8

AUTOMOTIVE ENGINE
DESIGNS AND DIAGNOSIS
CHAPTER OVERVIEW
This chapter introduces the student to the internal combustion engine. A variety of
popular designs are described and a general discussion of engine diagnosis and testing
is introduced.

CHAPTER OBJECTIVES
Describe the various ways in which engines can be classified.
Explain what takes place during each stroke in the four-stroke cycle.
Outline the advantages and disadvantages of the in-line and V-type engine designs.
Define important engine measurements and performance characteristics, including
bore and stroke, displacement, compression ratio, engine efficiency, torque, and
horsepower.
Explain how to evaluate the condition of an engine.
List and describe nine abnormal engine noises.
Outline the basics of diesel, stratified, and Miller-cycle engine operation.

INSTRUCTIONAL OUTLINE WITH TEACHING HINTS

I. Introduction to Engines
II. Engine Construction
III. Engine Classifications
A. Design Features
1. Operational Cycles
2. Number of Cylinders
3. Cylinder Arrangement
4. Valve Train Type
5. Ignition type
6. Cooling System
7. Fuel Type
Hint: Give examples of various engine classifications.

32

Automotive Engine Designs and Diagnosis

33

B. Four-Stroke Gasoline Engine

1. Intake Stroke
2. Compression Stroke
3. Power Stroke
4. Exhaust Stroke
C. Two-Stroke Gasoline Engine
D. Characteristics of Four-Stroke Engine Design
1. In-Line Engine
2. V-Type and W-Type Engines
3. Slant Cylinder Engine
4. Opposed Cylinder Engine
E. Valve and Camshaft Placement Configurations
1. Overhead Valve (OHV)
2. Overhead Cam (OHC)
F. Valve and Camshaft Operation
G. Engine Location
1. Front Engine Longitudinal
2. Front Engine Transverse
3. Mid-Engine Transverse
Hint: Describe changes in engine designs and discuss how engines will
change in the future.
H. Gasoline Engine Systems
1. Air/Fuel System
2. Ignition System
3. Lubrication System
4. Cooling System
5. Exhaust System
6. Emission Control System
III. Engine Measurement and Performance
A. Bore and Stroke
1. Oversquare
2. Undersquare
B. Displacement
C. Compression Ratio
1. Variable Compression Ratio Engines
D. Engine Efficiency
1. Volumetric Efficiency
2. Thermal Efficiency
3. Mechanical Efficiency
E. Torque versus Horsepower
Hint: Discuss how displacement, compression, torque, and horsepower affect
engine performance.
IV. Engine Identification
A. VIN
B. Underhood Label
Hint: Have the students use the VIN and the underhood label to identify the
model years and engine sizes of an assortment of vehicles.
V. Engine Diagnostics
A. Compression Test
B. Cylinder Leakage Test

34

Chapter 8

C. Cylinder Power Balance Test

D. Vacuum Tests
E. Oil Pressure Testing
Hint: Discuss when each of these tests would be the most useful. Describe
the difference between a compression test, a cylinder leakage test, and a
cylinder power balance test.
VI. Evaluating the Engines Condition
VII. Noise Diagnosis
A. Using a Stethoscope
B. Common Noises
1. Ring Noise
2. Piston Slap
3. Piston Pin Knock
4. Ridge Noise
5. Rod-Bearing Noise
6. Main or Thrust Bearing Noise
7. Tappet Noise
8. Abnormal Combustion Noises
Hint: Describe the various noises and whether they happen at crankshaft
or camshaft speed. If possible, record some normal and abnormal engine
noises for playback to the students.
VIII. Other Engine Designs
A. Diesel Engine
B. Rotary Engine
C. Stratified Charge Engine
D. Miller-Cycle Engines
E. Hybrid Vehicles
Hint: Assign students to find magazine articles about new engine designs.

ANSWERS TO TEXTBOOK REVIEW QUESTIONS

1. The combustion chamber is the space between the top of the piston and the cylinder
head. It is an enclosed area in which the gasoline and air mixture is burned.
2. The four strokes are intake, compression, power, and exhaust.
3. As an engines compression ratio increases, there should also be an increase in the
octane rating of the fuel in order to avoid abnormal combustion. Gasoline with too
low an octane rating may ignite before spark occurs due to the additional heat produced by a higher compression ratio, or it may burn in an explosive and destructive
manner.
4. A cylinder balance test can be used to compare the efficiency of each cylinder. Ideally,
all of the cylinders should produce an equal amount of power.
5. Tappet noise is a term used to describe a noisy valve train. It is characterized as a light
regular clicking noise, which is more noticeable at idle speed. Because the camshaft
rotates at one-half crankshaft speed, valve train noises may be identified by a lower
frequency.
6. b. Gasoline engines are only one of a variety of internal combustion engines.
7. a. The ignition of the fuel/air mixture begins the power stroke.

Automotive Engine Designs and Diagnosis

35

8. c. The compression ratio describes the amount that the air/fuel mixture will be
compressed.
9. a. The camshaft opens and closes the intake and exhaust valves.
10. a. A diesel engine may have a compression ratio of up to 25:1.
11. d. Because a compression test is performed while cranking the engine and a cylinder
leakage test is performed while the crankshaft is stationary, the results may vary
between these tests.
12. c. Piston slap is a hollow, bell-like noise that is produced when the piston slaps against
the cylinder wall due to excessive clearances. It is commonly heard when the engine
is cold, and gets louder when the engine is accelerated. Shorting out the spark plug
of the affected cylinder may quiet the noise.
13. a. The exhaust system.
14. In four stroke cycle engines, the order of the strokes is: intake, compression, power,
and exhaust. In the engine, mentioned in the question, when cylinder #1 is on the
power stroke, cylinder #2 will be on its compression stroke, cylinder #4 will be on the
intake stroke, and cylinder #2 will on the exhaust. Therefore, when cylinder #1 is on
its compression stroke, cylinder #3 will be on its intake stroke.
15. b. The stroke of an engine is twice the crankshaft throw.
16. True. Worn or damaged piston rings can cause air to be found escaping around the
dipstick tube during a cylinder leakage test.
17. c. Both technicians are correct. When an engine is cold, the oil pressure will be higher due to the viscosity of cold oil. An oil pressure regulator valve that is sticking can
also cause abnormally high oil pressure.
18. a. A sharp metallic rapping sound originating from the upper portion of an engine
would most likely be a piston pin knock. A damaged or worn crankshaft thrust bearing would result in a dull steady knock originating near the bottom of the engine.
19. b. A collapsed lifter would most likely not show up on either a compression or a
cylinder leakage test, but would cause the cylinder to produce less power than
other cylinders.
20. d. Thermal efficiency describes how well the engine converts the heat produced during combustion into usable power.

TECH MANUAL
The following procedures are included in Chapter 8 of the Tech Manual:
1. Performing a cylinder compression test.
2. Performing a cylinder leakage test.
3. Measuring engine oil pressure.

ADDITIONAL TEACHING HINTS

Demonstrate power balance testing, then evaluate the engines condition.
Have the students identify their family vehicles as to engine type, valve train,
camshaft location, and cylinder arrangement.

36

Chapter 8

ANSWERS TO TECH MANUAL REVIEW QUESTIONS

1. An engines compressions ratio expresses the decrease in the volume of the cylinder
as the pistons move from BDC to TDC. The pressure of the mixture changes proportionally with the change in volume.
2. An engines displacement is the total volume of all of the engines cylinders.
3. A VIN gives the year, make, model, country of origin, engine size, and serial number
of the vehicle.
4. Ring noise
5. Ridge noise
6. Loose crankshaft thrust bearing
7. Separate intake and exhaust camshafts allow the engineering of more flexibility in the
duration of the intake and exhaust valve duration.
8. c
9. The computer makes adjustments to the fuel and ignition systems of the vehicle to
match the temperature at which it is operating. Therefore, if the computer senses that
the engine is hot, it will make adjustments to maintain the present temperature or to
cool it down, even when the engine may need to become hotter. The end result may
be poor driveability and fuel economy.
10. Look for air leaking from the throttle body, tailpipe, or crankcase, and for air bubbles
in the radiator.
11. a. loss of performance
b. excessive engine noise
c. poor starting
12. a. low oil level
b. oil dilution
c. worn oil pump
d. worn main bearings
13. Carbon buildup on the piston and combustion chamber may cause an increase in compression ratio; therefore, the compression pressure readings may seem normal in spite
of the fact that the cylinder is not properly sealed.
14. Remove the air cleaner.
15. Usually 6 or 7 revolutions or 4 compression strokes

9
ENGINE DISASSEMBLY

CHAPTER OVERVIEW
This chapter instructs the student in engine removal and disassembly of the cylinder head
and cylinder block. Identification and cleaning of engine parts and crack detection and
repair are explained in depth.

CHAPTER OBJECTIVES
Prepare an engine for removal.
Remove an engine from an FWD and an RWD vehicle.
Describe how to disassemble and inspect an engine.
Name the three basic cleaning processes.
Identify the types of cleaning equipment.
Describe the common ways to repair cylinder head cracks.

INSTRUCTIONAL OUTLINE WITH TEACHING HINTS

I. Removing an Engine
A. FWD Vehicles
1. Removing the Engine Through the Hood Opening
2. Removing the Engine from Under the Vehicle
B. RWD Vehicles
Hint: Divide the students into several groups. Have them find the procedure
for removing an engine from several types of vehicles such as an FWD van
and an RWD light truck in the service manuals. Compare and discuss the
differences as a class.
II. Engine Disassembly and Inspection
A. Cylinder Head Removal
B. Cylinder Head Disassembly
C. Cylinder Block Disassembly

37

38

Chapter 9

III. Cleaning Engine Parts

A. Types of Soil Contaminants
1. Water-Soluble Soils
2. Organic Soils
(a) Petroleum By-Products
(b) By-Products of Combustion
(c) Coatings
3. Rust
4. Scale
B. Cleaning with Chemicals
1. Chemical Cleaning Machines
(a) Parts Washers
(b) Soak Tanks
(c) Hot Spray Tanks
C. Thermal Cleaning
D. Abrasive Cleaners
1. Abrasive Cleaning Methods
(a) Abrasive Blaster
(b) Parts Tumbler
(c) Vibratory Cleaning
(d) Cleaning by Hand
E. Alternative Cleaning Methods
1. Ultrasonic Cleaning
2. Citrus Chemicals
3. Salt Bath
Hint: Show the labels and MSDS for the chemicals used in the lab and
discuss how to safely store and use them.
IV. Crack Detection and Repair
A. Furnace Welding Crack Repairs
B. Repairing Aluminum Heads
1. Cracks Between the Valve Seat Rings
2. Cracks Coming from the Coolant Passages
3. Cracks Across the Main Oil Galley
4. Detonation Damage
5. Meltdown Damage
6. Coolant-related Metal Erosion
Hint: Arrange a field trip to a local machine shop.
C. Tungston Inert Gas (TIG) Welding

ANSWERS TO TEXTBOOK REVIEW QUESTIONS

1. All electronic and fuel injection parts should be covered with plastic bags during steam
or other cleaning procedures to avoid direct contact with steam, water, or other cleaning agents. EPA regulations should always be followed.
2. Wear protective gloves and goggles when using chemical cleaners.
3. False.
4. The best method for repairing cracked cast-iron heads is furnace welding by a
specialist.
5. The preferred method of welding damaged aluminum cylinder heads is TIG welding.
6. True.

Engine Disassembly

39

7. a. A crane is the correct equipment to use.

8. a. Measure valve stem height before removing the valves. Removing carbon deposits
is done after the head is disassembled.
9. a. The pushrods and rocker arms should be kept in order to aid in diagnosing valverelated problems. The cylinder head bolts should be loosened one or two turns beginning in the center and working outward.
10. b. The buildup of minerals and deposits is called scale.
11. c. Hydrocarbon based solvents are both toxic and flammable.
12. d. Neither technician is correct. Of the two types of abrasive media, shot is round
and is used for surface peening, and grit is angular and used for aggressive cleaning
jobs.
13. d. When a crack is found in the main oil gallery, it is recommended that the casting
be replaced.
14. a. Ultrasonic cleaning uses high-frequency sound waves to loosen dirt particles.
15. b. Do not use a fast cooling rate. Rapid cooling causes internal stress and distortion.
Use water or shot blasting to remove ash deposits after thermal cleaning.
16. d. Parts must be dry and grease-free before abrasive cleaning for best results.
17. c. Both technicians are correct. The choice of cleaning methods depends on the component to be cleaned, and sometimes it is best to clean by hand with soap and water.
18. d. There is no particular order to loosening connecting rod cap bolts.
19. a. Use at least four bolts to mount an engine block to an engine stand.
20. c. Both technicians are correct. Small surface cracks between valve seats can be
peened, and cracks to coolant passages should be repaired by TIG welding.

TECH MANUAL
The following procedures are included in Chapter 9 of the Tech Manual:
1. Preparing engine for removal.
2. Removing and disassembling the cylinder head.
3. Removing cylinder ring ridge.

ADDITIONAL TEACHING HINTS

Disassemble a cylinder block in the shop.
Display samples of soil contaminants for students to view.
Demonstrate chemical, abrasive, or some other cleaning method.
Use and review all MSDSs for the shop chemical cleaning agents.
Show how disassembled engine parts should be organized.

ANSWERS TO TECH MANUAL REVIEW QUESTIONS

1.
2.
3.
4.

Negative
File away the excess metal on the tip before pushing the valve out of the guide.
Label both sides of each connection to aid reassembly.
To prevent head warpage and to ensure a good seal

40

Chapter 9

5.
6.
7.
8.
9.

Reverse the procedure for tightening the bolts.

a
1.5 times the bolt diameter
b
Chemical, thermal, by hand with soap and water, abrasives, vibrations, ultrasonic, and
salt bath
10. With your fingernail

10
SHORT BLOCKS

CHAPTER OVERVIEW
This chapter discusses the cylinder block, crankshaft, crankshaft bearings, connecting
rods, pistons and rings, oil galley, core plugs, flywheel, and harmonic balancer, focusing
attention on the design and function of these essential parts.

CHAPTER OBJECTIVES
List the parts that make up a short block and briefly describe their operation.
Describe the major service and rebuilding procedures performed on cylinder
blocks.
Describe the purpose, operation, and location of the camshaft.
Describe four types of camshaft drives.
Inspect the camshaft and timing components.
Describe how to install a camshaft and its bearings.
Explain crankshaft construction, inspection, and rebuilding procedures.
Explain the function of engine bearings, flywheels, and harmonic balancers.
Explain the common service and assembly techniques used in connecting rod and
piston servicing.
Explain the purpose and design of the different types of piston rings.
Describe the procedure for installing pistons in their cylinder bores.

INSTRUCTIONAL OUTLINE WITH TEACHING HINTS

I. Cylinder Block
A. Lubrication and Cooling
B. Core Plugs
C. Cylinder Sleeves
II. Cylinder Block Reconditioning
A. Deck Flatness
B. Cylinder Walls
C. Cylinder Bore Inspection
1. Taper
2. Out-of-Roundness

41

42

Chapter 10

III.

IV.

V.

VI.

VII.

D. Cylinder Bore Surface Finish

1. Cylinder Deglazing
2. Cylinder Boring
3. Cylinder Honing
E. Lifter Bores
F. Checking Crankshaft Saddle Alignment
G. Installing Core Plugs
1. Disc- or Dished-Type
2. Cup-Type
3. Expansion-Type
Hint: Show examples of each type of plug and describe their proper
uses.
Camshaft
A. Timing Mechanisms
1. Gear Drive
2. Chain Drive
3. Belt Drive
B. Valve Lifters
1. Operation of Hydraulic Valve Lifters
C. Camshaft Bearings
D. Balance Shafts
Inspection of Camshaft and Related Parts
A. Timing Components
B. Lifters
C. Camshaft
Installing the Camshaft and Related Parts
A. Camshaft Bearings
B. Camshaft
Crankshaft
A. Vibration Damper
B. Flywheel
Hint: Show students different crankshaft configurations. Show both forged
and cast crankshafts.
Crankshaft Inspection and Rebuilding
A. Crankshaft Reconditioning
B. Checking Crankshaft Straightness
C. Flywheel Inspection
D. Crankshaft Bearings
E. Bearing Materials
F. Bearing Spread
G. Bearing Crush
H. Bearing Locating Devices
I. Oil Grooves
J. Oil Holes
K. Oil Clearance
L. Bearing Failure and Inspection
Hint: Show students a variety of damaged and worn bearings. Discuss the
causes of the failures. Have students look up crankshaft specifications in
service manuals.

Short Blocks

43

VIII. Installing Main Bearings and Crankshaft

A. Crankshaft Endplay
B. Connecting Rod
Hint: Demonstrate the use of Plastigage and crankshaft endplay
measurements.
IX. Piston and Piston Rings
A. Pistons
1. Head or Dome
2. Rings Lands
3. Piston Pin
B. Piston Rings
1. Compression Rings
2. Oil Control Rings
X. Installing Pistons and Connecting Rods
XI. Crankshaft and Camshaft Timing
A. Camshaft end Play
B. Lifters

ANSWERS TO TEXTBOOK REVIEW QUESTIONS

1. Camshaft lobe wear may be measured with an outside micrometer or with a dial
indicator.
2. The deck is the top surface of the block to which the cylinder head mounts.
3. Maximum cylinder bore wear occurs at the top of the ring travel area.
4. a. Hydraulic lifters automatically compensate for changes in engine temperature.
5. Compression rings form a seal between the piston and the cylinder walls using combustion pressure to force the ring against the bottom edge of the ring groove.
6. b. Aluminum pistons are most commonly used in automotive engines.
7. d. All of the above are true about core plugs.
8. a. Cylinder out-of-roundness specifications are typically 0.0015 inch (.0381 mm);
acceptable cylinder taper should be 0.006 inch (0.152 mm), not 0.010 inch
(.254 mm) as stated.
9. c. Both methods may be used to check for proper alignment of the bearing oil hole
with the block.
10. c. Both statements are correct. The cylinder wall surface should have a crosshatch
pattern and should not be so smooth that the rings are not able to seat properly.
11. d. Neither statement is correct. The timing chain should never be forced onto the
sprockets; it is unnecessary to cool the sprockets.
12. a. A cup-type core plug is installed with the flanged edges pointing outward; a dishtype plug is installed with the dished side facing outward, not inward as stated.
13. b. Bearing crush refers to each half of a split bearing being slightly greater than an
exact half. Bearing spread means that the distance across the parting edges of the insert
should be slightly greater than the diameter of the bearing bore.
14. d. The connecting rod journal is also called the crank pin.
15. c. An outside micrometer is used to measure for both taper and out-of-roundness.
16. b. Piston ring end gaps should be staggered, and most manufacturers recommend
locations for each ring. Piston ring end gap specifications vary according to ring location, with some manufacturers specifying a larger end gap for the second ring.

44

Chapter 10

17. c. Both methods are acceptable.

18. b. The cam changes rotary motion of the camshaft into the reciprocating motion of
the valves.
19. c. Both statements are correct.
20. c. Both cast-iron and segmented rings have slots to allow excess oil to pass through.

TECH MANUAL
The following procedures are included in Chapter 10 of the Tech Manual:
1.
2.
3.
4.
5.
6.
7.
8.

Measuring cylinder bore.

Measuring crankshaft journals.
Measuring crankshaft endplay.
Installing pistons and connecting rods.
Measuring camshaft lobes/cam and bearing journals.
Installing camshaft bearings.
Inspecting and replacing camshaft drives.
Testing for worn cam lobes.

ADDITIONAL TEACHING HINTS

Measure deck warpage.
Demonstrate deglazing and honing.
Demonstrate a crankshaft inspection.
Demonstrate how to use Plastigage on the main and rod bearings.

ANSWERS TO TECH MANUAL REVIEW QUESTIONS

1. a. crank
b. main bearing
c. rod bearing
2. Two
3. Ring expander
4. Micrometer
5. Dial indicator and feeler gauge
6. Before teardown is complete
7. The connecting rod bolts should be covered with rubber or aluminum protectors or
guides before piston and rod assembly installation.
8. A drop of anaerobic thread-locking compound
9. False
10. Criss-cross pattern with lines intersecting at 50-degree angles
11. Micrometer
12. At least eight
13. c

Short Blocks

45

14. Warped block, misaligned crankcase housing bores

15. Use a micrometer and measure the journal diameter vertically and horizontally at both
ends. Then compare measurements. If the vertical measurement is different than the
horizontal, the journal is out-of-round. If there is a difference between the ends,
the journal has taper.
16. Gears, belt, chain
17. Lift is the distance the valve moves on its seat or the difference between the base circle of the camshaft lobe and the nose of the lobe.
18. It is tapered to cause the rotation of the lifter in nonroller lifters
19. Case hardening of the camshaft lobes is important to prevent lobe wear, because there
is a high friction load between the lobes and the valve lifters.
20. Clockwise

11
CYLINDER HEADS, CAMSHAFTS,
AND VALVE TRAINS
CHAPTER OVERVIEW
This chapter draws attention to the different types of combustion chamber designs and
intake and exhaust valves. Additional information is given about reconditioning aluminum
cylinder heads, resurfacing cylinder heads, grinding valves, valve guide reconditioning, and
reconditioning of valve seats.

CHAPTER OBJECTIVES
Describe the purpose of an engines cylinder head, valves, and related valve parts.
Describe the types of combustion chamber shapes found on modern engines.
Explain the procedures involved in reconditioning cylinder heads, valve guides,
valve seats, and valve faces.
Explain the steps in cylinder head and valve reassembly.

INSTRUCTIONAL OUTLINE WITH TEACHING HINTS

I. Cylinder Head
II. Combustion Chamber
A. Wedge Chamber
B. Hemispherical Chamber
Hint: Show examples of different combustion chamber designs.
III. Intake and Exhaust Valves
A. Poppet Design
B. Valve Face
C. Margin
D. Important Valve Components of Four-Stroke Engines
1. Valve Guides
2. Valve Springs, Retainers, and Seals
3. Valve Rotators
4. Camshaft Bearings
5. Pushrods
Hint: Show some failed pushrods. Explain what to look for when
examining pushrods.

46

Cylinder Heads, Camshafts, and Valve Trains

IV.

V.
VI.

VII.
VIII.

IX.

47

6. Pushrod Guide Plates

7. Rocker Arms
E. Multivalve Engines
F. Variable Valve Timing
1. Valvetronic System
Inspection of Cylinder Head and Valve Train
A. Timing Components
B. Rocker Arms
C. Pushrods
D. Cam Followers and Lash Adjusters
E. Retainers and Keepers
F. Valve Rotators
G. Valve Springs
H. Cylinder Heads
I. Camshaft and Bearings
J. Valves
Hint: Show examples of each of the cylinder head and valve train
components listed. Show where to look for wear patterns.
Aluminum Cylinder Heads
A. Reconditioning Aluminum Cylinder Heads
Resurfacing Cylinder Heads
A. Surface Finish
1. Resurfacing Machines
(a) Belt Surfacers
(b) Milling Machines
(c) Broaching Machines
(d) Surface Grinders
2. Stock Removal Guidelines
(a) Combustion Chamber
(b) Compression Ratio
(c) Piston/Valve Interference and Misalignment
Hint: Discuss why cylinder heads may need resurfacing and the
relative merits of the various resurfacing methods.
Grinding Valves
Valve Guide Reconditioning
A. Knurling
B. Reaming and Oversized Valves
C. Thin-Wall Guide Liners
D. Valve Guide Replacement
1. Integral Guides
2. Insert Guides
Hint: Compare reaming and oversized valves with thin-walled and castiron inserts.
Reconditioning Valve Seats
A. Installing Valve Seat Inserts
B. Reconditioning Integral Seats
C. Grinding Valve Seats
D. Cutting Valve Seats
E. Machining Valve Seats
Hint: Show a valve seat insert and describe the method used to install it.

48

Chapter 11

X. Valve Stem Seals

A. Installing Positive Valve Seals
B. Installing Umbrella-Type Valve Seals
C. Installing O-Rings
Hint: Discuss the merits of positive seals over other types.
D. Valve Springs
1. Freestanding Height Test
2. Spring Squareness Test
3. Open/Close Spring Pressure Test
Hint: Discuss why valve springs need to be tested and the consequences
of omitting this service. Show examples of failed valve springs.
XI. Assembling the Cylinder Head
A. OHC Engines

ANSWERS TO TEXTBOOK REVIEW QUESTIONS

1. If valve spring tension is too low, the valves will not be closed promptly enough and
there will be valve float at higher engine speeds.
2. Valve margin is the area between the valve face and the head of the valve that allows
for some machining of the valve face, which is sometimes necessary to restore its finish, and allows the valve an extra capacity to hold heat.
3. Warpage in an aluminum cylinder head is usually the result of overheating or uneven
cooling within the cylinder head.
4. Pushrods may be checked for straightness while installed in the engine by rotating
them when the valve is closed and visually checking for indications of wobble. When
the pushrods are out of the engine, they can be checked by rolling them on a flat surface; a pushrod that is not straight will appear to hop. The most accurate method is
by using a dial indicator. If more than 0.003 (0.076 mm) TIR is found, the pushrod
should be replaced.
5. Because knurling only restores a portion of the valve guides ID to original dimensions.
The raised edges produced by knurling soon wear down, and clearances rapidly
become excessive.
6. c. Both the valve face and the tip are resurfaced by grinding.
7. c. Knurling will not restore badly worn guides to their original condition.
8. When the cylinder head of an OHC engine is resurfaced, the removal of material from
the head would result in the camshaft moving closer to the crankshaft, altering valve
timing. Special shims are used to raise the camshaft by the same amount as the material removed, thus restoring valve timing.
9. d. All of the above are true.
10. d. All of the above are true.
11. a. If the valve face and seat do not contact evenly, the seat should be reground using
the same stone as was used initially to correct the condition.
12. c. Both technicians are correct. Bronze valve guides retain oil better than cast-iron
guides do and they last longer, but they are more difficult to machine.
13. c. Both technicians are correct. Positive valve stem seals fit tightly around the stem
and scrape excess oil off the valve as it moves up and down.
14. d. If the valve margin is too small, the valve should be replaced. If the valve seat is too
high, the seat should be reground using a stone with a smaller angle to lower the seat.
15. d. All of the above are true.

Cylinder Heads, Camshafts, and Valve Trains

49

16. c. Low spring pressure may allow the valve to float at higher engine speed, and excessive spring pressure increases valve train wear.
17. b. Broaching machines use an underside rotary cutter.
18. b. Normally the desired face-to-seat contact area for exhaust valves is 3/32 inch, not
1/16 inch as stated.
19. d. Quenching is the cooling of gases by pressing them into a thin area.
20. c. Both technicians are correct. The Valvetronic system does not use a throttle plate,
but controls the flow of incoming air directly at the intake valves by altering their duration and lift.

TECH MANUAL
The following procedures are included in Chapter 11 of the Tech Manual:
1.
2.
3.
4.
5.
6.
7.

Inspecting cylinder head for wear.

Inspecting and testing valve springs for squareness, pressure, and free height comparison.
Inspecting valve spring retainers, locks, and valve lock grooves.
Replacing valve stem seals in vehicle.
Reconditioning valve faces.
Inspecting valve lifters, pushrods, and rocker arms.
Reconditioning valve seats.

ADDITIONAL TEACHING HINTS

Demonstrate carbon removal and cleaning techniques.
Check the head surface for warpage with a straightedge and feeler gauge.
Pass around a valve with a too-narrow margin.
Demonstrate how to check for valve spring tensions.
Check for cam bore warpage on an OHC head.
Demonstrate cylinder head disassembly and reassembly.
Demonstrate how disassembled cylinder head parts should be organized.

ANSWERS TO TECH MANUAL REVIEW QUESTIONS

1.
2.
3.
4.

5.
6.

7.
8.

1.1 to 1.75
Valve seats and coolant passages
Lower fuel consumption and emission levels
At the end of the camshaft near the drive pulley, a phasing mechanism reacts to a signal from the engine control computer and shifts the lobe of the camshaft in accordance with RPM. Phasers can be controlled either electronically or hydraulically.
Valvetronic system
a. inadequate lubrication
b. valve geometry problems
c. wrong valve stem-to-guide clearance
Exhaust valves require more clearance.
To allow for heat expansion (exhaust valves run hotter)

50

Chapter 11

9. Inadequate lubrication
10. Small hole gauge or telescoping gauge, and micrometer
11. Stem-to-guide clearance is the difference between the smallest diameter of the stem
and the largest diameter of the valve guide.
12. A valve seat runout gauge (also called a concentricity gauge) is used.
13. The valve seat should be replaced by either machining a counter bore to install an
inset seat, or an integral seat should be ground cut, or machined.
14. The face should be ground first.
15. 0.010 in. (.254 mm) can be removed from the valve tip before it must be replaced.

12
LUBRICATING AND
COOLING SYSTEMS
CHAPTER OVERVIEW
This chapter describes the functions of the components of a typical lubricating and cooling system. Also explained are service requirements such as oil types, oil pump inspection
and installation, and cooling system inspection and service.

CHAPTER OBJECTIVES
Name and describe the components of a typical lubricating system.
Inspect, service, and install an oil pump.
Describe the purpose of a crankcase ventilation system.
Explain oil service and viscosity ratings.
List and describe the major components of the cooling system.
Describe the operation of the cooling system.
Describe the function of the water pump, radiator, radiator cap, and thermostat in
the cooling system.
Test and service the cooling system.

INSTRUCTIONAL OUTLINE WITH TEACHING HINTS

I. Lubrication
A. Oil types
1. ISLAC Oil Ratings
2. Synthetic Oils
B. Oil Consumption
Hint: Show several oil containers and explain how to find and identify
the different ratings. Discuss the merits of using synthetic and synthetic
blended oils.
II. Lubricating Systems
A. Oil Pump
B. Oil Pump Pickup
C. Oil Pan or Sump
D. Pressure Relief Valve
E. Oil Filter
F. Engine Oil Passages or Galleries
G. Engine Bearings
51

52

Chapter 12

III.

IV.

V.
VI.

VII.

H. Oil Pressure Indicator

I. Oil Seals and Gaskets
J. Dipstick
Oil Pump
A. Types of Oil Pumps
1. Rotor-type
2. Gear-type
B. Pressure Regulation
Oil Pump Inspection and Service
Hint: Show several different types of oil pumps. Show how to disassemble and
examine them. Show the areas where wear is most likely to be found.
Installing the Oil Pump
Cooling Systems
A. Coolant
1. Chemical Treatments
B. Thermostat
1. Effects on Driveability
C. Water Pump
D. Radiator
1. Oil Cooler
E. Radiator Pressure Cap
1. Expansion Tank
F. Hoses
1. Water Outlet
2. Water Jackets
G. Hose Clamps
H. Belt Drives
I. Cooling Fans
1. Electric Cooling Fans
J. Temperature Indicators
1. Temperature Sensors
K. Heater System
Cooling System Servicing
A. Coolant Condition
B. Testing the Cooling System for Leaks
C. Repairing Radiators
D. Testing the Radiator Pressure Cap
E. Testing the Thermostat
F. Checking and Replacing Hoses
G. Water Pump Service
1. Replacing the Water Pump
H. Checking Fans and Fan Clutches
I. Checking Belts
1. Belt Replacement
2. Belt Tension
J. Coolant Recovery and Recycle System
K. Flushing Cooling Systems
L. Refilling and Bleeding
Hint: Show examples of various hose and belt failures. Cut an upper radiator
hose lengthwise so that students can see how hoses begin to deteriorate from

Lubricating and Cooling Systems

53

the inside first. Show a hose with ECD. Demonstrate testing a thermostat for
opening temperature and for sticking.

ANSWERS TO TEXTBOOK REVIEW QUESTIONS

1. Increase the difference between the temperature of the coolant and the outside air
flowing through it.
2. The closed system type radiator cap is the one that is most commonly used.
3. To determine whether the water pump is creating good circulation, warm up the
engine and run it at idle speed. Squeeze the upper radiator hose with one hand and
accelerate the engine with the other. If a surge of coolant is felt at the hose, the pump
is circulating coolant.
4. The oil pump is typically driven by the crankshaft or camshaft.
5. The pressure regulator valve
6. d. All of the above
7. b. Oil pressure is dependent upon oil viscosity. Rotor type pumps produce greater
flow than gear pumps.
8. c. Both technicians are correct. Oil filters may be equipped with a check valve, and
the input side of the oil pump has a filter screen to prevent large particles from entering the pump.
9. Electrochemical degradation (ECD) is the primary cause of hose failures.
10. False. The fan clutch operates only when the engine and radiator are heated up and
not as stated.
11. c. Both technicians are correct. A straightedge and feeler gauges are used to determine pump cover flatness, and an outside micrometer is used to measure the diameter and thickness of an oil pump outer rotor.
12. c. API oil classifications are grouped into S classifications (standard) for passenger
cars and C classifications for diesel (compression ignition) engines.
13. b. Higher viscosity oils receive higher rating numbers. The Society of Automotive
Engineers (SAE) establishes viscosity ratings, not API as stated.
14. b. Each pound of pressure on engine coolant raises the boiling point about 3F (16C).
15. c. Automotive water pumps are usually belt driven from the crankshaft.
16. d. The inner rotor to housing dimension is not measured, but the clearance between
the outer rotor and housing is checked with feeler gauges.
17. d. Premature bearing and bushing failure in water pumps, generators, and power
steering pumps results from excessive belt tension, not insufficient tension as stated.
18. c. A thermostat must be fully open when it is 20F (6.6C) above its opening
temperature.
19. b. An air leak on the suction side of an oil pump may cause the oil to become aerated.
20. b. When installing an oil pump, submerge it in clean oil and rotate it by hand until
oil emerges from the discharge port.

TECH MANUAL
The following procedures are included in Chapter 12 of the Tech Manual:
1. Servicing and installing oil pump and oil pan.
2. Inspecting, replacing, and adjusting drive belts and pulleys.
3. Cleaning, inspecting, testing, and replacing electric cooling fans and cooling systemrelated temperature sensors.

54

Chapter 12

ADDITIONAL TEACHING HINTS

Examine and discuss an oil pump pressure valve.
Examine an oil pressure system, pointing out the location of sending units, oil lines,
and gauges.
Completely inspect several types of oil pumps according to manufacturers
recommendations.
Examine the various types of radiator core constructions.
Pressure test the cooling system for leaks.

ANSWERS TO TECH MANUAL REVIEW QUESTIONS

1. a. ambient temperature
b. stuck pressure regulating valve
c. high-viscosity oil
2. Oil pumps are driven, directly, indirectly, and by the camshaft or by a gear at the front
of the crankshaft.
3. Air leaks on the inlet side of the pump can cause the pressure relief valve to hammer
back and forth, the oil can become aerated and foamy, and engine wear can occur due
to marginal lubrication.
4. If any part of the housing is scored or noticeably worn, replace the pump as an
assembly.
5. In newer engines, the baffle assembly is used to restrict oil movement in the oil sump.
6. Using a thermostat with a different opening temperature than was originally installed
on a computerized engine will cause many driveability problems including poor gas
mileage and excessive emissions.
7. A faulty head gasket and a cracked head or cylinder
8. True
9. The source of an external coolant leak can found by a thorough visual inspection or
the use of a dye penetrant.
10. Wait for 15 to 20 minutes and check for a pressure drop on the tester gauge.
11. False
12. False
13. c
14. c
15. c

13
ENGINE SEALING
AND REASSEMBLY

CHAPTER OVERVIEW
This chapter describes the gaskets, sealants, adhesives, and fasteners needed to correctly
seal an engine. Improvement in sealing technologies is introduced in this chapter.

CHAPTER OBJECTIVES
Explain the purpose of the various gaskets used to seal an engine.
Identify the major gasket types and their uses.
Explain general gasket installation procedures.
Describe the methods used to seal the timing cover and rear main bearing.
Reassemble and engine including core plugs, bearings, crankshaft, camshaft,
pistons, connecting rods, timing components, cylinder head, valve train
components, oil pump, oil pan, and timing covers.
Explain the ways to prelubricate a rebuilt engine.
Reinstall an engine and observe the correct starting and break-in procedures.

INSTRUCTIONAL OUTLINE WITH TEACHING HINTS

I. Torque Principles
A. Elasticity
B. Torque-to-yield (T-T-Y)
C. Thread Repair
II. Gaskets
A. Gasket Materials
B. General Gasket Installation Procedures
C. Cylinder Head Gaskets
1. Bimetal Engine Requirements
D. Manifold Gaskets
E. Valve Cover Gaskets
F. Oil Pan Gaskets

55

56

Chapter 13

III. Adhesives, Sealants, and Other Chemical Sealing Materials

A. Adhesives
B. Sealants
1. General-Purpose Sealants
2. Flexible Sealants
3. Silicone Formed-in-Place Sealants
4. Anaerobic Formed-in-Place Sealants
C. Antiseize Compounds
Hint: Discuss the importance of using oxygen sensorsafe RTV and antiseize
compounds.
IV. Oil Seals
A. Timing Cover Oil Seals
B. Rear Main Bearing Oil Seals
C. Other Seals
Hint: Discuss oil seal burning and emphasize the importance of lubricating
the oil seal lip.
V. Engine Reassembly
A. Installing the Cylinder Head and Valve Train
1. Torque Angle Gauge
B. Timing Belts
C. Adjusting Valves
D. Final Reassembly Steps
1. Install the Timing Cover
2. Install the Vibration Damper
3. Install the Valve Cover
4. Install Oil Pan
5. Install Intake Manifold
6. Prelubrication
7. Install the Thermostat and Water Outlet Housing
8. Install Exhaust Manifold
9. Install Flywheel or Flex Plate
10. Install Clutch Parts
11. Install Torque Converter
12. Install Motor Mounts
VI. Installing the Engine
A. Installing the Engine into a FWD Vehicle
B. Installing an Engine in a RWD Vehicle
C. Starting Procedure
D. Break-In Procedure
E. Relearn Procedures

ANSWERS TO TEXTBOOK REVIEW QUESTIONS

1.
2.
3.
4.
5.

True.
A bolt that has been stretched to its yield point will not return to its original length.
Cylinder head, exhaust manifold, and some intake manifold gaskets
On the threads of bolts exposed to fluids
Whether they cure in the presence or absence of air, and their gap filling ability

Engine Sealing and Reassembly

57

6. b. Most cylinder head bolts are tightened in a sequence that begins in the center, not
on one end as stated.
7. True.
8. b. Torque-to-yield bolts should not be reused. Head bolts that pass through a coolant
passage should be coated with a nonhardening sealer.
9. c. Both procedures are accepted.
10. c. Soft gaskets are used in both applications
11. c. Gaskets should not be reused. Silicone gasket material may be used to replace conventional paper, cork, or cork/rubber gaskets when necessary.
12. d. The cylinder head gasket does not meter oil onto the cylinder walls.
13. False. When the rocker arm is torqued, the plunger in the lifter is properly positioned;
hand priming is not recommended and could damage valve train components.
14. d. Graphite is neither an anaerobic nor an RTV. It is a lubricant.
15. c. Damaged threads on a bolt may sometimes be repaired using a tap and die set. If
the head of the bolt is not against the surface after it reaches the proper torque, it is
too long and should be removed and replaced with a shorter bolt or have a washer
placed under the head of the bolt. The bolt hole should first be reinspected for debris
that may have fallen in during the cleaning process, and a cleaning tap should be used
to clear the hole.
16. d. All of the above
17. b. Rear main seals are not made of RTV.
18. a. Aluminum expands at a greater rate than cast iron, not as stated by Technician B.
19. d. Neither technician is correct. Neither technique is recommended. After the engine
has started, it should be run at about 1,500 rpm until it reaches operating temperature, not at idle speed as stated by Technician A. During the test drive, the vehicle
should only be accelerated from 30 mph (48 km/h) to 50 mph (80 km/h) at least ten
times at full throttle. Some manufacturers of late model engines no longer recommend
a break-in procedure.
20. c. Run a nut over the bolts threads by hand, and if any binding occurs you should
discard the bolt, not tap the nut as stated.

TECH MANUAL
The following procedures are included in Chapter 13 of the Tech Manual:
1. Applying RTV silicone sealant.
2. Adjusting valves on an OHC engine.

ADDITIONAL TEACHING HINTS

Examine various metric and UNS bolts. Identify the size of the bolt head, and the
diameter, length, and thread pitch of each bolt.
Demonstrate impression testing.
Demonstrate RTV, antiseize, Loctite, and other gasket sealers.
Demonstrate engine prelubrication processes.
Demonstrate torque-to-yield bolt tightening.
Demonstrate valve lash adjustment.

58

Chapter 13

ANSWERS TO TECH MANUAL REVIEW QUESTIONS

1. True.
2. If dry nuts are reused, increased thread galling will result each time the nuts are reused
at the same torque.
3. Thread stripping
4. Hard gaskets are made of steel, stainless steel, copper, or a combination of metals with
a compound sandwiched between the metals. A soft gasket is made of cork, rubber, a
combination of cork and rubber, or rubber-coated steel, paper, or other compressible
materials.
5. Aerobic
6. In the absence of air or free oxygen
7. A T-T-Y bolt is tightened just barely into a yield condition. This stretches the bolt to
its near maximum amount without distorting it, providing for maximum clamping
ability.
8. Once the engine is bolted to its motor mounts
9. Tighten to the proper torque and in the order specified by the manufacturer
10. a. rocker arm with adjustable pivots
b. adjustable pushrods
c. rocker arms with adjustable screws
d. adjustable cam followers
11. Make a test run at 30 mph (48 km/h) and accelerate at full throttle to 50 mph (80
km/h). Repeat the acceleration cycle from 30 mph to 50 mph (48 km/h to 80 km/h)
at least ten times.
12. True
13. d
14. Engine will overheat
15. The relearn procedure involves operating the vehicle in a prescribed manner so the
computer learns the present condition of the vehicle. Always follow the manufacturers relearn procedures as outlined in the service manual.

SECTION 2
Answers to ASE Prep Test Questions
1.
2.
3.
4.
5.

c
c
a
c
a

6.
7.
8.
9.
10.

a
c
b
c
a

11.
12.
13.
14.
15.

c
b
b
c
b

16.
17.
18.
19.
20.

a
c
b
b
b