For every task in Gasoline Engines, the following safety task 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 federal, state, and local regulations.

The first task in Gasoline Engines is to listen to and verify the operator's concern, review past maintenance and repair documents, and determine necessary action.

I. GASOLINE ENGINES

A. General Engine Diagnosis; Removal and Reinstallation (R & R)

1. Inspect engine assembly for fuel, oil, coolant, and other leaks; determine needed action. P-1

2. Check level and condition of fuel, oil, and coolant; determine needed action. P-1

3. Listen to engine noises; determine needed action. P-2

4. Check color, odor, and quantity of the engine exhaust smoke; determine needed action. P-1

5. Perform engine vacuum tests; determine needed action. P-1

6. Perform cylinder power balance tests; determine needed action. P-1

7. Perform cylinder compression tests; determine needed action. P-1

8. Perform cylinder leakage tests; determine needed action. P-1

9. Diagnose engine mechanical, ignition, or fuel problems with an engine oscilloscope and/or analyzer (scan tool); determine needed action. P-2

10. Inspect engine compartment wiring harness, connectors, and vacuum hoses; determine needed action. P-1

11. Observe and interpret instrument panel gauge readings; determine needed action. P-1

I. GASOLINE ENGINES

B. Cylinder Head and Valve Train Diagnosis and Repair

1. Inspect cylinder heads for cracks and gasket surface areas for warpage; check passage condition. P-2

2. Inspect valve springs, retainers, rotators, locks and valve stem seals; determine needed action. P-2

3. Inspect valve guides for wear, and check valve guide-to-stem fit; determine needed action. P-3

4. Inspect valves; determine needed action. P-3

5. Inspect valve seats; determine needed action. P-3

6. Inspect pushrods, rocker arms, rocker arm pivots, and shafts for wear, bending, cracks, looseness, and blocked oil passages; determine needed action. P-3

7. Inspect hydraulic or mechanical lifters; determine needed action. P-3

8. Adjust valves. P-1

9. Install cylinder head(s) and gasket(s). P-2

I. GASOLINE ENGINES

C. Engine Block Diagnosis and Repair

1. Inspect pans, covers, gaskets, and seals; determine needed action. P-1

2. Inspect engine block for cracks, passage condition, core and gallery plug condition, threaded hole condition, and surface warpage; determine needed action. P-3

3. Inspect and measure cylinder walls for wear and damage; determine needed action. P-2

4. Remove cylinder wall ridges; hone and clean cylinder walls. P-3

5. Inspect camshaft and bearings for wear and damage; check bearing clearance; determine needed action. P-3

6. Inspect crankshaft for surface cracks and journal damage and wear; measure journals; check oil passage condition; determine needed action. P-3

7. Inspect and replace main and rod bearings; check assembled clearances. P-3

8. Recognize piston and bearing wear patterns that indicate connecting rod alignment and bearing bore problems; inspect rod alignment and bore condition; determine needed action. P-3

9. Inspect, measure, or replace pistons, pins, and bushings. P-2

10. Measure piston-to-cylinder bore clearance; determine needed action. P-2

11. Replace piston rings; check ring groove clearance and end gap. P-3

12. Inspect or replace crankshaft vibration damper (harmonic balancer) and flywheel. P-3

13. Reassemble engine using appropriate gaskets, sealants, and fasteners. P-2

14. Prime engine lubrication system. P-2

I. GASOLINE ENGINES

D. Lubrication and Cooling Systems Diagnosis and Repair

1. Perform oil pressure tests; determine needed action. P-1

2. Inspect and clean oil pump and drive; determine needed action. P-3

3. Inspect, clean, and test oil cooler, lines and hoses; determine needed action. P-2

4. Inspect and adjust belts, pulleys, and tensioners; determine needed action. P-1

5. Perform cooling system pressure tests (including pressure cap); determine needed action. P-1

6. Inspect thermostat, by-pass, and housing; determine needed action. P-2

7. Drain, flush, refill and bleed cooling system. P-1

8. Inspect water pump, gaskets, and hoses; determine needed action. P-1

9. Inspect radiator, pressure cap, expansion tank and coolant recovery system; determine needed action. P-1

10. Clean and inspect fan (both electrical and mechanical), fan clutch, fan shroud, and cooling related circuits, sensors, and controls; determine needed action. P-2

11. Inspect coolant type, contamination, protection level, and pH; determine needed action. P-1

I. GASOLINE ENGINES

E. Ignition System Diagnosis and Repair

1. Diagnose ignition-related problems such as no-starting, hard starting, engine misfire, poor driveability, spark knock, power loss, and poor mileage on vehicles with distributor and distributorless ignition systems; determine needed action. P-1

2. Check for possible ignition system-related diagnostic trouble codes (DTC). P-1

3. Inspect and test ignition primary circuit wiring and components; determine needed action. P-2

4. Inspect and test distributor and components; determine needed action. P-3

5. Inspect and test ignition system secondary circuit wiring and components; determine needed action. P-2

6. Inspect and test ignition coil(s); determine needed action. P-3

7. Check and adjust ignition system base timing and timing advance/retard. P-3

8. Inspect and test ignition system pick-up sensor or trigger devices; determine needed action. P-2

9. Inspect and test ignition control module; determine needed action. P-2

I. GASOLINE ENGINES

F. Fuel and Exhaust Systems Diagnosis and Repair

1. Diagnose no-starting, hard starting, poor idle, flooding, hesitation, engine misfiring, power loss, poor mileage, and/or dieseling problems on vehicles with fuel injection systems; determine needed action. P-1

2. Check for possible fuel or induction system related diagnostic trouble codes (DTCs); determine needed action. P-1

3. Inspect and test fuel pumps, pump control circuits, and pressure regulators; inspect fuel filter, gas cap, fuel lines, fuel tank, hoses, and fittings; determine needed action. P-1

4. Remove, clean, and replace throttle body; adjust related linkages. P-3

5. Inspect and replace throttle body mounting plates, intake manifold, and gaskets. P-3

6. Inspect air filtration system; determine needed action. P-1

7. Inspect exhaust manifold, exhaust pipe, muffler, and other components of the exhaust system; determine needed action. P-1

I. GASOLINE ENGINES

G. Emissions Control Systems Diagnosis and Repair

1. Test and inspect exhaust gas recirculation (EGR) valves, base plates, tubing, and passages of EGR systems; perform needed action. P-1

2. Inspect controls, wires, and hoses of exhaust gas recirculation (EGR) systems; perform needed action. P-1

3. Inspect and test pressure relief valves, filters, pulleys, belts, check valves, diverter valves, air manifolds, and hoses of secondary air injection systems (AIR); perform needed action. P-3

4. Inspect and test positive crankcase ventilation (PCV) valve and system components; perform needed action. P-1

5. Inspect and test components of catalytic converter systems; perform needed action. P-1

6. Inspect and test mechanical components, electrical components, and hoses of evaporative emissions control system (EVAP); determine needed action. P-3

H. Computerized Engine Diagnosis and Repair

1. Diagnose the causes of emissions or driveability problems resulting from failure of computerized engine controls with stored diagnostic trouble codes (DTC); determine needed action. P-1

2. Diagnose the causes of emissions or driveability problems resulting from failure of computerized engine controls with no stored diagnostic trouble codes. P-1

3. Inspect and test sensor, control, and actuator components and circuits of computerized engine control systems; determine needed action. P-1

4. Use and interpret digital multimeter (DMM) readings. P-1

5. Read and interpret technical literature (service publications and information, including wiring schematics). P-1

6. Test, remove, and inspect electrical power and ground circuits and connections; perform needed action. P-1

7. Diagnose driveability and emissions problems resulting from failures of interrelated systems (cruise control, engine alarms, non-OEM installed accessories, and similar systems); determine needed action. P-2