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. Identify and interpret engine
concern; determine necessary action. P-1
2. Research
applicable vehicle and service information, such as internal
engine operation, vehicle service history, service precautions,
and technical service bulletins. P-1
3. Locate and
interpret vehicle and major component identification numbers (VIN,
vehicle certification labels, and calibration decals).
P-1
4. Inspect engine assembly for fuel, oil, coolant, and
other leaks; determine necessary action. P-1
5. Diagnose
engine noises and vibrations; determine necessary action.
P-2
6. Diagnose the cause of excessive oil consumption,
unusual engine exhaust color, odor, and sound; determine necessary
action. P-2
7. Perform engine vacuum tests; determine
necessary action. P-1
8. Perform cylinder power balance
tests; determine necessary action. P-1
9. Perform cylinder
compression tests; determine necessary action. P-1
10.
Perform cylinder leakage tests; determine necessary action.
P-1
11. Remove and reinstall engine in a late model
front-wheel drive vehicle (OBDI or newer);
reconnect all attaching components and restore the vehicle to
running condition. P-1
12. Remove and reinstall engine in a
late model rear-wheel drive vehicle (OBDI or
newer); reconnect all attaching components and restore the vehicle
to running condition. P-3
I. ENGINE REPAIR
B. Cylinder Head and Valve
Train Diagnosis and Repair
1. Remove cylinder
head(s); visually inspect cylinder head(s) for cracks; check
gasket surface areas for warpage and leakage; check passage
condition. P-2
2. Install cylinder heads and gaskets;
tighten according to manufacturer’s specifications and procedures.
P-1
3. Inspect valve springs for squareness and free height
comparison; determine necessary action. P-2
4. Replace
valve stem seals on an assembled engine; inspect valve spring
retainers, locks, and valve grooves; determine necessary action.
P-2
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 face-to-seat contact and valve seat
concentricity (runout); determine necessary action. P-3
8.
Check valve spring assembled height and valve stem height;
determine necessary action. P-3
9. Inspect pushrods, rocker
arms, rocker arm pivots and shafts for wear, bending, cracks,
looseness, and blocked oil passages (orifices); determine
necessary action. P-2
10. Inspect hydraulic or mechanical
lifters; determine necessary action. P-2
11. Adjust valves
(mechanical or hydraulic lifters). P-1
12. Inspect camshaft
drives (including gear wear and backlash, sprocket and chain
wear); determine necessary action. P-2
13. Inspect and
replace timing belts (chains), overhead camdrive sprockets, and
tensioners; check belt/chain tension; adjust as necessary.
P-1
14. Inspect camshaft for runout, journal wear and lobe
wear. P-2
15. Inspect camshaft bearing surface for wear,
damage, out-of-round, and alignment; determine necessary action.
P-3
16. Establish camshaft(s) timing and cam sensor
indexing according to manufacturer’s specifications and
procedures. 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-2
2. Inspect engine block for
visible cracks, passage condition, core and gallery plug
condition, and surface warpage; determine necessary action.
P-2
3. Inspect internal and external threads; restore as
needed (includes installing thread inserts). P-2
4. Inspect
and measure cylinder walls for damage, wear, and ridges; determine
necessary action. P-2
5. Deglaze and clean cylinder walls.
P-2
6. Inspect and measure camshaft bearings for wear,
damage, out-of-round, and alignment; determine necessary action.
P-3
7. Inspect crankshaft for end play, straightness,
journal damage, keyway damage, thrust flange and sealing surface
condition, and visual surface cracks; check oil passage condition;
measure journal wear; check crankshaft sensor reluctor ring (where
applicable); determine necessary action. P-2
8. Inspect and
measure main and connecting rod bearings for damage, clearance,
and end play; determine necessary action (includes the proper
selection of bearings). P-2
9. Identify piston and bearing
wear patterns that indicate connecting rod alignment and main
bearing bore problems; inspect rod alignment and bearing bore
condition. P-3
10. Inspect and measure pistons; determine
necessary action. P-2
11. Remove and replace piston pin.
P-3
12. Inspect, measure, and install piston rings.
P-1
13. Inspect auxiliary (balance, intermediate, idler,
counterbalance or silencer) shaft(s); inspect shaft(s) and support
bearings for damage and wear; determine necessary action;
reinstall and time. P-2
14. Inspect or replace crankshaft
vibration damper (harmonic balancer). P-3
15. Assemble the
engine using gaskets, seals, and formed-in-place (tube-applied)
sealants, thread sealers, etc. according to manufacturer’s
specifications. P-2
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, cap, and
recovery system tests (pressure, combustion leakage, and
temperature); 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 housing. P-2
7. Test
coolant; drain and recover coolant; flush and refill cooling
system with recommended coolant; bleed air as required.
P-1
8. Inspect, test, remove, and replace water pump.
P-1
9. Remove and replace radiator. P-2
10. Inspect,
and test fans(s) (electrical or mechanical), fan clutch, fan
shroud, and air dams. P-2
11. Inspect auxiliary oil 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-2
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