Active Outline

General Information

Course ID (CB01A and CB01B)
APRN D064.
Course Title (CB02)
Automotive Machining and Engine Repair
Course Credit Status
Credit - Degree Applicable
Effective Term
Fall 2021
Course Description
Repair and rebuilding of engine cylinder heads and block components, engine assembly and testing. Includes theory, diagnosis, disassembly, cleaning, inspection and failure analysis. Preparation for Automotive Service Excellence (ASE) examinations for Areas A1 and M1, M2 and M3.
Faculty Requirements
Course Family
Not Applicable

Course Justification

This is an apprenticeship course that is only offered to a target population of students who have been approved for the Automotive Technologies Apprenticeship Program. It is also a recommendation from industry advisory committees to help better prepare students for the automotive job market, with a better foundation of engine theory, diagnosis, and repair.

Foothill Equivalency

Does the course have a Foothill equivalent?
No
Foothill Course ID

Course Philosophy

Formerly Statement

Course Development Options

Basic Skill Status (CB08)
Course is not a basic skills course.
Grade Options
  • Letter Grade
  • Pass/No Pass
Repeat Limit
0

Transferability & Gen. Ed. Options

Transferability
Transferable to CSU only

Units and Hours

Summary

Minimum Credit Units
9.0
Maximum Credit Units
9.0

Weekly Student Hours

TypeIn ClassOut of Class
Lecture Hours9.018.0
Laboratory Hours0.00.0

Course Student Hours

Course Duration (Weeks)
12.0
Hours per unit divisor
36.0
Course In-Class (Contact) Hours
Lecture
108.0
Laboratory
0.0
Total
108.0
Course Out-of-Class Hours
Lecture
216.0
Laboratory
0.0
NA
0.0
Total
216.0

Prerequisite(s)

Corequisite(s)

Advisory(ies)

Limitation(s) on Enrollment

(Open only to apprentices in the Automotive Technologies Apprenticeship Program (an approved program by the Division of Apprenticeship Standards).)

Entrance Skill(s)

General Course Statement(s)

Methods of Instruction

Lecture and visual aids

Discussion and problem solving performed in class

Homework and extended projects

Collaborative learning and small group exercises

Assignments

  1. Reading from text and handouts
  2. Engine related research assignments

Methods of Evaluation

  1. Ten multiple choice examinations covering lecture units
  2. Comprehensive multiple choice final examination covering all units
  3. Written engine related research assignment graded using a rubric

Essential Student Materials/Essential College Facilities

Essential Student Materials: 
  • Safety glasses for shop demonstrations
Essential College Facilities:
  • Automotive machine shop laboratory
  • Computers and required software

Examples of Primary Texts and References

AuthorTitlePublisherDate/EditionISBN
Lewis, W.G. "Automotive Machining and Engine Repair." Engine Books, 2011.

Examples of Supporting Texts and References

AuthorTitlePublisher
ProSIS information system. Software is installed locally
"Engine Analyzer Ver. 3.2," Performance Trends Inc. Software is installed locally

Learning Outcomes and Objectives

Course Objectives

  • Demonstrate an understanding of the proper use of automotive measuring tools and the ability to read them
  • Identify various types of fasteners, their properties, and their automotive uses
  • Examine the theory of the different types of automotive engines and compare their uses
  • Analyze the need for engine diagnosis by solving faults at the system level
  • Describe the proper procedure for cylinder head disassembly and interpret engine failures
  • Describe the proper methods and materials used for cleaning engine parts in an environmentally safe manner
  • Demonstrate the proper techniques of failure analysis for valve train components
  • Demonstrate the proper technique of failure analysis for short block components
  • Describe the techniques of crack detection for engine castings of differing materials
  • Explain the various procedures of reconditioning valve train components
  • Explain the various procedures of reconditioning engine block components
  • Explain the proper and safe methods of resurfacing cylinder heads and blocks
  • List the proper order of engine assembly as it relates to the different engine configurations

CSLOs

  • Student should be able to answer selected questions on the final concerning engine theory, valve events, engine diagnostics, and engine assembly.

Outline

  1. Demonstrate an understanding of the proper use of automotive measuring tools and the ability to read them
    1. Understanding specifications and tolerances
    2. Calculating thermal expansion
    3. Comparing units of measurement
    4. Using micrometers
    5. Making transfer measurements
    6. Using dial indicators
    7. Using dial bore gauges
    8. Using vernier calipers
    9. Checking alignments
    10. Measuring surface finishes
    11. Measuring thicknesses of castings
  2. Identify various types of fasteners, their properties, and their automotive uses
    1. Determining the strength of fasteners
    2. Comparing clamping force and torque
    3. Identifying threads
    4. Using pipe threads and fittings
    5. Removing broken fasteners
    6. Installing helicoils
    7. Removing broken tools
  3. Examine the theory of the different types of automotive engines and compare their uses
    1. The four-stroke cycle
    2. Compression ignition engines
    3. Valve timing and camshafts
    4. Valve train configurations
    5. Valve lifters and lash compensators
    6. Engine oiling
    7. Engine oils
    8. Engine measurements
    9. Fits and clearances
    10. Cooling system operation
    11. Combustion efficiency
  4. Analyze the need for engine diagnosis by solving faults at the system level
    1. Looking for signs of engine wear
    2. Checking the block assembly
    3. Testing power balance
    4. Testing compression
    5. Testing cylinder leakage
    6. Checking valve timing
    7. Testing manifold vacuum
    8. Testing exhaust back pressure
    9. Diagnosing engine noises
    10. Measuring exhaust gas pressure
    11. Testing engine oil pressure
  5. Describe the proper procedure for cylinder head disassembly and interpret engine failures
    1. Hints for in-chassis repairs
    2. Using valve spring compressors
    3. Recording dimensions
    4. Keeping parts in order
    5. Removing the timing chain and sprockets
    6. Removing camshaft bearings
    7. Removing oil plugs and core plugs
  6. Describe the proper methods and materials used for cleaning engine parts in an environmentally safe manner
    1. Using solvent and cold solutions
    2. Cleaning in hot tanks
    3. Degreasing in ovens
    4. Using airless shot blasters
    5. Bead blasting
    6. Small parts tumbling
    7. Using hand and power tools
    8. Removing rust and scale
    9. Working under regulations
  7. Demonstrate the proper techniques of failure analysis for valve train components
    1. Determining valve guide wear
    2. Checking valves
    3. Testing valve springs
    4. Inspecting the camshafts, lifters, and followers
    5. Checking timing chains and gears
    6. Inspecting rocker arms and pushrods
    7. Checking cylinder head castings
  8. Demonstrate the proper technique of failure analysis for short block components
    1. Measuring pistons and cylinder wear
    2. Measuring crankshaft wear and checking alignment
    3. Gauging connecting rods
    4. Inspecting bearings
    5. Inspecting camshafts and followers
    6. Inspecting deck surfaces
  9. Describe the techniques of crack detection for engine castings of differing materials
    1. Using dry magnetic particle testing
    2. Using wet magnetic particle testing
    3. Using dye penetrants
  10. Explain the various procedures of reconditioning valve train components
    1. Removing and replacing valve guides
    2. Knurling valve guides
    3. Fitting oversized valve stems
    4. Replacing integral valve guide
    5. Refacing valves and valve stems
    6. Grinding valve seats
    7. Cutting valve seats
    8. Installing valve seats
    9. Fitting valve seals
    10. Replacing rocker arm studs
    11. Correcting installed spring height
    12. Correcting installed stem height
    13. Refacing rocker arms
    14. Straightening aluminum heads
    15. Correcting overhead camshaft center lines
  11. Explain the various procedures of reconditioning engine block components
    1. Honing cylinders for overhaul
    2. Knurling pistons and recutting ring grooves
    3. Reboring and honing cylinders
    4. Sleeving cylinders
    5. Line boring and honing
    6. Fitting piston pins
    7. Resizing connecting rod housing bores
    8. Assembling and aligning pistons and connecting rods
    9. Regrinding camshafts and related operations
    10. Regrinding and polishing crankshafts
    11. Overhauling oil pumps
    12. Resurfacing flywheels and replacing ring gears
  12. Explain the proper and safe methods of resurfacing cylinder heads and blocks
    1. Comparing resurfacing machines
    2. General precautions
    3. Correcting v-block intake manifold alignment
    4. Determining v-block ratios
    5. Resurfacing overhead cam cylinder heads
    6. Resurfacing diesel cylinder heads
    7. Resurfacing air cooled cylinder heads
  13. List the proper order of engine assembly as it relates to the different engine configurations
    1. Cleaning and deburring for assembly
    2. Assembling cylinder heads
    3. Installing core plugs
    4. Installing camshaft bearings and camshaft
    5. Installing oil galley plugs
    6. Sealing rotating shafts; the basics
    7. Fitting the rear main seal
    8. Installing the main bearings and crankshaft
    9. Setting valve timing
    10. Installing piston rings
    11. Installing piston and connecting assemblies
    12. Assembling cylinder heads to engine blocks
    13. Installing rocker arms
    14. Adjusting valves
    15. Installing the oil pump
    16. Pre-oiling the engine
    17. Hints on gaskets, seals and sealants
    18. Engine assembly checklists
    19. Attaching bellhousings
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