Automotive Engine Repair
Unit: 1-4
General Engine Diagnosis, Removal, and Reinstallation
Content
Standard(s) and
Depth of
Knowledge
Level(s):
Students will:
1. Identify automotive engine systems concerns.
• Determining necessary action for engine system concerns
2. Perform diagnosis of general engine systems to determine corrective action.
• Demonstrating proper work order procedures
3. Research vehicle and service information.
Examples: vehicle service history, technical service bulletins, interpreting vehicle and major component
identification numbers
4. Demonstrate procedures for removing, disassembling, and reinstalling both front-wheel and rear-wheel drive
engines.
Learning
Objective(s) and
Depth of
Knowledge
Level(s):
Students will:
1. Complete work order to include customer information, vehicle identifying information, customer concern, related
service history, cause, and correction.
2. Identify and interpret engine concern; determine necessary action.
3. Research applicable vehicle and service information, such as internal engine operation, vehicle service history,
service precautions, and technical service bulletins.
4. Locate and interpret vehicle and major component identification numbers.
5. Inspect engine assembly for fuel, oil, coolant, and other leaks; determine necessary action.
6. Diagnose engine noises and vibrations; determine necessary action.
7. Diagnose the cause of excessive oil consumption, coolant consumption, unusual engine exhaust color and odor;
determine necessary action.
8. Perform engine vacuum tests; determine necessary action.
9. Perform cylinder power balance tests; determine necessary action.
10. Perform cylinder cranking and running compression tests; determine necessary action.
11. Perform cylinder leakage tests; determine necessary action.
12. Remove and install engine in an OBDII or newer vehicle; reconnect all attaching components and restore the vehicle
to running condition.
13. Install engine covers using gaskets, seals and sealers as required.
14. Perform common fastener and thread repair, to include: remove broken bolt, restore internal and external threads, and
repair internal threads with thread insert.
15. Inspect, remove and replace engine mounts.
Why is it important to properly diagnose a problem before repairing an engine?
How does the technician perform an engine vacuum test?
Essential
Question(s):
Content Knowledge
Safety
Work orders
Vehicle identifying information
Customer concern
Related service history
Internal engine operation
Vehicle service history
Service precautions
Technical service bulletins
Inspecting engine for fuel, oil, coolant, and other
leaks
Engine noises and vibrations
Excessive oil consumption
Excessive coolant consumption
Engine exhaust
Engine vacuum tests
Cylinder power balance tests
Cylinder cranking and running compression tests
Cylinder leakage tests
Removing the engine
Engine installation
Engine covers
Gaskets
Seal and sealers
Fastener and thread repair
Engine mounts
Unit
Assessment:
Unit/Course
CTSO Activity:
Suggested Instructional Activities
Rigor & Relevance Framework (Quadrant)
Brainstorming/Discussion
Case Studies/ Scenarios
Collaborative Learning
Cooperative learning
Demonstration
Experiments
Field Trips
Five plus one (5+1)
Games
Group investigation
Guest Speaker
Guided Practice
Instructional Technology
Laboratory/ Shop Exercise
Lecture, Lecture/Demonstration
Note Taking
PBL (Problem based Learning)
Ten plus two (10+2)
Work Based Learning
Work Sheets
Suggested Materials, Equipment and
Technology Resources
Laboratory shop equipment
Sample MSDS sheets
Tools, supplies adequate for class numbers
PPE in sufficient quantity for each student
PowerPoint presentations
Handouts
Textbook, online and print
Modules
Online technical reference [AllData, Mitchell]
Computers, laptop and desktop
LCD projector
SkillsUSA Technical Standards
SkillsUSA PDP
Student will take written tests, demonstrate knowledge of system operation, and successfully complete applied skills performance
tasks (hand on).
Successful completion of Industry-based written and performance testing
1. Continue SkillsUSA Leadership Development Programs
2. Establish documentation for students’ career portfolio
3. Students review SkillsUSA Technical Standards and Contest Projects
Unit/Course
Culminating
Product:
Student will demonstrate knowledge of system being taught; provide accurate diagnosis of system and industry standard repairs.
Removing repairing and replacing components of a vehicle located in the laboratory
Accomplishment of appropriate NATEF performance standards
Course/Program Credential(s):
Other: NATEF Standards
Credential
Certificate
Postsecondary Degree
University Degree
Automotive Engine Repair
Cylinder Head and Valve Train Diagnosis and Repair
Unit: 5
Content
Standard(s) and
Depth of
Knowledge
Level(s):
Learning
Objective(s) and
Depth of
Knowledge
Level(s):
Essential
Question(s):
Students will:
5. Demonstrate procedures involved with the cylinder head and valve train service, including removing, inspecting,
testing, repairing, installing, resurfacing, measuring, and adjusting components of the cylinder head and valve
train.
Students will:
1. Remove cylinder head; inspect gasket condition; install cylinder head and gasket; tighten according to
manufacturer’s specifications and procedures.
2. Clean and visually inspect a cylinder head for cracks; check gasket surface areas for warpage and surface finish;
check passage condition.
3. Inspect valve springs for squareness and free height comparison; determine necessary action.
4. Replace valve stem seals on an assembled engine; inspect valve spring retainers, locks/keeper grooves; determine
necessary action.
5. Inspect valve guides for wear; check valve stem-to-guide clearance; determine necessary action.
6. Inspect valves and valve seats; determine necessary action.
7. Check valve spring assembled height and valve stem height; determine necessary action.
8. Inspect pushrods, rocker arms, rocker arm pivots and shafts for wear, bending, cracks, looseness, and blocked oil
passages (orifices); determine necessary action.
9. Inspect valve lifters; determine necessary action.
10. Adjust valves (mechanical or hydraulic lifters).
11. Inspect and replace camshaft and drive belt/chain (includes checking drive gear wear and backlash, end plat,
sprocket and chain wear, overhead cam drive sprocket(s), drive belt(s), belt tension, tensioners, camshaft reluctor
ring/tone-wheel, and variable valve timing components).
12. Inspect and/or measure camshaft for runout, journal wear and lobe wear.
13. Inspect camshaft bearing surface for wear, damage, out-of-round, and alignment; determine necessary action.
14. Establish camshaft position sensor indexing.
How does a technician determine if a cylinder head can be repaired or if it must be replaced?
What is the function of the camshaft?
Content Knowledge
Suggested Instructional Activities
Suggested Materials, Equipment and
Rigor & Relevance Framework (Quadrant)
Brainstorming/Discussion
Case Studies/ Scenarios
Collaborative Learning
Cooperative learning
Demonstration
Experiments
Field Trips
Five plus one (5+1)
Games
Group investigation
Guest Speaker
Guided Practice
Instructional Technology
Laboratory/ Shop Exercise
Lecture, Lecture/Demonstration
Note Taking
PBL (Problem based Learning)
Ten plus two (10+2)
Work Based Learning
Work Sheets
Cylinder head inspection
Cylinder head installation
Gaskets
Valve springs
Valve stem seals
Valve guides
Valve inspection
Valve seats
Camshaft inspection
Valve spring assembly
Pushrods
Rocker arm shafts
Valve lifters
Valve adjustment
Cam drive
Camshaft bearing surface
Camshaft position sensor indexing
Unit
Assessment:
Unit/Course
CTSO Activity:
Unit/Course
Culminating
Product:
Technology Resources
Laboratory shop equipment
Sample MSDS sheets
Tools, supplies adequate for class numbers
PPE in sufficient quantity for each student
PowerPoint presentations
Handouts
Textbook, online and print
Modules
Online technical reference [AllData, Mitchell]
Computers, laptop and desktop
LCD projector
SkillsUSA Technical Standards
SkillsUSA PDP
Student will take written tests, demonstrate knowledge of system operation, and successfully complete applied skills performance
tasks (hand on).
Successful completion of industry-based written and performance testing
1. Continue SkillsUSA Leadership Development Programs.
2. Establish documentation for students’ career portfolio.
3. Students review SkillsUSA Technical Standards and Contest Projects.
Student will demonstrate knowledge of system being taught; provide accurate diagnosis of system and industry standard repairs.
Removing repairing and replacing components of a vehicle located in the laboratory
Accomplishment of appropriate NATEF performance standards
Course/Program Credential(s):
Other: NATEF Standards
Credential
Certificate
Postsecondary Degree
University Degree
Automotive Engine Repair
Unit: 6
Content
Standard(s) and
Depth of
Knowledge
Level(s):
Learning
Objective(s) and
Depth of
Knowledge
Level(s):
Essential
Question(s):
Engine Block Assembly, Diagnosis, and Repair
Students will:
6. Demonstrate procedures involved with engine overhaul, including removing, inspecting, testing, repairing,
installing, and adjusting components of the engine block assembly.
Students will:
1. Disassemble engine block; clean and prepare components for inspection and reassembly.
2. Inspect engine block for visible cracks, passage condition, core and gallery plug condition, and surface warpage;
determine necessary action.
3. Inspect and measure cylinder walls/sleeves for damage, wear, and ridges; determine necessary action.
4. Deglaze and clean cylinder walls.
5. Inspect and measure camshaft bearings for wear, damage, out-of-round, and alignment; determine necessary action.
6. 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); determine necessary action.
7. Inspect main and connecting rod bearings for damage and wear; determine necessary action.
8. Identify piston and bearing wear patterns that indicate connecting rod alignment and main bearing bore problems;
determine necessary action.
9. Inspect and measure piston skirts and ring lands; determine necessary action.
10. Remove and replace piston pin.
11. Determine piston-to-bore clearance.
12. Inspect, measure, and install piston rings.
13. Inspect auxiliary shaft(s) (balance, intermediate, idler, counterbalance or silencer); inspect shaft(s) and support
bearings for damage and wear; determine necessary action; reinstall and time.
14. Remove, inspect or replace crankshaft vibration damper (harmonic balancer).
15. Assemble engine block.
What is the procedure to analyze an engine block for wear or damage?
How are cylinder walls inspected for damage and wear?
How is the piston-to-bore clearance determined?
Suggested Instructional Activities
Rigor & Relevance Framework (Quadrant)
Brainstorming/Discussion
Case Studies/ Scenarios
Collaborative Learning
Cooperative learning
Demonstration
Experiments
Field Trips
Five plus one (5+1)
Games
Group investigation
Guest Speaker
Guided Practice
Instructional Technology
Laboratory/ Shop Exercise
Lecture, Lecture/Demonstration
Note Taking
PBL (Problem based Learning)
Ten plus two (10+2)
Work Based Learning
Work Sheets
Content Knowledge
Engine block inspection
Pistons
Piston skirts
Piston rings
Piston pins
Auxiliary shafts
Crankshafts
Engine block assembly
Cylinder walls/sleeves
Cylinder wall patterns
Camshaft bearings
Crankshaft inspection
Connecting rod bearings
Unit
Assessment:
Unit/Course
CTSO Activity:
Unit/Course
Culminating
Product:
Suggested Materials, Equipment and
Technology Resources
Laboratory shop equipment
Sample MSDS sheets
Tools, supplies adequate for class numbers
PPE in sufficient quantity for each student
PowerPoint presentations
Handouts
Textbook, online and print
Modules
Online technical reference [AllData, Mitchell]
Computers, laptop and desktop
LCD projector
SkillsUSA Technical Standards
SkillsUSA PDP
Student will take written tests, demonstrate knowledge of system operation, and successfully complete applied skills performance
tasks (hand on).
Successful completion of Industry-based written and performance testing
1. Continue SkillsUSA Leadership Development Programs.
2. Establish documentation for students’ career portfolio.
3. Students review SkillsUSA Technical Standards and Contest Projects.
Student will demonstrate knowledge of system being taught; provide accurate diagnosis of system and industry standard repairs.
Removing repairing and replacing components of a vehicle located in the laboratory
Accomplishment of appropriate NATEF performance standards
Course/Program Credential(s):
Other: NATEF Standards
Credential
Certificate
Postsecondary Degree
University Degree
Automotive Engine Repair
Lubrication and Cooling System Diagnosis and Repair
Unit: 7-8
Content
Standard(s) and
Depth of
Knowledge
Level(s):
Learning
Objective(s) and
Depth of
Knowledge
Level(s):
Essential
Question(s):
Students will:
7. Demonstrate testing and evaluation procedures regarding lubrication and cooling systems.
8. Demonstrate procedures for removing, inspecting, testing, repairing, installing, and adjusting components of
lubrication and cooling systems.
Students will:
1. Perform oil pressure tests; determine necessary action.
2. Inspect oil pump gears or rotors, housing, pressure relief devices, and pump drive; perform necessary action.
3. Perform cooling system pressure tests; check coolant condition; inspect and test radiator, pressure cap, coolant
recovery tank, and hoses; determine necessary action.
4. Inspect, replace, and adjust drive belts, tensioners, and pulleys; check pulley and belt alignment.
5. Inspect and replace engine cooling and heater system hoses.
6. Inspect, test, and replace thermostat and gasket/seal.
7. Test coolant; drain and recover coolant; flush and refill cooling system with recommended coolant; bleed air as
required.
8. Inspect, remove and replace water pump.
9. Remove and replace radiator.
10. Inspect, and test fan(s) (electrical or mechanical), fan clutch, fan shroud, and air dams.
11. Inspect auxiliary coolers; determine necessary action.
12. Inspect, test, and replace oil temperature and pressure switches and sensors.
13. Perform oil and filter change.
14. Identify causes of engine overheating.
What components of the engine are affected by a faulty cooling system?
Why is a proper cooling system necessary for the operation of diesel engines?
How does the lubrication system affect the operation of a vehicle?
What is the primary function of the lubrication system?
Content Knowledge
Suggested Instructional Activities
Rigor & Relevance Framework (Quadrant)
Suggested Materials, Equipment and
Technology Resources
Coolants
Coolant recovery
Pressure tests
Radiators
Pressure caps
Coolant recovery tank
Hoses
Thermostats
Gaskets/seals
Flush/refill cooling system
Fans
Fan clutch
Fan shroud
Air dams
Engine cooling and heater system hoses
Water pumps
Radiators
Troubleshooting
Types of anti-freeze
Drive belts
Tensioners
Pulleys
Oil temperature sensors
Oil temperature pressure switch
Oils
Oil filters
Oil pressure tests
Oil pump gears
Oil pump rotors
Pressure relief devices
Auxiliary coolers
Unit
Assessment:
Unit/Course
CTSO Activity:
Brainstorming/Discussion
Case Studies/ Scenarios
Collaborative Learning
Cooperative learning
Demonstration
Experiments
Field Trips
Five plus one (5+1)
Games
Group investigation
Guest Speaker
Guided Practice
Instructional Technology
Laboratory/ Shop Exercise
Lecture, Lecture/Demonstration
Note Taking
PBL (Problem based Learning)
Ten plus two (10+2)
Work Based Learning
Work Sheets
Laboratory shop equipment
Sample MSDS sheets
Tools, supplies adequate for class numbers
PPE in sufficient quantity for each student
PowerPoint presentations
Handouts
Textbook, online and print
Modules
Online technical reference [AllData, Mitchell]
Computers, laptop and desktop
LCD projector
SkillsUSA Technical Standards
SkillsUSA PDP
Student will take written tests, demonstrate knowledge of system operation, and successfully complete applied skills performance
tasks (hand on).
Successful completion of Industry-based written and performance testing
1. Continue SkillsUSA Leadership Development Programs.
2. Establish documentation for students’ career portfolio.
3. Students review SkillsUSA Technical Standards and Contest Projects.
Unit/Course
Culminating
Product:
Student will demonstrate knowledge of system being taught; provide accurate diagnosis of system and industry standard repairs.
Removing repairing and replacing components of a vehicle located in the laboratory
Accomplishment of appropriate NATEF performance standards
Course/Program Credential(s):
Other: NATEF Standards
Credential
Certificate
Postsecondary Degree
University Degree