. smooth power impulses, starter ring gear, clutch surface 10. no 11. V-8s: 90° in-line sixes: 120° in-line four cylinders: 180° 12. diesel 13. Otto-cycle engine 8:1 to 10:1 diesel-cycle 16:1 to 22:1 14. 180° 15. injection of fuel into compressed air (heat) [return to top]

CHAPTER 1 ANSWERS TO ASE-STYLE REVIEW QUESTIONS 1. A 2. D 3. A 4. B 5. A 6. A 7. D 8. C 9. C 10. C [return to top]

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 2: Engine Shop Safety

Instructor Manual Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 2: Engine Shop Safety

TABLE OF CONTENTS Purpose and Perspective of the Chapter ................................................................................................... 8 Chapter Objectives ...................................................................................................................................... 8 Complete List of Chapter Activities and Assessments ............................................................................. 8 Key Terms .................................................................................................................................................... 8 What’s New in This Chapter ...................................................................................................................... 9 Chapter Outline ........................................................................................................................................... 9 ASE Education Foundation Tasks ........................................................................................................... 11 Job Sheets................................................................................................................................................... 11 Lesson Hints............................................................................................................................................... 12 Reading Assignment .................................................................................................................................. 12 Written Assignments ................................................................................................................................. 12 Chapter 2 Answers to Engine Shop Safety Test ...................................................................................... 12

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 2: Engine Shop Safety

PURPOSE AND PERSPECTIVE OF THE CHAPTER The purpose of this chapter is to introduce students to safety in an automotive shop environment. Not understanding the different chemicals and safety procedures can cause students to injury themselves or someone else when they operate in this environment. Without a comprehensive understanding of all of the proper tools and techniques, students may conduct procedures in an unsafe way.

CHAPTER OBJECTIVES Upon completion of this chapter, the student should be able to:   

Use shop tools and equipment safely. Determine whether a chemical is safe to use. Locate and read a material safety data sheet.

COMPLETE LIST OF CHAPTER ACTIVITIES AND ASSESSMENTS For additional guidance, refer to the Teaching Online Guide. Chapter Objective

Activity/Assessment

Duration

Icebreaker

Source (i.e., PPT slide, Workbook) PPT slide 2

Explain the reasons behind knowing how to safely operate in a shop environment Identify how to safely hoist a vehicle

Activity

PPT slide 24

10–20 minutes

Explain what an SDS is

Self-Assessment

PPT slide 32

5–10 minutes

10–15 mins

[return to top]

KEY TERMS backfire: When an air-fuel mixture explodes in the exhaust system barrier creams: Aid in cleaning hands; sometimes rubbed on the skin prior to working in a greasy environment

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 2: Engine Shop Safety

chlorinated solvent: A solvent that has chlorine atoms. Chlorinated solvents are harmful to the environment and their use is usually restricted. dermatitis: Irritated skin; it can result from exposure to solvents that are damaging to the skin flash point: The lowest point at which a liquid will give off flammable vapors greasesweep: A material used to soak up spills Hazard Communication Standards: The regulations outlined by the EPA for the disposal of hazardous materials HEPA Vacuum: A special vacuum for asbestos SDS: Material Safety Data Sheet mushroomed chisel: When the head of a chisel gets rounded over popback: When an air-fuel mixture explodes in the intake system spontaneous combustion: When a flammable substance ignites on its own [return to top]

WHAT’S NEW IN THIS CHAPTER The following elements are improvements in this chapter from the previous edition: 

New case histories added

[return to top]

CHAPTER OUTLINE 

Accidents are usually caused by people not paying attention to their environment and conducting themselves in an unsafe manner; thinking through the procedures will minimize the possibility of becoming injured while conducting the procedure. (PPT Slide 4)



Wearing proper eye and face protection is key to keeping your face protected. (PPT Slide 5)



One of the most common injuries is back injuries because of improper lifting procedures. (PPT Slide 6)



Using the proper PPE is key to keeping your whole body protected. (PPT Slide 7)

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 2: Engine Shop Safety



Picking up your area and keeping the shop in a tidy manner will ensure you do not trip over materials left on the floor or chemicals won’t be spilled into the work area. (PPT Slides 8, 9)



Fire prevention is as simple as removing flammable material away from open flames. (PPT Slide 10)



If a fire does occur, knowing what type of fire it is will help in selecting the proper fire extinguisher. (PPT Slides 11)



The first step in putting out an electrical fire is to remove power from the circuit so it is not being continuously fed with power to keep the fire going. (PPT Slide 12)



Electrical shock and fuel fires are two major issues present in an automotive facility. Being aware of the environment that is around you will minimize the possibility of a major electrical or fuel fire. (PPT Slide 13-14)



General hybrid safety requires trained personnel to power down a hybrid vehicle before servicing any high-voltage component. (PPT Slides 15)



Cooling temperature should be checked before removing any cooling system component, or burns could occur. (PPT Slides 16)



Checking tooling for serviceability before using them is vital. (PPT Slides 17)



When using pullers and presses, eye protection is a must, and the technician should understand how these components operate before using them. (PPT Slides 18–20)



Air tool usage must be done in a safe manner, as compressed air could penetrate the skin and cause other health issues. (PPT Slides 21–23)



When using electric hand tools or electric bench top tooling, making sure the ground pin on the plug is in good condition will minimize the possibility of shock. (PPT Slides 24–25)



When lifting a vehicle, the technician should utilize service information to determine the proper lift points and set the lift properly before hoisting that vehicle into the air. (PPT Slides 26–29)



When charging batteries, make sure to have the proper charger for the battery chemistry and also make sure to turn it off before you remove it from the battery you are charging. (PPT Slides 30– 31)



An automotive repair facility has a lot of hazardous materials around, and the technician should know first aid and how to make that material inert. The SDS is key to helping technicians understand all of the properties of these materials (PPT Slides 32–34)

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 2: Engine Shop Safety

ASE EDUCATION FOUNDATION TASKS 1.1

Identify general shop safety rules and procedures. (RST)

1.2

Utilize safe procedures for handling of tools and equipment. (RST)

1.3

Identify and use proper placement of floor jacks and jack stands. (RST)

1.4

Identify and use proper procedures for safe lift operation. (RST)

1.5

Utilize proper ventilation procedures for working within the lab/shop area. (RST)

1.6

Identify marked safety areas. (RST)

1.7

Identify the location and the types of fire extinguishers and other fire safety equipment; demonstrate knowledge of the procedures for using fire extinguishers and other fire safety equipment. (RST)

1.8

Identify the location and use of eye wash stations. (RST)

1.10

Comply with the required use of safety glasses, ear protection, gloves, and shoes during lab/shop activities. (RST)

1.11

Identify and wear appropriate clothing for lab/shop activities. (RST)

1.12

Secure hair and jewelry for lab/shop activities. (RST)

1.13

Demonstrate awareness of the safety aspects of supplemental restraint systems (SRS), electronic brake control systems, and hybrid vehicle high-voltage circuits. (RST)

1.14

Demonstrate awareness of the safety aspects of high-voltage circuits (such as high-intensity discharge (HID) lamps, ignition systems, injection systems, etc.). (RST)

1.15

Locate and demonstrate knowledge of safety data sheets (SDS). (RST)

2.1

Identify tools and their usage in automotive applications. (RST)

2.3

Demonstrate safe handling and use of appropriate tools. (RST)

2.4

Demonstrate proper cleaning, storage, and maintenance of tools and equipment. (RST)

I.A.7

Identify service precautions related to service of the internal combustion engine of a hybrid vehicle. (MLR) P-2

I.A.9

Identify service precautions related to service of the internal combustion engine of a hybrid vehicle. (AST/MAST) P-2

JOB SHEETS No Job sheets applicable [return to top]

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 2: Engine Shop Safety

LESSON HINTS Several safety programs are available commercially. In our engine repair classes, we use a safety test and PowerPoint slides of various pieces of equipment in our shop. Should an accident occurring in your lab result in a lawsuit, the investigator will want proof that safety instruction was provided to the student(s) involved. A safety test is required for each student in all of our lab courses before that student may work in the lab. It is more meaningful to the student if he or she does not see the same safety program for each class. [return to top]

READING ASSIGNMENT Read pages 25–52 in Automotive Engines: Diagnosis, Repair, Rebuilding, 9E.

WRITTEN ASSIGNMENTS Complete Chapter 2 Study Questions (found on pp. 51–52 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E).

CHAPTER 2 ANSWERS TO ENGINE SHOP SAFETY TEST 16. back, eyes 17. freeze 18. legs 19. fire 20. B 21. spontaneous 22. vapor 23. gasoline 24. flash 25. ground 26. electrical 27. water 28. asbestos 29. green 30. disconnected

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 2: Engine Shop Safety

31. squeezing 32. professional 33. reground 34. eye or face 35. handle 36. air 37. blowguns 38. impact 39. wrench 40. air 41. grinders 42. pipe 43. talk 44. drill 45. drilling 46. side 47. rest 48. hydraulic 49. manual 50. hydraulic jack 51. jack 52. 6 inches 53. 1 ½ 54. picker 55. jack 56. end 57. explosions 58. charger 59. water 60. instructor

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 3: Diagnosing Engine Problems

61. toxicity 62. corrosive 63. material 64. smaller 65. systemic [return to top]

Instructor Manual Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 3: Diagnosing Engine Problems

TABLE OF CONTENTS Purpose and Perspective of the Chapter ................................................................................................. 15 Chapter Objectives .................................................................................................................................... 15 Complete List of Chapter Activities and Assessments ........................................................................... 15 Key Terms .................................................................................................................................................. 15 What’s New in This Chapter .................................................................................................................... 16 Chapter Outline ......................................................................................................................................... 16 ASE Education Foundation Tasks ........................................................................................................... 17 Job Sheets................................................................................................................................................... 18 Lesson Hints............................................................................................................................................... 18 Reading Assignment .................................................................................................................................. 19 Written Assignments ................................................................................................................................. 19 Chapter 3 Answers to Study Questions .................................................................................................... 19 Chapter 3 Answers to ASE-Style Review Questions................................................................................... 20

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 3: Diagnosing Engine Problems

PURPOSE AND PERSPECTIVE OF THE CHAPTER The purpose of this chapter is to introduce students to the concept that they should diagnosis why the engine failed before repairing the engine. Not fixing the underlying issue before repairing the failure will result in the repair failing in the near future. Without this forward-thinking mindset, the customer will likely return for a repeat repair.

CHAPTER OBJECTIVES Upon completion of this chapter, the student should be able to:  

Use engine diagnostic tools and equipment safely and properly. Diagnose engine and related problems and determine the proper repair procedure.

COMPLETE LIST OF CHAPTER ACTIVITIES AND ASSESSMENTS For additional guidance, refer to the Teaching Online Guide. Chapter Objective

Activity/Assessment

Duration

Icebreaker

Source (i.e., PPT slide, Workbook) PPT slide 2

Discuss the different types of engine problems you have to diagnosis Identify the difference between a cylinder leakdown tester and compression gauge Explain what you are looking for when disassembling an engine before replacing any components

Activity

PPT slide 17

10–20 minutes

Self-Assessment

PPT slide 30

5–10 minutes

10–15 minutes

[return to top]

KEY TERMS ATF: Automatic transmission fluid black light testing: A black light tester is used for finding oil leaks. A fluorescent dye is added to the oil.

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 3: Diagnosing Engine Problems

block check tester: A tester that has a liquid that changes color when exposed to exhaust gas. It sniffs the air above a radiator’s coolant. cranking vacuum test: A test of an engine’s condition that is done with a vacuum gauge while the engine cranks crankshaft position sensor: A sensor that relays crankshaft speed and position cross fluid contamination: When oil and coolant mix due to an internal leak EGR: Exhaust gas recirculation foamy emulsion: A combination of oil vapors and moisture that appears in cooler areas of the engine, looks like vanilla pudding intake manifold vacuum: The vacuum that an engine makes as it runs. It can be measured anywhere in the intake manifold. PCV: Positive crankcase ventilation powertrain control module: Powertrain control module, or computer ring ridge: A ridge that forms at the top of the cylinder as the cylinder wall wears seized engine: When an engine is damaged to the point where its crankshaft will not turn [return to top]

WHAT’S NEW IN THIS CHAPTER The following elements are improvements in this chapter from the previous edition:    

New case histories New note boxes Updated PCV information Updated terms

[return to top]

CHAPTER OUTLINE 

Diagnosing the root cause of the failure is key to making sure the repair that you are conducting will last a long time. (PPT Slide 4)



Oil consumption or leaks is one of the main complaints from any internal combustion engine. Determining if it is an internal issue or if it is leaking externally is key to diagnosing an oil consumption complaint. (PPT Slides 5–8)

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 3: Diagnosing Engine Problems



Compression loss is another issue that is common on an internal combustion engine. Determining what has caused this issue before removing any components is key to evaluating the cost and time of the repair. (PPT Slides 9–13)



Utilizing diagnostic tools to conduct power balances and other tests will help the technician to determine which cylinder is the source of the issue. (PPT Slides 14–17)



Cylinder leakdown testing can determine if the cylinder can seal itself and hold the combustion event. (PPT Slides 18–19)



Using a vacuum gauge to determine if there is an internal mechanical issue is a quick way to determine what type of repair the vehicle needs. (PPT Slides 20–24)



Engine noises are another source of diagnosing where there is an issue. The speed, location, and tone of the noise can help the technician indicate at what point the engine is failing. (PPT Slides 25–29)



Preignition and detonation is having a spark and combustion event before the mechanical parts of the engine catch up. Over time, this will cause the engine components to fail. (PPT Slides 30–31)



Lack of oil pressure or engine cooling will cause the engine systems to fail. This could be a low fluid condition to a failed component, and understanding how it failed will keep the repair from failing the same way. (PPT Slides 32–33)

ASE EDUCATION FOUNDATION TASKS I.A.4

Inspect engine assembly for fuel, oil, coolant, and other leaks; determine necessary action. (MLR/AST/MAST) P-1

I.A.7

Inspect, remove, and/or replace engine mounts. (AST/MAST) P-2

I.D.3

Perform cooling system pressure and dye tests to identify leaks; check coolant condition and level; inspect and test radiator, pressure cap, coolant recovery tank, heater core; determine necessary action. (MLR/AST/MAST) P-1

I.D.4

Identify causes of engine overheating. (MLR/AST/MAST) P-1

I.D.11 Perform oil pressure tests; determine necessary action. (AST/MAST) P-1 VIII.A.5 Identify and interpret engine performance concerns; determine needed action. (AST/MAST) P-1 VIII.A.6 Diagnose abnormal engine noises and vibrations; determine needed action. (AST/MAST) P3

VIII.A.8 Perform engine absolute (vacuum/boost) manifold pressure tests; document results. (AST/Mast) P-1

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 3: Diagnosing Engine Problems

VIII.A.9 Perform cylinder power balance tests; document results. (AST/Mast) P-1 VIII.A.10 Perform cylinder cranking and running compression tests; document results. (AST/Mast) P1 VIII.A.11

Perform cylinder leakage tests; determine needed action. (AST/Mast) P-1

JOB SHEETS ASE Education Foundation Job Sheet 1: Inspect an Engine for Fluid Leaks. MLR/AST/MAST: I.A.4, P-1 ASE Education Foundation Job Sheet 2: Engine Vacuum Testing. AST/MAST: VIII.A.8, P-1 ASE Education Foundation Job Sheet 3: Engine Compression Testing. AST/Mast: VIII.A.10, P-1 ASE Education Foundation Job Sheet 3: Engine Compression Testing. MLR: I.A.1, P-1; AST/MAST: I.A.2, P-1 ASE Education Foundation Job Sheet 4: Engine Power Balance Testing. AST/Mast: VIII.A.9, P-2 ASE Education Foundation Job Sheet 5: Engine Cylinder Leakage Testing. AST/MAST: VIII.A.11, P-1;

[return to top]

LESSON HINTS Using examples of worn and broken parts, discuss various engine problems. Describe the different testing instruments before demonstrating them in the lab. Discuss the use of diagnostic flow charts found in service manuals. Demonstrations: 1. Compression test 2. Cylinder leakage test 3. Cylinder power balance test 4. Cooling system pressure test 5. Combustion leak test 6. PCV test 7. Modulator check 8. Stethoscope 9. Inspection mirror and flashlight

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 3: Diagnosing Engine Problems

10. Pinch pliers 11. Smoke testing [return to top]

READING ASSIGNMENT Read pages 53–95 in Automotive Engines: Diagnosis, Repair, Rebuilding, 9E.

WRITTEN ASSIGNMENTS Complete Chapter 3 Study Questions [found on p. 94 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E]. Complete Chapter 3 ASE-Style Review Questions [found on p. 95 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E]. [return to top]

CHAPTER 3 ANSWERS TO STUDY QUESTIONS 66. burned parts (pistons, valves, pointed spark plug electrodes, head gasket) 67. valve guide seals 68. bad valve guide seal 69. reset the ignition timing 70. exhaust 71. a dark ring appears 72. spark plugs 73. four 74. EGR valve stuck open at idle 75. 1000 76. 3 inches 77. rod knock 78. broken timing chain or timing belt 79. piston or pin clearance 80. a. oil leaking past the rings b. oil leaking from a valve guide or bad valve guide seal

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 4: Engine Removal, Disassembly, Inspection, and In-Chassis Repairs

[return to top]

CHAPTER 3 ANSWERS TO ASE-STYLE REVIEW QUESTIONS 11. C 12. D 13. A 14. B 15. C 16. A 17. C 18. C 19. C 20. C [return to top]

Instructor Manual Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 4: Engine Removal, Disassembly, Inspection, and In-Chassis Repairs

TABLE OF CONTENTS Purpose and Perspective of the Chapter ................................................................................................. 21 Chapter Objectives .................................................................................................................................... 21 Complete List of Chapter Activities and Assessments ........................................................................... 21 Key Terms .................................................................................................................................................. 21 What’s New in This Chapter .................................................................................................................... 22 Chapter Outline ......................................................................................................................................... 22 ASE Education Foundation Tasks ........................................................................................................... 23 Job Sheets................................................................................................................................................... 24 Lesson Hints............................................................................................................................................... 24 Reading Assignment .................................................................................................................................. 25 Written Assignments ................................................................................................................................. 25 Chapter 4 Answers to Study Questions .................................................................................................... 25 Chapter 4 Answers to ASE-Style Review Questions................................................................................... 26

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 4: Engine Removal, Disassembly, Inspection, and In-Chassis Repairs

PURPOSE AND PERSPECTIVE OF THE CHAPTER The purpose of this chapter is to introduce students to basic engine removing and disassembly. As you are aware, every engine removal is different and every engine disassembly is different. This chapter will focus on the basic systems that need to be looked at to effectively remove and disassemble the engine. As always, refer to service information for proper procedures for your application.

CHAPTER OBJECTIVES Upon completion of this chapter, the student should be able to:    

Locate repair information in shop manuals. Safely and properly remove an engine from a vehicle. Disassemble an engine in an orderly manner. Select the most appropriate method of engine repair.

COMPLETE LIST OF CHAPTER ACTIVITIES AND ASSESSMENTS For additional guidance, refer to the Teaching Online Guide. Chapter Objective

Activity/Assessment

Duration

Icebreaker

Source (i.e., PPT slide, Workbook) PPT slide 2

Explain the use of the VIN and what proper procedures are for component replacement. Identify engine disassembly tooling.

Activity

PPT slide 27

10–20 minutes

Evaluate your understanding of how you would attack engine disassembly.

Self-Assessment

PPT slide 29

5–10 minutes

10–15 minutes

[return to top]

KEY TERMS aftermarket: Automobile parts that are made by other than original equipment manufacturers custom engine rebuild: When a complete engine is disassembled and rebuilt

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 4: Engine Removal, Disassembly, Inspection, and In-Chassis Repairs

freewheeling engine: An engine that will not have a valve contact a piston if the timing chain or belt breaks long block: A complete engine assembly R&R: Remove and replace ring ridge: A ridge that forms at the top of the cylinder as the cylinder wall wears short blocks: Complete block assembled without heads stock: The way an engine comes from the factory stress raiser: When the surface of a part is damaged, stress is raised in that area. If a break occurs it will probably be there thrust bearing surfaces: Flat bearing surfaces at 90° to the bearing load surface that control fore and aft movement of the crankshaft [return to top]

WHAT’S NEW IN THIS CHAPTER The following elements are improvements in this chapter from the previous edition:    

Updated information on rebuilding and replacing Information about fractured connection rods Updated information about cross bolts Updated information about OHC camshaft removal.

[return to top]

CHAPTER OUTLINE 

The Vehicle Identification Number (VIN) is key to ordering components for the vehicle. (PPT Slide 4)



Before conducting any repairs on the vehicle, make sure the repair order is filled out completely and properly so the technician knows exactly what the complaint is. (PPT Slide 5)



Service information is key to the proper repair of the vehicle in the least amount of time. (PPT Slide 6)



First step in removing the vehicle’s engine is to drain the fluids and remove the battery and air cleaner assembly. (PPT Slide 7)



Second step is to remove the accessories and cooling system components. (PPT Slide 8)

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 4: Engine Removal, Disassembly, Inspection, and In-Chassis Repairs



Third step is to remove any fuel lines and remaining sensor wiring. (PPT Slide 9)



Fourth step is to remove any intake and exhaust components and determine if the transmission needs to be removed or left in the vehicle. (PPT Slide 10)



In some situations, it is easier to remove the transmission and engine as an assembly and then split them after they are removed. (PPT Slide 12-15)



Once the engine is out, evaluate what the best process would be to repair or replace the engine. This will have to take the cost factor into the decision, as each way costs a different amount. (PPT Slide 16)



When disassembling the engine, organization is key to efficient reassembly after component evaluation. (PPT Slides 17–21)



Disassembling the short block requires the technician to carefully remove the cylinder ridge, protecting the crankshaft as the connecting rods are removed and making sure all of the core plugs are removed for proper engine cleaning. (PPT Slides 22–26)



Once the engine is disassembled, evaluating which components will need to be replaced will make it easier to order the correct parts the first time. (PPT Slide 27)

ASE EDUCATION FOUNDATION TASKS 2.6

Perform common fastener and thread repair, including removing broken bolts, restoring internal and external threads, and repairing internal threads with thread inserts.

I.A.9

Remove and reinstall engine on a newer vehicle equipped with OBD; reconnect all attaching components and restore the vehicle to running condition. (MAST) P-3

I.B.2

Remove cylinder head; inspect gasket condition; install cylinder head and gasket; tighten according to manufacturer’s specifications and procedures. (AST/MAST) P-1

I.B.3

Clean and visually inspect a cylinder head for cracks; check gasket surface areas for warpage and surface finish; check passage condition. (AST/MAST) P-1

I.B.9

Inspect valve guides for wear; check valve stem-to-guide clearance; determine needed action. (AST/MAST) P-1

I.B.10 Inspect valves and valve seats; determine needed action. (MAST) P-3

I.C.2

Remove, inspect, or replace crankshaft vibration damper (harmonic balancer). (AST/MAST) P-2

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 4: Engine Removal, Disassembly, Inspection, and In-Chassis Repairs

I.C.3

Disassemble engine block; clean and prepare components for inspection and reassembly. (MAST) P-2

I.C.8

Inspect crankshaft for straightness, journal damage, keyway damage, thrust flange and sealing surface condition, and visual surface cracks; check oil passage condition; measure end play and journal wear; check crankshaft position sensor reluctor ring (where applicable); determine needed action. (MAST) P-2

I.C.9

Inspect main and connecting rod bearings for damage and wear; determine needed action. (MAST) P-2

JOB SHEETS ASE Education Foundation Job Sheet 6: Engine Removal (FWD). AST: I.A.9, P-3 ASE Education Foundation Job Sheet 7: Engine Removal (RWD). AST: I.A.9, P-3 ASE Education Foundation Job Sheet 13: OHC Cylinder Head Disassembly and Inspection. AST/MAST: I.B.3, P-1 ASE Education Foundation Job Sheet 14: OHV Cylinder Head Disassembly and Inspection. AST/MAST: I.B.3, P-1 ASE Education Foundation Job Sheet 15: Valve, Guide, and Seat Inspection. MAST: I.B.9, I.B.10 P3. ASE Education Foundation Job Sheet 29: Inspecting and Measuring the Piston Rings. MAST: I.C.3, P-2 ASE Education Foundation Job Sheet 37: Thread Repair. RST: 2.6 ASE Education Foundation Job Sheet 11: Engine Block Disassembly, Inspection, and Cleaning. MAST: I.C.3, P2

[return to top]

LESSON HINTS Handouts: 1. Engine removal checklist 2

Engine teardown checklist

3. Firing orders fill-in 4. Engine parts checklist 5. Engine specifications fill-in Demonstrations:

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 4: Engine Removal, Disassembly, Inspection, and In-Chassis Repairs

1. Service information retrieval 2. Mounting sling on engine 3. Ring ridge removal 4. Lifter removal 5. Damper removal 6. Piston/rod removal 7. Main and rod cap marking procedure 8. Cam removal 9. R and R crank sprocket and woodruff key [return to top]

READING ASSIGNMENT Read pages 96–151 in Automotive Engines: Diagnosis, Repair, Rebuilding, 9E.

WRITTEN ASSIGNMENTS Complete Chapter 4 Study Questions [found on p. 150 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E]. Complete Chapter 4 ASE-Style Review Questions [found on p. 151 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E]. [return to top]

CHAPTER 4 ANSWERS TO STUDY QUESTIONS 81. VIN (Vehicle Identification Number) 82. 8th 83. flat rate manual 84. TSB (technical service bulletins) 85. a ground strap 86. pressurized refrigerant will escape, which is a safety hazard 87. to prevent gas from siphoning out when gas expands; the vapor canister should be plugged, too 88. to keep oil in the pan from running back into the engine

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 5: Cleaning the Engine

89. adjustable wrench on woodruff key, turn damper bolt with socket, flywheel turning tool on starter ring gear 90. rod bolt protectors or fuel hose 91. keep them in order 92. no 93. by using a magnet 94. clean the carbon off of the top and look for a marking 95. core [return to top]

CHAPTER 4 ANSWERS TO ASE-STYLE REVIEW QUESTIONS 21. B 22. A 23. A 24. B 25. D 26. D 27. B 28. C 29. A 30. A [return to top]

Instructor Manual Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 5: Cleaning the Engine

TABLE OF CONTENTS Purpose and Perspective of the Chapter Chapter Objectives

Complete List of Chapter Activities and Assessments 28 Key Terms

What’s New in This Chapter 29 Chapter Outline

ASE Education Foundation Tasks

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 5: Cleaning the Engine

Job Sheets

Lesson Hints

Reading Assignment

Written Assignments 30 Chapter 5 Answers to Study Questions30 Chapter 5 Answers to ASE-Style Review Questions

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 5: Cleaning the Engine

PURPOSE AND PERSPECTIVE OF THE CHAPTER The purpose of this chapter is to introduce students to basic engine removal and disassembly. As you are aware, every engine removal is different, and every engine disassembly is different. This chapter will focus on the basic systems that need to be looked at to effectively remove and disassemble the engine. As always, refer to service information for proper procedures for your application.

CHAPTER OBJECTIVES Upon completion of this chapter, the student should be able to:  

Safely and correctly use cleaning tools and equipment. Describe the best choice of cleaning method for particular applications.

COMPLETE LIST OF CHAPTER ACTIVITIES AND ASSESSMENTS For additional guidance, refer to the Teaching Online Guide. Chapter Objective

Activity/Assessment

Duration

Icebreaker

Source (i.e., PPT slide, Workbook) PPT slides 4–7

Safely and correctly use cleaning tools and equipment Describe the best choice of cleaning method for the particular application

Activity

PPT slides 11–18

10–20 minutes

Evaluate your understanding of how you would clean engine components

Self-Assessment

PPT slide 19

5–10 minutes

10–15 minutes

[return to top]

KEY TERMS agitation: Moving a liquid so that it cleans better ferrous: Iron and steel labor intensive: A method of work that cannot be done

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 5: Cleaning the Engine

by machine only, requiring an operator

pH scale: A measurement of whether a material is alkaline/ base/caustic or acid scale: A hard insulating substance that occurs on the inside of cast iron water jackets when the cooling system is not maintained sludge: A mixture of water and oil that resembles dirty mayonnaise that results when oil is not changed often enough [return to top]

WHAT’S NEW IN THIS CHAPTER No substantive changes to this chapter in the new edition [return to top]

CHAPTER OUTLINE 

Chemical cleaning can be conducted on engine components, with the proper outcome based on the material that is to be removed. (PPT Slide 4)



Before conducting any cleaning, understand how bases remove oil and debris. (PPT Slide 5)



Cleaning with acids will remove rust and scale. (PPT Slide 6)



Solvent-based cleaning allows for removal of debris that the type of solvent is designed for. Disposing of the chemicals should be thought of before introducing the chemicals to the repair facility. (PPT Slides 7 and 9)



Hot soak tanks heat up the chemicals, which allows them to be cleaned properly and usually is quicker than a cold tank. (PPT Slide 10)



Manual cleaning allows the technician to finely remove any material that is left after the machining or major cleaning process. (PPT Slides 12–14)



Blasting cabinets allow the different media to pulverize the component with different types of medium to remove the material on the component. (PPT Slides 15–17)



Thermal cleaning heats up the components to a temperature that vaporizes the attached material on the component. (PPT Slide 18)



Ultrasonic cleaning provides cleaning through sound waves that are gentle on the component. (PPT Slide 20)

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 5: Cleaning the Engine



Marking the components as they get cleaned will allow the technician to identify what components are completed after they are done. (PPT Slide 22)

ASE EDUCATION FOUNDATION TASKS I.C.3

Disassemble engine block; clean and prepare components for inspection and reassembly. (MAST) P-2

JOB SHEETS ASE Education Foundation Job Sheet 11: Engine block disassembly, inspection and cleaning. MAST: I.C.3, P-2 [return to top]

LESSON HINTS Discuss the theory and use of the pressure washer, hot tank, bead blaster, various blasters, cleaning tanks, etc. [return to top]

READING ASSIGNMENT Read pages 153–168 in Automotive Engines: Diagnosis, Repair, Rebuilding, 9E.

WRITTEN ASSIGNMENTS Complete Chapter 5 Study Questions [found on p. 168 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E]. Complete Chapter 5 ASE-Style Review Questions [found on pp. 168–169 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E]. [return to top]

CHAPTER 5 ANSWERS TO STUDY QUESTIONS 96. The cleaning solution may foam. 97. by using a magnet 98. lubricate

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 6: Measuring

99. glass 100.

false

101.

blaster

102.

shot blaster

103.

open flame oven

104.

rust, scale

105.

convection

[return to top]

CHAPTER 5 ANSWERS TO ASE-STYLE REVIEW QUESTIONS 31. true 32. C 33. C 34. true 35. false 36. D 37. true 38. A 39. C 40. D [return to top]

Instructor Manual Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 6: Measuring

TABLE OF CONTENTS Purpose and Perspective of the Chapter Chapter Objectives

Complete List of Chapter Activities and Assessments 33 Key Terms

What’s New in This Chapter 34 Chapter Outline

ASE Education Foundation Tasks Job Sheets

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 6: Measuring

Lesson Hints

Reading Assignment

Written Assignments 35 Chapter 6 Answers to Study Questions36 Chapter 6 Answers to ASE-Style Review Questions

Chapter 6 Answers to Micrometer Practice Questions

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 6: Measuring

PURPOSE AND PERSPECTIVE OF THE CHAPTER The purpose of this chapter is to introduce students to engine component measurement to verify the serviceability of those components. Without knowing whether the component is within specification; the engine may fail if put back into service with failed components.

CHAPTER OBJECTIVES Upon completion of this chapter, the student should be able to:  

Perform measurements using any of the tools in this chapter Have a working understanding of the metric and English systems of measurement

COMPLETE LIST OF CHAPTER ACTIVITIES AND ASSESSMENTS For additional guidance, refer to the Teaching Online Guide. Chapter Objective

Activity/Assessment

Duration

Icebreaker

Source (i.e., PPT slide, Workbook) PPT slide 2

Explain differences between the English and Metric measurement systems. Perform measurements using any of the tools in this chapter.

Activity

PPT slides 12–14

10–20 minutes

Evaluate your understanding of engine measurement tooling.

Self-Assessment

PPT slide 18

5–10 minutes

10–15 minutes

[return to top]

KEY TERMS British Imperial (UK) System: The standard system of measurement used for many years in the United States and England caliper: A measuring tool for making outside or inside measurements foot-pounds/newtons: The standard method of measuring torque

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 6: Measuring

gauge standard: A calibration tool for a precision measuring instrument I.D.: Inside diameter LCD: Liquid crystal display Metric system: The system of measurement used throughout the world O.D.: Outside diameter Plastigage: A thin strip of plastic that is used to measure bearing clearances Vernier scale: A short scale that reads against a longer scale to tell divisions [return to top]

WHAT’S NEW IN THIS CHAPTER No substantive changes to this chapter in the new edition [return to top]

CHAPTER OUTLINE 

The metric system utilizes liters, grams, kilograms per square centimeter, Centigrade, and Newton meters. (PPT Slide 4)



Any type of distance or space should be measured with the proper type of tool. Rulers, feeler gauges, or gappers are used to measure this space. (PPT Slide 5)



Vernier caliper allows inside and outside measurements along with depth based on a 7-inch ruler. (PPT Slide 7-9)



Micrometers are used for precise measurement of flat surfaces, for thickness or diameter. Other tooling is used for the inside diameters. (PPT Slides 10–14)



Split ball gauges allow an inside diameter reading of small blind holes in components. (PPT Slide 15)



Telescoping gauges are used for deep measurement in a cylinder. Utilizing these and a micrometer, you can generate a cylinder diameter or taper reading. (PPT Slide 16)



Dial indicators are very sensitive and can generate play measurements or unevenness. (PPT Slides 17–20)

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 6: Measuring

ASE EDUCATION FOUNDATION TASKS 2.2

Identify standard and metric designation. (RST)

I.B.3

Clean and visually inspect a cylinder head for cracks; check gasket surface areas for warpage and surface finish; check passage condition. (AST/MAST) P-1

I.B.9 Inspect valve guides for wear; check valve stem-to-guide clearance; determine needed action. (MAST) P-3 I.C.5

Inspect and measure cylinder walls/sleeves for damage, wear, and ridges; determine needed action. (MAST) P-2

I.C.13 Inspect, measure, and install piston rings. (MAST) P-2

JOB SHEETS ASE Education Foundation Job Sheet 12: Using precision measuring tools. AST/MAST: I.B.3, P-1

ASE Education Foundation Job Sheet 29: Inspecting and Measuring the Piston Rings. AST/MAST: I.C.13, P-2 [return to top]

LESSON HINTS Discuss decimal values to four places. Describe various measuring instruments, including cover indicators, micrometers, telescopes, hole gauges, and vernier calipers. Demonstrations: 1. Using vernier calipers 2. Using a micrometer 3. Using dial indicators [return to top]

READING ASSIGNMENT Read pages 170–184 in Automotive Engines: Diagnosis, Repair, Rebuilding, 9E.

WRITTEN ASSIGNMENTS Complete Chapter 6 Study Questions [found on p. 184 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E].

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 6: Measuring

Complete Chapter 6 ASE-Style Review Questions [found on pp. 184–185 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E]. Complete Chapter 6 Micrometer Practice Questions [found on p. 185 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E]. [return to top]

CHAPTER 6 ANSWERS TO STUDY QUESTIONS 106.

0.100 inch

107.

gauge block

108.

Vernier

109.

90 degrees to it

110.

dial indicator or feeler gauge

111.

a revolution counter

112.

127mm

113.

5 inches

114.

61 cubic inches

115.

164 cubic inches

[return to top]

CHAPTER 6 ANSWERS TO ASE-STYLE REVIEW QUESTIONS 41. A 42. C 43. B 44. D 45. D [return to top]

CHAPTER 6 ANSWERS TO MICROMETER PRACTICE QUESTIONS 1. 2. 3. 4. 5. 6.

0.220 0.593 0.245 0.139 0.234 0.782

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 7: Cylinder Head: Parts and Service

7. 0.471 8. 0.080 [return to top]

Instructor Manual Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 7: Cylinder Head: Parts and Service

TABLE OF CONTENTS Purpose and Perspective of the Chapter Chapter Objectives

Complete List of Chapter Activities and Assessments 38 Key Terms

What’s New in This Chapter 39 Chapter Outline

ASE Education Foundation Tasks Job Sheets

Lesson Hints

Reading Assignment

Written Assignments 41 Chapter 7 Answers to Study Questions41 Chapter 7 Answers to ASE-Style Review Questions

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 7: Cylinder Head: Parts and Service

PURPOSE AND PERSPECTIVE OF THE CHAPTER The purpose of this chapter is to introduce students to cylinder head disassembly, valve guide inspection, and replacement. Resurfacing cylinder heads is also covered, as it is one of the key components to keeping the cylinder head in operational condition.

CHAPTER OBJECTIVES Upon completion of this chapter, the student should be able to:    

Disassemble, clean and inspect cylinder heads Analyze wear and damage to cylinder head parts Understand theory related to cylinder head parts Select and perform the correct repair

COMPLETE LIST OF CHAPTER ACTIVITIES AND ASSESSMENTS For additional guidance, refer to the Teaching Online Guide. Chapter Objective

Activity/Assessment

Duration

Icebreaker

Source (i.e., PPT slide, Workbook) PPT slide 2

Understand theory related to cylinder head parts.

Analyze wear and damage to cylinder head parts.

Activity

PPT slides 13–21

10–20 minutes

Evaluate the cylinder head for proper specifications before installation. [return to top]

Self-Assessment

PPT slide 24

5–10 minutes

10–15 minutes

KEY TERMS alloy: A substance that is a combination of two or more metals heli-arc/TIG welding: A welding process for welding aluminum that uses an inert gas shield

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 7: Cylinder Head: Parts and Service

integral valve guides: When the seat or guide is part of the cylinder head knurling: A metal deformation process used to enlarge a metal surface mushroomed valve tip: When a valve tip wears, it becomes larger on the tip pinning/stitching a crack: A process of crack repair using tapered, threaded plug valve stem height: The amount that the valve stem tip extends above the upper surface of the cylinder head. As the valve and seat are ground, the valve stem height changes. [return to top]

WHAT’S NEW IN THIS CHAPTER The following elements are improvements in this chapter from the previous edition: 

Updated information about cylinder head rebuilding

[return to top]

CHAPTER OUTLINE 

Before disassembling the cylinder heads, it is best to run the heads through a hot tank to remove all the oil and to make it easier to remove buildup. (PPT Slide 4-6)



Once the cylinder heads are disassembled, take an initial valve stem height measurement. (PPT Slide 7)



After the valves are removed, start by cleaning out the combustion chamber to make sure it is free of all carbon debris; this may be done with various methods. (PPT Slide 8)



Take each valve and remove the carbon build-up to allow the technician to verify the valves are in serviceable condition. (PPT Slide 9)



Once everything is clean and disassembled, inspect all the components for cracks and serviceability. (PPT Slide 10)



When repairing cracks in a set of iron heads, pinning is common by drilling out the crack and filling it with pipe plugs and re-machining. (PPT Slides 11 and 12)



Valve guide inspection should be done by rocking the valve in the guide to determine how much clearance is between the guide and valve. (PPT Slides 13 and 14)



If a valve guide is out of specification, replacement or knurling is required to bring it back into serviceability limits. (PPT Slides 15–17)

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 7: Cylinder Head: Parts and Service



When reassembling the cylinder heads, replacement of the valve seals is recommended to minimize the possibility of oil leaking into the combustion chamber. (PPT Slides 18–20)



The cylinder head should be checked for flatness and resurfaced if the deck is not flat. (PPT Slides 21–24)

ASE EDUCATION FOUNDATION TASKS I.B.3

Clean and visually inspect a cylinder head for cracks; check gasket surface areas for warpage and surface finish; check passage condition. (AST/MAST) P-2

I.B.8

Replace valve stem seals on an assembled engine; inspect valve spring retainers, locks/keepers, and valve lock/keeper grooves; determine needed action. (MAST) P-3

I.B.9

Inspect valve guides for wear; check valve stem-to-guide clearance; determine needed action. (MAST) P-3

I.B.11 Check valve spring assembled height and valve stem height; determine needed action. (MAST) P-3

JOB SHEETS ASE Education Foundation Job Sheet 16: Inspect and Test Valve Springs. AST/MAST: I.B.7, P-3 ASE Education Foundation Job Sheet 19: Valve Train Component Inspection. MAST: I.B.4, P-2, I.B.12, P-2 ASE Education Foundation Job Sheet 20: Checking and Adjusting Valve Clearance. MAST: I.B.5, P2 ASE Education Foundation Job Sheet 23: Inspecting the Camshaft and Bearings. MAST: I.B.13, P-3, I.B.14, P-3. I.C.7, P-2 ASE Education Foundation Job Sheet 24: Inspecting and Measuring the Cylinder Walls. MAST: I.C. 5, P-2 [return to top]

LESSON HINTS Demonstrations: 1. Head disassembly 2. Crack checking 3. Measuring valve guide wear 4. Checking flatness of head and block

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 7: Cylinder Head: Parts and Service

5. Bronze Bullet™ liner 6. Winona bronzewall 7. Guide replacement 8. Knurling guides [return to top]

READING ASSIGNMENT Read pages 187–222 in Automotive Engines: Diagnosis, Repair, Rebuilding, 9E.

WRITTEN ASSIGNMENTS Complete Chapter 7 Study Questions [found on p. 222 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E]. Complete Chapter 7 ASE-Style Review Questions [found on pp. 222-223 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E]. [return to top]

CHAPTER 7 ANSWERS TO STUDY QUESTIONS 116.

Don’t bend any open valves.

117.

the spring retainer

118.

the valve

119.

yes

120.

any that have oil galleries

121.

magnetic, dye penetrant, zyglow, bead blasting

122.

stitching a crack

123.

drill it

124.

bellmouth

125.

ball gauge and micrometer, dial indicator

126.

knurling

127.

intake seal leakage

128.

O-ring, umbrella, positive

129.

0.002"

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 8: Cylinder Head: Springs, Valves, and Valve Seats

130.

milling, cutting, grinding, sanding

[return to top]

CHAPTER 7 ANSWERS TO ASE-STYLE REVIEW QUESTIONS 46. C 47. A 48. B 49. B 50. C 51. C 52. D 53. C 54. C 55. A [return to top]

Instructor Manual Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 8: Cylinder Head: Springs, Valves, and Valve Seats

TABLE OF CONTENTS Purpose and Perspective of the Chapter Chapter Objectives

Complete List of Chapter Activities and Assessments 43 Key Terms

What’s New in This Chapter 44 Chapter Outline

ASE Education Foundation Tasks Job Sheets

Lesson Hints

Reading Assignment

Written Assignments 46 Chapter 8 Answers to Study Questions46 Chapter 8 Answers to ASE-Style Review Questions

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 8: Cylinder Head: Springs, Valves, and Valve Seats

PURPOSE AND PERSPECTIVE OF THE CHAPTER The purpose of this chapter is to introduce students to cylinder head valves, springs, and seats. When reconditioning a cylinder head, the technician should be inspecting all the components to make sure they are in serviceable limits before putting the cylinder head back into service.

CHAPTER OBJECTIVES Upon completion of this chapter, the student should be able to:    

Analyze wear and damage to valves, springs, and seats. Understand theory related to valves, seats, springs, and other related parts. Select and perform the correct repair. Reassemble the cylinder head.

COMPLETE LIST OF CHAPTER ACTIVITIES AND ASSESSMENTS For additional guidance, refer to the Teaching Online Guide. Chapter Objective

Activity/Assessment

Duration

Icebreaker

Source (i.e., PPT slide, Workbook) PPT slide 2

Explain what a valve spring does in the cylinder head. Identify and perform the correct repair.

Activity

PPT slides 18–26

10–20 minutes

Evaluate your understanding of how to properly recondition a cylinder head before reassembly. [return to top]

Self-Assessment

PPT slide 27

5–10 minutes

10–15 minutes

KEY TERMS Carbon-manganese steel: Iron combined with 0.35% carbon, 0.2% silicon, and 1.5% manganese

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 8: Cylinder Head: Springs, Valves, and Valve Seats

induction hardened: A process by which an integral part is hardened integral seats: When the seat or guide is part of the cylinder head interference angle: When the valve and seat are ground at a different angle; it increases seating pressure, which helps the valve to seat initially Low-carbon steel: Iron with 0.2% carbon and 0.8% manganese Medium-carbon steel: Iron that is alloyed with 0.555% carbon, 0.2% silicon, and 0.65% manganese proud surface: When the surface of a part extends above the surrounding surface runout: An error in alignment from a rotating machine tool that causes two mating parts to be offcenter solvent test: A wet test following valve and seat machining valve lash: Clearance at the end of the valve stem valve spring inserts: Shims used to increase valve spring tension [return to top]

WHAT’S NEW IN THIS CHAPTER The following elements are improvements in this chapter from the previous edition: 

Updated information about pushrods

[return to top]

CHAPTER OUTLINE 

Before removing any component or rebuilding anything, the technician should diagnosis the problem first so that once it is repaired it will not fail again based on a previous condition. (PPT Slide 4)



Valve springs should be removed and inspected for fit and function before it is determined if it can be reused. The valve spring is integral to the sealing of the valve on the seat. (PPT Slides 5– 8)



Pushrods and rocker arms transfer the force from the camshaft and lift to the valve. (PPT Slides 9–10)

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 8: Cylinder Head: Springs, Valves, and Valve Seats



When measuring the valves for serviceability, note any damage or other situations that require replacement. (PPT Slides 11–16)



When grinding the valves, grind them in a way to create an interference fit between the valve and the seat for proper sealing. (PPT Slides 17–24)



When servicing an OHC engine, buckets may be used as a lash adjuster between the camshaft and the valve spring. Verify they are in serviceable condition before reinstallation. (PPT Slide 26)



When reassembling the cylinder head valvetrain, make sure all the components are clean and torqued to specification. Also be sure the proper shims are installed to keep the clearances in specification. (PPT Slide 27)

ASE EDUCATION FOUNDATION TASKS I.B.2

Remove cylinder head; inspect gasket condition; install cylinder head and gasket; tighten according to manufacturer’s specifications and procedures. (AST/MAST) P-1

I.B.3

Clean and visually inspect a cylinder head for cracks; check gasket surface areas for warpage and surface finish; check passage condition. (AST/MAST) P-2

I.B.4

Inspect valve actuating mechanisms for wear, bending, cracks, looseness, and blocked oil passages (orifices); determine needed action. (AST/MAST) P-2

I.B.7

Inspect valve springs for squareness and free height comparison; determine needed action. (MAST) P-3

I.B.10 Inspect valves and valve seats; determine needed action. (MAST) P-3 I.B.11 Check valve spring assembled height and valve stem height; determine needed action. (MAST) P-3

JOB SHEETS ASE Education Foundation Job Sheet 15: Valve, Guide, and Seat Inspection. AST/MAST: I.B.9, P-3, I.B.10, P-3 ASE Education Foundation Job Sheet 16: Inspect and Test Valve Springs. MAST: I.B.7, P-3 ASE Education Foundation Job Sheet 17: Valve and Seat Repair. MAST: I.B.11, P-3; ASE Education Foundation Job Sheet 19: Valve Train Component Inspection. AST/MAST: I.B.4, P2; MAST: I.B.12, P-2 ASE Education Foundation Job Sheet 21: Replace an OHC Timing Belt/Chain. AST/MAST: I.B.6, P1, I.D,7 P-2 ASE Education Foundation Job Sheet 22: Replace an OHV Timing Chain. AST/MAST: I.B.6, P-1

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 8: Cylinder Head: Springs, Valves, and Valve Seats

ASE Education Foundation Job Sheet 23: Inspecting the Camshaft and Bearings. AST/MAST: I.B.13, P-3, I.B.14, P-3, I.C.7, P-2 ASE Education Foundation Job Sheet 35: Flush and Refill a Cooling System. AST/MAST: I.D.6, P-1 [return to top]

LESSON HINTS Demonstrations: 1. Checking valve springs 2. Grinding valves 3. Refinishing seats 4. Replacing seats 5. Reassembling heads [return to top]

READING ASSIGNMENT Read pages 225–266 in Automotive Engines: Diagnosis, Repair, Rebuilding, 9E.

WRITTEN ASSIGNMENTS Complete Chapter 8 Study Questions [found on pp. 266–267 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E]. Complete Chapter 8 ASE-Style Review Questions [found on pp. 267–268 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E]. [return to top]

CHAPTER 8 ANSWERS TO STUDY QUESTIONS 131.

tension, squareness, height

132.

true

133.

B (exhaust)

134.

the margin

135.

induction hardening

136.

spring pressure, compression/combustion, width of seat area/seat angle

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 9: Camshafts, Lifters, Timing Belts, and Chains

137.

the guides

138.

face, throat, top

139.

A (30°)

140.

0.060 (1/16)

141.

0.090 (3/32)

142.

It is frozen.

143.

A (shorter)

144.

after the valve spring is compressed

145.

OHC

[return to top]

CHAPTER 8 ANSWERS TO ASE-STYLE REVIEW QUESTIONS 56. A 57. C 58. C 59. A 60. C 61. A 62. C 63. C 64. C 65. D [return to top]

Instructor Manual Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 9: Camshafts, Lifters, Timing Belts, and Chains

TABLE OF CONTENTS Purpose and Perspective of the Chapter ................................................................................................. 48 Chapter Objectives .................................................................................................................................... 48 Complete List of Chapter Activities and Assessments ........................................................................... 48 Key Terms .................................................................................................................................................. 49 What’s New in This Chapter .................................................................................................................... 49 Chapter Outline ......................................................................................................................................... 49

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 9: Camshafts, Lifters, Timing Belts, and Chains

ASE Education Foundation Tasks ........................................................................................................... 50 Job Sheets................................................................................................................................................... 51 Lesson Hints............................................................................................................................................... 51 Reading Assignment .................................................................................................................................. 51 Written Assignments ................................................................................................................................. 51 Chapter 9 Answers to Study Questions .................................................................................................... 52 Chapter 9 Answers to ASE-Style Review Questions................................................................................... 52

PURPOSE AND PERSPECTIVE OF THE CHAPTER The purpose of this chapter goes more in depth at discussing camshafts, lifters, and timing components on an internal combustion engine. Understanding how these components work will help the student to determine what needs to happen to repair a failure in these systems.

CHAPTER OBJECTIVES Upon completion of this chapter, the student should be able to:    

Analyze the theories of the camshaft and related parts Describe the operation of hydraulic lifters and lash adjusters Install single and dual overhead camshafts with correct valve timing Verify valve timing and be able to correctly position a camshaft in relation to TDC

COMPLETE LIST OF CHAPTER ACTIVITIES AND ASSESSMENTS For additional guidance, refer to the Teaching Online Guide. Chapter Objective

Activity/Assessment

Duration

Icebreaker

Source (i.e., PPT slide, Workbook) PPT slide 2

Explain how the camshaft runs the valve train.

Describe the operation of hydraulic lifters.

Activity

PPT slide 8–12

10–20 minutes

10–15 mins

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 9: Camshafts, Lifters, Timing Belts, and Chains

Evaluate your understanding of how the camshaft operates the valves within the engine. [return to top]

Self-Assessment

PPT slide 27

5–10 minutes

KEY TERMS backlash: Clearance between gears CAFE: Corporate Average Fuel Economy; a government standard used to charge a gas guzzler tax on autos that are inefficient duration: The length of time in crankshaft degrees that a valve remains open edge loading: When a lifter becomes concave, it wears the sides of a cam lobe leak down: When a hydraulic lifter bleeds off until a valve is no longer held open lift: The amount that a cam lobe lifts the valve off its valve seat valve overlap: When the intake and exhaust valves are both open at the same time zero lash: When there is no clearance in the valvetrain

[return to top]

WHAT’S NEW IN THIS CHAPTER No substantive changes to this chapter in the new edition [return to top]

CHAPTER OUTLINE 

Camshafts are located in the block or on the cylinder head and are made from hardened cast iron or steel. (PPT Slide 4)



When the camshaft moves forward or backward, that is called camshaft end thrust. (PPT Slide 5)



Valve lash is adjustable on some applications and nonadjustable on a hydraulic valvetrain. (PPT Slides 8–12)

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 9: Camshafts, Lifters, Timing Belts, and Chains



Valve lifters can be solid or hydraulic. Proper oil flow to each lifter is required to maintain lifter operation. (PPT Slides 11–16)



The camshaft lobe shape has the base circle, opening flank, and closing flank on each lifter lobe. (PPT Slides 13 and 14)



Valve timing is related to the location of the lobe on each journal of the camshaft. (PPT Slide 15)



On an interference engine any time the timing components fail and the engine spins without spinning the camshaft in time, there is a possibility the valves may strike the pistons. (PPT Slide 16)



Timing chains can be single row or double row, depending on the application. (PPT Slide 17)



Timing chain tensioners can be oil fed or spring loaded and can fail, which can cause a timing issue. (PPT Slide 18)



When replacing the timing chain or belt, timing marks can be located on each to aid in setting up the timing when replacing the components. (PPT Slides 19 and 20)



Timing belts are made of neoprene or saturated nitrile, which are susceptible to any solvent types that are used on them. Avoid any petroleum-based solvents when cleaning or checking components for serviceability. (PPT Slides 21–26)

ASE EDUCATION FOUNDATION TASKS I.B.4

Inspect valve actuating mechanisms for wear, bending, cracks, looseness, and blocked oil passages (orifices); determine needed action. (AST/MAST) P-1

I.B.6

Inspect and replace the camshaft and drive belt/chain; includes checking drive gear wear and backlash, end play, sprocket and chain wear, overhead cam drive sprocket(s), drive belt(s), belt tension, tensioners, camshaft reluctor ring/tone-wheel, and valve timing components; verify correct camshaft timing. (AST/MAST) P-1

I.B.12 Inspect valve lifters; determine needed action. (MAST) P-2 I.B.13 Inspect and/or measure camshaft for runout, journal wear, and lobe wear. (MAST) P-3 I.B.14 Inspect camshaft bearing surface for wear, damage, out-of-round, and alignment; determine needed action. (MAST) P-3 I.C.7

Inspect and measure camshaft bearings for wear, damage, out-of-round, and alignment; determine needed action. (MAST) P-2

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 9: Camshafts, Lifters, Timing Belts, and Chains

JOB SHEETS ASE Education Foundation Job Sheet 19: Valve Train Component Inspection. AST/MAST: I.B.4, P2; I.B.12, P-2 ASE Education Foundation Job Sheet 21: Replace an OHC Timing Belt/Chain. AST/MAST: I.B.6, P1 ASE Education Foundation Job Sheet 22: Replace an OHV Timing Chain. MAST: I.B.6, P-1 ASE Education Foundation Job Sheet 23: Inspecting the camshaft and bearings. MAST: I.B.13, P-3; I.B.14, P-1; I.C.7, P-2 [return to top]

LESSON HINTS Provide links to the websites of Crane, Iskenderian, etc., so that interested students can review catalogs. Discuss cam timing and lifter operation. Demonstrations: 1. Check TDC 2. Check cam timing 3. Disassemble hydraulic lifter Suggested Handouts: 1. Speed-Pro: How to check TDC 2. Timing Gears Co: Cam timing sketches [return to top]

READING ASSIGNMENT Read pages 267–307 in Automotive Engines: Diagnosis, Repair, Rebuilding, 9E.

WRITTEN ASSIGNMENTS Complete Chapter 9 Study Questions [found on pp. 305–306 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E]. Complete Chapter 9 ASE-Style Review Questions [found on pp. 306–307 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E]. [return to top]

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 10: Cylinder Block: Inspection and Service

CHAPTER 9 ANSWERS TO STUDY QUESTIONS 146.

four

147.

end thrust

148.

auxiliary

149.

tappets, cam followers

150.

zero lash

151.

positive stop adjustment

152.

base

153.

duration

154.

This causes the lifter to spin.

155.

156.

B (Exhaust)

157.

valve overlap

158.

clearance

159.

interference engine

160.

the coolant pump

[return to top]

CHAPTER 9 ANSWERS TO ASE-STYLE REVIEW QUESTIONS 66. A 67. B 68. B 69. A 70. B 71. C 72. C 73. C 74. C 75. B [return to top]

Instructor Manual Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 10: Cylinder Block: Inspection and Service

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 10: Cylinder Block: Inspection and Service

TABLE OF CONTENTS Purpose and Perspective of the Chapter Chapter Objectives

Complete List of Chapter Activities and Assessments 53 Key Terms

What’s New in This Chapter 55 Chapter Outline

ASE Education Foundation Tasks Job Sheets

Lesson Hints

Reading Assignment

Written Assignments 57 Chapter 10 Answers to Study Questions

Chapter 10 Answers to ASE-Style Review Questions

PURPOSE AND PERSPECTIVE OF THE CHAPTER The purpose of this chapter is to introduce students to cylinder block inspection and getting cylinder blocks ready for reassembly. The engine cylinder block is the backbone of the internal combustion engine as it combines the all the components needed for proper ICE operation. Before conducting an assembly, make sure the foundation is in operational condition. This chapter will touch on what type of procedures are appropriate for reconditioning a cylinder block.

CHAPTER OBJECTIVES Upon completion of this chapter, the student should be able to:     

Analyze wear and damage to the cylinder block Select and perform the most appropriate repairs to the block R&R cam bearings, gallery plugs, and core plugs Explain theories of cylinder wall surface finishes Prepare a block for assembly

COMPLETE LIST OF CHAPTER ACTIVITIES AND ASSESSMENTS For additional guidance, refer to the Teaching Online Guide.

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 10: Cylinder Block: Inspection and Service

Chapter Objective

Activity/Assessment

Duration

Icebreaker

Source (i.e., PPT slide, Workbook) PPT slide 2

Explain theories of cylinder wall surface finishes.

Analyze wear and damage to the cylinder block and learn how to rectify.

Activity

PPT slides 5–24

10–20 minutes

Discuss how to recondition the cylinder block before reassembly.

Self-Assessment

PPT slide 228

5–10 minutes

10–15 mins

[return to top]

KEY TERMS choke bore: When the bottom of the bore is larger than the top crosshatch: A crisscross finish that is desirable when honing cylinder walls cylinder sleeve: A replacement cylinder liner used to repair a damaged bore decking a block: When the head gasket surface of a block is remachined glazed: A smooth, shiny area where the piston rings ride against the cylinder wall line boring or honing: Resizing the main bearing bores to realign them and make them the original size microinches: One microinch equals 1 millionth of an inch plateau honing: The cylinder is honed to a rough finish, followed by a fine finish rigid hone: A hone for making a cylinder larger after boring it torque plate: Also called deck plate or honing plate, it is used when honing to keep the cylinder bores from distorting [return to top]

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 10: Cylinder Block: Inspection and Service

WHAT’S NEW IN THIS CHAPTER No substantive changes to this chapter in the new edition. [return to top]

CHAPTER OUTLINE 

Before any evaluation or conclusions are drawn, the cylinder block should be hot-tanked to remove any debris or buildup before it is used for the build. (PPT Slide 4)



Oil and water plugs should be removed before hot-tanking the block. (PPT Slides 5 and 6)



Remove oil jets to allow the debris to be removed from the oil gallery that feeds them. (PPT Slide 7)



Verify alignment dowels are in the proper location and in serviceable shape. (PPT Slide 8)



When evaluating the main bearing saddles and caps, verify the crankshaft hasn’t shifted in the block and wore the main bearing saddles out of specification. (PPT Slides 9-14)



The block decks should be checked for warpage. If they are found to be warped, they will need to be decked so they can be brought back into specification. (PPT Slides 15 and 16)



The cylinder bores should be checked for taper and crosshatch and brought back into specification if found that they are out of specification. (PPT Slides 17–24)



Finishing up the cylinder with honing and checking the core for shift with ultrasonic thickness testing. (PPT Slide 25)



If a cylinder is found to be out of specification, a sleeve could be installed to provide a new surface for the piston to operate on. (PPT Slide 26)



Final block preparation requires new oil plugs, core plugs, and thorough cleaning. (PPT Slides 27–30)



Installing camshaft bearings requires special tooling to makes sure it is not destroyed when it is driven into the cylinder block. Along with proper driving, aligning the oil hole with the hold in the cylinder block will allow for proper oil flow to the camshaft. (PPT Slides 31-33)

ASE EDUCATION FOUNDATION TASKS I.B.2

Remove cylinder head; inspect gasket condition; install cylinder head and gasket; tighten according to manufacturer’s specification and procedure.. (AST/MAST) P-1

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 10: Cylinder Block: Inspection and Service

I.C.1

Identify engine block assembly components and configurations. (MLR, AST, MAST) P-1

I.C.2 Remove, inspect, and/or replace crankshaft vibration damper (harmonic balancer). (AST/ MAST) P-1 I.C.3

Disassemble engine block; clean and prepare components for inspection and reassembly. (MAST) P-2

I.C.4

Inspect engine block for visible cracks, passage condition, core and gallery plug condition, and surface warpage; determine needed action. (MAST) P-2

I.C.5

Inspect and measure cylinder walls/sleeves for damage, wear, and ridges; determine needed action. (MAST) P-2

I.C.6

Deglaze and clean cylinder walls. (MAST) P-2

I.C.8

I.C.9 Inspect main and connecting rod bearings for damage and wear; determine needed action. (MAST) P-2 I.C.15 Assemble engine block. (MAST) P-1

JOB SHEETS ASE Education Foundation Job Sheet 11: Engine block disassembly, inspection and cleaning. MLR, AST, MAST: I.C.1, P-1; AST, MAST I.B.2, P-1: I.C.2, P-1; MAST I.C.3, P-2; I.C.4, P-2; I.C.6, P-2 ASE Education Foundation Job Sheet 24: Inspecting and Measuring the Cylinder Walls. MAST: I.C.5, P-2 ASE Education Foundation Job Sheet 25: Inspecting and Measuring the Crankshaft, Main Bearings and Saddle Bores. MAST: I.C.8, P-2; I.C.9, P-2 ASE Education Foundation Job Sheet 38: Reassembling the Engine Short Block. MAST: I.C.8, P-2; I.C.15, P-1 [return to top]

LESSON HINTS Explain theories of cylinder wall surface finishes. Discuss all procedures to be demonstrated in the lab. Demonstrations: 1. 2. 3. 4.

R&R of cam bearings Boring bar R&R oil gallery plugs Honing

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 10: Cylinder Block: Inspection and Service

5. R&R sending units 6. Glaze breaking 7. Cleaning oil galleries 8. R&R core plugs 9. Washing block 10. Chase threaded hole with bottom tap [return to top]

READING ASSIGNMENT Read pages 310–343 in Automotive Engines: Diagnosis, Repair, Rebuilding, 9E.

WRITTEN ASSIGNMENTS Complete Chapter 10 Study Questions [found on p. 342 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E]. Complete Chapter 10 ASE-Style Review Questions [found on pp. 342–343 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E]. [return to top]

CHAPTER 10 ANSWERS TO STUDY QUESTIONS 161.

They should be lubricated.

162.

pipe threads, such as oil and water sending units, heater connections, and coolant plugs

163.

8-point

164.

oval, or out-of-round

165.

0.010"

166.

divide the difference by 3

167.

glaze

168.

crosshatch

169.

0.015"

170.

They can be out of round.

171.

plateau

172.

0.0005" per inch of bore

173.

Until its lip is just past the chamfer on the block

174.

Loosen the mandrel one-eighth turn.

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 11: Crankshaft, Bearings, and Engine Balancing

175.

lubricant

[return to top]

CHAPTER 10 ANSWERS TO ASE-STYLE REVIEW QUESTIONS 76. B 77. C 78. A 79. C 80. A 81. C 82. A 83. A 84. D 85. A [return to top]

Instructor Manual Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 11: Crankshaft, Bearings, and Engine Balancing

TABLE OF CONTENTS Purpose and Perspective of the Chapter Chapter Objectives

Complete List of Chapter Activities and Assessments 59 Key Terms

What’s New in This Chapter 61 Chapter Outline

ASE Education Foundation Tasks Job Sheets

Lesson Hints

Reading Assignment

Written Assignments 63 Chapter 11 Answers to Study Questions

Chapter 11 Answers to ASE-Style Review Questions

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 11: Crankshaft, Bearings, and Engine Balancing

PURPOSE AND PERSPECTIVE OF THE CHAPTER The purpose of this chapter is to provide information for the student on how to evaluate the crankshaft and bearings and how to make sure the engine is balanced. This chapter goes over crankshaft bearings and harmonics of the engine operation.

CHAPTER OBJECTIVES Upon completion of this chapter, the student should be able to:    

Analyze wear and damage to the crankshaft and bearings Select the most appropriate crankshaft repairs Explain the theory of engine balancing Describe the related theory of the bearings, crankshaft, and related parts

COMPLETE LIST OF CHAPTER ACTIVITIES AND ASSESSMENTS For additional guidance, refer to the Teaching Online Guide. Chapter Objective

Activity/Assessment

Duration

Icebreaker

Source (i.e., PPT slide, Workbook) PPT slide 4

Explain the theory of engine design and balancing.

Selecting the most appropriate crankshaft repairs.

Activity

PPT slides 8–10

10–20 minutes

Evaluate your understanding of how an unbalanced crankshaft can cause component failure. [return to top]

Self-Assessment

PPT slides 27 and 28

5–10 minutes

10–15 mins

KEY TERMS bearing crush: The end of the bearing sticks out of the bore. When it is tightened against the bearing on the other side, it is held from spinning.

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 11: Crankshaft, Bearings, and Engine Balancing

bearing spread: The bearing is distorted slightly so that it will remain in the bearing bore during engine assembly. bob weights: Weights attached to the connecting rod throws when balancing an engine to simulate rotating and reciprocating weight conformability: The ability of a bearing to conform to the shape of the journal it protects. crocus cloth: Used for very fine polishing, it is 1200-grit jeweler’s rouge abrasive on a cloth backing embeddability: The ability of a bearing to absorb debris to protect the journal of the crankshaft. end thrust: Fore or aft force on a shaft externally balanced: When a crankshaft does not have enough material on its counterweights, external balancing is provided on the vibration damper and flywheel or torque converter. fatigue strength: A property that allow a bearing to undergo intermittent loads without deteriorating. fillet radius: The curved area on the sides of a crankshaft journal flat cranks: A V8 crankshaft with the rod throws spaced 180° apart, located only at the top (0°) and bottom (180°) of the crankshaft flexplate: A part attached to the crankshaft to transmit power to the torque converter. Also includes a ring gear that the starter uses to turn the engine during start up. gas nitriding: A heat treatment procedure to harden a steel surface. hard chrome: A process used mostly in the heavy-duty industry to restore worn or poorly machined crankshaft journals to their original size. It is done by a specialty plating business. locating lug or tang: A tab extending from the parting line of the bearing that locates it correctly in the bearing bore during engine assembly lower end: All of the parts in the engine block, not including the heads oversquare: When the cylinder bore diameter is larger than the stroke length. piston dwell time: The time that the piston remains still at TDC while the crankshaft continues rotating for several degrees Rockwell “C” scale: A hardness rating for metals commonly used in industry tolerance: The allowable amount of variation of a clearance between two parts. torsional vibration: The twisting force imparted on a crankshaft from the firing impulses of the cylinders tufftriding: A metal hardening procedure.

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 11: Crankshaft, Bearings, and Engine Balancing

undersquare: When the cylinder bore diameter is smaller than the stroke length. [return to top]

WHAT’S NEW IN THIS CHAPTER 

No substantive changes to this chapter in the new edition

[return to top]

CHAPTER OUTLINE 

The crankshaft converts reciprocating motion into rotary motion. (PPT Slide 4)



The crankshaft counterweights are utilized to offset the weight of the connecting rod and the piston within each cylinder. (PPT Slide 5)



Checking the crankshaft usability should be done before conducting any machine work on the crankshaft. (PPT Slides 6–10)



The vibration damper is used to minimize the vibrations that happen when the engine is operating. (PPT Slides 11 and 12)



When evaluating a crankshaft, the technician should look at each journal for serviceability and cracking. This should be determined before polishing or other machine work. (PPT Slides 13–16)



When checking the bearings and bearing clearance, the technician should be using Plastigage to measure the bearing clearance to verify everything is within specification. (PPT Slides 17–19)



As the bearings are installed and torqued, when a bearing is pushed against another bearing, bearing crush occurs and conforms to the machined journal. As the bearing wears, the bearing will spread. (PPT Slide 20)



Excessive loads or clearances within a bearing will cause a bearing or component failure. (PPT Slides 21 and 22)



Thrust bearing wear can cause the crankshaft to walk forward and backward. Verifying the proper amount of thrust play will minimize the failure of the other bearings within the engine. (PPT Slide 22 and 23)



When the engine is imbalanced, component failure can occur as the vibrational factors will accelerate wear on the components. (PPT Slides 24–28)

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 11: Crankshaft, Bearings, and Engine Balancing

ASE EDUCATION FOUNDATION TASKS I.C.2

Remove, inspect, or replace crankshaft vibration damper (harmonic balancer). (AST/MAST) P-1

I.C.8

I.C.9

Inspect main and connecting rod bearings for damage and wear; determine needed action. (MAST) P-2

I.C.10 Identify piston and bearing wear patterns that indicate connecting rod alignment and main bearing bore problems; determine needed action. (MAST) P-2 I.C.14 Inspect auxiliary shaft(s) (balance, intermediate, idler, counterbalance, or silencer); inspect shaft(s) and support bearings for damage and wear; determine needed action; reinstall and time. (MAST) P-2 I.C.15 Assemble engine block. (MAST) P-1

JOB SHEETS ASE Education Foundation Job Sheet 25: Inspecting and Measuring the crankshaft, Main Bearings and Saddle Bores. MAST: I.C.8, P-2; I.C.9, P-2 ASE Education Foundation Job Sheet 26: Inspecting Balance Shafts and Harmonic Balancers. AST/MAST: I.C.2, P-1; I.C.14, P-2 ASE Education Foundation Job Sheet 27: Inspecting and Measuring the connecting Rods and Bearings. MAST: I.C.9, P-2; I.C.10, P-2 ASE Education Foundation Job Sheet 38: Reassembling the Engine Short Block. MAST: I.C.8, P-2; I.C.15, P-1

[return to top]

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 11: Crankshaft, Bearings, and Engine Balancing

LESSON HINTS Demonstrations: 1. 2. 3. 4. 5. 6. 7.

Cleaning piston top Cleaning ring grooves Piston knurler Rod hone Rod aligner Pressing rod from piston Rod heater

[return to top]

READING ASSIGNMENT Read pages 344–383 in Automotive Engines: Diagnosis, Repair, Rebuilding, 9E.

WRITTEN ASSIGNMENTS Complete Chapter 11 Study Questions [found on pp. 382–383 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E]. Complete Chapter 11 ASE-Style Review Questions [found on p. 383 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E]. [return to top]

CHAPTER 11 ANSWERS TO STUDY QUESTIONS 176.

crankpin

177.

radius

178.

A V8 rod journal is wider.

179.

forged

180.

thrust

181.

rod alignment

182.

0.010", 0.020", 0.030"

183.

tufftriding, nitriding

184.

Rockwell

185.

fillets

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 12: Piston, Rings, and Connecting Rods

186.

0.010"

187.

wider

188.

conformability, embeddability, fatigue strength

189.

B (bottom)

190.

shadow graph, balance beam, digital

[return to top]

CHAPTER 11 ANSWERS TO ASE-STYLE REVIEW QUESTIONS 86. C 87. B 88. A 89. D 90. C 91. A 92. C 93. B 94. C 95. B [return to top]

Instructor Manual Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 12: Piston, Rings, and Connecting Rods

TABLE OF CONTENTS Purpose and Perspective of the Chapter Chapter Objectives

Complete List of Chapter Activities and Assessments 65 Key Terms

What’s New in This Chapter 66 Chapter Outline

ASE Education Foundation Tasks Job Sheets

Lesson Hints

Reading Assignment

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 12: Piston, Rings, and Connecting Rods

Written Assignments 68 Chapter 12 Answers to Study Questions

Chapter 12 Answers to ASE-Style Review Questions

PURPOSE AND PERSPECTIVE OF THE CHAPTER The purpose of this chapter is to introduce students to pistons, rings, and connecting rods in the engine. The rotating assembly is the heart of the engine and must be scrutinized when looking to determine the serviceability of the engine components.

CHAPTER OBJECTIVES Upon completion of this chapter, the student should be able to:   

Analyze wear and damage to the pistons, rings, pins, and rods Select the most appropriate repairs to perform Describe the theory of pistons, rings, piston pins, connecting rods, and related parts

COMPLETE LIST OF CHAPTER ACTIVITIES AND ASSESSMENTS For additional guidance, refer to the Teaching Online Guide. Chapter Objective

Activity/Assessment

Duration

Icebreaker

Source (i.e., PPT slide, Workbook) PPT slide 2

Describe the theory of pistons, rings, piston pins, connecting rods and related parts. Identify and perform piston service.

Activity

PPT slides 10–22

10–20 minutes

Evaluate your understanding of how to properly recondition connecting rods.

Self-Assessment

PPT slides 23–25

5–10 minutes

10–15 mins

[return to top]

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 12: Piston, Rings, and Connecting Rods

KEY TERMS cam ground: The piston is oval when it is cold and becomes more round as it heats up. full-floating pin: A piston pin that floats in the rod and the piston. Lock rings keep it from coming out of the piston. hypereutectic: A high silicon content aluminum piston that expands less major thrust surface: The surface within the cylinder that the piston skirt slides against during the power stroke. piston compression height: If the piston pin is higher or lower on the piston, its compression height changes. ring flutter: A condition when the rings vibrate in the ring groove due to low tension.

[return to top]

WHAT’S NEW IN THIS CHAPTER The following elements are improvements in this chapter from the previous edition:  

Updated piston head information Updated information about marking connection rods

[return to top]

CHAPTER OUTLINE 

There are two main types of pistons: cast and forged. (PPT Slide 4)



The top of the piston or the piston head is .022” of an inch less than the diameter of the skirt of the piston. (PPT Slide 5)



The design of the piston head and the height of the compression ring will depend on the application and the design of the combustion chamber. (PPT Slides 6 and 7)



As the piston heats up, it starts to expand. To manage the expansion, the designer of the piston has made the piston skirt its cam ground, which allows for room for expansion. (PPT Slide 8)



In some applications, the piston pin is offset to minimize piston slap and better align the combustion force with the center of the connecting rod journal on the camshaft. (PPT Slide 9)

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 12: Piston, Rings, and Connecting Rods



When looking at piston wear, the technician should be evaluating what is causing the wear. It could be from lack of oil pressure to a bent connecting rod. Identifying the root cause will keep it from happening to the new components. (PPT Slides 10 and 11)



When servicing pistons, the technician should determine what type of pin is installed and replace them during the refitting. (PPT Slide 12)



If the pistons are being reused, the technician should clean the ring grooves out with the proper tool so the new rings have the room necessary to move within the cavity. (PPT Slide 13)



Automotive pistons usually have two compression and one oil control ring per piston. (PPT Slide 14)



Piston rings are described by the width (height of the ring) and the radial thickness of the ring (depth of the ring into the groove). (PPT Slide 15)



The pistons are made of varying materials depending on the ring’s position on the piston. Depending on application, the piston ring design can be plain, taper face, barrel face, or napier shaped. Each type has a different purpose. (PPT Slides 16–18)



Oil control rings provide a path for oil that is scraped down by the scraper ring to make it back to the crankcase. These rings can be a three-piece variety and can fail if they become clogged with carbon or sludge. (PPT Slide 19)



Piston ring wear can be due to poor oiling or debris from dirty air entering the combustion chamber. (PPT Slide 20)



Piston pins are usually made of high-grade carbon steel and require lubrication from the connecting rod. Poor lubrication can cause engine knock and would require replacement of pin and piston. (PPT Slide 22)



Connecting rod service is necessary to verify the connecting rod is not bent or twisted, which could cause increased piston wear. Another place to verify if the connecting rod is twisted is the connecting rod bearing. If the top half of the bearing is worn more heavily than the bottom, suspect the connecting rod is twisted and will need to be replaced. (PPT Slides 23–25)

ASE EDUCATION FOUNDATION TASKS I.C.9

Inspect main and connecting rod bearings for damage and wear; determine needed action. (MAST) P-2

I.C.10 Identify piston and bearing wear patterns that indicate connecting rod alignment and main bearing bore problems; determine needed action. (MAST) P-2 I.C.11 Inspect and measure piston skirts and ring lands; determine needed action. (MAST) P-2 I.C.12 Determine piston-to-bore clearance. (MAST) P-2

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 12: Piston, Rings, and Connecting Rods

I.C.13 Inspect, measure, and install piston rings. (MAST) P-2 I.C.15 Assemble Engine Block (MAST) P-1

JOB SHEETS ASE Education Foundation Job Sheet 28: Inspecting and Measuring the Pistons. MAST: I.C.11, P-2; I.C.12, P-2 ASE Education Foundation Job Sheet 29: Inspecting and Measuring the Piston Rings. MAST: I.C.13, P-2 ASE Education Foundation Job Sheet 40: Reassembling the Engine Short Block. MAST: I.C.8, P-2; I.C.15, P-1

[return to top]

LESSON HINTS Demonstrations: 1. 2. 3. 4. 5.

Ring groove cleaning Measuring ring side clearance Pressing piston pins Using a rod heater to install piston pins Resizing connecting rods

[return to top]

READING ASSIGNMENT Read pages 384-421 in Automotive Engines: Diagnosis, Repair, Rebuilding, 8E.

WRITTEN ASSIGNMENTS Complete Chapter 12 Study Questions [found on p. 420 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E]. Complete Chapter 12 ASE-Style Review Questions [found on p. 421 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E]. [return to top]

CHAPTER 12 ANSWERS TO STUDY QUESTIONS 191.

opposite the piston pin at the bottom of the skirt

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 13: Lubrication

192.

The diameter of the skirt is larger.

193.

top

194.

provides a path for oil return to crankcase

195.

slipper

196.

trunk

197.

yes

198.

to control piston slap

199.

with a feeler gauge

200.

full floating

201.

pressed in rod

202.

feeler gauge

203.

none

204.

V-type

205.

B (false)

[return to top]

CHAPTER 12 ANSWERS TO ASE-STYLE REVIEW QUESTIONS 96. A 97. C 98. C 99. D 100. 101. 102. 103. 104. 105.

D B B A D A

[return to top]

Instructor Manual Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 13: Lubrication

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 13: Lubrication

TABLE OF CONTENTS Purpose and Perspective of the Chapter Chapter Objectives

Complete List of Chapter Activities and Assessments 70 Key Terms

What’s New in This Chapter 72 Chapter Outline

ASE Education Foundation Tasks Job Sheets

Lesson Hints

Reading Assignment

Written Assignments 74 Chapter 13 Answers to Study Questions

Chapter 13 Answers to ASE-Style Review Questions

PURPOSE AND PERSPECTIVE OF THE CHAPTER The purpose of this chapter is to introduce students to lubrication theory and how to conduct lubrication system service. Understanding how the various systems affect the operation of the lubrication system will provide the student with a checklist of areas to evaluate when they are diagnosing lubrication problems.

CHAPTER OBJECTIVES Upon completion of this chapter, the student should be able to:   

Analyze wear and damage to lubrication system parts Explain lubrication system theory Select and perform the most appropriate repairs to the lubrication system

COMPLETE LIST OF CHAPTER ACTIVITIES AND ASSESSMENTS For additional guidance, refer to the Teaching Online Guide. Chapter Objective

Activity/Assessment

Source (i.e., PPT slide, Workbook)

Duration

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 13: Lubrication

Explain the reasons behind lubricating the engine.

Icebreaker

PPT slide 2

10–15 minutes

Identify oil service ratings and understand how they grade oil.

Activity

PPT slide 9

10–20 minutes

Explain how a properly operating PCV system can minimize engine oil leakage.

Self-Assessment

PPT slide 27

5–10 minutes

[return to top]

KEY TERMS antidrainback valve: A valve in a horizontally mounted oil filter that prevents it from draining when the engine is off API: American Petroleum Institute boundary lubrication: When the oil film partially breaks down bypass oil filter: An oil filter that filters a smaller amount of oil than a full-flow filter, sometimes used as an auxiliary filter bypass valve: An oil filter valve that allows oil to bypass the filter when the engine oil is too thick or too much oil is being supplied to the filter dry start: A term that describes the period of time after engine startup when oil has not yet been supplied to engine bearings full-flow oil filter: An oil filter designed to filter all of the oil most of the time polymers: Oil additives that thicken when an oil is heated SAE: Society of Automotive Engineers viscosity: The tendency of a liquid to resist flow. A thicker oil has a higher viscosity. viscosity index: A rating that tells how well an oil resists changes in its viscosity with temperature change

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 13: Lubrication

[return to top]

WHAT’S NEW IN THIS CHAPTER The following elements are improvements in this chapter from the previous edition:     

New case history Updated information about oil viscosity New information about Vane type oil pumps Updated information about cartridge filters Updated PCV systems information

[return to top]

CHAPTER OUTLINE 

The lubrication system provides the engine with the proper amount of oil to allow the internal components to operate without failing. (PPT Slide 4)



Oil pressure is created by the resistance to flow by minimizing the space oil can be sent through. (PPT Slide 5)



Moving parts are separated by an oil film that allows each part to move independently of each other, or some parts can stay stationary. (PPT Slide 6)



The viscosity rating of oil is governed by the SAE and various other organizations to allow the consumer to understand how each different type of oil can protect the engine. (PPT Slides 7 and 8)



Using the viscosity ratings, the API designates various oils for different applications which are approved by the OEM. (PPT Slide 9)



Putting additives in oil will help to increase the longevity of the oil, clean the engine, and minimize the negative effects oil has on the environment. (PPT Slide 10)



If the engine is not maintained properly or if it continually doesn’t get up to operating temperature, sludge can form within the engine and gum up any moving components. (PPT Slide 11)



Synthetic oils utilize a man-made lubricating structure, which is more uniform than conventional oil. (PPT Slide 12)

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 13: Lubrication



Regular engine maintenance includes changing the oil; failure to maintain the engine will cause the engine to potentially fail with diluted oil. (PPT Slide 13)



Engine oil pumps can come in various configurations based on the design of the engine. Verifying proper operation and maintaining the oil clearance is key to keeping the oil pressure where it needs to stay. (PPT Slides 14–19)



Oil pump failure can be related to continual low oil level, poor oil maintenance, or just age. (PPT Slides 20 and 21)



Installing a new oil pump requires proper priming to limit the time the engine is running without oil pressure. Proper torquing of the oil pump to the base will limit the possibility of failure from warpage. (PPT Slide 22)



Priming a freshly rebuilt engine will make sure all of the oil-related surfaces will have plenty of oil when the engine is started for the first time. (PPT Slides 23 and 24)



The oil filter bypass valve will still allow oil to flow through the engine if the oil filter becomes clogged and does not allow oil to flow. (PPT Slide 25)



When changing the engine oil, the oil filter must be replaced at the same time because it is where all of the deposits from the engine operation are filtered out. (PPT Slide 26)



The PCV system must be checked periodically for proper operation, or the crankcase pressure can increase to a point it will cause a gasket leak or cause pressure to push oil into the combustion chamber to be burnt. (PPT Slide 27)

ASE EDUCATION FOUNDATION TASKS I.A.4 Inspect engine assembly for fuel, oil, coolant and other leaks (MLR/AST/MAST) P-1 I.D.1

Identify components of the lubrication and cooling systems. (MLR) P-1

I.D.2

Perform engine oil and filter change; use proper fluid type per manufacturer specification; reset maintenance reminder as required. (AST/MAST) P-1

I.D.11 Perform oil pressure tests; determine needed action (AST/MAST) P-1 I.D.13 Inspect, test, and replace oil temperature and pressure switches and sensors. (AST/MAST) P2 I.D.14 Inspect oil pump gears or rotors, housing, pressure relief devices, and pump drive; perform needed action. (MAST) P-2

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 13: Lubrication

JOB SHEETS ASE Education Foundation Job Sheet 1: Inspect an engine for fluid leaks. MLR/AST/MAST: I.A.4, P-1

ASE Education Foundation Job Sheet 30: Perform an oil pressure test. AST/MAST: I.D.11, P-1, AST/MAST: I.D.13. P-1.

ASE Education Foundation Job Sheet 31: Inspect and measure an oil pump. MAST: I.D.14, P-2 [return to top]

LESSON HINTS Discuss oil filters using cutaways. Describe oil pump problems and service. Discuss engine oil classifications. Describe engine oil change procedures. Demonstrations: 1. 2. 3. 4.

Oil pump disassembly and measurement R & R oil pump relief valve R & R pressed-fit oil pump sump screen Lubrication system pressure tester

[return to top]

READING ASSIGNMENT Read pages 422–454 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E.

WRITTEN ASSIGNMENTS Complete Chapter 13 Study Questions (found on p. 455 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E). Complete Chapter 13 ASE-Style Review Questions (found on pp. 455–456 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E). [return to top]

CHAPTER 13 ANSWERS TO STUDY QUESTIONS 206.

during start-up

207.

Society of Automotive Engineers

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 14: Cooling System

208.

209.

polymer, or viscosity index improver

210.

heat

211.

212.

detergent

213.

bypass valve

214.

A (inner)

215.

camshaft

216.

ten

217.

distributor

218.

worn main bearings or excessive clearance anywhere in the lubrication system.

219.

external gear, rotor, internal/external (gerotor)

220.

positive

[return to top]

CHAPTER 13 ANSWERS TO ASE-STYLE REVIEW QUESTIONS 106. 107. 108. 109. 110. 111. 112. 113. 114. 115.

C C C A C C C A C D

[return to top]

Instructor Manual Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 14: Cooling System

TABLE OF CONTENTS Purpose and Perspective of the Chapter

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 14: Cooling System

Chapter Objectives

Complete List of Chapter Activities and Assessments 77 Key Terms

What’s New in This Chapter 78 Chapter Outline

ASE Education Foundation Tasks Job Sheets

Lesson Hints

Reading Assignment

Written Assignments 81 Chapter 14 Answers to Study Questions

Chapter 14 Answers to ASE-Style Review Questions

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 14: Cooling System

PURPOSE AND PERSPECTIVE OF THE CHAPTER The purpose of this chapter is to introduce students to engine cooling systems and related components. Control of the temperature of the engine is key to long engine life. This system employs coolant, a coolant pump, radiator, fans, and cooling passages throughout the engine. Keeping the components all in operational condition will allow the engine to live a long life.

CHAPTER OBJECTIVES Upon completion of this chapter, the student should be able to:   

Analyze wear and damage to cooling system parts Explain cooling system theory Select and perform the most appropriate repairs to the cooling system

COMPLETE LIST OF CHAPTER ACTIVITIES AND ASSESSMENTS For additional guidance, refer to the Teaching Online Guide. Chapter Objective

Activity/Assessment

Duration

Icebreaker

Source (i.e., PPT slide, Workbook) PPT slide 2

Explain how the cooling system operates and why it is needed. Identify the different cooling system components on a vehicle in the lab.

Activity

PPT slide 7

10–20 minutes

Explain what can happen if the cooling system fails on a particular engine.

Self-Assessment

PPT slide 39

5–10 minutes

10–15 minutes

[return to top]

KEY TERMS cavitation: The formation of air bubbles in coolant, often caused by coolant boiling, air in the coolant, a suction restriction, overpumping, or vibration of the cylinder walls during combustion serpentine: Type of accessory drive belt. “Serpentine” refers to the snakelike route that the belt follows.

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 14: Cooling System

stray current: Abnormal voltage induced into a system, generally from a faulty ground thermoplastic seizure: The result of coolant entering the engine oil; it prevents the crankshaft from rotating. thermostat bypass: A passage that allows coolant to circulate in the block when the thermostat is closed weep hole: A hole in the water pump casting that allows coolant to seep [return to top]

WHAT’S NEW IN THIS CHAPTER The following elements are improvements in this chapter from the previous edition:  

Added section about stretch belts Updated cooling system electrolysis test

[return to top]

CHAPTER OUTLINE 

The purpose of the cooling system is to maintain the temperature of the engine and eliminate the possibility of thermoplastic seizure. (PPT Slide 4)



The gasoline internal combustion engine is very inefficient in using the heat produced from the combustion process. (PPT Slide 5)



Types of cooling systems depend on the size of the engine. Smaller engines utilize air cooling, and larger engines require liquid cooling to manage the heat generated. (PPT Slide 6)



The cooling system on a conventional engine utilizes a water pump, radiator, cooling fan, thermostat, and coolant. (PPT Slide 7)



The water pump utilizes a pulley, bearing, seals, and impeller to allow the engine to provide power to the pump to move the coolant in the engine. (PPT Slides 8 and 9)



Accessory drive belts are built from various types of materials that allow it to be flexible to bend around the front or back of the pulleys on the engine. (PPT Slides 10 and 11)



Stretch belts do not require a tensioner and require special tools to install and remove them. (PPT Slides 12 and 13)

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 14: Cooling System



When looking at the serviceability of a serpentine belt, verify the belt is in good condition and make sure the tensioner is operating properly. (PPT Slides 14–16)



Make sure that the belt is routed the proper way so the components are turning in the right direction. (PPT Slide 17)



The thermostat is used to control the flow of coolant throughout the engine at the proper time when it is at the correct temperature. (PPT Slide 18)



Thermostat operation happens from the wax pellet in the bulb of the thermostat. On later model vehicles, the thermostat can be controlled with an electrical heater controlled by the power coolant module (PCM). (PPT Slides 19 and 20)



Radiators have coolant passages in the core of the radiator to allow coolant to come into contact with air moving through the core. External or internal damage to the cooling tubes in the radiator could cause a condition where the engine will not be properly cooled. (PPT Slides 21 and 22)



Heater cores operate like radiators, as the blower motor blows air across the heater core to transfer heat from the coolant to the interior of the vehicle. (PPT Slide 23)



When evaluating the hoses and hose fittings, make sure the hose is not separated and evaluate the metal component to see if it will not leak. (PPT Slides 24 and 25)



The coolant pressure cap needs to be evaluated anytime it is thought it will not hold cooling system pressure. (PPT Slides 26–28)



The radiator fan can be electric or a mechanical thermal clutch type. (PPT Slides 29 and 30)



Coolant freeze protection and additives help to make the coolant last long and protect the engine internals. (PPT Slides 31–33)



Electrolysis and electric coolant conductivity is one of the main issues of coolant failure. (PPT Slides 34 and 35)



Testing coolant condition should be done on a periodic basis to verify the system is in operational condition. (PPT Slides 36 and 37)



Before running the engine after a cooling system repair, the system must be bled of air to minimize the possibility of an air pocket. (PPT Slide 38)



Cavitation is when micro bubbles burst and cause metal to be eaten away from the cylinder block. (PPT Slide 39)

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 14: Cooling System

ASE EDUCATION FOUNDATION TASKS I.D.1

Identify lubrication and cooling system components and configurations. (MLR/AST/MAST) P-1

I.D.3

I.D.3 Perform cooling system pressure and dye tests to identify leaks; check coolant condition and level; inspect and test radiator, pressure cap, coolant recovery tank, heater core, and galley plugs; determine needed action. (MLR/AST/MAST) P-1 I.D.4

Identify causes of engine overheating.. (MLR/AST/MAST) P-1

I.D.5

Inspect, replace, and/or adjust drive belts, tensioners, and pulleys; check pulley and belt alignment.. (MLR/AST/MAST) P-1

I.D.6

Inspect and test coolant; drain and recover coolant; flush and/or refill cooling system; use proper fluid type per manufacturer specification; bleed air as required.. (MLRAST/MAST) P1

I.D.7

Inspect, remove, and replace water pump.. (MLR/AST/MAST) P-2

I.D.8

Remove, inspect, and replace thermostat and gasket/seal. (MLR/AST/MAST) P-1

I.D.12 Inspect auxiliary coolers; determine necessary actions. (AST/MAST) P-2 VII.A.3 Verify proper engine cooling system operation; determine needed action.. (MLR/AST/MAST) P-1

JOB SHEETS ASE Education Foundation Job Sheet 1: Inspect an engine for fluid leaks. MLR/AST/MAST: I.A.4, P-1; I.D.3, P-1. ASE Education Foundation Job Sheet 32: Inspect and test coolant. MLR/AST/MAST: I.D.6 P-1. ASE Education Foundation Job Sheet 33: Perform a cooling system inspection and test. MLR/AST/MAST: I.D.3, P-1; MLR/AST/MAST: I.D.4, P-1 ASE Education Foundation Job Sheet 34: Remove and replace a water pump. MLR/AST/MAST: I.D.4, P-1; MLR/AST/MAST: I.D.5, P-1; AST/MAST; I.D.7, P-2 ASE Education Foundation Job Sheet 35: Flush and refill a cooling system. MAST: I.D.6, P-1 ASE Education Foundation Job Sheet 36: Inspect, test and replace a thermostat. MLR/AST/MAST: I.D.4, P-1; MLR/AST/MAST: I.D.6, P-1; AST/MAST; I.D.8, P-1

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 14: Cooling System

[return to top]

LESSON HINTS Discuss the different types of coolant and their applications. Describe different methods for purging air from the cooling system after refilling the engine with coolant. Demonstrations: 1. Pressure test radiator cap 2. Pressure test cooling system 3. Test a thermostat [return to top]

READING ASSIGNMENT Read pages 457–500 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E.

WRITTEN ASSIGNMENTS Complete Chapter 14 Study Questions (found on p. 499 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E). Complete Chapter 14 ASE-Style Review Questions (found on p. 500 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E). [return to top]

CHAPTER 14 ANSWERS TO STUDY QUESTIONS 221.

The ceramic seal can crack.

222.

three

223.

water

224.

electrolysis

225.

silicate

226.

the vacuum valve

227.

exchanger

228.

Wax

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 15: Engine Hardware: Fasteners, Thread Repair, and Gaskets

229.

Bypass

230.

A (true)

231.

Rodded

232.

0.5 volt

233.

Hydrometer

234.

It is poisonous

235.

To allow air to bleed through

[return to top]

CHAPTER 14 ANSWERS TO ASE-STYLE REVIEW QUESTIONS 116. 117. 118. 119. 120. 121. 122. 123. 124. 125.

D A C D D C C A B C

[return to top]

Instructor Manual Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 15: Engine Hardware: Fasteners, Thread Repair, and Gaskets

TABLE OF CONTENTS Purpose and Perspective of the Chapter Chapter Objectives

Complete List of Chapter Activities and Assessments 83 Key Terms

What’s New in This Chapter 84 Chapter Outline

ASE Education Foundation Tasks Job Sheets

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 15: Engine Hardware: Fasteners, Thread Repair, and Gaskets

Lesson Hints

Reading Assignment

Written Assignments 86 Chapter 15 Answers to Study Questions

Chapter 15 Answers to ASE-Style Review Questions

PURPOSE AND PERSPECTIVE OF THE CHAPTER The purpose of this chapter is to discuss the proper hardware usage and learn how to repair any broken fasteners. This includes rethreading bolt holes, determining the proper hardware to be used, and learning what can happen to the gaskets if these fasteners fail. Gaskets and seals are what keep the fluids and combustion in the engine and keep the debris out. Understanding how these components keep the engine operating at the proper power output is key to a long engine life.

CHAPTER OBJECTIVES Upon completion of this chapter, the student should be able to:    

List fasteners and the methods in which they are used for repair Describe the various methods of thread repair Perform repairs to flared lines Explain the theory related to gaskets and seals

COMPLETE LIST OF CHAPTER ACTIVITIES AND ASSESSMENTS For additional guidance, refer to the Teaching Online Guide. Chapter Objective

Activity/Assessment

Duration

Icebreaker

Source (i.e., PPT slide, Workbook) PPT slide 2

Explain the reasons behind inspecting every fastener and source of leak. Explain how to properly torque fasteners on the engine.

Activity

PPT slides 8–10

10–20 minutes

10–15 minutes

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 15: Engine Hardware: Fasteners, Thread Repair, and Gaskets

Examine proper gasket surface preparation and usage.

Self - Assessment

PPT slides 21–32

5–10 minutes

[return to top]

KEY TERMS aerobic: A sealer that cures in the presence of air anaerobic: A sealer that cures without air clamping force: When two parts are tightened together, the stretch of the fastener results in clamping force elastic limit: The point at which a bolt that is being stretched will fail electrical discharge machine (EDM): A machine used for eroding broken fasteners flare: A sealing angle or bubble formed at the end of a piece of tubing flare nut: A hollow nut that surrounds a piece of tubing hardening: The process of heating and quenching to increase hardness of metal hydrostatic lock: Hydrolock; when a liquid is trapped between two parts, preventing them from coming any closer to each other room temperature vulcanizing (RTV): Aerobic sealer, commonly known as silicone softening: The process of heating and then allowing to cool slowly to soften or anneal a metal tap drill: The correct size drill to use before tapping threads in a part yield point: The point where a fastener will not return to its original length [return to top]

WHAT’S NEW IN THIS CHAPTER The following elements are improvements in this chapter from the previous edition: No substantive changes to this chapter in the new edition

[return to top]

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 15: Engine Hardware: Fasteners, Thread Repair, and Gaskets

CHAPTER OUTLINE 

The purpose of fasteners is to apply clamping force between two components and hold those components together. (PPT Slide 4)



If fasteners are overtorqued, they can stretch and not provide the clamping force necessary to eliminate any leaks or allow a component to rotate within the housing. (PPT Slide 5)



Bolts are graded on tensile strength, yield point, and maximum strength. (PPT Slide 6)



Measuring the torque put into a fastener can be done by utilizing a torque wrench to indicate to the technician how much torque they are applying to the fastener. (PPT Slides 7–9)



Torquing a fastener will bring the bolt to the yield point which will provide the most clamping pressure. If it goes pass the yield point the bolt will fail. (PPT Slide 10)



Hardened nuts are also graded and can be identified by the dots or slashes on the nut. (PPT Slide 11)



Selecting the proper drill bit and using it at the proper speed will provide the proper cutting and bit longevity throughout the usage life. (PPT Slides 12 and 13)



When rethreading a bolt or retaping a hole, the technician should measure the thread pitch on the bolt to determine the proper tap size. Along with proper tap size, the proper type of tap should be utilized based on the type of hole it is being used in. (PPT Slides 14 and 15)



When repairing a damaged hole that is beyond just using a tap, you may need to install a heli-coil to provide a new set of threads for the bolt to be installed in. (PPT Slides 16 and 17)



When repairing any metal tubing, determining what type of flare needs to be created is key to making sure the tube will not leak. This could be a double flare, bubble flare, or single flare. (PPT Slides 18–20)



The cylinder head gasket is one of the most crucial gaskets that is under heavy pressure situations. With the use of iron cylinder blocks and aluminum cylinder heads, each metal expands at a different rate, which requires a gasket that allows the cylinder head to expand at a quicker rate than the iron block it is mated to. (PPT Slides 21–24)



Valve gaskets are molded to fit the valve covers to virtually eliminate the possibility of leakage. (PPT Slide 25)



Intake and exhaust manifold gaskets are designed to be installed in very harsh environments that change temperatures rapidly. (PPT Slides 26 and 27)

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 15: Engine Hardware: Fasteners, Thread Repair, and Gaskets



Gasket sealers are used in different applications. Some are aerobic and some are anaerobic, depending on the material type. (PPT Slides 28–30)



Seals are designed to seal moving parts that are rotating. These types of seals are usually utilized around crankshafts, camshafts, and water pump shafts. (PPT Slides 31 and 32)

ASE EDUCATION FOUNDATION TASKS 2.1

Identify tools and their usage in automotive applications. (RST)

I.A.5

Install engine covers using gaskets, seals, and sealers as required. (AST/MAST) P-1

JOB SHEETS ASE Education Foundation Job Sheet 37: Thread repair. [return to top]

LESSON HINTS Demonstrations: 1. 2. 3. 4.

Drilling and tapping a hole Installing a heli-coil Torquing a cylinder head Cutting and flaring a steel tube

[return to top]

READING ASSIGNMENT Read pages 502–557 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E.

WRITTEN ASSIGNMENTS Complete Chapter 15 Study Questions (found on p. 556 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E). Complete Chapter 15 ASE-Style Review Questions (found on pp. 556–557 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E). [return to top]

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 16: Reassembly and Starting

CHAPTER 15 ANSWERS TO STUDY QUESTIONS 236.

taper, plug, bottom, pipe

237.

238.

to break the chips

239.

70%

240.

The fastener is stretched.

241.

Keensert, Slimsert

242.

on pipe plugs and sending units

243.

electrical discharge machining

244.

37 foot pounds

245.

A (toward)

246.

A (offset)

247.

red

248.

room temperature vulcanizing

249.

volatile

250.

It should be unwound.

[return to top]

CHAPTER 15 ANSWERS TO ASE-STYLE REVIEW QUESTIONS 126. 127. 128. 129. 130. 131. 132. 133. 134. 135.

C D C A A C B B C D

[return to top]

Instructor Manual Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 16: Reassembly and Starting

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 16: Reassembly and Starting

TABLE OF CONTENTS Purpose and Perspective of the Chapter Chapter Objectives

Complete List of Chapter Activities and Assessments 89 Key Terms

What’s New in This Chapter 90 Chapter Outline

ASE Education Foundation Tasks Job Sheets

Lesson Hints

Reading Assignment

Written Assignments 93 Chapter 16 Answers to Study Questions

Chapter 16 Answers to ASE-Style Review Questions

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 16: Reassembly and Starting

PURPOSE AND PERSPECTIVE OF THE CHAPTER The purpose of this chapter is to discuss the proper engine reassembly and installation into the vehicle. This also includes checks that should be performed prior to starting the engine after the installation. Once the engine is running, monitoring the proper system is key to long engine life.

CHAPTER OBJECTIVES Upon completion of this chapter, the student should be able to:    

Reassemble an engine in a proper and organized manner Install an engine in a vehicle Pre-lube and make all required adjustments prior to starting an engine Inspect and complete the job following engine starting and break-in

COMPLETE LIST OF CHAPTER ACTIVITIES AND ASSESSMENTS For additional guidance, refer to the Teaching Online Guide. Chapter Objective

Activity/Assessment

Duration

Icebreaker

Source (i.e., PPT slide, Workbook) PPT slide 2

Explain how to reassemble an engine in an organized fashion.

Discuss what the technician should do before starting a freshly installed engine.

Activity

PPT slide 27

10–20 minutes

Evaluate your understanding on what happens after the engine is running and the vehicle is being returned to the customer. [return to top]

Self - Assessment

PPT slide 29

5–10 minutes

10–15 minutes

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 16: Reassembly and Starting

KEY TERMS assembly lubricants: A special lubricant with extreme pressure characteristics that will remain on the surface of a part that is stored run-in stand: A stand for running a newly rebuilt engine spin test: When a newly rebuilt engine is spun by a machine. Oil pressure and compression can be checked. static timing: Setting ignition timing while the engine is not running tack coat: The first coat when painting. It is allowed to get tacky before the second coat is sprayed. vapor lock: When fuel boils in the line and cannot be pumped, the vehicle stops running [return to top]

WHAT’S NEW IN THIS CHAPTER The following elements are improvements in this chapter from the previous edition: No substantive changes to this chapter in the new edition [return to top]

CHAPTER OUTLINE 

Prior to reassembly, verify you have all the components, tightening specifications, and check service information to verify the proper procedures. (PPT Slide 4)



When looking at the supporting systems present on the vehicle, make sure the cooling systems, transmission systems, AC systems, and everything that supports the engine are in operational condition. (PPT Slide 5)



Make sure to lube anything that moves within the engine prior to installing. Make sure to clean all passages. (PPT Slide 6)



When installing a crankshaft, verify the clearances of the bearings with Plastigauge and check the thrust of the crankshaft to make sure they are within specification. (PPT Slides 7–9)



Install each connecting rod/piston assembly and spin the crankshaft over after each torque event to make sure the connecting rod is not putting the engine in a bind. (PPT Slides 10–12)



When installing the camshaft, make sure to fully lubricate it with assembly lube so the valvetrain will have lubrication from the first rotation. (PPT Slide 13)

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 16: Reassembly and Starting



Install the head gasket with the embossed side up; make sure to use alignment pins to align the cylinder head with the cylinder block so that head gasket damage does not occur. (PPT Slide 14)



Once cylinder head and camshafts are installed, set camshaft timing according to specifications so the engine is in time before installing the rocker arms. (PPT Slide 15)



After installing timing components, install the rocker arms and oil pumps to round off the front of the engine. (PPT Slide 16)



Install the front covers and oil pan, then install the harmonic balancer on the front of the engine. (PPT Slides 17 and 18)



Set valve lash and make any required valvetrain adjustments before installing the valve covers and intake manifold. (PPT Slides 19 and 20)



Paint the completed engine assembly to give it a new look and maintain a professional appearance. (PPT Slide 21)



Spin test the engine assembly to make sure it rotates properly before installing the assembly into the vehicle. (PPT Slide 22)



Install the engine into the vehicle, making sure to align any alignment dowels, install accessories, and hook up fuel and coolant systems. (PPT Slides 23 and 24)



A distributor-equipped ignition system will need the distributor timing set before cranking the engine. On a distributorless ignition system, make sure the camshaft and crankshaft sensors are hooked up before attempting to start the vehicle. (PPT Slides 25 and 26)



On initial startup, the load should be light; you should be checking for any noises or leaks on the engine. Follow piston ring and camshaft procedures for proper break in. (PPT Slide 27)



Final inspection should occur after the engine has been run up to stable temperature; check for any leaks and make sure all wires/lines are correctly installed so a failure does not occur once the vehicle leaves your bay. (PPT Slide 28)



Discuss the break-in procedures with the customer and instruct them to return after 500 miles for an inspection. (PPT Slide 29)

ASE EDUCATION FOUNDATION TASKS 3.5

Demonstrate use of three C’s (concern, cause and correction). (RST)

I.A.5

Install engine covers using gaskets, seals, and sealers as required. (MLR/AST/MAST) P-1

I.A.7

Inspect, remove, and/or replace engine mounts. (AST/MAST) P-2

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 16: Reassembly and Starting

I.A.9

Remove and reinstall engine on a newer vehicle equipped with OBD (on-board diagnostic); reconnect all attaching components and restore the vehicle to running condition. (MAST) P-3

I.B.2

Remove cylinder head; inspect gasket condition; install cylinder head and gasket; tighten according to manufacturer’s specifications and procedures. (AST/MAST) P-1

I.B.5

Adjust valves (mechanical or hydraulic lifters). (AST/MAST) P-1

I.B.6 Inspect and replace camshaft and drive belt/chain; includes checking drive gear wear and backlash, end play, sprocket and chain wear, overhead cam drive sprocket(s), drive belt(s), belt tension, tensioners, camshaft reluctor ring/tone-wheel, and valve timing components; verify correct camshaft timing. (AST/MAST) P-1 I.B.14 Inspect camshaft bearing surface for wear, damage, out-of-round, and alignment; determine needed action. (MAST) P-3 I.C.2

Remove, inspect, or replace crankshaft vibration damper (harmonic balancer). (AST/MAST) P-1

I.C.13 Inspect, measure, and install piston rings. (MAST) P-2 I.C.15 Assemble engine block. (MAST) P-1

JOB SHEETS ASE Education Foundation Job Sheet 20: Checking and adjusting valve clearance. MAST: I.B.5, P-2 ASE Education Foundation Job Sheet 38: Reassembling the engine short block. MAST: I.C.8, I.C.15 ASE Education Foundation Job Sheet 39: Installing the camshaft (OHV). AST/MAST: I.B.6, P-1; I.B.14, P-3; I.C.15, P-1 ASE Education Foundation Job Sheet 40: Installing the cylinder head onto the block. MAST: I.C.15, P-1 ASE Education Foundation Job Sheet 41: Engine installation (FWD). MLR/AST/MAST: I.A.7, P-2; I.A.9, P-3 ASE Education Foundation Job Sheet 42: Engine installation (RWD). MLR/AST/MAST: I.A.7, P-2; I.A.9, P-3

[return to top]

LESSON HINTS You can assemble a machined and cleaned engine block and complete master engine kit as a demonstration. Enlist two of the top students as assistants while you discuss the various items during reassembly. Demonstrations:

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 16: Reassembly and Starting

1. 2. 3. 4.

Complete engine reassembly Adjusting valves Priming lubrication system Setting static timing

[return to top]

READING ASSIGNMENT Read pages 558–597 in Automotive Engines: Diagnosis, Repair, Rebuilding, 9E.

WRITTEN ASSIGNMENTS Complete Chapter 16 Study Questions (found on pp. 595–596 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E). Complete Chapter 16 ASE-Style Review Questions (found on p. 596–597 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E). [return to top]

CHAPTER 16 ANSWERS TO STUDY QUESTIONS 251.

Chase them with a tap.

252.

to align the thrust surfaces

253.

rod bolt protectors

254.

to be sure it turns easily and to be sure nothing is binding

255.

valve clearance adjustment

256.

257.

using the damper or balancer

258.

They are straightened with a hammer.

259.

Put grease on them.

260.

inside

261.

the transmission front pump seal

262.

engine mounts

263.

264.

Accelerate and then decelerate on the highway.

265.

500

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 17: Engine Breathing: Intake and Exhaust Systems

[return to top]

CHAPTER 16 ANSWERS TO ASE-STYLE REVIEW QUESTIONS 136. 137. 138. 139. 140. 141. 142. 143. 144. 145.

B C C C C C A B C D

[return to top]

Instructor Manual Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 17: Engine Breathing: Intake and Exhaust Systems

TABLE OF CONTENTS Purpose and Perspective of the Chapter Chapter Objectives

Complete List of Chapter Activities and Assessments 95 Key Terms

What’s New in This Chapter 96 Chapter Outline Lesson Hints

Reading Assignment

Written Assignments 98 Chapter 17 Answers to Study Questions

Chapter 17 Answers to ASE-Style Review Questions

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 17: Engine Breathing: Intake and Exhaust Systems

PURPOSE AND PERSPECTIVE OF THE CHAPTER The purpose of this chapter is to explore intake and exhaust systems of the internal combustion engine. The intake is key to getting air and fuel into the engine’s combustion chambers to produce power. The exhaust system is key to getting the exhaust out of the combustion chamber and away from the vehicle. A good breathing system will help to provide the engine with a lot of power output.

CHAPTER OBJECTIVES Upon completion of this chapter, the student should be able to:   

Describe the effects of the supercharger/turbocharger on engine performance Understand various intake and exhaust manifold designs Advise a customer on high-performance options for his or her engine

COMPLETE LIST OF CHAPTER ACTIVITIES AND ASSESSMENTS For additional guidance, refer to the Teaching Online Guide. Chapter Objective

Activity/Assessment

Duration

Icebreaker

Source (i.e., PPT slide, Workbook) PPT slide 2

Explain the reasons behind the intake and exhaust systems design. Discuss how a crossflow cylinder head increases power.

Activity

PPT slide 11

10–20 minutes

Explain how the exhaust systems move the exhaust from the cylinder head through the exhaust system.

Self - Assessment

PPT slide 21–23

5–10 minutes

10-15 minutes

[return to top]

KEY TERMS back-cut valve: A valve with two or more angles cut on its face to improve airflow

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 17: Engine Breathing: Intake and Exhaust Systems

butterfly valve: A round plate that controls airflow; for example, the throttle plate in the fuel system catalytic converter: It resembles a muffler but contains catalysts to reduce engine emissions before the exhaust stream exits the exhaust pipe. CFM: Cubic feet per minute CNC machine: A computer numerical control milling machine cross-flow head: A head on an in-line engine that has intake and exhaust manifolds on opposite sides curtain area: When valve lift reaches 25% of the diameter of the head of the valve, this equals the curtain area; further valve lift will not flow more air. mandrel bender: A tubing bender that uses a mandrel to maintain the inside and outside diameters of exhaust pipe plenum: The air space in the manifold below a carburetor or throttle body polishing: Smoothing the surfaces of a port porting: When the size of a passageway is altered red line: The highest rpm point on a tachometer when the engine is shifted regenerative characteristic: When there is a return of energy, such as when one valve spring is compressed as another extends resonant frequency: The frequency at which a part reacts to an external driving force and vibrates or oscillates with more amplitude, like a tuning fork restrictor plate racing: Racing rules that include a metered restriction to limit the amount of air that can enter the engine shrouding: An area in a valve port or combustion chamber that obstructs the smooth flow of air wet manifold: An intake manifold used with a carburetor or throttle body fuel injection designed to provide optimum flow for the air-fuel mixture

[return to top]

WHAT’S NEW IN THIS CHAPTER The following elements are improvements in this chapter from the previous edition: No substantive changes to this chapter in the new edition

[return to top]

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 17: Engine Breathing: Intake and Exhaust Systems

CHAPTER OUTLINE 

A wet intake manifold flows both air and fuel within the intake manifold and is introduced to the intake valve as a complete unit. (PPT Slide 4)



Manifolds have a plenum, which is the air space below the carburetor or throttle body and allows space for air movement. (PPT Slide 5)



Dual- and single-plane manifolds are suited to different applications. Dual-plane manifolds are more suited to lower RPM, and single-plane manifolds are more suited for high-speed applications. (PPT Slide 6)



Plastic intake manifolds weigh less and can be formed in unique shapes. They are usually molded in multiple pieces and then they are bonded together. (PPT Slide 7)



Intake manifold tuning and variable length runners allow the designers to change the torque capacity of the engine and moderate the high RPM power. (PPT Slides 8 and 9)



Older manifolds require intake manifolds to get heated for the carburetor to operate properly. PFI systems do not require heating, though on V-type engines the intake manifold does sometimes utilize the intake manifold as a crossover from cylinder head to cylinder head. (PPT Slide 10)



Crossflow cylinder heads allow for quick intake and exhaust flow with quick airflow through the cylinder head. (PPT Slide 11)



When disassembling the engine, looking for witness marks of valve float will allow the technician to change the required components to put it back into service. (PPT Slide 12)



Cylinder head modifications are done to increase the flow of air in and exhaust out of the engine. (PPT Slide 13)



Valve lift and diameter ratios help to further tune the engine to meet the real-world application of the engine. (PPT Slide 14)



If the valve lift is too great, a coil bind situation can occur when the engine is at higher RPMs. (PPT Slide 15)



As the engine is disassembled, pay attention to the valve and the valve tip to evaluate if the valve float is a concern. (PPT Slide 16)



When porting and polishing, the valve port can increase flow from the intake to the cylinder head. Utilizing a flow bench to measure the amount of flow, fine-tuning the port will help increase the power output of the engine. (PPT Slides 17 and 18)

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 17: Engine Breathing: Intake and Exhaust Systems



Combustion chamber shapes help to provide airflow into and out of the cylinder. (PPT Slide 19)



The complete exhaust system provides a path for the exhaust to flow from the engine to external of the vehicle. (PPT Slide 20)



Exhaust manifolds provide a path of exhaust flow from the cylinder head and transition to the rest of the exhaust system. (PPT Slides 21 and 22)



Headers and exhaust tubing are key to providing the backpressure needed to increase the power output of the engine. (PPT Slides 23–25)



Mufflers are usually one of two different types: straight through or reverse flow. Each has a purpose and each provides different outputs for the vehicle. More of the performance-minded applications prefer a straight through application and the reverse flow muffler is for quieter applications. (PPT Slides 26 and 27)



Catalytic converters convert the emissions from the engine into harmless CO2 and water. (PPT Slide 28)

LESSON HINTS 1. Discuss intake and exhaust systems, including cylinder head modifications to improve airflow. Use diagrams to compare dual-plane and single-plane intake manifolds. 2. If available, show a vintage carburetted intake manifold to your class. Demonstrate how to use a flow bench. [return to top]

READING ASSIGNMENT Read pages 599–619 in Automotive Engines: Diagnosis, Repair, Rebuilding, 9E.

WRITTEN ASSIGNMENTS Complete Chapter 17 Study Questions (found on p. 618 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E). Complete Chapter 17 ASE-Style Review Questions (found on pp. 618–619 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E). [return to top]

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 18: Turbochargers and Superchargers

CHAPTER 17 ANSWERS TO STUDY QUESTIONS 266.

Siamese

267.

port fuel injection of PFI

268.

port

269.

plenum

270.

dual plane

271.

Helmholtz

272.

tuned

273.

a cross-flow head

274.

resonant

275.

bind

276.

CFM or cubic feet per minute

277.

flow

278.

30° (the flatter angle)

279.

headers

280.

hardened shims

[return to top]

CHAPTER 17 ANSWERS TO ASE-STYLE REVIEW QUESTIONS 146. 147. 148. 149. 150. 151. 152. 153. 154. 155.

C D C B (false) D D B A B (false) C

[return to top]

Instructor Manual Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 18: Turbochargers and Superchargers

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 18: Turbochargers and Superchargers

TABLE OF CONTENTS Purpose and Perspective of the Chapter Chapter Objectives

101

Complete List of Chapter Activities and Assessments 101 Key Terms

101

What’s New in This Chapter 103 Chapter Outline

103

ASE Education Foundation Tasks Job Sheets

105

Lesson Hints

105

Reading Assignment

105

Written Assignments 106 Chapter 18 Answers to Study Questions

106

Chapter 18 Answers to ASE-Style Review Questions

106

100

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 18: Turbochargers and Superchargers

PURPOSE AND PERSPECTIVE OF THE CHAPTER The purpose of this chapter is to expand students’ knowledge of how turbochargers and superchargers provide an added benefit to the engine. Forced induction allows the engine to operate above 100% efficiency and transforms the ability of the engine to produce power that it could not normally produce.

CHAPTER OBJECTIVES Upon completion of this chapter, the student should be able to:  

Explain the differences between turbochargers and superchargers Diagnose problems with turbochargers and superchargers

COMPLETE LIST OF CHAPTER ACTIVITIES AND ASSESSMENTS For additional guidance, refer to the Teaching Online Guide. Chapter Objective

Activity/Assessment

Duration

Icebreaker

Source (i.e., PPT slide, Workbook) PPT slide 2

Explain the reasons for putting a turbocharger or supercharger on an engine. Identify the components related to a turbocharged engine.

Activity 7

PPT slide 24

10–20 minutes

Discuss the differences of how turbochargers and superchargers provide increased pressure to the intake system. [return to top]

Self-Assessment

PPT slide 29

5–10 minutes

10–15 minutes

KEY TERMS aftercooler: An air cooler installed at a point after air has been compressed by a supercharger or turbocharger. Also called intercooler or charge air cooler.

101

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 18: Turbochargers and Superchargers

backpressure: Exhaust system pressure resulting from too much exhaust flow for a given crosssectional opening blower: Another name for a supercharger blow-off valve (BOV): A valve that prevents turbo surge by dumping boost pressure when the throttle is closed quickly blow-through: A supercharger that pressurizes the air cleaner above a carburetor or fuel injection system boost differential: When there is more pressure in a turbocharger turbine than the compressor, or vice versa boost pressure: The amount of pressure that a turbocharger or supercharger puts into the intake manifold boost threshold: The point at which boost starts charge air cooler: An air cooler installed at a point after air has been compressed by a supercharger or turbocharger. Also called aftercooler or intercooler. compressor bypass valve: A relief valve on the intake side of a turbocharger that is quieter than a blowoff valve, dumping its pressure back into the fresh air intake instead of into the atmosphere diffuser: The part of the turbocharger compressor cover where the air exits draw-through: A turbocharger or supercharger system that pressurizes the intake manifold after the air cleaner and carburetor or fuel injection system inducer: The leading edge of a turbocharger compressor wheel where the air enters intercooler: An air cooler installed at a point after air has been compressed by a turbocharger or supercharger. Also called aftercooler or charge air cooler. nitrous oxide system: A system used to induce pressurized nitrous oxide into the intake air to provide more oxygen to the combustion process. When combined with more fuel, it makes more power. normally aspirated or naturally aspirated: An engine that is not turbocharged or supercharged positive displacement pump: A pump that delivers the same amount of air with each revolution regardless of its speed. The faster it turns, the more air it pumps. rotor: The assembled turbine wheel and shaft and compressor wheel of a turbocharger splitter blade wheel: A turbocharger wheel that has alternating blades of short and full lengths spooling: When an engine produces enough exhaust flow to spin a supercharger or turbocharger enough to create boost supercharging: An air pump designed to increase air density in the cylinder and produce more power

102

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 18: Turbochargers and Superchargers

turbo lag: The time required to bring the turbo up to a speed, where it can function effectively turbo surge: A back-and-forth movement of the air above the throttle plate that occurs when there is high boost pressure, and the throttle plate is closed quickly turbocharger: An exhaust-driven air pump designed to increase air density in the cylinder and produce more power volumetric efficiency: The amount of air that an engine could theoretically breathe volute: The curved funnel in a turbocharger cover that increases in size from small to large wastegate: A valve in a turbocharger system that is opened when boost pressure reaches a specified point, relieving pressure by allowing exhaust flow to bypass the turbine, limiting its speed and output

[return to top]

WHAT’S NEW IN THIS CHAPTER The following elements are improvements in this chapter from the previous edition:  

Added information about electrically assisted turbos. Added information about electric wastegates.

[return to top]

CHAPTER OUTLINE 

Supercharging are air pumps that increase the amount of air that is entering the engine. (PPT Slide 4)



Depending on the system it could be a blow-through or draw-through system. (PPT Slide 5)



Turbochargers are exhaust-driven compressors that compress air before it enters the intake manifold. (PPT Slide 6)



Turbochargers are a centrifugal pump that utilizes a snail-shaped outlet to use exhaust gas pressure to compress incoming air. (PPT Slide 7)



Turbocharger airflow is created by the compressor and the design of the housing the compressor wheel is compressing against. (PPT Slide 8)



Turbo boost and lag are dependent on the proper sizing of the turbocharger based on the engine exhaust output specification. (PPT Slide 9)

103

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 18: Turbochargers and Superchargers



Electrically assisted turbocharger helps to spin up the turbocharger before the extra power is requested by the driver; it virtually eliminates turbo lag. (PPT Slide 10)



The use of twin turbochargers helps to spool up quicker, as they are smaller than a larger single turbocharger. (PPT Slide 11)



Wastegates help to control the turbocharger speed. (PPT Slides 12 and 13)



Some turbocharger applications utilize an electric wastegate, which allows the PCM to directly control the boost output of the turbocharger. (PPT Slides 14)



When a quick deceleration event does occur, the built-up pressure in the intake must go somewhere, so a blow-off valve provides a path for that pressure to escape and component failure does not occur. (PPT Slide 15)



Variable geometry turbochargers (VGT) can adjust the size of the turbo based on the position of the vanes in the turbocharger. These are controlled by the PCM to minimize the effect of turbo lag on the engine operation. (PPT Slide 16)



Aftercooler/intercoolers cool the air charge after the air gets compressed in the turbocharger, before it enters the intake manifold. This provides for a denser air charge. They can be air-to-air or air-to-water cooled. (PPT Slides 17 and 18)



The turbocharger has many moving components that must be precisely controlled to allow for a long engine life. Boost differential, thermal requirements, and lubrication must all be kept in check or the turbocharger will fail. (PPT Slides 19–21)



When troubleshooting a turbocharger for failure, determining the root cause of it will be the key to making sure the new turbocharger will not fail. (PPT Slide 22)



Superchargers are belt driven and compress the air before it enters the intake, just as a turbocharger does. (PPT Slides 23 and 24)



Positive displacement superchargers produce the same amount of air output no matter what the RPM is. (PPT Slide 25)



Just like a turbocharger, supercharged engines have a pressure relief valve present, so if there is a quick change in air demand the valve will blow the excess pressure external to the intake system to save the components. (PPT Slide 26)



Single- and twin-scroll turbochargers provide multiple paths to compression and are very popular with OEMs. (PPT Slide 27)



Dynamic superchargers usually run at higher RPMs than the crankshaft and provide a smooth, even boost to the engine. (PPT Slide 28)

104

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 18: Turbochargers and Superchargers

ASE EDUCATION FOUNDATION TASKS VIII.A.7 Diagnose the cause of excessive oil consumption, coolant consumption, unusual exhaust color, odor, and sound; determine needed action. (AST/MAST) P-2 VIII.D.4 Inspect integrity of the exhaust manifold, exhaust pipes, muffler(s), catalytic converter(s), resonator(s), tail pipe(s), and heat shields; determine needed action. (MLR/AST/MAST) P-1 VIII.D.5 Inspect condition of exhaust system hangers, brackets, clamps, and heat shields; determine needed action. (MLR/AST/MAST) P-1 VIII.D.12 Perform exhaust system back-pressure test; determine needed action. (AST/MAST) P-2 VIII.D.14 Test the operation of turbocharger/supercharger systems; determine needed action. (MAST) P-2

JOB SHEETS ASE Education Foundation Job Sheet 43: Exhaust System Inspection. MLR/AST/MAST: VIII.D.4, P-1, VIII.D.5, P-1

ASE Education Foundation Job Sheet 44: Perform an exhaust backpressure test. MLR/AST/MAST: VI1I.D.4, P-1, VIII.D.5. P-1. AST/MAST, VIII.D.12, P-2

ASE Education Foundation Job Sheet 45: Perform a Turbocharger System Inspection. AST/MAST: VIII.A.7, P-2, AST/MAST, VIII.D.4, P-1, MAST, VIII.D.14, P-2

LESSON HINTS Distinguish between engines that are normally aspirated (naturally aspirated) and those with a turbocharger or supercharger. Describe ways to prevent turbocharger damage from lack of lubrication or excessive heat, and demonstrate how to diagnose turbocharger damage (reference the troubleshooting chart in the appendix). [return to top]

READING ASSIGNMENT Read pages 620–639 in Automotive Engines: Diagnosis, Repair, Rebuilding, 9E.

105

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 18: Turbochargers and Superchargers

WRITTEN ASSIGNMENTS Complete Chapter 18 Study Questions (found on p. 638 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E). Complete Chapter 18 ASE-Style Review Questions (found on pp. 639 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E). [return to top]

CHAPTER 18 ANSWERS TO STUDY QUESTIONS 281.

aspirated

282.

40% more

283.

284.

285.

compressor

286.

spooling

287.

boost threshold

288.

turbo surge

289.

lag

290.

wastegate

291.

10°F

292.

centrifugal, roots

293.

positive displacement

294.

roots

295.

supercharger

[return to top]

CHAPTER 18 ANSWERS TO ASE-STYLE REVIEW QUESTIONS 156. 157. 158. 159. 160. 161.

A C A (true) C C D

106

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 19: Producing Power; Valve Timing, Power and Torque Measurement

162. 163. 164. 165.

C B A (true) C

[return to top]

Instructor Manual Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 19: Producing Power; Valve Timing, Power and Torque Measurement

TABLE OF CONTENTS Purpose and Perspective of the Chapter Chapter Objectives

108

Complete List of Chapter Activities and Assessments 108 Key Terms

109

What’s New in This Chapter 110 Chapter Outline Lesson Hints

110

111

Reading Assignment

111

Written Assignments 111 Chapter 19 Answers to Study Questions

111

Chapter 19 Answers to ASE-Style Review Questions

112

107

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 19: Producing Power; Valve Timing, Power and Torque Measurement

PURPOSE AND PERSPECTIVE OF THE CHAPTER The purpose of this chapter is to inform students about how the engine produces power and how that power is measured. Understanding how horsepower, torque, and other engine measurements are created allows the student to understand the different specifications that are given to them from the OEM. Camshafts play a large role within power production and should be viewed as a very vital component to proper engine operation. Without these measurements or an understanding of engines, the student will not know what the engine should do.

CHAPTER OBJECTIVES Upon completion of this chapter, the student should be able to:   

Describe how cam lobe profile affects high and low rpm engine performance Advise customers on high-performance options for their engines Discuss the operation of variable valve timing under various operating conditions

COMPLETE LIST OF CHAPTER ACTIVITIES AND ASSESSMENTS For additional guidance, refer to the Teaching Online Guide. Chapter Objective

Activity/Assessment

Duration

Icebreaker

Source (i.e., PPT slide, Workbook) PPT slide 2

Learn the benefit of the ability to adjust the valve timing as the engine is operating in a VVT engine. Discuss what can happen if the camshaft profile is changed in the engine.

Activity

PPT slide 14

10–20 minutes

Using a dynamometer, and understanding what the technician is measuring.

Self-Assessment

PPT slide 34

5–10 minutes

10–15 minutes

[return to top]

108

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 19: Producing Power; Valve Timing, Power and Torque Measurement

KEY TERMS advanced cam: When the intake valve is open more at TDC than the exhaust asymmetrical cam lobe: A lobe that is ground differently on its opening and closing sides. Also called non-symmetrical. blowdown period: The time in degrees at the end of the power stroke when combustion pressure is bled off before the piston begins to move up on the exhaust stroke BMEP: Brake mean effective pressure dynamometer: A brake device for loading the engine and measuring torque and horsepower gross valve lift: Lobe lift multiplied by the rocker arm ratio horsepower: The measurement of an engine’s ability to perform work. ICE: Internal combustion engine. lobe center angle: A camshaft angle, measured in camshaft degrees, that describes the lobe-to-lobe distance by adding the centerlines of the intake and exhaust lobes together and then dividing by 2. lobe lift: Lift measured at the cam lobe. lost motion device: Movement of a reciprocating device where no work is done. net valve lift: Gross valve lift minus valve lash specification. Newton’s third law of motion: For every action there is an equal and opposite reaction. phaser: Replaces the traditional camshaft sprocket to provide variable camshaft timing pumping loss: When the engine has to work harder during idle or low-to-medium speed operation to move air to TDC retarded cam: When the exhaust valve is open more at TDC than the intake split overlap: When the intake and exhaust valves are equally open at TDC tolerance stacking: When two manufactured parts are combined, one on the large end of a tolerance specification and the other on the small end of the tolerance torque: A twisting effort that is the ability to make power valve lift: Lift measured at the valve volumetric efficiency (VE): The amount of air that an engine could theoretically breathe [return to top]

109

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 19: Producing Power; Valve Timing, Power and Torque Measurement

WHAT’S NEW IN THIS CHAPTER The following elements are improvements in this chapter from the previous edition: No substantive changes to this chapter in the new edition

[return to top]

CHAPTER OUTLINE 

The camshaft and the engine performance are related and must be selected based on the components present in the engine. Fine-tuning the fuel mapping to the engine is key to a properly running engine. (PPT Slides 4 and 5)



Effective compression ratio is computed at the point the intake valve is closed, which is lower than the static compression ratio. (PPT Slide 6)



Valve overlap occurs at the top of the intake stroke. (PPT Slide 7)



At high rpm, the inertia of moving exhaust gas leaving the cylinder results in lower pressure behind it; as this strengthens, it sucks in the new intake air charge. (PPT Slide 8)



To verify the proper camshaft is in the engine and is in serviceable condition, a dial indicator and a degree wheel will allow the technician to understand if the camshaft will sustain the operational characteristics. (PPT Slides 9 and 10)



The rocker arm ratio will multiply the lift the camshaft provides for each valve. (PPT Slide 11)



Measuring valve lift should be done prior to final assembly to make sure the combination of the lift and rocker arm will not put the valve spring in a coil bind situation. (PPT Slide 12)



When determining the type of camshaft needed for the engine and the application, the technician should take the lift, lobe separation, and rate of lift into consideration. (PPT Slides 14–16)



Fine-tuning the camshaft timing can be accomplished a few ways, depending on the application. From adjustable camshaft sprockets to offset bushings, the application will dictate how to adjust the camshaft. (PPT Slides 17–19)



Variable valve timing changes the duration between low and high rpm operation. It is adjustable to the needs of the engine at the current point in time. (PPT Slides 20–27)

110

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 19: Producing Power; Valve Timing, Power and Torque Measurement



Variable displacement is done by deactivating cylinders by disabling lifters and turning off the fuel injector and spark plug. (PPT Slide 28)



The principles of work explain how to measure work in foot-pounds. Changing the liquid energy into mechanical energy allows for work to be accomplished. (PPT Slides 29 and 30)



Horsepower ratings are based on different points of measurement, depending on what the technician is trying to understand. (PPT Slides 31 and 32)



The dynamometer measures real output of the engine with the drivetrain to get an actual realworld operational reading of the vehicles output. (PPT Slides 33–36)

[return to top]

LESSON HINTS Discuss camshafts, turbochargers, superchargers, and variable valve timing. Demonstrations: 1. 2. 3. 4. 5.

Locating TDC Checking cam timing Measuring valve lift Adjusting cam phasing Using a dynamometer safely

[return to top]

READING ASSIGNMENT Read pages 639–676 in Automotive Engines: Diagnosis, Repair, Rebuilding, 9E.

WRITTEN ASSIGNMENTS Complete Chapter 19 Study Questions (found on p. 675 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E). Complete Chapter 19 ASE-Style Review Questions (found on p. 676 of Automotive Engines: Diagnosis, Repair, Rebuilding, 9E). [return to top]

CHAPTER 19 ANSWERS TO STUDY QUESTIONS 296.

crankshaft

111

Instructor Manual: Tim Gilles, Tim LeVan, Automotive Engines: Diagnosis, Repair, and Rebuilding, 9e, 9780357766248; 2024; Chapter 19: Producing Power; Valve Timing, Power and Torque Measurement

297.

90°

298.

short stroke

299.

intake

300.

blowdown

301.

pumping losses

302.

scavenging

303.

valve overlap

304.

after

305.

0.450"

306.

3°

307.

asymmetric or nonsymmetrical

308.

lobe center angle LCA, or lobe separation angle

309.

brake horsepower

310.

water brake

[return to top]

CHAPTER 19 ANSWERS TO ASE-STYLE REVIEW QUESTIONS 166. 167. 168. 169. 170. 171. 172. 173. 174. 175.

C A A A A B A A D C

[return to top]

112