Snap On Engine Repair PDF

AS:
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Welcome to FAST PASE~

the exciting video-based
program that will help you
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National Institute for
Automotive Service Excellence
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1989, 1994 Aspire, Inc. All Rights Reserved. Printed in U.SA.
Engine Repair
The goal of the FAST PASEID series is to develop your ASE test taking
skills which will enhance the technical knowledge you already possess.
There are presently seven videotape /workbook programs available

including:
Introduction to Test Taking
Engine Repair (Test A1)
Suspension and Steering (Test A4)
Brakes (Test A5)
Electrical Systems (Test A6)
Heating and Air Conditioning (Test A7)
Engine Performance (Test AB)
Tills program will give you some practice answering "ASE-type" ques-
tions on an "ASE-type" answer sheet. It will also review the types of
questions asked, with an explanation of how to approach each type.
The objective is for you to avoid some of the common errors made by
technicians in these areas when taking the actual ASE tests.
'Task Sheets" are included in the support package which cover the
"Key Vocabulary" and specific test procedures associated with each
task. These are used in all of the FAST PASE programs and are a
good way to lock various procedures and vocabulary words in your
memory. While they cover several of the more important areas of each
subject, they are not all inclusive. For a complete list of tasks included
in each of the ASE tests, refer to the official "ASE Preparation Guide"
booklet. Be sure to take the time to view this valuable booklet. You can
order a Prep Guide or Registration Booklet from ASE, 13505 Dulles
Technology Drive, Hemdon, VA 22071-3415.
t,' \
~~~~:the,.videotape, and watch

the first section, explaining
how to use this program.
Page 2 1989, 1994 Aspire, Inc.

Read this page...
. . .before you attempt the Mini-Test!
This Is a self-paced program. There are a few things you should keep
in mind while using this program:
Self-paced means just that - you set the pacing. Go as quickly
or slowly as you wish. Don't feel pressured to move any faster
than you want to.
If you haven't watched the "Introduction to Test Taking Skills"
program yet, we suggest you do that first, before using this
program. It provides in-depth explanations on how to complete
the demographic information [your name, address, etc.) on the
ASE answer sheet, and gives you some valuable tips on how to
approach the various types of questions on the ASE tests.
Have a sharp #2 pencil ready.
Remove the answer sheet from the back of your book, and fill in
blocks A, B and C.
Watch for these icons:

~ This tells you to return to the videotape and watch the next
~ section.
This provides you with instructions for the workbook.

'
Now, turn the page

ar1d take the Mini~Test.
1989, 1994 Aspire, Inc. Page 3

Engine Repair
Mini-Test

Question 1
A compression test shows all cyUnders have low compression.
Which of the following is the most Ukely cause?
(A) Wom valve guides
(B) SUpped timing chain
(C) Intake manifold leak
(D) Carbon buildup on pistons
Question 2
A technician is doing a compression test.
On one cylinder, compression is low on the first puff, then steadlly
increases to normal.
Technician A says wom piston rings could be the cause.
Technician B says a burnt valve could be the cause.
Who is right?
(A) Aonly (C) Both A and B
(B) B only (D) Neither A nor B
Question 3
An engine with a manual transmission has a heavy knocking
sound at idle. When the clutch pedal is depressed, the noise goes
away. What is the most Ukely cause?
(A) Rod bearing knock
(B) Excessive piston to cylinder clearance
(C) Excessive wrist pin clearance
(D) Wom crankshaft thrust bearing
Question 4
An engine is running at idle, with a vacuum gauge attached. En-
gine vacuum level is good; however, the needle has a regular,
downscale fluctuation
Technician A says there may be an intake manifold vacuum leak.
Technician B says one or more cylinders may have a compression
problem.
Who is right?
Page6 1989, 1994 Aspire, Inc.
Question 5
What measurement reading is

indicated on this micrometer?
(FIG. 1)
(A) .0515
(B) .565 FIG.1
(C) .590
(D) .615
Question 6
The gauge setup shown (FIG. 2) is
used to check:
(A) valve guide clearance.

(B) valve face angle.
(C) valve face runout.
(D) valve stem installed height.
Question 7
When grinding valve face and seat angles, which of the following
is true?
(A) The valve face angle and the valve seat angle should always be
identical.
(B) Some engine designs use a %0 to 1 o difference between the
valve face and seat angle.
(C) The valve seat is always groWld to a 35 angle, then the face is
ground to match.
(D) None of the above.

Question 8
The measurement shown (FIG. 3) is greater

than the specification.
Technician A says this could be caused
from cutting the valve seat and face.
Technician B says a valve shim can be
added to bring the measurement to
specification.
Who is right? FIG. 3

Question 9
Valve overlap indicates the degrees of crankshaft rotation in

which:
(A) Both valves are open.

(B) Each valve is open.
(C) Both valves are closed.
Question 10
Two technicians are discussing camshaft bearings.

Technician A says you can remove camshaft bearings to inspect
them, then reinstall them.
Technician B says you can measure cam bearing clearance by
measuring the camshaft journal with an outside micrometer, and
the bearing with an inside micrometer, and then subtract the
difference.
Who is right?

PageS 1989, 1994 Aspire, Inc.

Question 11
What does the mustration

shown (FIG. 4) indicate?
(A) Excessive clearance at the

thrust bearing
(B) Not enough clearance at
# 1 rod bearing
(C) Excessive clearance at #3
rod bearing
(D) The setup shown is not a FIG. 4
valid test.
Question 12 A
Mter examining the crankshaft

main bearings shown (FIG. 5):
Technician A states that bearing
C controls crankshaft endplay.
Technician B states that only
the lower bearings are shown. FIG. 5
Who is right?


Question 13
In the illustration shown above (FIG. 6), a technician

is measuring points A and B with a micrometer.
What is he measuring?
(A) rod journal diameter

(B) bearing clearance
(C) rod endplay FIG.6
(D) journal taper
Question 14
What is the technician measuring in the

illustration shown above (FIG. 7)?
(A) piston-to-cylinder wall clearance

(B) cylinder taper
(C) ring end gap
FIG. 7
Question 15
All of the following are true about the use of plastigage, except:
(A) The less clearance there is, the more it will crush.
(B) One size is used for all applications.
(C) The engine should not be rotated with plastigage installed.
(D) Both surfaces should be free of on and dirt.
Question 16
A crankshaft is being reconditioned. The rod bearing journals are

being cut .010". What size rod bearings should a technician use
when assembling the engine?
(A) Standard size

(B) Standard size with a shim
(C) .010" oversized
(D) .010" undersized

l
Question 17
When installing a piston, the notch on top of the piston should

face:
(A) the direction of crankshaft rotation.

(B) the rear of the engine.
(C) the front of the engine.
(D) Either B or C.
Question 18
Two technicians are discussing checking an on pump.

Technician A says you should measure the clearance between the
on pump gears and the housing.
Technician B says you should measure the clearance between the
on pump gears and the pump cover.
Who is right?

Question 19
Two technicians are discussing an engine that tends to overheat

only when sitting in traffic.
Technician A says a faulty coolant fan clutch could be the cause.
Technician B says the thennostat could be stuck closed.
Who is right?


Question 20
A vehicle has returned to the shop for the third time with blown
Ueaking) valve cover gaskets:
Technician A says excessive on pressure could be the cause.
Technician B says a clogged PCV system could be the cause.
Who is right?

Question 21
When performing a cylinder balance

test, cylinders 1, 4, 6 and 7 show very
little RPM drop when defeated (FIG. 8).
Technician A says carburetor imbal-
ance could be the cause.
Technician B says a cracked distributor
cap could be the cause.
Who is right?
FIG. a
Question 22
When adjusting valves:

Technician A says, with hydraulic valves, tighten the adjustment
screw until there is zero valve lash.
Technician B says mechanical Ufters can be adjusted with the
engine cold or hot.
Who is right?


Question 23
A reconditioned head is being installed on a block:

Technician A says to tighten the head bolts with a torque wrench,
beginning with the outer corners of the head.
Technician B says to look up the torque specification and torque
method, which differs from engine to engine.
Who is right?

Question 24
An oily sludge is present in the neck of a radiator:

Technician A says a blown head gasket or cracked head is indi-
cated.
Technician B says check the transmission fluid; the transmission
cooler could be leaking.
Who is right?

Question 25
A stretched timing chain will have the following effect on valve

events:
(A) Intake valve will open earlier and close later, causing higher
compression.
(B) Intake valve will open later and close later, causing lower
compression.
(C) Both A and B.
(D) Neither A nor B.

Engine Repair
Workbook

Engine Repair
Welcome back to FAST PASE~ Before going any further, check your
answers against the key shown here.
Answer Key
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If you did well, and found the questions on the Engine Repair Mini-
Test easy to answer, congratulations; you have a strong grasp of the
subject and this program will serve mainly as a refresher before you
take the test. If, however, you found the questions difficult to answer,
this program should be used as a study guide to point out areas of this
subject that you are not that strong in. When you discover a weak
area, study the task sheets covering that area or check the recom-
mended reference material for a detailed description of the subject.
Questions not analyzed in the video will be covered in this workbook.
Start the videotape, and follow

along in your book. Any
questions that aren't covered
in the tape will be covered in
the workbook.

Engine repair, as with some of the other test topics covered in this
series, involves the mastering of many disciplines. Mechanical repair
disciplines, such as close tolerance measuring techniques, diagnostic
test interpretation, and proper machining operations are the least
understood by technicians for this topic and are the subjects we will
emphasize during this program.
Question 1
A compression test shows all cylinders have low compression.

Which of the following is the MOST LIKELY cause?
(A) Worn valve guides

(B) Slipped timing chain
(C) Intake manifold leak
(D) Carbon buildup on pistons
Analysis:
Tilis straight pick type of question has one of those phrases to look out
for, MOST LIKELY. You were to pick the response that best answers
the question. Looking at the possibilities, we know that an intake mani-
fold leak would have no bearing on a compression test for several rea-
sons, the most notable being the throttle plates should be blocked open
during the test, allowing as much air as possible to fill the cylinder. An
intake manifold leak would not alter the air entering the engine in this
case. Carbon buildup on the pistons would actually increase compres-
sion pressure, because the carbon displaces a portion of the combustion
chamber volume and when the air/fuel charge is compressed during
the compression stroke, it's compressed into a smaller pocket. When a

gas is compressed into a smaller volume, the pressure exerted by the
gas increases. Worn valve guides are not a usual source of low compres-
sion in all cylinders because it's unlikely that all the guides will wear
evenly in an engine. But a slipped timing chain will cause unifonn
low compression in all the cylinders, due to altered valve timing.
The correct answer is response B - slipped timing chain.
Question 2
A technician is doing a compression test.

On one cyllnder, compression is low on the first puff, then
steadily increases to normal.
Technician A says worn piston rings could be the cause.
Technician B says a burnt valve could be the cause.
Who is right?

Analysis:
This comparative statement tests your ability to interpret the results of a
particular diagnostic test. Both technicians came to different conclu-
sions from the same test results, so chances are they can't both be
correct. Let's look at the described test and detennine if either
technician's statement is true. Observing the first puff during a com-
pression test can give us very useful diagnostic information about cylin-
der seal. Small leaks, such as those found with wom piston rings or
light cylinder wall scoring will not produce high compressions on the
first compression cycle, but will produce satisfactory results on subse-
quent cycles due to increased cylinder sealing efficiency caused by
increased RPM and hydraulic sealing, overcoming the slight leakage.
A low first puff, typically less than 50% of the forth or fifth puff, can
indicate wom rings. Technician .A:s statement is true, so responses B
and D can be eliminated as the correct answer to the question. A
burnt valve, as suggested by Technician B, is a large leak in the cylin-
der seal, which will cause low compression on the first compression
cycle and low compression on the subsequent compression cycles. In
this case, the increased engine speed does not increase sealing efil-

ciency. Technician B's statement is false. Now we can eliminate re-
sponse C as the correct answer, leaving response A- for A only- as
the correct answer to the question.
Remember to follow proper procedures when performing a compres-
sion test.
Bring the engine to normal operating temperature.
Stop the engine and disable the ignition system.
Remove the air cleaner.
Block open the throttle plates.
Remove all the spark plugs.

Don't forget to "read," or examine the plugs while they're out.
Plugs can tell you a lot about engine condition.
Install the gauge in each cylinder and crank the engine

at least four revolutions per cylinder to obtain the highest read-
ing.
Record the readings on the first puff and final puff, and compare
to manufacturer's specs.
Consistent cranking speed is very important to accurate compression

testing. if the engine cranks slowly, test the battery and starting sys-
tems before continuing the test
Engine Noises
Interpreting engine noises is also an important diagnostic procedure.
Rurming noises can be caused by lots of different engine failures, as
well as auxiliru:y component failures. Reaction of failed components to
changes in engine operating modes can help us pinpoint the failed
components. Auxiliru:y components such as water pumps, power
steering pumps and altemators, can be quickly isolated by belt re-
moval. Isolating intemal engine noises involves a few more tricks, such
as grounding spark plug wires, loading or unloading the engine and
determining whether the noise is present when the engine is cold,
warm or both.

Question 3
An engine with a manual transmission has a heavy knocking

sound at idle. When the clutch pedal is depressed the noise goes
away. What is the MOST LIKELY cause?
(A) Rod bearing knock

(B) Excessive piston-to-cylinder clearance
(C) Excessive wrist pin clearance
(D) Wom crankshaft thrust bearing
Analysis:
Familiarity with the "noise prints" of the responses will help us quickly
identify the correct response to this simple choice question.
A worn rod bearing knock can be eliminated as the cause of our prob-
lem. Rod bearing knocks are most noticeable off idle, and increase
with engine speed. They become louder when the engine is unloaded,
and usually disappear when the spark is eliminated from the affected
cylinder.
Excessive piston-to-cylinder clearance can also be eliminated. This
failure would produce a hollow sound, usually under a load, that
diminishes as the engine warms up.
Piston wrist pins with excessive clearance, as stated in response C,
produce a sharp, double knock sound, which is louder when the engine
is cold. In addition, grounding the spark plug of the affected cylinder
would eliminate the knock, so this response can also be eliminated.
The crankshaft thrust bearing keeps the crankshaft from moving end
to end. When this bearing develops wear on the thrust surfaces of the
bearing, the crankshaft can move end to end, creating a noise. When
the clutch pedal is depressed, it prevents the crankshaft from moving,
eliminating the knocking noise. The correct answer, therefore, is D -
worn crankshaft thrust bearing.

Question 4
An engine is running at idle with a vacuum gauge attached. En-

gine vacuum level is good; however, the needle has a regular,
downscale fluctuation.
Technician A says there may be an intake manifold vacuum leak.
Technician B says one or more cylinders may have a compression
problem.
Who is right?

Analysis:
A vacuum gauge is still a very important tool for diagnosing engine
problems. Before we answer this comparative statement, let's review
how engine vacuum is produced.
As each piston moves downward on its intake stroke, with the throttle
closed at idle, vacuum is created in the intake manifold. In a cylinder
which has low compression, due to a leak in the cylinder seal, such as
a valve or ring, when the piston moves downward on its intake stroke,
air would also enter through the cylinder seal leak. The vacuum cre-
ated by that cylinder would be less than the vacuum created by the
other cylinders, so the vacuum gauge needle would drop regularly
each time that cylinder began its intake stroke.
Technician A's statement then is false. If the engine had an intake
manifold vacuum leak, engine vacuum would be low, but the needle
would be steady.
Technician B's statement is true. If one or more of the cylinders had a
leak in the cylinder seal, the vacuum gauge needle would drop on the
intake stroke of those cylinders. The correct answer is response B, for
Technician B only.
1989. 1994 Aspire. Inc. Page 25

Question 5
What measurement reading is indicated on this micrometer?

.500
(A) .0515" .025
(B) .565" .025
(C) .590" .025
(D) .615" + .015
.590
Analysis:
To rebuild an engine properly, you must be able to use many measur-
ing instruments and gauges. As a rule, the tools must be capable of
reading accurately to one thousandth of an inch, which is written as
.001. Though we will discuss how to read a micrometer in this ques-
tion, you should be familiar with other measuring instruments, such
as dial indicators, bore gauges, vernier calipers and feeler gauges.
To use the micrometer, place the object being measured between the
anvil and spindle measuring surfaces. 1\nn the thimble until the
spindle contacts the object. The dimension of the object is then found
from the micrometer by looking at the graduations on the sleeve and
thimble. Each line on the sleeve indicates 25 thousandths of an inch.
Evecy fourth line is numbered, so between each number is 100 thou-
sandths of an inch. Since each revolution of the thimble moves the
measuring face one graduation on the sleeve, one revolution of the
thimble equals 25 thousandths of an inch travel.
The thimble is marked with 25 graduations, each representing one
thousandth of an inch. To obtain the total measurement, start with
highest exposed number on the sleeve, then add .025 for each addi-
tional graduation to the right of the number on the sleeve, and finally
add the additional number indicated on the thimble. In this case, the
number 5 is exposed on the sleeve, as well as 3 additional lines. So far
we have 575 thousandths of an inch. We see an additional 15 thou-
sandth of an inch on the thimble, for a total measurement of 590
thousandths of an inch, which would be written .590". So response C
is the correct answer to the question.

Question 6
The gauge setup shown is used to check:
(AJ valve guide clearance.

(B) valve face angle.
(C) valve face runout.
(D) valve stem installed height.
Analysis:
Engine valves operate in an extremely tolerance-critical world, and as
such should undergo very close scrutiny during cylinder head over-
haul. There are several different gauge setups and measurements
necessary to do the job right. For instance, the setup shown checks
valve guide clearance as mentioned by response A. Valve guide clear-
ance is the fit of the valve in its guide. This is very important for proper
valve seating and oil control. With the valve held off the seat, while
moving the valve back and forth, the dial indicator will show valve
guide wear. Play in excess of as little as 3 thousandths of an inch
could mean valve or guide seiVicing is necessary. The rest of the re-
sponses listed in the question are measurements having to do with
valves which you should be aware of.
Valve face angle, as mentioned in response B, is determined when
the valve is cut or ground.
Valve face runout, as mentioned in response C, is measured with a
special fixture. Runout is measured by rotating the valve in the fixture
and watching the indicator.
Special fixtures are also available for measuring valve stem straight-
ness.
Valve stern installed height, as mentioned in response D, and valve
spring installed height, which is not mentioned, are two important
measurements that must be taken whenever a valve face or valve seat
is cut. If a valve face or seat is cut, the valve will move further into the
head. The valve stem will now sit higher in the cylinder head. Upon
valve train assembly, the valve clearance may not be sufficient and the
valve will not close. Also, rocker arm operating angle will be incorrect,
causing side loading and premature wear of the valve and guide. The
solution is to trim the required amount of material from the top of the
valve stem.

Valve spring installed height should also be checked whenever a valve
face or seat is cut. The increase in valve stem installed height will
increase the valve spring installed height. This will decrease the valve
spring tension. Valve springs must be compressed a specified amount
to provide proper tension and proper valve function. Valve spring
installed height can be checked by measuring the springs height or
length when it is installed on the cylinder head.
Spring shims can be used to correct excessive spring height, but don't
use shims to compensatefor weak springs.
Before assembly, the springs should always be checked for squareness
and proper tension.
Question 7
When grinding valve face and seat angles, which of the following
is TRUE?
(A) The valve face angle and the valve seat angle should always be
identical.
(B) Some engine designs use a ~o to 1 o difference between the
valve face and seat angle.
(C) The valve seat is always ground to a 35 angle, then the face is
ground to match.
Analysis:
There are two basic types of fit used when designing cylinder head
valve angles: parallel fit and interference fit. Factors such as valve
operating temperature, heat transfer, speed and airflow characteristics
must be taken in to consideration.
Parallel ftt means the valve face angle and the valve seat angle are
parallel or identical.
Interference :ftt means there is a half to one degree difference between
the valve face angle and valve seat angle. For instance, if the valve face
is ground to 45, the valve seat would be ground to 46. Because of the
rapid movement of the valves at high speed and high engine tempera-
tures, which cause the valves to flex and distort, the interference angle
is used quite often.

Looking at our responses we see the correct answer, therefore, is
response B - some engine designs use a ~o to 1o difference between
the valve face and seat angle.
Other valve measurements, such as valve margin and seat width,
must also be considered when grinding or cutting valves and seats.
When measuring and adjusting seat width and location, procedures
such as topping or throating may be necessary. Be sure to review
these procedures before taking the ASE engine repair test.
Question 8
The measurement shown is greater than the specification.

Technician A says this could be caused from cutting the valve
face and seat.
Technician B says a valve shim can be added to bring the meas-
urement to specification.
Who is right?

Analysis:
The valve spring installed height is being measured in this illustration.
When a valve face or its seat is cut, the valve will sit higher in the
cylinder head. When the spring is installed in the cylinder head, it will
not be compressed as much as it should. This could result in the
valves floating at higher RPM. The solution is to place a shim under
the valve spring to restore it to the proper installed height. Valve shims
come in different sizes and thickness to fit many applications. The
correct answer is response C -both A and B.

Question 9
Valve overlap indicates the degrees of crankshaft rotation in

which:
(A) both valves are open.

(B) each valve is open.
(C) both valves are closed.
Analysis:
Valve overlap refers to the number of degrees of crankshaft rotation
when both valves are open at the same time.
The exhaust valve will remain open a small amount of time after the
piston reaches top dead center, at the end of the exhaust stroke. Even
though the piston starts moving downward on the intake stroke, ex-
haust will continue to flow out of the cylinder, due to its momentum.
The intake valve, however, is also starting to open at this time. The
fresh air/fuel charge will enter the cylinder, due to the momentum of
the air/fuel mixture m the intake manifold. This overlap period helps
to purge the exhaust gases remaining in the cylinder. Also, at higher
engine speeds, when the actual time of the valve events occur very
rapidly, volumetric efficiency is increased by packing the maximum
amount of fresh charge in the cylinder.
Looking at our question, you will see the correct answer is response A,
describing proper valve position during valve overlap.

Question 10
Two technicians are discussing camshaft bearings.

Technician A says you can remove camshaft bearings to inspect
them, then reinstall them.
Technician B says you can measure cam bearing clearance by
measuring the camshaft journal with an outside micrometer and
the bearing with an inside micrometer, and then subtract the
difference.
Who is right?

Analysis:
When rebuilding an engine or replacing the camshaft, you should
always inspect the camshaft bearings. They should be visually in-
spected for signs of wear. If you are not planning on replacing the
bearings, do not remove them from the block or head. Unlike rod and
main bearings, camshaft bearings are pressed in place. Once they are
removed, they may not be reinstalled. If the bearings show no signs of
wear, you can measure the cam bearing clearance by measuring the
camshaft journal with an outside micrometer and the cam bearing
with an inside micrometer. The cam bearing must be measured while
it is in the block. As you can see only Technician B's statement is true.
The correct answer is response B, for B only.

Question 11
What does the illustration shown indicate?
(A) Excessive clearance at the thrust bearing.

(B) Not enough clearance at #1 rod bearing.
(C) Excessive clearance at #3 rod bearing.
(D) The setup shown is not a valid test.
Analysis:
When oil pressure is low but there are no engine noises to indicate the
problem area, and the oil pump checks out OK, the equipment shown
can pinpoint the source of the pressure loss. By connecting pressur-
ized oil to an oil galley, you can see where there is excessive oil flow.
Pay close attention to the rod and main bearings, camshaft bearings,
and the lifter bores.
If the rocker arm shafts are pressurized, remove the valve covers and
view the rocker arm shafts for leakage. This procedure will also help
locate a crack in one of the oil galleys in the block.
Some bearings will show excessive flow when the oil hole in the crank-
shaft matches up with the oil hole in the bearing. Because of this, if a
rod or main bearing shows excessive flow, the crankshaft should be
rotated by hand while performing this procedure.
In the illustration shown, number 3 rod bearing has excessive flow,
indicating excessive clearance. The correct answer, therefore, is re-
sponse C - excessive clearance at #3 rod bearing.

A 8 c
Question 12
After examining the crankshaft main bearings shown:

Technician A states that bearing C controls crankshaft endplay.
Technician B states that only the lower bearings are shown.
Who is right?

Analysis:
While the crankshaft bearings support the crankshaft, bearing C also
keeps it from moving end to end. Technician A's statement, therefore,
is true. Technician B's statement, however, is false. The bearings
shown have a hole drilled in the center. This hole is where pressurized
oil is fed to the crankshaft bearings from the oil galleys in the engine
block. These bearings must be installed in the upper half of the block
so the holes in the block line up with the holes in the bearings. There-
fore, the bearings shown are the upper crankshaft bearings. The cor-
rect answer is response A, for A only.
Question 13
In the illustration shown, a technician is mea-

suring points A and B with a micrometer.
What is he measuring?
(A) rod journal diameter

(B) bearing clearance
(C) rod endplay
(D) journal taper

Analysis:
A crankshaft should always be checked before installing new bearings.
It should be inspected for roundness, taper, diameter and finish. The
finish is checked with a visual inspection. Look for ridges, grooves,
scratches etc. Roundness and diameter are checked by measuring the
journal's diameter with a micrometer. Measurements must be taken at
the center of the joumal, in at least two locations, 90 apart. Any
difference between the two readings indicates an out-of-round journal.
Journal taper is checked by measuring the joumal at both ends. Any
difference in the two readings indicates joumal taper. TIIis is what the
technician is measurtng at points A and B. The correct answer is
response D -joumal taper.
Question 14
What is the technician measuring in the

illustration shown?
(A) piston to cyUnder wall clearance

(B) cyUnder taper
(C) ring end gap
(D) none of the above
Analysis:
There are many important measurements that should be made when
replacing pistons and rings. Among them are ring groove wear, piston
clearance, cylinder taper and ring end gap.
Piston clearance is checked by measuring the piston diameter with
an outside micrometer or caliper. Then measure the cylinder bore with
an inside micrometer. Clearance is determined by subtracting the
difference between the two.
An altemate way to measure piston clearance is to place the piston in
the cylinder bore, upside down, and use a feeler gauge to measure the
clearance.
CyUnder taper must also be checked. Cylinder wear varies from top to
bottom, with most wear occurring at the top.

I
J
Cylinder taper may be checked with a cylinder bore gauge, a special

tool which uses a dial indicator, or by measuring the bore at the top
and bottom of the cylinder with an inside micrometer and subtracting
the difference.
Ring groove wear is measured by placing a new ring in the top groove
and measuring the remaining clearance in the groove with feeler
gauges. The top compression ring groove is the one that usually wears.
When piston rings are replaced, each ring must be checked for ring
end gap. After placing the ring in the cylinder, square it up by posi-
tioning it with an inverted piston. Measure the ring end gap with feeler
gauges. Always check the manufacturer's specification for the ring end
gap, but a general specification is .003" to .004" clearance for each
inch of cylinder diameter. If the gap is too large, oversize rings may be
required. If the gap is too small, file the ends of the ring until the
proper clearance is established. Looking at these procedures, you see
the correct answer is response C - ring end gap.
If ring end gap is being checked in wom cylinders, the measurement
should be performed in the lower portion of the cylinder, which tends
to show less wear, thus showing less ring end gap.
New or newly reconditioned cylinders can be checked at the top or
bottom. It is important that the rings have at least the minimum gap,
otheiWise the ring ends may butt, causing ring or cylinder damage.

Question 15
All of the following are true about the use of plastigage, EXCEPT:
(A) The less clearance there is, the more it will crush.
(B) One size is used for all appHcations.
(C) The engine should not be rotated with plastigage installed.
(D) Both surfaces should be free of on and dirt.
Analysis:
Plastigage is a small strip of plastic that is placed between a bearing
and the crankshaft to measure its oil clearance. The less clearance
there is, the more the plastic crushes.
Before using plastigage, both the bearing and the crankshaft must be
cleaned of oil and dirt. After placing a piece of plastlgage across a
bearing surface and torquing the cap in place, carefully disassemble
the bearing and compare the crushed plastlgage to the scale on the
plastigage sleeve.
If the plastigage does not crush, or if it crushes too much, a different
size plastlgage must be used; there are three sizes available. By the
way, the engine must not be rotated while the plastigage is in place or
a false reading will occur. From the discussion of this "except" type of
question, you can see that the false statement- but correct answer-
is response B.

Question 16
A crankshaft is being reconditioned. The rod bearing journals are

being cut .010". What size rod bearings should a technician use
when assembling the engine?
(A) Standard size

(B) Standard size with a shim
(C) .010" oversized
(D) .010" undersized
Analysis:
If a rod bearingjoumal is cut .010", it is now undersized. A .010"
undersized bearing should be used. When the bearing is installed in
the rod, its inside diameter will be .010" smaller than the standard
size. This is why it is referred to as undersize. The correct answer is
response D.
Question 17
When installing a piston, the notch on top of the piston should

face:
(A) the direction of crankshaft rotation.

(B) the rear of the engine.
(C) the front of the engine.
(D) Either B or C.
Analysis:
On a piston with a dome, it is usually obvious which way to install the
piston; however, if the piston has a flat top, it's not as obvious. On
most pistons, the wrist pin is offset from the centerline. This helps
reduce piston slap noise on a cold engine.
The notch on top of a piston should always face the front of the engine
when installed. The correct answer is response C - the front of the
engine.

Question 18
Two technicians are discussing checking an on pump.

Technician A says you should measure the clearance between the
on pump gears and the housing.
Technician B says you should measure the clearance between the
on pump gears and the pump cover.
Who is right?

Analysis:
To check an oil pump you must measure the clearance between the oil
pump gears and the housing, and between the oil pump gears and the
cover. All components must be cleaned before any measurements are
taken. When measuring the clearance between the gears and the
cover, use a straight edge. Always check the manufacturer's specifica-
tion for the acceptable clearances; however, as a rule there should be
between .002" and .005" clearance. If the gears, housing or cover have
any ridges or grooves present, they must be replaced. Any measure-
ments that are taken when there are grooves or scoring present will be
inaccurate. By the way, don't forget to check the pressure regulator
valve. Inspect the valve and seat for a good sealing surface and the
regulator spring for good tension. As you can see from this discussion,
both Technicians A and B are correct. The correct answer is response
C -both A and B.

Question 19
Two technicians are discussing an engine that tends to overheat

only when sitting in traffic.
Technician A says a faulty coolant fan clutch could be the cause.
Technician B says the thennostat could be stuck closed.
Who is right?

Analysis:
Our main clue here is that the engine only overheats when sitting in
traffic. When a vehicle is moving there is plenty of air flow through the
radiator to remove heat. When a vehicle is not moving, the radiator fan
must draw a sufficient volume of air through the radiator to provide
cooling.
Many vehicles use a clutch type coolant fan. These units use a silicone
fluid clutch controlled by a bimetallic thermostatic spring. This clutch
allows the fan to slip when the engine is cold, or when down-the-road
driving supplies enough air to control coolant temperature. This re-
duces engine drag- increasing fuel mileage -when the fan is not
needed. As the thermostatic spring heats up from hot air passing
through the radiator, the clutch reduces the fan's slippage to increase
air flow through the radiator.
A defective coolant fan clutch could allow the fan to slip when the
engine is hot, allowing the engine to overheat when the vehicle is not
moving. Technician ~s statement is true. Looking at Technician B's
statement, if the thermostat was stuck closed, the engine would over-
heat all the time. Technician B's statement is, therefore, false. The
correct answer is response A, for Technician A only.
Now, turn the page, and read

through the rest of the
explanations in your
workbook.
1989. 1994 Aspire. Inc. Page 53
I
I
Question 20
A vehicle has returned to the shop for the third time with blown
(leaking) valve cover gaskets.
Technician A says excessive on pressure could be the cause.
Technician B says a clogged PCV system could be the cause.
Who is right?

Analysis:
By the third time a vehicle retums to a shop for an oil leak from the
valve covers, it's safe to assume the problem is not gasket or work-
manship related. Oil is being forced passed the gaskets. If the engine
has excessive lube oil pressure, oil retention seals, such as the crank-
shaft seals or the oil filter 0-ring would leak, but not the valve cover
gaskets. Technician A's statement is false.
On the other hand, if the PCV system was clogged, the crankcase and
valve covers could become pressuiized by exhaust gases forced past
the pistons into the crankcase (blowby). Tills pressure will be forced
through the crankcase gaskets, such as the dipstick 0-ring or valve
cover gaskets. Because the valve cover gaskets are exposed to the
constant splashing of oil, some oil will be forced through or around the
gaskets by the crankcase pressure. So Technician B's statement is
true. The correct answer to this question is response B, for B only.

Question 21
When performing a cyUnder balance test, cyUnders 1, 4, 6 and 7

show very Uttle RPM drop when defeated.
Technician A says carburetor imbalance could be the cause.
Technician B says a cracked distributor cap could be the cause.
Who is right?
Analysis:
A cylinder balance test indicates the power contribution that each
cylinder contributes to total engine perlormance Low power contribu-
tion by a cylinder can be compression-, air/fuel- or ignition-related.
The obvious clue to the problem with this engine is manifold-related.
The typical "H" type intake manifold (see above illustration) delivers
fuel from one carburetor barrel to four distinct cylinders - 1, 4, 6 and
7; the other carburetor barrel delivers to the other four cylinders- 2,
3, 5and8.
In this question, all cylinders fed by one barrel of the carburetor con-
tribute low power output, suggesting the problem is air/fuel related, as
indicated by Technician A An ignition problem, such as a cracked
distributor cap could cause low power contribution in several cylin-
ders; however, those cylinders would be sequential in firing order, or in
close proximity to each other on the cap. Such is not the case in this
question, so Technician B is incorrect. The correct answer is response
A, for A only.

I
Question 22
When adjusting valves:

Technician A says, with hydraulic valves, tighten the adjustment
screw untn there is zero valve lash.
Technician B says mechanical Hfters can be adjusted with the
engine cold or hot.
Who is right?

Analysis:
Hydraulic valves are adjusted differently from engine application to
engine application; however, some of the techniques are standard for
all. The valve rockers are tightened until there is zero lash, and then
tightened some additional amount. Technician A is, therefore, wrong.
Mechanical lifters are adjusted so that there is a specified valve lash
(gap). This gap will vruy depending upon engine temperature. Specifi-
cations for this gap are usually given at both cold and hot tempera-
tures, so the technician can perlorm this adjustment at either tem-
perature. Technician B's statement is true, so the correct answer is
response B, for B only.
Question 23
A reconditioned head is being installed on a block:

Technician A says to tighten the head bolts with a torque wrench,
beginning with the outer comers of the head.
Technician B says to look up the torque specification and torque
method, which differs &om engine to engine.
Who is right?

Analysis:
Reinstallation of a head requires specific steps for satisfacto:cy perfor-
mance. Bolt torque values and tightening sequence are critical.

Though each engine has a listed bolt tightening sequence, typically the
center most bolts are tightened first, followed by the next bolts closest
to the center, and finally the outer comers. So you can see Technician
A's statement is false. In addition to bolt tightening sequence, the
actual method for tightening the bolts can differ from application to
application. Not only do torque values change, but methods, such as
torque to yield, need to be known for each job. Technician B's state-
ment is correct. The correct answer to the question is response B, for
B only.
Question 24
An oily sludge is present in the neck of a radiator:

Technician A says a blown head gasket or cracked head is indi-
cated.
Technician B says check the transmission fluid; the transmission
cooler could be leaking.
Who is right?

Analysis:
Oil in the radiator indicates that the cooling system and a lubrication
system have come in contact with one another. This can happen at
several points in the typical engine. The most obvious, and usually the
least expensive to repair, is the head gasket. However, cracks in the
water jacket of the cylinder block or cylinder head can allow the cool-
ant and lubricant to mix. One area often overlooked is the radiator
itself. On vehicles with automatic transmissions, often there is an oil
cooler built into the radiator. A hole in between the water cooling
section and the oil cooling section would allow these two fluids to mix,
and should not be overlooked during diagnosis. Both technicians'
statements are true. The correct answer, therefore, is response C, for
both A and B.

I
Question 25
A stretched timing chain will have the following effect on valve

events:
(AJ Intake valve will open earUer and close later, causing higher
compression.
(B) Intake valve will open later and close later, causing lower
compression.
(C) Both A and B
(D) Neither A nor B
Analysis:
When a timing cham stretches, the planned relationship between
camshaft timing and piston timing changes. The action of the cam-
shaft happens later than expected; that is, the intake valve opens later
in the intake stroke, allowing less air/fuel intake during this portion of
the cycle. The intake valve will also close later in the compression
stroke allowing air volume to escape from the valve prior to sealing.
The net result of these two events is less air volume to be compressed,
and lower compression pressure is produced. Response B describes
this relationship, and is the correct answer to this question.

In this program we've looked at questions from some of the content
areas found on the ASE exam. You should be aware that questions on
the following subjects probably will also appear, and you should be
familiar with them as well:
Inspecting and replacing hydraulic or mechanical lifters, camshaft

drives, pushrods, rocker arms and shafts
Identifi.Jing piston and bewing wear patterns to determine con-

necting rod alignment and bewing bore problems
Diagnosing causes of excessive oil conswnption, unusual exhaust

color, odor and sound
Fuel pwnps and controls; inspecting, testing and replacing
Peiforrn.iJlg oil pressure tests and determining needed repairs
Peiforrn.iJlg cooling system tests and detennining needed repairs
If you feel comfortable with this list of subjects and the subjects cov-
ered in this program, you're ready for the ASE test. If not so comfort-
able, review this program and the subject material until you are.
GOOD LUCK!
Now, turn to the Task Sheets

on the next page. Read
through the sheets, and
become familiar with the
information covered there.

I
Engine Repair
Task Sheets

ENGINE REPAIR
GENERAL ENGINE DIAGNOSIS
Task #5 Vacuum Tests (No Load)
.. '-.~
( __I(_E_Y_Vi_O_C_A_B_UL_A_R_Y_ _)
Atmospheric Pressure- Weight of air at sea level, about 14.7 pounds per square inch ( 101 kPa),
decreasing at higher altitudes.
Backpre88ure - A pressure that tends to slow the exit of exhaust gases from the combustion
chamber. Usually caused by restrictions in the exhaust system (catalytic converter, muffier,
collapsed pipes etc.)
Blowby- Combustion gases which leak past the piston rings into the crankcase. Blowby gases are
composed of unburned hydrocarbons (fuel) and water vapor. A positive pressure is formed in
the crankcase.
Manifold Pre88ure - Pressure in the intake manifold; a combination of atmospheric pressure and
manifold vacuum or boost pressure.
Normally Aspirated -An engine that uses normal air pressure to force in its air /fuel mixture (or
normal vacuum to draw in its air/fuel mixture). Not supercharged or turbocharged.
Ported Vacuum -Vacuum immediately above the throttle plates in a carburetor.
Veuturl Vacuum - Low pressure in the venturi of a carburetor. Caused by the speed of airflow
through the venturi.
(PROCEDURESandRESUL TS)
Vacuum Tests
Use vacuum gauge measuring in "inches of mercury" (in. Hg.) scaled 0-30 in. Hg. Connect vacuum
gauge to an intake manifold port common to all cylinders. If engine runs, warm to normal operating
temperature before beginning tests.
Cranking Vacuum
Disable ignition.
Close throttle plates.
Crank the engine and observe and record the vacuum gauge reading,
needle action and cranking speed.
Should be 3-5 inches.
Idle Vacuum
Enable ignition.
Start engine and allow to stabilize.
Observe vacuum gauge reading, and needle action at idle in Park/
Neutral.
Should be between 17- 21 in. Hg with a steady needle.
Idle Throttle Angle Check
Connect vacuum gauge to a ported vacuum gauge port.
Record vacuum (no vacuum should be present)
If more than 1" of vacuum is present, this indicates the throttle plate is open further than it should
for engine idle. This could be compensating for a lean idle mixture or an idle mixture problem.
2500 RPM Vacuum
Disable EGR
Increase engine speed to 2500 RPM and hold for several seconds.
Observe gauge reading and needle action (gauge reading should be equal to or higher than idle
reading).
If vacuum shows a steady drop while holding 2500 RPM a problem is indicated. A restricted
exhaust, timing or fuel mixture problem may be the cause. Further testing is necessary (exhaust
backpressure test. timing advance curve, artificial (propane) enrichment etc.)
If an overactive EGR is suspected (hesitation, surge etc.) road test with EGR disconnected. If
symptom is not present, retest vacuum with the EGR operational and look for an excessive vacuum
decrease when EGR opens. (more than 4 in Hg.)
Piston Ring Test
If idle and cruise vacuum tests check OK, hold engine speed at 2500 RPM. Observe vacuum gauge.
Quickly close throttle and again observe maximum gauge reading. Vacuum should increase 4 - 5 in
Hg. over 2500 RPM reading.
Page 66 1989, 1994Aspire, Inc.

Additional Piston Ring Test
T
Remove PCV valve
I
Remove breather hose to air cleaner
p
Snap accelerate engine while observing for excessive blowby.
s Excessive blowby would help confirm a piston ring problem.
Notes

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Welcome to FAST PASE~

There are presently seven videotape /workbook programs available

~~~~:the,.videotape, and watch

Page 2 1989, 1994 Aspire, Inc.

Watch for these icons:

This provides you with instructions for the workbook.

Now, turn the page

1989, 1994 Aspire, Inc. Page 3

1989, 1994 Aspire, Inc. Page 5

What measurement reading is

(A) valve guide clearance.

1989, 1994 Aspire, Inc. Page 7

The measurement shown (FIG. 3) is greater

(A) Aonly (C) Both A and B

Valve overlap indicates the degrees of crankshaft rotation in

(A) Both valves are open.

Two technicians are discussing camshaft bearings.

(A) Aonly (C) Both A and B

PageS 1989, 1994 Aspire, Inc.

What does the mustration

(A) Excessive clearance at the

Mter examining the crankshaft

(A) Aonly (C) Both A and B

1989, 1994 Aspire, Inc. Page 9

In the illustration shown above (FIG. 6), a technician

(A) rod journal diameter

What is the technician measuring in the

(A) piston-to-cylinder wall clearance

A crankshaft is being reconditioned. The rod bearing journals are

(A) Standard size

Page 10 1989, 1994 Aspire, Inc.

When installing a piston, the notch on top of the piston should

(A) the direction of crankshaft rotation.

Two technicians are discussing checking an on pump.

(A) Aonly (C) Both A and B

Two technicians are discussing an engine that tends to overheat

(A) Aonly (C) Both A and B

1989, 1994 Aspire, Inc. Page 11

(A) Aonly (C) Both A and B

When performing a cylinder balance

When adjusting valves:

(A) Aonly (C) Both A and B

Page 12 1989, 1994 Aspire, Inc.

A reconditioned head is being installed on a block:

(A) Aonly (C) Both A and B

An oily sludge is present in the neck of a radiator:

(A) Aonly (C) Both A and B

A stretched timing chain will have the following effect on valve

1989, 1994 Aspire, Inc. Page 13

1989, 1994 Aspire, Inc. Page 15

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(~) (~) 1 . ~) (! II (~?) (~?) (B) (I?) () /~) I '(J lJ (~) (J I. (~ /)

Start the videotape, and follow

Page 16 1989, 1994 Aspire, Inc.

A compression test shows all cylinders have low compression.

(A) Worn valve guides

1989, 1994 Aspire, Inc. Page 17

A technician is doing a compression test.

(A) Aonly (C) Both A and B

1989, 1994 Aspire, Inc. Page 19

Bring the engine to normal operating temperature.

Stop the engine and disable the ignition system.

~~ f~.~r&~ ~ . ~~~.] fl l f!@ ~.~~~1r.~t.~l 1f '~l@ ~~.~il