AUT 2012 - Engine Repair II

A. General

1. Section A tasks are covered in Engine Repair I

B. Cylinder Head and Valve Train

1. Identify cylinder head and valve train components and configurations.
2. Remove cylinder head; inspect gasket condition; install cylinder head and gasket; tighten according to manufacturer’s specification and procedure.
3. Clean and visually inspect a cylinder head for cracks; check gasket surface areas for warpage and surface finish; check passage condition.
4. Inspect valve actuating mechanisms for wear, bending, cracks, looseness, and blocked oil passages (orifices); determine needed action.
5. Adjust valves (mechanical or hydraulic lifters).
6. 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; verify correct camshaft timing.

C. Engine Block Assembly

1. Identify engine block assembly components and configurations.
2. Remove, inspect, and/or replace crankshaft vibration damper (harmonic balancer).

D. Lubrication and Cooling Systems

1. Identify lubrication and cooling system components and configurations.
2. Perform engine oil and filter change; use proper fluid type per manufacturer specifications; reset maintenance reminder as required. (Also Covered in ER I - task 9)
3. Perform cooling system pressure and dye tests to identify leaks; check coolant condition and level; inspect and test radiator, pressure cap, coolant recovery tank, heater core, and gallery plugs; determine needed action.
4. Identify causes of engine overheating.
5. Inspect, replace, and/or adjust drive belts, tensioners, and pulleys; check pulley and belt alignment.
6. Inspect and test coolant; drain and recover coolant; flush and/or refill cooling system; use proper fluid type per manufacturer specifications; bleed air as required.
7. Inspect, remove, and replace water pump.
8. Remove, inspect, and replace thermostat and gasket/seal.
9. Remove and replace radiator.
10. Inspect and test fan(s), fan clutch (electrical or mechanical), fan shroud, and air dams; determine needed action.
11. Perform oil pressure tests; determine needed action.
12. Inspect auxiliary coolers; determine needed action.
13. Inspect, test, and/or replace oil temperature and pressure switches and sensors.