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Automotive Engines : Theory and Servicing,9780137997015
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Automotive Engines : Theory and Servicing

by ;
Edition:
4th
ISBN13:

9780137997015

ISBN10:
0137997019
Format:
Package
Pub. Date:
1/1/2001
Publisher(s):
PRENTICE HALL

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Summary

For courses in Automotive Engines, Engine Rebuilding, and Engine Theory and Repair. This text presents the principles and practices of engine rebuilding, engine theory and in-the-vehicle service in a clear, concise format. Each chapter makes clear connections between theory and servicing, opening coverage with technical material, then moving into diagnosis, troubleshooting and service procedures. The Fourth Edition has been both updated and streamlined to reflect the latest engine developments, techniques and terminology in the field and make learning even more accessible.

Table of Contents

Preface xvii
Acknowledgments xviii
Tools, Fasteners, and Safety
1(24)
Objectives
1(1)
Threaded Fasteners
1(1)
Metric Bolts
2(1)
Grades of Bolts
2(1)
Nuts
3(1)
Washers
4(1)
Basic Tool List
4(7)
Brand Name versus Proper Term
11(1)
Safety Tips for Using Hand Tools
12(1)
Safety Tips for Technicians
12(1)
Safety in Lifting (Hoisting) a Vehicle
13(4)
Hazardous Materials
17(1)
Material Safety Data Sheets
18(6)
Summary
24(1)
Review Questions
24(1)
ASE Certification-Type Questions
24(1)
Engine Operation and Identification
25(14)
Objectives
25(1)
Energy and Power
25(1)
Four-Stroke Cycle Operation
25(1)
The 720-Degree Cycle
26(1)
Engine Classification
27(2)
VIN Year Chart
29(1)
Engine Design Classification
30(2)
Engine Rotation Direction
32(1)
Bore
32(1)
Stroke
32(1)
Over Square and Under Square
32(2)
Engine Displacement
34(1)
Engine Size versus Horsepower
34(1)
Compression Ratio
34(1)
Horsepower
35(1)
Brake-Specific Fuel Consumption
36(1)
Where the Energy Goes
36(1)
Watts and Horsepower
36(1)
Taxable Horsepower
36(1)
SAE Gross versus Net Horsepower
36(1)
Metric versus Brake Horsepower
37(1)
Deutsche Industrie Norm Horsepower versus SAE Horsepower
37(1)
Japan Industry Standard versus SAE Horsepower
37(1)
Horsepower and Altitude
37(1)
Summary
38(1)
Review Questions
38(1)
ASE Certification-Type Questions
38(1)
Lubrication System Operation and Diagnosis
39(17)
Objectives
39(1)
Lubrication Principles
39(1)
Engine Lubrication Systems
40(1)
Properties of Engine Oil
40(1)
SAE Rating
40(1)
API Rating
41(1)
ILSAC Oil Rating
42(1)
European Oil Ratings
42(1)
Japanese Oil Ratings
42(1)
Engine Oil Additives
42(1)
Energy-Conserving Engine Oils
43(1)
Oil Brand Compatibility
43(1)
Synthetic Oil
43(1)
Oil Temperature
44(1)
Oil Change Intervals
44(1)
Oil Change Procedure
44(1)
Oil Filters
45(1)
Changing Oil in a Turbocharged Engine
45(2)
Oil Pumps
47(1)
Oil Pressure Regulation
48(1)
Factors Affecting Oil Pressure
49(1)
Oil Pump Checks
50(1)
Oil Passages in the Block
51(1)
Valve Train Lubrication
51(2)
Oil Pans
53(1)
Oil Coolers
53(1)
Positive Crankcase Ventilation
54(1)
Summary
54(1)
Review Questions
54(1)
ASE Certification-Type Questions
54(2)
Starting and Charging System Operation and Diagnosis
56(25)
Objectives
56(1)
Purpose of a Battery
56(1)
How a Battery Works
56(1)
Specific Gravity
57(2)
Battery Ratings
59(1)
Battery Service
59(4)
Jump Starting
63(1)
Cranking Circuit
63(1)
Starting System Troubleshooting
64(1)
Starter Amperage Testing
65(1)
Bench Testing
66(1)
AC Generators
66(13)
Summary
79(1)
Review Questions
79(1)
ASE Certification-Type Questions
79(2)
Ignition System Operation and Diagnosis
81(28)
Objectives
81(1)
Ignition System Operation
81(1)
Primary Circuit Operation
82(1)
Direct-Fire Ignition Systems
83(4)
Coil-on-Plug Ignition
87(1)
Checking for Spark
87(3)
Pickup Coil Testing
90(1)
Distributor Cap and Rotor Inspection
90(2)
Spark Plug Wire Inspection
92(1)
Firing Order
93(1)
Spark Plug Service
93(4)
Ignition Timing
97(10)
Summary
107(1)
Review Questions
107(1)
ASE Certification-Type Questions
107(2)
Fuel and Emission System Operation and Diagnosis
109(35)
Objectives
109(1)
Gasoline
109(1)
Volatility
109(1)
Volatility Problems
110(1)
Normal and Abnormal Combustion
110(2)
Research and Motor Methods of Octane Rating
112(1)
Gasoline Grades and Octane Number
112(1)
Oxygenated Fuels
113(1)
Combustion Chemistry
114(1)
Valve Recession and Unleaded Fuel
114(1)
Reformulated Gasoline
115(1)
Government Test Fuel
115(1)
General Gasoline Recommendations
115(1)
Fuel System Operation
115(1)
Mechanical Fuel Pump
116(1)
Electronic Fuel-Injection Operation
116(2)
Throttle-Body Injection
118(1)
Port Fuel Injection
119(2)
Need for Emission Controls
121(2)
Positive Crankcase Ventilation System
123(1)
PCV System Performance Check
124(1)
Air-Pump System
124(2)
Evaporative Emission Control System
126(1)
Exhaust Gas Recirculation System
126(4)
Catalytic Converters
130(12)
Summary
142(1)
Review Questions
142(1)
ASE Certification-Type Questions
142(2)
Cooling System Operation and Diagnosis
144(27)
Objectives
144(1)
Cooling System Purpose and Function
144(1)
Low-Temperature Engine Problems
144(1)
High-Temperature Engine Problems
145(1)
Cooling System Design
146(1)
Thermostat Temperature Control
147(1)
Testing the Thermostat
148(1)
Thermostat Replacement
149(1)
Antifreeze
150(1)
Organic Additive Technology Coolant
150(1)
Propylene Glycol Antifreeze
151(1)
Phosphate-Free Antifreeze
151(1)
Antifreeze Can Freeze
151(1)
Hydrometer Testing
151(1)
Recycling Coolant
152(1)
Disposing of Used Coolant
152(1)
Radiator
153(1)
Pressure Cap
154(1)
Metric Radiator Caps
155(1)
Coolant Recovery System
155(1)
Pressure Testing
156(1)
Coolant Dye Leak Testing
156(1)
Water Pump Operation
157(1)
Coolant Flow in the Engine
157(1)
Water Pump Service
158(1)
Cooling Fans
159(2)
Thermostatic Fans
161(1)
Heater Core
162(1)
Heater Problem Diagnosis
162(1)
Coolant Temperature Warning Light
163(1)
Common Causes of Overheating
164(1)
Cooling System Maintenance
164(1)
Flush and Refill
165(1)
Burping the System
165(2)
Hoses
167(1)
Back Flushing a Radiator
167(1)
Cleaning the Radiator Exterior
167(2)
Summary
169(1)
Review Questions
169(1)
ASE Certification-Type Questions
169(2)
Engine Condition Diagnosis
171(31)
Objectives
171(1)
Typical Engine-Related Complaints
171(1)
Engine Smoke Diagnosis
172(1)
The Driver Is Your Best Resource
172(1)
Visual Checks
172(2)
Engine Noise Diagnosis
174(3)
Oil Pressure Testing
177(1)
Oil Pressure Warning Lamp
177(1)
Oil Analysis
178(1)
Getting the Sample
178(1)
Studying the Results
178(2)
Compression Test
180(1)
Wet Compression Test
181(1)
Running Compression Test
182(1)
Cylinder Leakage Test
182(1)
Cylinder Power Balance Test
183(1)
Power Balance Test Procedure
184(1)
Vacuum Testing
184(1)
Exhaust Restriction Test
185(1)
Testing Back Pressure with a Vacuum Gauge
185(1)
Testing Back Pressure with a Pressure Gauge
186(1)
Timing Chain Slack Diagnosis
186(1)
Exhaust Analysis and Combustion Efficiency
187(1)
Diagnosing Head Gasket Failure
188(1)
Dash Warning Lights
189(11)
Summary
200(1)
Review Questions
200(1)
ASE Certification-Type Questions
200(2)
Engine Removal and Disassembly
202(16)
Objectives
202(1)
Component Repair
202(1)
Valve Job
202(1)
Minor Overhaul
203(1)
Major Overhaul
203(1)
Short Block
203(1)
Fitted Block
204(1)
Long Block
204(1)
Remanufactured Engines
204(1)
Engine Removal
204(3)
Engine Disassembly
207(1)
Removing the Cylinder Ridge
208(1)
Piston Removal
209(1)
Piston Condition
209(4)
Rotating Engine Assembly Removal
213(1)
Cylinder Head Disassembly
214(2)
Summary
216(1)
Review Questions
216(1)
ASE Certification-Type Questions
216(2)
Engine Cleaning, Crack Detection, and Repair
218(13)
Objectives
218(1)
Mechanical Cleaning
218(1)
Chemical Cleaners
219(1)
Solvent-Based Cleaning
220(1)
Water-Based Chemical Cleaning
220(1)
Spray Washing
220(1)
Steam Cleaning
220(1)
Thermal Cleaning
221(1)
Cold Tank Cleaning
221(1)
Hot Tank Cleaning
221(1)
Vapor Cleaning
222(1)
Ultrasonic Cleaning
222(1)
Vibratory Cleaning
222(1)
Blasters
222(1)
Visual Inspection
223(1)
Magnetic Crack Inspection
223(1)
Dye Penetrant Testing
223(1)
Fluorescent Penetrant Testing
224(1)
Pressure Testing
224(1)
Crack Repair
224(2)
Crack Welding Cast Iron
226(1)
Crack Welding Aluminum
226(1)
Crack Plugging
227(3)
Summary
230(1)
Review Questions
230(1)
ASE Certification-Type Questions
230(1)
Engine Measuring and Math
231(15)
Objectives
231(1)
Micrometer
231(1)
Crankshaft Measurement
231(2)
Telescopic Gauge
233(1)
Small-Hole Gauge
234(1)
Vernier Dial Caliper
234(2)
Feeler Gauge
236(1)
Straightedge
237(1)
Dial Indicator
237(1)
Dial Bore Gauge
237(1)
Engine Math and Formulas
237(7)
Summary
244(1)
Review Questions
244(1)
ASE Certification-Type Questions
244(2)
Intake and Exhaust Manifolds
246(21)
Objectives
246(1)
Carburetor and Throttle-Body Injection Intake Manifolds
246(2)
Open and Closed Intake Manifolds
248(2)
Manifold Heat
250(3)
Choke Heat
253(1)
Port-Injection Intake Manifolds
254(1)
Plastic Intake Manifolds
254(1)
Exhaust Gas Recirculation
254(1)
Intake Manifold Gaskets
255(1)
Turbocharging
256(1)
Wastegate Operation
257(1)
Turbocharger Failures
258(1)
Supercharging
259(1)
Boost Is the Result of Restriction
259(1)
Exhaust Manifold Design
259(1)
Exhaust Manifold Gaskets
260(1)
How Headers Work
261(1)
Heat Risers
262(1)
Catalytic Converters
263(1)
Mufflers
264(1)
Summary
265(1)
Review Questions
265(1)
ASE Certification-Type Questions
266(1)
Cylinder Head and Valve Guide Service
267(25)
Objectives
267(1)
Hemispherical Combustion Chamber
267(1)
Wedge Combustion Chamber
268(1)
Surface Quenching
268(1)
Stratified Charge Combustion Chamber
269(1)
Multiple-Valve Combustion Chamber
270(1)
Four-Valve Head
271(1)
Intake and Exhaust Ports
272(1)
Cylinder Head Coolant Passages
273(2)
Lubricating Overhead Valves
275(1)
Removing the Overhead Camshaft
275(1)
Disassembly of the Cylinder Head
275(1)
Cylinder Head Reconditioning Sequence
275(1)
Cylinder Head Resurfacing
276(1)
Aluminum Cylinder Head Straightening
277(1)
Resurfacing Methods
278(1)
Surface Finish
279(1)
Correcting Intake Manifold Alignment
279(2)
Valve Guides
281(1)
Valve Stem-to-Guide Clearance
281(1)
Measuring Valve Guides for Wear
282(1)
Oversize Stem Valves
282(1)
Valve Guide Knurling
283(1)
Valve Guide Replacement
284(1)
Valve Guide Inserts
285(1)
Spiral Bronze Insert Bushings
285(6)
Summary
291(1)
Review Questions
291(1)
ASE Certification-Type Questions
291(1)
Valve and Seat Service
292(39)
Objectives
292(1)
Intake and Exhaust Valves
292(1)
Valve Size Relationships
293(1)
Valve Design
293(1)
Valve Materials
294(1)
Sodium-Filled Valves
294(1)
Valve Seats
294(1)
Valve Inspection
295(4)
Valve Springs
299(1)
Valve Spring Inspection
300(1)
Valve Keepers
301(1)
Valve Rotators
302(1)
Valve Reconditioning Procedure
302(1)
Valve Face Grinding
303(3)
Valve Seat Reconditioning
306(2)
Valve Guide Pilots
308(1)
Valve Seat Grinding Stones
309(1)
Dressing the Grinding Stone
310(1)
Valve Seat Grinding
310(1)
Narrowing the Valve Seat
311(2)
Valve Seat Cutters
313(1)
Valve Seat Testing
313(1)
Valve Seat Replacement
314(2)
Valve Stem Height
316(2)
Checking Installed Height
318(1)
Valve Stem Seals
318(3)
Installing the Valves
321(1)
Flow Testing Cylinder Heads
322(2)
Cylinder Head Flow versus Horsepower
324(6)
Summary
330(1)
Review Questions
330(1)
ASE Certification-Type Questions
330(1)
Camshaft and Valve Train Service
331(38)
Objectives
331(1)
Camshaft Function
331(1)
Camshaft Location
331(1)
Camshaft Problem Diagnosis
332(1)
Camshaft Removal
333(1)
Camshaft Design
333(1)
Composite Camshafts
334(1)
Camshaft Lubrication
335(1)
Fuel-Pump Eccentrics
335(2)
Camshaft Drives
337(1)
Camshaft Chain Drives
337(1)
Camshaft Belt Drives
337(1)
Camshaft Twisting Movement
337(1)
Cam Chucking
337(1)
Lifter Rotation
337(4)
Camshaft Lift
341(1)
Rocker Arms
342(3)
Pushrods
345(1)
Pushrod Length
346(1)
Camshaft Duration
347(1)
Valve Overlap
347(1)
Lobe Centers
348(1)
How to Determine Lobe Center Angle
348(1)
Cam Timing Specifications
349(1)
Intake Valve
349(1)
Exhaust Valve
349(1)
Cam Timing Chart
349(1)
Measuring and Regrinding Camshafts
350(1)
Installing the Camshaft
350(2)
Degreeing the Camshaft
352(3)
Lifters or Tappets
355(1)
Solid Lifters
356(1)
Hydraulic Lifters
356(3)
Lifter Preload
359(1)
Determining Lifter Preload
359(2)
Determining Proper Lifter Travel
361(1)
Valve Noise Diagnosis
361(1)
Mechanical Lifter Service
362(1)
Hydraulic Lifter Service
362(1)
Hydraulic Valve Lifter Installation
363(1)
Bleeding Hydraulic Lifters
363(5)
Summary
368(1)
Review Questions
368(1)
ASE Certification-Type Questions
368(1)
Engine Block Construction and Service
369(30)
Objectives
369(1)
Block Manufacturing
369(1)
Casting Numbers
370(1)
Block Machining
370(1)
Aluminum Blocks
371(1)
Block Condition Inspection
372(1)
Lower Engine Block Design
373(1)
The Block Deck
373(1)
Cylinder Skirts
373(2)
Cooling Passages
375(1)
Lubricating Passages
375(1)
Main Bearing Caps
375(2)
Engine Block Service
377(1)
Main Bearing Housing Bore Alignment
377(2)
Machining the Deck Surface of the Block
379(1)
Cylinder Boring
380(4)
Sleeving the Cylinder
384(1)
Cylinder Honing
384(2)
Cylinder Surface Finish
386(2)
Plateau Honing
388(1)
Cylinder Cleaning
388(1)
Block Detailing
388(8)
Summary
396(1)
Review Questions
397(1)
ASE Certification-Type Questions
398(1)
Pistons, Rings, and Connecting Rods
399(38)
Objectives
399(1)
Purpose and Function of Pistons, Rings, and Connecting Rods
399(1)
Piston and Rod Removal
400(1)
Piston Design
401(1)
Piston Heads
402(1)
Piston Ring Grooves
403(1)
Cam Ground Pistons
404(1)
Piston Head Size
404(1)
Piston Strut Inserts
405(1)
Hypereutectic Pistons
406(1)
Forged Pistons
406(1)
Piston Skirt Finish
406(1)
Piston Balance
407(1)
Piston Service
408(1)
Piston Pins
408(2)
Piston Pin Offset
410(1)
Piston Pin Fit
411(1)
Piston Pin Retaining Methods
412(1)
Piston Pin Service
412(1)
Piston Rings
413(1)
Compression Rings
414(1)
Piston Ring Forces
414(1)
Ring Gap
415(1)
Piston Ring Cross Sections
415(1)
Chromium Piston Rings
416(1)
Molybdenum Piston Rings
416(1)
Moly-Chrome-Carbide Rings
417(1)
Oil Control Rings
417(1)
Connecting Rods
417(1)
Connecting Rod Design
418(1)
Rod Twist
419(2)
Connecting Rod Service
421(2)
Piston and Rod Balancing
423(1)
Piston and Rod Assembly
423(1)
Piston Ring Service
424(2)
Summary
426(10)
Review Questions
436(1)
ASE Certification-Type Questions
436(1)
Crankshafts and Bearings
437(31)
Objectives
437(1)
Crankshaft Purpose and Function
437(1)
Forged Crankshafts
437(1)
Cast Crankshafts
438(1)
Six-Cylinder Engine Crankshafts
439(1)
V-8 Engine Crankshafts
439(1)
Four-Cylinder Engine Crankshafts
440(1)
Five-Cylinder Engine Crankshafts
440(1)
Three-Cylinder Engine Crankshafts
441(1)
Odd-Firing 90-Degree V-6 Engine Crankshafts
441(1)
Even-Firing 90-Degree V-6 Engine Crankshafts
441(1)
60-Degree V-6 Engine Crankshafts
441(1)
Crankshaft Oiling Holes
442(1)
Crankshaft Lightening Holes
443(1)
Crankshaft Forces
443(2)
Crankshaft Balance
445(2)
Thrust Surface
447(1)
Crankshaft Inspection
447(1)
Crankshaft Grinding
447(2)
Welding a Crankshaft
449(1)
Balancing a Crankshaft
449(2)
Stress Relieving the Crankshaft
451(1)
Auxiliary Shafts
451(1)
Balance Shafts
451(1)
Causes of Unbalance
452(2)
Engine Bearings
454(1)
Bearing Loads
455(1)
Bearing Fatigue
456(1)
Bearing Conformability
457(1)
Bearing Embedability
457(1)
Bearing Damage Resistance
457(2)
Bearing Materials
459(1)
Bearing Manufacturing
459(1)
Bearing Sizes
460(1)
Bearing Clearance
460(1)
Bearing Spread and Crush
460(1)
Cam Bearings
461(6)
Summary
467(1)
Review Questions
467(1)
ASE Certification-Type Questions
467(1)
Engine Assembly
468(30)
Objectives
468(1)
Block Preparation
468(1)
Installing Cups and Plugs
468(1)
Cam Bearings
469(1)
Causes of Premature Bearing Failure
470(1)
Measuring Main Bearing Clearance
470(1)
Correcting Bearing Clearance
471(1)
Lip Seal Installation
472(1)
Rope Seal Installation
473(1)
Additional Sealing Locations
474(1)
Installing the Crankshaft
474(1)
Thrust Bearing Clearance
475(1)
Tightening Procedure for the Main Bearing
475(1)
Installing Timing Chains and Gears
476(1)
Piston Fitting
477(1)
Ring End Gap
477(2)
Installing Piston and Rod Assemblies
479(3)
Connecting Rod Side Clearance
482(1)
Installing the Camshaft for Overhead Cam Engines
482(1)
Head Gaskets
482(3)
Installing the Head Gasket
485(1)
Head Bolt Torque Sequence
486(1)
Torque-to-Yield Bolts
486(1)
Timing Drives for Overhead Cam Engines
487(1)
Lifter and Pushrod Installation
488(1)
Hydraulic Lifters
488(1)
Solid Lifters
488(1)
Assembly Sealants
489(1)
Installing Manifolds
490(1)
Cover Gasket Materials
490(1)
Hints for Gasket Usage
491(1)
Installing Timing Covers
491(1)
Installing the Vibration Damper
491(1)
Installing the Oil Pump
492(1)
The Oil Pan
492(1)
Installing the Water Pump
492(1)
Engine Painting
493(1)
Checking for Proper Oil Pressure
493(2)
Setting Initial Ignition Timing
495(2)
Summary
497(1)
Review Questions
497(1)
ASE Certification-Type Questions
497(1)
Engine Installation and In-Vehicle Service
498(47)
Objectives
498(1)
Manual Transmission Installation
498(1)
Automatic Transmission Installation
499(1)
Starter
499(1)
Accessories
500(1)
Engine Installation
500(1)
Cooling System
500(1)
Fuel and Emission Controls
500(1)
Electrical System
501(1)
Break-In Engine Oil
501(1)
Engine Break-In
501(1)
Normal Operating Temperature
502(1)
How to Warm Up a Cold Engine
502(1)
Break-In Precautions
502(12)
Summary
514(1)
Review Questions
514(1)
ASE Certification-Type Questions
514(1)
APPENDIXES
1 Engine Repair (A1) Sample ASE Certification Test (70)
515(6)
2 Cylinder Head Specialist (M1) Sample ASE Certification Test (40)
521(4)
3 Cylinder Block Specialist (M2) Sample ASE Certification Test (40)
525(4)
4 Engine Assembly Specialist (M3) Sample ASE Certification Test (40)
529(4)
5 Fraction/Decimal/Millimeter Conversion Chart
533(2)
6 Fraction/Decimal Equivalents
535(1)
7 Newton-Meter to Pound-Feet Conversion Chart
536(1)
8 Pound-Feet to Newton-Meter Conversion Chart
537(1)
9 Celsius Degrees to Fahrenheit Degrees Conversion Chart
538(1)
10 Timing Belt Replacement Guide
539(6)
Answers to Even-Numbered ASE Certification-Type Questions 545(1)
Glossary 546(7)
Index 553
Safety
Material Safety Data Sheet (MSDS) Worksheet
1
Vehicle Hoisting Worksheet
2
Safety Check Worksheet
3
Temporary Disabling of an Air Bag Worksheet
4
Vehicle and Engine Identification
VIN Code Worksheet
5
Engine Identification Worksheet
6
General Engine Specifications Worksheet
7
Casting Number Worksheet
8
Introduction to Automotive Service
Service Manual Usage Worksheet
9
Repair Order Worksheet
10
Fluids and Belts
Fluids Check Worksheet
11
Accessory Drive Belt Inspection Worksheet
12
Starting and Charging Systems
Starting and Charging Voltmeter Test Worksheet
13
Battery Load Test Worksheet
14
Starter Amp Draw Worksheet
15
Generator (Alternator) Output Test Worksheet
16
Cooling System
Engine Cooling System Identification Worksheet
17
Engine Cooling System Inspection Worksheet
18
Radiator Testing with an Infrared Pyrometer Worksheet
19
Lubrication System
Engine Lubrication Specifications Worksheet
20
Engine Oil Dipstick Test Worksheet
21
Engine Oil Change Worksheet
22
Oil Pressure Measurement Worksheet
23
Fuel System
Fuel Pump Pressure Test Worksheet
24
Port Fuel Injected System Diagnosis Worksheet
25
Injector Balance Testing Worksheet
26
Fuel Pressure Regulator Test Worksheet
27
Engine Computer Sensor Diagnosis
Throttle Position (TP) Sensor Worksheet
28
Engine Coolant Temperature (ECT) Worksheet (Scan Tool Method)
29
Engine Coolant Temperature (ECT) Worksheet (Digital Voltmeter Meth)
30
Intake Air Temperature (IAT) Worksheet
31
Oxygen Sensor (O2S) Worksheet
32
Manifold Absolute Pressure (MAP) Worksheet
33
Engine Condition Diagnosis
Paper Test Worksheet
34
Compression Testing Worksheet
35
Cylinder Leakage Test Worksheet
36
Vacuum Testing Worksheet
37
Oil Pressure Measurement Worksheet
38
Oil Leak Diagnosis Worksheet
39
Timing Chain Diagnosis Worksheet
40
Scan Tool Diagnosis Worksheet
41
Head Gasket Diagnosis Worksheet
42
Engine Noise Diagnosis Worksheet
43
Engine Disassembly, Cleaning, and Crack Detection
Engine Disassembly Worksheet
44
Cylinder Ridge Reaming Worksheet
45
Cylinder Head Disassembly Worksheet
46
Cleaning and Crack Detection Worksheet
47
Engine Measurement
Micrometer Worksheet
48
Vernier Dial Caliper Worksheet
49
Feeler Gauge Worksheet
50
Straight-Edge Worksheet
51
Dial Indicator Worksheet
52
Plastigage Worksheet
53
Dial Bore Gauge Worksheet
54
Telescopic Gauge Worksheet
55
Manifolds and Cylinder Head Covers
TBI/Carburetor Intake Manifold Worksheet
56
Port Fuel Injection Intake Manifold Worksheet
57
Exhaust Manifold Worksheet
58
Cylinder Head Cover Identification Worksheet
59
Camshafts and Valve Trains
Valve Train Identification Worksheet
60
Camshaft Identification Worksheet
61
Camshaft Specification Worksheet
62
Cylinder Heads and Valves
Cylinder Head Specifications Worksheet
63
Cylinder Head Flatness Measurement Worksheet
64
Valve Spring Specifications and Measurements Worksheet
65
Aluminum Cylinder Head Straightening Worksheet
66
Valve Guide Specifications and Measurement Worksheet
67
Valve Guide Replacement Worksheet
68
Valve Guide Knurling Worksheet
69
Valve Face Grinding Worksheet
70
Valve Seat Grinding Worksheet
71
Combustion Chamber Volume Test Worksheet
72
Cylinder Head Assembly Worksheet
73
Engine Block
Cylinder Block Specification and Measurement Worksheet
74
Cylinder Bore Measurement Worksheet
75
Block Deck Measuring Worksheet
76
Block Deck Machining Worksheet
77
Align Honing Worksheet
78
Cylinder Boring Worksheet
79
Cylinder Honing Worksheet
80
Cylinder Bore Deglazing Worksheet (New)
81
Piston Fitting Worksheet
82
Crankshafts, Piston, and Connecting Rods
Crankshaft Specification and Measurement Worksheet
83
Connecting Rod Specification and Measurement Worksheet
84
Piston Specification and Measurement Worksheet
85
Piston Ring Specification and Measurement Worksheet
86
Connecting Rod Reconditioning Worksheet
87
Pistons and Rods Balancing Worksheet
88
Crankshaft Balancing Worksheet
89
Engine Assembly
Preparing the Block for Assembly Worksheet
90
Camshaft Bearing Installation Worksheet
91
Expansion Cups and Plugs Installation Worksheet
92
Torque Specification Worksheet
93
Main Bearing Installation Worksheet
94
Piston Ring Fitting Worksheet
95
Piston and Rod Installation Worksheet
96
Connecting Rod Bolt Stretch Worksheet
97
Gasket Selection Worksheet
98
Cylinder Head Installation Worksheet
99
Timing Gears/Chain/Belt Installation Worksheet
100
Engine Prelubrication Worksheet
101
Preparing the Engine for Starting Worksheet
102
In-Vehicle Engine Service
Thermostat Replacement Worksheet
103
Water Pump Replacement Worksheet
104
Timing Belt Replacement Worksheet
105
Timing Chain Replacement Worksheet
106
Intake Manifold Gasket Replacement Worksheet
107
EGR Cleaning Worksheet
108
Exhaust System Inspection Worksheet
109
Valve Cover Gasket Replacement Worksheet
110
Ignition Timing Worksheet
111
Spark Plug Wire Worksheet
112
Spark Plugs Worksheet
113
Distributor Cap and Rotor Worksheet
114
Camshaft Replacement (OHV) Worksheet
115
Cylinder Head Replacement Worksheet
116
Oil Pan Gasket Replacement Worksheet
117
Appendix
Tool List
119
Fraction/Decimal/Millimeter Conversion Chart
120
Newton Meter to Pound Feet Conversion Chart
122
Pound Feet to Newton Meter Conversion Chart
123
Celsius Degrees to Fahrenheit Degrees Conversion Chart
124
Automotive Resources with Web Sites
125


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