~ November 2011 ~
Oct 2011
Sunday
Monday
Tuesday
Wednesday
Dec 2011
Thursday
Friday
Saturday
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
26
28
29
30
No class
No class
No class
Dave conference
Dave conference
Dave conference
25
No class
T
Auto 94B Lab Final Schedule
Fall 2011
This performance evaluation will consist of 3 stations, each having a task with a 10minute time limit. These tasks include, but are not limited to, catalog usage, measuring
for clearance, and fastener identification.
~ December 2011 ~
Nov 2011
Sunday
Monday
Tuesday
Wednesday
Jan 2012
Thursday
1
No class
Friday
2
Saturday
3
Regular class time
Dave conference
4
5
11
12
6
7
8
9
10
17
13
14
15
16
Lab finals
Lab finals
Review, shop work
Written final
Shop clean-up
18
25
Quick quiz on cleaning engine parts
Auto 94
1. Solvent is safe to use on all engine parts. True or false.
_
2. Caustic hot tanks are used to clean engine parts of what type of material?
_
3. Describe the type of hot tank/spray jet machine that is safe to
Chapter 8
CLEANING ENGINE PARTS
Directions:
A.
Use a pencil and Scantron answer form
B.
Write your name on the answer form
C.
Mark the letter choice of the best answer
D.
Do not write on the test
1.
Machinist A recommends caustic degreasers for aluminum.
Performance engine preparation
Valve events
What are they?
How are they measured?
Which cam lobe leads the other?
Performance engine preparation
Valve events
IVC (Intake valve closing)
Determines effective compression ratio
Piston direction @ IVC ?
Early
Performance engine preparation
Engine realities
Production engines used as a base
Designed for WOT 10% of the time
RPM limits & improved components are needed
Cold starts and operation
Enrichment & idle speed
Fuel vaporization
Street engines require va
Measuring tools
Modern engines use thinner casting and require
more precise measuring
Selectively fit engines
All parts are measured and marked according to size
Then selectively assembled for optimum clearance
Copyright 2003 Gary Lewis - Dave Capitolo
Performance engine preparation
Intake formula
Air flow requirements at 100% VE
RPM x displacement
3456
* displacement in cubic inches
* 3456 = cubic inches of air
Performance engine preparation
Exhaust formulas
Exhaust runner diameter
Minimum ID = exhaus
Performance engine preparation
Cam timing
Check accuracy of TDC mark
Use a positive stop to determine
Rotate crankshaft each direction
Difference is TDC
Performance engine preparation
Timing a cam using the intake centerline
Install degree wheel on da
Engine assembly
Before final cleaning
Remove all sharp edges created by machining
Combustion chamber
Crankshaft oil holes
Top & bottom of cylinders
Oil pump gears
Clean all internal & external threads
Chamfer top of bolt holes
Use tap or die for restori
Balancing engines
For smoother engine operation & longevity
Forces multiply as engine RPM increase
Copyright 2003 Gary Lewis Dave Capitolo
Balancing engines
First step in diagnosing engine vibration
Isolate engine mounts/insulators
Balancing engines
Wei
Chapter 13 - Reconditioning engine blocks
Topics to be covered
Line honing or boring
Honing cylinders for overhaul
Boring and honing oversize
Installing sleeves
Reconditioning connecting rods
Preparing piston and rod assemblies
Grinding and polishing cran
Reconditioning valve train components
Knurling valve guides
For correcting worn guides
Mostly for integral guides
Use wear limit of .004 (Use Go/No-Go)
Fixed arbor or roller
Copyright 2003 Gary Lewis Dave Capitolo
Reconditioning valve train components
Crack detection & repair
Causes of cracks in heads & blocks
Overheating
Freezing
Expansion and contraction
Cracks start from water jacket side
Only heads and blocks are repaired
Copyright 2003 Gary Lewis Dave Capitolo
Crack detection & repair
Design &
Valve train inspection
Inspect . . .
Cylinder head castings
Valves
Guides
Springs
Cam and lifters
Rocker arms and push rods
Timing chains and gears
Copyright 2003 Gary Lewis Dave Capitolo
Valve train inspection
Cylinder head castings
Visual inspec
Cleaning engine parts
Debris often missed
Leading cause of bearing failure
Under side of intake
Particle contamination
Oil pump pick-up screen
Cleaning engine parts
Solvent tanks
Small degreasing jobs
Safe for all metals in engines
Cleaning engine pa
Engine disassembly
Cylinder head removal
Loosening sequence
Note location of different length bolts
Inspect combustion chambers and ports
Inspect gasket seal
Keep parts in order until inspected
Copyright 2003 Gary Lewis - Dave Capitolo
Engine disasse
Engine diagnosis
On-board diagnostics
Codes for misfires (OBDII)
Functional tests for power balance (Prior to OBDII)
Further considerations
Mileage
Oil consumption
Noises
Copyright 2003 Gary Lewis - Dave Capitolo
Check engine performance
Valve-to-sea
Four stroke cycle theory
Intake stroke
Piston moving down
Intake valve open
Exhaust valve closed
Copyright 2003 Gary Lewis - Dave Capitolo
Four stroke cycle theory
Compression stroke
Piston moving up
Intake valve closed
Exhaust valve closed
Four stroke cy
