Course Name:  Toyota Engines 

Course Prefix: AUSV

Course Number: 1160
             Submitted by (Name & E-Mail):  John Kelly , jkelly1@weber.edu

Current Date:  11/18/2008
College: Applied Science & Technology
Department:   Automotive Technology                              
From Term: Fall  2009 

Substantive
change  Current Course Subject N/A
Current Course Number

AUSV 1160. Toyota Engines (3) Theory, operation, diagnosis, repair, and overhaul of Toyota engines. Prerequisite: AUSV 1000.

New/Revised Course Information:

Subject:  AUTOSV            

Course Number: 1160

 Check all that apply:
    This is for courses already approved for gen ed.
    Use a different form for proposing a new gen ed designation.
DV  SI  CA  HU  LS  PS  SS 
EN  AI  QL  TA  TB  TC  TD  TE

Course Title: Toyota Engines

Abbreviated Course Title: Toyota Engines

Course Type:  LEL

Credit Hours:  4  or if variable hours:    to

Contact Hours: Lecture 2  Lab 4   Other

Repeat Information:  Limit 0   Max Hrs 0 

Grading Mode:  standard

This course is/will be: a required course in a major program
a required course in a minor program
a required course in a 1- or 2- year program
elective

Prerequisites/Co-requisites:

Prerequisite/Co-requisite: AUSV 1000.

Course description (exactly as it will appear in the catalog, including prerequisites):

AUSV 1160. Toyota Engines (4) Theory, operation, diagnosis, repair, and overhaul of Toyota engines. Prerequisite/Co-requisite: AUSV 1000.

Justification:  Automotive technology and the automotive industry are constantly changing because of U.S. Environmental Protection Agency (EPA) emissions regulations, National Highway Traffic Safety Administration (NHTSA) Federal Motor Vehicle Safety Standards (FMVSS), Corporate Average Fuel Economy (CAFE) regulations and customer demand for more fuel-efficient vehicles. Additional technological advances require additional lecture and lab time. This course is required for certification/accreditation of this program.

INFORMATION PAGE
for substantive proposals only

1. Did this course receive unanimous approval within the Department?

true

If not, what are the major concerns raised by the opponents?

2. If this is a new course proposal, could you achieve the desired results by revising an existing course within your department or by requiring an existing course in another department?

3. How will the proposed course differ from similar offerings by other departments? Comment on any subject overlap between this course and topics generally taught by other departments, even if no similar courses are currently offered by the other departments. Explain any effects that this proposal will have on program requirements or enrollments in other department. Please forward letters (email communication is sufficient) from all departments that you have identified above stating their support or opposition to the proposed course.

No similar offerings

4. Is this course required for certification/accreditation of a program?

yes

If so, a statement to that effect should appear in the justification and supporting documents should accompany this form.

5. For course proposals, e-mail a syllabus to Faculty Senate which should be sufficiently detailed that the committees can determine that the course is at the appropriate level and matches the description. There should be an indication of the amount and type of outside activity required in the course (projects, research papers, homework, etc.).

 

 

Syllabus – AUSV 1160 – Fall Semester 2009

Toyota Engine Mechanical Systems

(4 credit hours)

Course Description:

Theory, operation, diagnosis, and repair of Toyota automotive engines.  Emphasis is on the use of electronic service information (TIS2), the proper diagnostic processes, and proper diagnostic service tools. 

 

This course will cover Toyota Engines Systems.  We will cover topics in Automotive Engines, Theory and Servicing.  You will disassemble, clean, inspect, and reassemble a Toyota engine according to the proper repair information.  You will be able to correctly identify and describe the function of each part.  You will use micrometers and other measuring devices to determine serviceability during inspection. You will use the Toyota Information System (TIS2), diagnostic processes, and the TechStream diagnostic tool to identify faults in various engine mechanical systems.

 

ASE/NATEF area A1 will be covered in this course.  This course will prepare you for the ASE certification exam A1. A minimum grade of a “C” for this course is required to graduate.

Instructor Contact Information:

Class Time and Location:

 

Prerequisites:

Learning Outcomes:

This course will consist of a combination of class lecture and shop lab activities.  Daily lecture will cover topics that you will then practice in the shop.  You should expect to spend about an hour per day in class and the remaining time in the shop.

The following list of learning outcomes will be addressed in this course.  These learning outcomes have been derived from the A1 NATEF task list (See the complete A1 NATEF task list on page 10) for Engine Repair.

 

Automotive Engines, Theory and Servicing

  1. Shop Safety
    1. Identify situations in which hearing protection should be worn.
    2. Discuss how to safely handle tools and equipment.
    3. Discuss how to properly use a fire extinguisher.
    4. Discuss shop safety procedures.
  2. Environmental and Hazardous Materials
    1. Prepare for the ASE assumed knowledge content required by all service technicians to adhere to environmentally appropriate actions and behavior.
    2. Define the Occupational Safety and Health Act (OSHA).
    3. Explain the term Material Safety Data Sheet (MSDS).
    4. Identify hazardous waste materials in accordance with state and federal regulations and follow proper safety precautions while handling hazardous waste materials.
    5. Define the steps required to safely handle and store automotive chemicals and waste.
  3. Fasteners and Thread Repair
    1. Explain the terms used to identify bolts and other threaded fasteners.
    2. Explain the strength ratings of threaded fasteners.
    3. Describe the proper use of non-threaded fasteners.
    4. Discuss how snap rings are used.
  4. Hand Tools
    1. Describe what tool is best to use for each job.
    2. Discuss how to safely use hand tools.
    3. Explain the difference between brand name (trade name) and the proper name for tools.
    4. Explain how to maintain hand tools.
  5. Power Tools and Shop Equipment
    1. Identify commonly used power tools.
    2. Identify commonly used shop equipment.
    3. Discuss the proper use of power tools and equipment.
    4. Describe the safety procedures that should be followed when working with power tools and shop equipment.
  6. Vehicle Lifting and Hoisting
    1. Identify vehicle hoisting and lifting equipment.
    2. Discuss safety procedures related to hoisting or lifting a vehicle.
    3. Describe the proper methods to follow to safely hoist a vehicle.
  7. Measuring Systems and Tools
    1. Describe how to read a ruler.
    2. Explain how to use a micrometer and a vernier caliper.
    3. Describe how to use a telescoping gauge and a micrometer to measure cylinder and lifter bores.
    4. Discuss how to measure valve guides using a small-hole gauge and a micrometer.
    5. Calculate engine displacement and compression ratios.
  8. Service Information
    1. Discuss the importance of vehicle history.
    2. Review vehicle service information.
    3. Read and interpret service manuals and electronic service information.
    4. Describe the use of the vehicle owner’s manual.
  9. Vehicle Identification and Emission Ratings.
    1. Identify a vehicle.
    2. Interpret vehicle identification numbers and placard information.
    3. Interpret vehicle emissions and emission control information.
    4. Read and interpret casting numbers.
    5. Locate calibration codes.
  10. Gasoline Engine Operation, Parts, and Specifications
    1. Prepare for Engine Repair (A1) ASE certification test area “A” (General Engine Diagnosis).
    2. Explain how a 4-stroke cycle gasoline engine operates.
    3. List the various characteristics by which vehicle engines are classified.
    4. Discuss how a compression ratio is calculated.
    5. Explain how engine size is determined.
    6. Describe how turbocharging or supercharging increase engine power.
  11. Gasoline and alternative fuels
    1. Describe how the proper grade of gasoline affects engine performance.
    2. List gasoline purchasing hints.
    3. Discuss how volatility affects driveability.
    4. Explain how oxygenated fuels can reduce CO exhaust emissions.
    5. Discuss the advantages and disadvantages of various alternative fuels.
  12. Diesel Engine Operation and Diagnosis
    1. Prepare for ASE Engine Performance (A8) certification test content area “C” (Fuel, Air Induction, and Exhaust Systems Diagnosis and Repair).
    2. Explain how a diesel engine works.
    3. Describe the difference between direct injection (DI) and indirect injection (IDI) diesel engines.
    4. List the parts of the typical diesel engine fuel system.
    5. Explain how glow plugs work.
    6. List the advantages and disadvantages of a diesel engine. 
    7. Describe how diesel fuel is rated and tested.
  13. Cooling System Operation and Diagnosis
    1. Prepare for Engine Repair (A1) ASE certification test content area “D” (Lubrication and Cooling Systems Diagnosis and Repair).
    2. Describe how coolant flows through an engine.
    3. Discuss the operation of the thermostat.
    4. Explain the radiator pressure cap purpose and function.
    5. Describe the various types of antifreezes and how to recycle and discard used coolant.
    6. Discuss how to diagnose cooling system problems.
  14. Lubrication System Operation and Diagnosis
    1. Prepare for Engine Repair (A1) ASE certification test content area “D” (Lubrication and Cooling Systems Diagnosis and Repair).
    2. Explain engine oil ratings.
    3. Describe how an oil pump and engine lubrication work.
    4. Discuss how often and when to change the engine oil and filter.
    5. Discuss how to inspect and oil pump for wear.
  15. Starting and Charging System Operation and Diagnosis
    1. Prepare for Engine Repair (A1) ASE certification test content area “E” (Fuel, Electrical, Ignition, and Exhaust Systems Inspections and Service).
    2. List the precautions necessary whenever working with batteries.
    3. Describe how to test a battery.
    4. Explain how to safely charge a battery.
    5. Describe how the cranking circuit works.
    6. Describe how to perform cranking system testing procedures.
    7. Discuss the various AC generator test procedures.
  16. Ignition System Operation and Diagnosis
    1. Prepare for Engine Repair (A1) ASE certification test content area “E” (Fuel, Electrical, Ignition, and Exhaust Systems Inspections and Service).
    2. Explain how ignition coils create 40,000 volts.
    3. Discuss crankshaft position sensor and pickup coil operation.
    4. Describe the operation of waste-spark or coil-on-plug ignition systems.
  17. Emission Control Devices Operation and Diagnosis
    1. Prepare for the ASE Engine Performance (A8) certification test content area “D” (Emission Control Systems).
    2. Describe the purpose and function of the exhaust gas recirculation system.
    3. Explain methods for diagnosing and testing for faults in the exhaust gas recirculation system.
    4. Describe the purpose and function of the positive crankcase ventilation (PCV) and the air induction reaction (AIR) system.
    5. Explain methods for diagnosing and testing faults in the PCV and AIR systems.
    6. Describe the purpose and function of the catalytic converter.
    7. Explain the method for diagnosing and testing the catalytic converter.
  18. Intake and Exhaust Systems
    1. Prepare for ASE Engine Performance (A8) certification test content area “C” (Air Induction and Exhaust Systems Diagnosis and Repair).
    2. Discuss the purpose and function of intake manifolds.
    3. Explain the difference between throttle fuel injection manifolds and port fuel injection manifolds.
    4. Describe the operation of the Exhaust Gas Recirculation (EGR) system in the intake manifold.
    5. List the materials used in exhaust manifolds and exhaust systems.
  19. Turbocharging and Supercharging
    1. Prepare for ASE Engine Performance (A8) certification test content area “C” (Air Induction and Exhaust Systems Diagnosis and Repair).
    2. Explain the difference between a turbocharger and a supercharger.
    3. Describe how the boost levels are controlled.
    4. Discuss maintenance procedures for turbochargers and superchargers.
  20. Engine Condition Diagnosis
    1. Prepare for ASE Engine Performance (A8) certification test content area “A” (General Engine Diagnosis).
    2. List the visual checks to determine engine condition.
    3. Discuss engine noise and its relation to engine condition.
    4. Describe how to perform a dry and wet compression test.
    5. Explain how to perform a cylinder leakage test.
    6. Discuss how to measure the amount of timing chain slack.
    7. Describe how an oil sample analysis can be used to determine engine condition.
  21. Engine Disassembly, Cleaning, and Crack Detection
    1. Prepare for Engine Repair (A1) ASE certification test area “A” (General Engine Diagnosis).
    2. Describe how to remove an engine from a vehicle.
    3. Discuss how to remove cylinder heads without causing warpage.
    4. List the steps necessary to remove a piston from a cylinder.
    5. Explain how to remove a valve from a cylinder head.
    6. List the types of engine cleaning methods.
    7. List the various methods that can be used to check engine parts for cracks.
    8. Describe crack repair procedures.
  22. Cylinder Head and Valve Guide Service
    1. Prepare for Engine Repair (A1) ASE certification test area “B” (Cylinder head and Valve Train Diagnosis and Repair).
    2. Identify combustion chamber types.
    3. Explain the operation of a stratified charge combustion chamber.
    4. List the necessary steps to recondition a cylinder head.
    5. Describe how to inspect and measure valve guides.
    6. Discuss valve guide repair options.
  23. Valve and Seat Service
    1. Prepare for Engine Repair (A1) ASE certification test area “B” (Cylinder head and Valve Train Diagnosis and Repair).
    2. Discuss various engine valve types and materials.
    3. Describe how to test valve springs.
    4. Explain the purpose, function, and operation of valve rotators.
    5. List the steps necessary to reface a valve.
    6. Describe how to grind valve seats.
    7. Discuss how to measure and correct installed height and valve stem height.
  24. Camshafts and Valve Trains
    1. Prepare for Engine Repair (A1) ASE certification test area “B” (Cylinder head and Valve Train Diagnosis and Repair).
    2. Describe how the camshaft and valve train function.
    3. Discuss valve train noise and its causes.
    4. Explain how to degree a camshaft.
    5. Explain how a hydraulic lifter works.
  25. Pistons, Rings, and Connecting Rods
    1. Prepare for Engine Repair (A1) ASE certification test area “C” (Engine Block Diagnosis and Repair).
    2. Describe the purpose and function of pistons, rings, and connecting rods.
    3. Explain how pistons and rods are constructed and what to look for during an inspection.
    4. Discuss connecting rod reconditioning procedures.
    5. Explain how piston rings operate and how to install them on a piston.
  26. Engine Blocks
    1. Prepare for Engine Repair (A1) ASE certification test area “C” (Engine Block Diagnosis and Repair).
    2. Describe the types of engine blocks and how they are manufactured.
    3. List the machining operations required on most engine blocks.
    4. List the steps necessary to prepare an engine block for assembly.
  27. Crankshafts and Bearings
    1. Prepare for Engine Repair (A1) ASE certification test area “C” (Engine Block Diagnosis and Repair).
    2. Describe the purpose and function of a crankshaft.
    3. Explain how crankshafts are machined and polished.
    4. Discuss engine bearing construction and installation procedures.
  28. Engine Balancing and Balance Shafts
    1. Prepare for Engine Repair (A1) ASE certification test area “C” (Engine Block Diagnosis and Repair).
    2. Explain the causes of primary and secondary engine vibration.
    3. Describe why balance shafts are used.
    4. Explain what parts are rotating weight and what parts are reciprocating weight.
    5. List the steps needed to balance an engine.
  29. Preparation for Assembly
    1. Describe the steps that should be followed in preparation for assembly.
    2. Explain clamping force.
    3. Discuss the advantages of performing a trial assembly of the engine.
  30. Engine Blueprinting and Assembly
    1. Prepare for Engine Repair (A1) ASE certification test area “C” (Engine Block Diagnosis and Repair).
    2. List the steps for assembling an engine.
    3. Describe how to measure bearing oil clearance using plastic gauging material (Plasti-Gage™).
    4. Explain how to check for crankshaft end-play and connecting rod side clearance.
    5. Discuss how to fit pistons to individual cylinder bores.
    6. Describe how to test for proper oil pressure before starting the engine.
  31. Engine Installation and In-Vehicle Service
    1. Prepare for Engine Repair (A1) ASE certification test content area “E” (Fuel, Electrical, Ignition, and Exhaust Systems Inspections and Service).
    2. List the steps necessary to install and start-up a rebuilt engine.
    3. Discuss the importance of torquing all bolts or fasteners that connect accessories to the engine block.
    4. Describe what precautions must be taken to prevent damage to the engine when first started.
    5. Explain how to break-in a newly rebuilt engine.
    6. Describe how to replace a timing belt on an overhead cam engine.

 

 

 

 

 

Toyota T-TEN Requirements:

This course encompasses all of the tasks required by Toyota, Lexus, and Scion for Toyota, Lexus, and Scion T-TEN Students. 

NATEF Tasks:

The Automotive Technology Department at Weber State University is certified by the National Automotive Technicians Education Foundation (NATEF).  For more information on NATEF, go to www.natef.org.  To obtain NATEF certification, certain tasks must be taught or performed in each of the eight Automotive Service Excellence (ASE) areas.  The tasks covered in this course are from ASE area 1 – Engine Repair.  All required A1 NATEF tasks are covered in this class.

 

 

Required Materials:

·         A WSU Student Photo ID card – this is required to check out tools from the tool room.

Grading Criteria:

The following criteria will determine your grade

Letter grades are determined by the percentage of possible points accumulated.

 

Schedule:

The following is the class schedule.  The chapters and topics covered on each date are tentative and subject to change as material is covered. 

 

There will be no class held the following days:

 

Week One:

Monday                        Class introduction, Safety Exercise, S/P2, Tools, Expectations, Lisa Burr

Tuesday                        Hazardous materials, Fasteners, hand tools, and power tools

Wednesday                   Lifting, Hoisting, and Measuring.  S/P2 due today.

Thursday                       Service Information, Vehicle Identification and Emissions

                                   

Week Two:

Monday                                    Gasoline Engines, Alternative Fuels

Tuesday                        Diesel Engines, Cooling Systems, Lubrication Systems

Wednesday                   Starting Systems, Charging Systems, and Ignition Systems

Thursday                       Intake, Exhaust, Turbo and Supercharging

                                   

Week Three:

Monday                                    Engine Condition Diagnosis

Tuesday                        Engine Disassembly

Wednesday                   Cylinder Head and Valve Guides

Thursday                       Valves and Seats

                                   

Week Four:      

Monday                                    Camshaft, Valve Trains, VVT-I and ACIS

Tuesday                        Pistons, Rings, and Connecting Rods

Wednesday                   Engine Blocks

Thursday                       Crankshafts and bearings

                                   

Week Five:

Monday                                    Engine Balancing

Tuesday                        Preparation for Assembly

Wednesday                   Blueprinting and Assembly

Thursday                       Engine Installation, In-Vehicle Service

 

Week Six:

Monday                                    Diagnostics     

Tuesday                        Written final exam

Wednesday                   Hands on final exam

 

           

Policies:

  1. Safety glasses/goggles must be worn in the shop at all times.
  2. While working in the shop, proper attire must be worn.  This applies, but is not limited, to:
  3. A student WSU ID card is required to check out tools from the tool room.
  4. Respect:
  5. All of your assignments must be completed on the day assigned.  Class will follow the sequence listed in the schedule above.  All the weeks are full of work to do and tasks to perform.  Late work will not be accepted.
  6. Text messaging and/or phone calls during class is unprofessional, distracting, and is prohibited.  Many automotive service managers do not allow cell phone use during normal work hours.  Please silence all cell phones and audible “silent” vibrations.  Communication with the instructor via phone, email, and text messaging is allowed until 9:00 p.m.  Unwanted phone calls and/or text messaging is considered harassment and is against the law.
  7. Unless you are assigned to work in groups for lab work, you must do your own work.  Collaboration with other students is not allowed.
  8. Dishonesty will not be tolerated and will result in a score of zero for the assignment, quiz, or exam.
  9. There is a lot of information to cover each day and it is important to be in class and on time every day.

 

Recommendations to get the most from this course:

 

  1. Be early or on time.  Class will begin without you.
  2. Ask questions to clarify points that you do not understand. 
  3. Follow directions as they are given to you.  The directions that I give you come from my previous experience in the dealership.

Services for Students with Disabilities:

"Any student requiring accommodations or services due to a disability must contact Services for Students with Disabilities (SSD) in room 181 of the Student Services Center. SSD can also arrange to provide course materials (including the syllabus) in alternative formats if necessary." 

For more information about the SSD contact them at 801-626-6413, ssd@weber.edu, or http://departments.weber.edu/ssd/


 

NATEF AREA A1 ENGINE REPAIR

 

For every task in Engine Repair, the following safety requirement must be strictly enforced:

 

Comply with personal and environmental safety practices associated with clothing; eye protection; hand tools; power equipment; proper ventilation; and the handling, storage, and disposal of chemicals/materials in accordance with local, state, and federal safety and environmental regulations.

 

I.          ENGINE REPAIR

 

A.    General Engine Diagnosis; Removal and Reinstallation (R & R)

 

1.         Complete work order to include customer information, vehicle identifying information, customer concern, related service history, cause, and correction.

P-1

 

 

2.         Identify and interpret engine concern; determine necessary action.

P-1

 

 

3.         Research applicable vehicle and service information, such as internal engine operation, vehicle service history, service precautions, and technical service bulletins.

P-1

 

 

4.         Locate and interpret vehicle and major component identification numbers.

P-1

 

 

5.         Inspect engine assembly for fuel, oil, coolant, and other leaks; determine necessary action.

P-1

 

 

6.         Diagnose engine noises and vibrations; determine necessary action.

P-2

 

 

7.         Diagnose the cause of excessive oil consumption, coolant consumption, unusual engine exhaust color and odor; determine necessary action.

P-2

 

 

8.         Perform engine vacuum tests; determine necessary action.

P-1

 

 

9.         Perform cylinder power balance tests; determine necessary action.

P-2

 

 

10.        Perform cylinder cranking and running compression tests; determine necessary action.

P-1

11.        Perform cylinder leakage tests; determine necessary action.

P-1

 

12.        Remove and reinstall engine in  an OBDII or newer vehicle; reconnect all attaching components and restore the vehicle to running condition.

 

P-2

13.        Install engine covers using gaskets, seals and sealers as required.

P-1

14.          Perform common fastener and thread repair, to include: remove broken bolt, restore internal and external threads, and repair internal threads with thread insert.

P-1

15.  Inspect, remove and replace engine mounts.

P-2

 

 

I.          ENGINE REPAIR

 

 

 

            B.  Cylinder Head and Valve Train Diagnosis and Repair

 

 

 

1.         Remove cylinder head; inspect gasket condition; install cylinder head and gasket; tighten according to manufacturer’s specifications and procedures.

P-1

 

 

2.         Clean and visually inspect a cylinder headfor cracks; check gasket surface areas for warpage and surface finish; check passage condition.

P-1

 

 

3.         Inspect valve springs for squareness and free height comparison; determine necessary action.

P-3

 

 

4.         Replace valve stem seals on an assembled engine; inspect valve spring retainers, locks/keepers, and valve lock/keeper grooves; determine necessary action.

P-3

 

 

5.         Inspect valve guides for wear; check valve stem-to-guide clearance; determine necessary action.

P-3

 

 

6.         Inspect valves and valve seats; determine necessary action.

P-3

 

 

7.         Check valve spring assembled height and valve stem height; determine necessary action.

P-3

 

 

8.         Inspect pushrods, rocker arms, rocker arm pivots and shafts for wear, bending, cracks, looseness, and blocked oil passages (orifices); determine necessary action.

P-2

 

 

9.         Inspect valve lifters; determine necessary action.

P-2

 

 

10.        Adjust valves (mechanical or hydraulic lifters).

P-1

 

 

11.        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 variable valve timing components).

P-1

 

 

12.        Inspect and/or measure camshaft for runout, journal wear and lobe wear.

P-2

 

 

13.        Inspect camshaft bearing surface for wear, damage, out-of-round, and alignment; determine necessary action.

P-2

 

 

14.        Establish camshaft position sensor indexing.

P-1

 

 

I.          ENGINE REPAIR

 

 

 

            C.  Engine Block Assembly Diagnosis and Repair

 

 

 

1.         Disassemble engine block; clean and prepare components for inspection and reassembly.

P-1

 

 

2.         Inspect engine block for visible cracks, passage condition, core and gallery plug condition, and surface warpage; determine necessary action.

P-2

 

 

3.         Inspect and measure cylinder walls/sleeves for damage, wear, and ridges; determine necessary action.

P-2

 

 

4.         Deglaze and clean cylinder walls.

P-2

 

 

5.         Inspect and measure camshaft bearings for wear, damage, out-of-round, and alignment; determine necessary action.

P-3

 

 

6.         Inspect crankshaft forstraightness, 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.

P-1

 

 

7.         Inspect main and connecting rod bearings for damage and wear; determine necessary action.

P-2

           

 

8.         Identify piston and bearing wear patterns that indicate connecting rod alignment and main bearing bore problems; determine necessary action.

P-3

 

9.         Inspect and measure piston skirts and ring lands; determine necessary action.

P-2

 

 

10.        Remove and replace piston pin.

P-3

 

 

11.        Determine piston-to-bore clearance.

P-2

 

 

12.        Inspect, measure, and install piston rings.

P-2

 

 

13.        Inspect auxiliary shaft(s) (balance, intermediate, idler, counterbalance or silencer); inspect shaft(s) and support bearings for damage and wear; determine necessary action; reinstall and time.

 

P-2

14.        Remove, inspect or replace crankshaft vibration damper (harmonic balancer).

P-2

 

 

15.        Assemble engine block.

P-1

 

 

I.          ENGINE REPAIR

 

 

 

            D.  Lubrication and Cooling Systems Diagnosis and Repair

 

 

 

1.         Perform oil pressure tests; determine necessary action.

P-1

 

 

2.         Inspect oil pump gears or rotors, housing, pressure relief devices, and pump drive; perform necessary action.

P-2

 

 

3.         Perform cooling system pressure tests; check coolant condition; inspect and test radiator, pressure cap, coolant recovery tank, and hoses; determine necessary action.

P-1

 

 

4.         Inspect, replace, and adjust drive belts, tensioners, and pulleys; check pulley and belt alignment.

P-1

 

 

5.         Inspect and replace engine cooling and heater system hoses.

P-1

 

 

6.         Inspect, test, and replace thermostat and gasket/seal.

P-1

 

 

7.         Test coolant; drain and recover coolant; flush and refill cooling system with recommended coolant; bleed air as required.

P-1

 

 

 

8.         Inspect, remove and replace water pump.

P-2

 

 

9.         Remove and replace radiator.

P-2

 

 

10.        Inspect, and test fans(s) (electrical or mechanical), fan clutch, fan shroud, and air dams.

P-1

 

 

11.        Inspect auxiliary coolers; determine necessary action.

P-3

 

 

 

12.        Inspect, test, and replace oil temperature and pressure switches and sensors.

P-2

 

 

13.        Perform oil and filter change.

P-1

 

 

14.        Identify causes of engine overheating.

P-1