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