HEV 3030 - Internal Combustion Engines

1. General: Engine Diagnosis
   1. Complete work order to include customer information, vehicle identifying information, customer concern, related service history, cause, and correction.
   2. Research vehicle service information including fluid type, internal engine operation, vehicle service history, service precautions, and technical service bulletins.
   3. 3. Verify operation of the instrument panel engine warning indicator
   4. Inspect engine assembly for fuel, oil, coolant, and other leaks; determine needed action. 
   5. Install engine covers using gaskets, seals, and sealers as required.
   6. Identify service precautions related to service of the internal combustion engine of a hybrid vehicle.
2. Cylinder Head and Valve Train
   1. Clean and visually inspect a cylinder head for cracks; check gasket surface areas for warpage and surface finish; check passage condition.
   2. Inspect pushrods, rocker arms, rocker arm pivots and shafts for wear, bending, cracks, looseness, and blocked oil passages (orifices).
   3. Inspect and replace camshaft and drive belt/chain; includes checking drive gear wear and backlash, end play, sprocket and chain wear, overhead cam drive sprocket(s), drive belt(s), belt tension, tensioners, camshaft reluctor ring/tone-wheel, and valve timing components.
   4. Inspect valve springs for squareness and free height comparison.
   5. Inspect valve guides for wear; check valve stem-to-guide clearance.
   6. Inspect valves and valve seats.
   7. Check valve spring assembled height and valve stem height.
   8. Inspect valve lifters.
   9. Inspect camshaft bearing surface for wear, damage, out-of-round, and alignment.
3. Engine Block Assembly Diagnosis and Repair
   1. Inspect engine block for visible cracks, passage condition, core and gallery plug condition, and surface warpage.
   2. Inspect crankshaft for straightness, journal damage, keyway damage, thrust flange and sealing surface condition, and visual surface cracks; check oil passage condition; measure end play and journal wear; check crankshaft position sensor reluctor ring (where applicable).
   3. Inspect main and connecting rod bearings for damage and wear.
   4. Inspect auxiliary shaft(s) (balance, intermediate, idler, counterbalance and/or silencer); inspect shaft(s) and support bearings for damage and wear.
4. Lubrication and Cooling Systems
   1. Perform cooling system pressure test to identify leaks; check coolant condition and level;       inspect and test radiator, pressure cap, coolant recovery tank, heater core, and galley plugs
   2. Identify causes of engine overheating.
   3. Inspect, replace, and/or adjust drive belts, tensioners, and pulleys; check pulley and belt alignment.
   4. Inspect and/or test coolant; drain and recover coolant; flush and refill cooling system; use proper fluid type per manufacturer specification; bleed air as required.
   5. Inspect, remove, and replace water pump.
   6. Remove and replace radiator.
   7. Remove, inspect, and replace thermostat and gasket/seal.
   8. Inspect and test fan(s), fan clutch (electrical or mechanical), fan shroud, and air dams
   9. Perform oil pressure tests
   10. Perform engine oil and filter change; use proper fluid type per manufacturer specification.
   11. Inspect auxiliary coolers
   12. Inspect, test, and replace oil temperature and pressure switches and sensors.
   13. Inspect oil pump gears or rotors, housing, pressure relief devices, and pump drive