Part I: ENGINE CONSTRUCTION, DIAGNOSIS, DISASSEMBLY, AND INSPECTION. 1. ENGINE OPERATION. Simple Engine. Four-Stroke Engine Operation. Cylinder Arrangement. Valve Train. Cylinder Block. Front-Wheel Drive. Engine Classifications. Combustion Chamber Designs. Firing Order. Types of Cooling Systems. Ignition Types. Study Questions. ASE-Style Review Questions. 2. ENGINE SHOP SAFETY. General Shop Health and Safety. Hazardous Materials. Safety Test. 3. DIAGNOSING ENGINE PROBLEMS. Diagnosing Problems Before an Overhaul. Oil Consumption. Fuel Mixture Problems. Compression Loss. Engine Noises. Oil Pressure Problems. Cooling System Problems. Electronic Failures/Engine Damage. Study Questions. ASE-Style Review Questions. 4. ENGINE REMOVAL, DISASSEMBLY, INSPECTION, AND IN-CHASSIS REPAIRS. Shop Manuals. Engine Removal. Engine Disassembly. Ordering Parts. Major Engine Repair - Engine in the Vehicle. Study Questions. ASE-Style Review Questions. 5. CLEANING THE ENGINE. Cleaning Methods. Cleaning the Inside of the Engine. Study Questions. ASE-Style Review Questions. 6. MEASURING. Metric System. Measuring Tools. Precision Measuring Tools. Study Questions. ASE-Style Review Questions. Part II: THE BREATHING SYSTEM. 7. CYLINDER HEAD: PARTS AND SERVICE. Head Disassembly. Carbon Removal. Crack Inspection. Crack Repair. Valve Guide Inspection. Valve Guide Repair. Valve Guide Seals. Resurfacing Heads. Study Questions. ASE-Style Review Questions. 8. CYLINDER HEAD: SPRINGS, VALVES, AND VALVE SEATS. Valve Springs. Push Rods. Rocker Arms. Valves and Valve Service. Valve Seats and Service. Reassembling the Head. Study Questions. ASE-Style Review Questions. 9. CAMSHAFTS, LIFTERS, TIMING BELTS AND CHAINS. Camshaft. Hydraulic Lifters and Lash Adjusters. Hydraulic Lifter Operation. Roller Cam and Lifters. Cam Drives. Timing Drive Maintenance. Timing the Cam to the Crank. Timing Belts. Timing Belt Replacement. Study Questions. ASE-Style Review Questions. Part III: CYLINDER BLOCK ASSEMBLY. 10. CYLINDER BLOCK - INSPECTION AND SERVICE. Cleaning the Block. Oil and Water Plugs. Main Bearing Caps. Main Bearing Bore Alignment. Decking the Block. Inspecting Cylinder Bores. Deglazing Cylinders. Reboring Cylinders. Honing Cylinders to Size. Chamfering the Cylinder. Cylinder Sleeves. Lifter Bores. Final Block Preparation. Study Questions. ASE-Style Review Questions. 11. CRANKSHAFT, BEARINGS, AND ENGINE BALANCING. Crankshaft Design. Crank End Thrust. Checking Crank Condition. Bearing Inserts. Engine Balancing. Study Questions. ASE-Style Review Questions. 12. PISTON, RINGS, AND CONNECTING ROD. Pistons. Piston Rings. Connecting Rods. Wrist Pins. Study Questions. ASE-Style Review Questions. 13. LUBRICATION SYSTEM. The Lubrication System. Oil. Oil Pumps. Priming the System. Oil Filters. Filter Bypass System. Crankcase Ventilation. Study Questions. ASE-Style Review Questions. 14. COOLING SYSTEM. The Cooling System. Cooling System Circulation. Water Pump. Belts. Thermostat. Thermostat Bypass. Radiators. Study Questions. ASE-Style Review Questions. Part IV: ENGINE REPAIR AND REASSEMBLY. 15. ENGINE HARDWARE: FASTENERS, THREAD REPAIR, AND GASKETS. Characteristics of Fasteners. Bolt Stretch. Torque and Friction. Bolt Failures. Drill Bits. Taps and Threads. Repairing Broken Fasteners. Flared Lines. Gaskets. Gasket Sealer. Seals. Study Questions. ASE-Style Review Questions. 16. REASSEMBLY AND STARTING. Warranty. Reassembly. Completion of Assembly. Engine Installation. Engine Starting and Initial Break-in of the Camshaft. Final Inspection and Cleaning. Study Questions. ASE-Style Review Questions. Part V: ENGINE POWER AND PERFORMANCE. 17. ENGINE BREATHING: INTAKE AND EXHAUST SYSTEMS. Intake and Exhaust Manifolds. Engine Modifications to Improve Air Flow. High-Performance Valves and Valve Springs. Exhaust Manifolds and Headers. Mufflers. Study Questions. ASE-Style Review Questions. 18. TURBOCHARGERS AND SUPERCHARGERS. Supercharging and Engine Power. Turbochargers. Turbo Boost and Lag. Supercharger Pressure Control. Variable Geometry Turbochargers. Aftercooler/Intercooler. Turbocharger Troubleshooting. Turbocharger Damage Diagnosis. Belt-driven Superchargers/ Blowers. Pressure Relief Valves. Dynamic Superchargers. Blower Problems. Study Questions. ASE-Style Review Questions. 19. PRODUCING POWER: VALVE TIMING, POWER AND TORQUE MEASUREMENT. Camshaft and Engine Performance. Checking Camshaft Timing. Camshaft Phasing, Lobe Centers, and Lobe Spread. Variable Valve Timing. Active Fuel Management/Displacement on Demand. Power and Torque. Measuring Torque and Horsepower. Dynamometer Safety Concerns. Study Questions. ASE-Style Review Questions.
