Chabot College
Fall 2010
Course Outline for Automotive Technology 63A
INTRODUCTION TO ENGINES AND MACHINING PROCESSES
Catalog Description:
63A - Introduction to Engines and Machining Processes
May be repeated three times
3 units
Diagnosis, inspection and repair of various engine types; machining operations, use of instruments
and automotive machinist equipment in repairing engines, valve train assemblies and cylinder head
reconditioning, cooling and lubrication system fundamentals. Prerequisite: Automotive Technology
50 (may be taken concurrently) or equivalent. Strongly recommended: Industrial Technology 74. 1.5
hours lecture, 5 hours laboratory.
[Typical contact hours: lecture 26.25, laboratory 87.5]
Prerequisite Skills:
Before entering the course, the student should be able to:
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recognize unsafe working conditions and practices;
use common automotive shop equipment safely;
identify and recognize common automotive tools and equipment;
identify fasteners;
demonstrate proper procedures to repair a broken fastener and/or repair threads;
discuss automotive engine fundamentals;
perform engine vacuum tests;
perform cylinder compression tests;
perform cylinder leakage tests;
perform oil pressure tests;
perform oil and filter change;
assess and use service information;
demonstrate proper use of metric and standard micrometers;
demonstrate proper use of an analog or digital volt/ohmmeter;
select the appropriate automotive fluid for the selected application;
use appropriate methods for hazardous waste handling and disposal;
discuss potential areas of employment in the automotive industry.
Expected Outcomes for Students:
Upon completion of the course the student should be able to:
1. verify and interpret engine concerns, and determine necessary action;
2. inspect an engine assembly for fuel, oil, coolant, and other leaks, and determine necessary
action;
3. perform cooling system, cap, recovery system tests (pressure, combustion leakage, and
temperature), and determine necessary action;
4. inspect, replace, and adjust drive belts, tensioners, and pulleys;
5. test coolant; drain and recover coolant; flush and refill cooling system with recommended
coolant; bleed air as required;
6. inspect, test, remove, and replace engine cooling and heater system hoses, radiator,
thermostat and housing, and water pump;
7. inspect, and test fans(s) (electrical or mechanical), fan clutch, fan shroud, and air dams;
8. inspect, test, and replace oil temperature and pressure switches and sensors;
9. Inspect oil pump gears or rotors, housing, pressure relief devices, and pump drive; perform
necessary action;
10. perform cylinder power balance tests, and determine necessary action;
11. diagnose engine noises and vibrations, and the cause of excessive oil consumption, unusual
engine exhaust color, odor, and sound; determine necessary action;
Chabot College
Course Outline for Automotive Technology 63A, Page 2
Fall 2010
12. visually inspect cylinder head(s) for cracks, check gasket surface areas for warpage and
leakage;
13. install cylinder heads and gaskets, and tighten according to manufacturers specifications and
procedures;
14. inspect and test valve springs for squareness, pressure, free-height comparison, valve spring
retainers, locks, and valve grooves and replace as needed;
15. inspect valve guides for wear, check valve guide height, and stem-to-guide clearance,
recondition or replace as needed;
16. resurface valves, valve seats and perform necessary action;
17. check valve spring assembled height and valve stem height; service valve and spring
assemblies as needed;
18. inspect pushrods, rocker arms, rocker arm pivots and shafts for wear, bending, cracks,
looseness, and blocked oil passages (orifices), and perform necessary action;
19. adjust valves (mechanical or hydraulic lifters);
20. inspect and replace timing belt(s), overhead cam drive sprockets, and tensioners, check belt
tension, and adjust as necessary;
21. verify camshaft(s) timing according to manufacturer’s specifications and procedures;
22. inspect camshaft drives (including gear wear and backlash, sprocket and chain wear);
replace as necessary.
Course Content (Lecture):
1. Automotive safety and shop practice
2. Proper care and manipulation of basic hand tools
3. Engine fundamentals, types, construction, operation and identification
a. Four stroke cycle
b. Flathead, OHV, SOHC, DOHC
c. Valve timing relationship
d. Ignition timing
e. Cooling system operation
f. Lubrication system
4. Engine condition diagnosis, inspection and repair
a. Compression tests
b. Cylinder leakage tests
c. Engine vacuum tests
d. Oil pressure tests
e. Engine combustion four-gas analysis
5. Engine precision measurement, proper care, and operation of precision measurement tools
6. Engine disassembly, cleaning techniques and procedures
7. Cylinder head diagnosis, disassembly, testing, and inspection
8. Valve guide, valve and valve seat inspection, and servicing
9. Cylinder head reconditioning, reassembly and inspection
10. Camshaft, timing belts, timing chains and valve train service
11. Hazardous waste handling
Course Content (Laboratory):
Each of the lecture content items is accompanied by a required NATEF (National Automotive
Technical Education Foundation) lab “task sheet” with required levels of exposure (general
knowledge, demonstration, basic skill level, advanced skill level.
Examples include:
1. Demonstrated use and care of basic shop tools
Chabot College
Course Outline for Automotive Technology 63A, Page 3
Fall 2010
2. Performance of engine compression test
3. Diagnosis of engine problems as a result of conducting engine test
a. Compression tests
b. Cylinder leakage tests
c. Engine vacuum tests
d. Oil pressure tests
e. Engine combustion four-gas analysis
Methods of Presentation:
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Lecture/discussion
Laboratory
Guest speakers
Field trips
Assignments and Methods of Evaluating Student Progress:
1. Typical Assignments
a. Read Chapter titled “Engine Condition Diagnosis”
b. Perform cylinder leakage test worksheet following directions listed and the class
lecture/discussion
2. Methods of Evaluating Student Progress
a. Class participation
b. Performance of laboratory task lists and projects
c. Homework assignments
d. Quizzes
e. Midterm exam
f. Final exam
Textbook(s) (Typical):
Intro to Engines and Machining, Author-Gilles, Publisher-Prentice Hall, 2007
Special Student Materials:
1. Safety glasses
2. Shop/safety clothing
JGB
ATEC 63A course outline
Revised: Sept2009