AUT 163 - Automotive Engine Repair

This course will consist of classroom and lab instruction covering the theory of operation, disassembly, measurement, and reassembly of internal combustion gasoline and diesel power plants. When possible, power plants will be operationally tested prior to disassembly and after assembly. This course will help students refine their critical thinking skills as they evaluate various topics and concepts while searching for underlying connections between the concepts, which is a skill that should be beneficial in any/all types of careers. The students will increase their mechanical aptitude that can be used in many aspects of their life.

Prerequisites: A student is to have completed all prior program courses with a “C” or better grade. Any exception will have to be approved in writing by the Program Coordinator and Department Chair. Because of changes in technology, students taking program over an extended period of time may be advised to retake courses to update skills and competencies.
Prerequisites/Corequisites: A student is to have completed all prior program courses with a “C” or better grade. Any exception will have to be approved in writing by the Program Coordinator and Department Chair. Because of changes in technology, students taking program over an extended period of time may be advised to retake courses to update skills and competencies.

Mode(s) of Instruction: Traditional/face-to-face

Credit for Prior Learning: There are no Credit for Prior Learning opportunities for this course.

Course Fees: None

Common Course Assessment(s): All assessments are common amongst all course sections.

Student Learning Outcomes and Objectives:

• Student Learning Outcomes:
  •  Comprehends General Engine Diagnosis; Removal & Reinstallation
  •  Demonstrates Cylinder Head & Valve-Train Diagnosis & Repair
  •  Demonstrates Engine Block Assembly Diagnosis & Repair
  •  Demonstrates Lubrication & Cooling Systems Diagnosis & Repair
• Course Objectives:
  •  Complete work order to include customer information, vehicle identifying information, customer concern, related service history, cause, and correction.
  •  Research applicable vehicle and service information, such as internal engine operation, vehicle service history, service precautions, and technical service bulletins.
  •  Locate and interpret vehicle and major component identification numbers.
  •  Install engine covers using gaskets, seals and sealers as required.
  •  Perform common fastener and thread repair, to include: remove broken bolt, restore internal and external threads, and repair internal threads with thread insert.
  •  Remove cylinder head; inspect gasket condition; install cylinder head and gasket; tighten according to manufacturer’s specifications and procedures.
  •  Clean and visually inspect a cylinder head for cracks; check gasket surface areas for warpage and surface finish; check passage condition.
  •  Inspect valve springs for squareness and free height comparison; determine necessary action.
  •  Replace valve stem seals on an assembled engine; inspect valve spring retainers, locks/keepers, and valve lock/keeper grooves; determine necessary action.
  •  Inspect valve guides for wear; check valve stem-to-guide clearance; determine necessary action.
  •  Inspect valves and valve seats; determine necessary action.
  •  Check valve spring assembled height and valve stem height; determine necessary action.
  •  Inspect pushrods, rocker arms, rocker arm pivots and shafts for wear, bending, cracks, looseness, and blocked oil passages (orifices); determine necessary action.
  •  Inspect valve lifters; determine necessary action.
  •  Adjust valves (mechanical or hydraulic lifters).
  •  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/tonewheel, and variable valve timing components).
  •  Inspect and/or measure camshaft for runout, journal wear and lobe wear.
  •  Inspect camshaft bearing surface for wear, damage, out-of-round, and alignment; determine necessary action.
  •  Disassemble engine block; clean and prepare components for inspection and reassembly.
  •  Inspect engine block for visible cracks, passage condition, core and gallery plug condition, and surface warpage; determine necessary action.
  •  Inspect and measure cylinder walls/sleeves for damage, wear, and ridges; determine necessary action.
  •  Deglaze and clean cylinder walls.
  •  Inspect and measure camshaft bearings for wear, damage, out-of-round, and alignment; determine necessary action.
  •  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 necessary action.
  •  Inspect main and connecting rod bearings for damage and wear; determine necessary action.
  •  Identify piston and bearing wear patterns that indicate connecting rod alignment and main bearing bore problems; determine necessary action.
  •  Inspect and measure piston skirts and ring lands; determine necessary action.
  •  Determine piston-to-bore clearance.
  •  Inspect, measure, and install piston rings.
  •  Remove, inspect or replace crankshaft vibration damper (harmonic balancer).
  •  Assemble engine block.
  •  Inspect oil pump gears or rotors, housing, pressure relief devices, and pump drive; perform necessary action.
  •  Inspect, remove and replace water pump.
  •  Verify correct camshaft timing.