ENGINE REPAIR (A1)
Content Area Questions in Test
Percentage of Test
A. General Engine Diagnosis
17 24%
B. Cylinder Head and Valve Train Diagnosis and
Repair
18 26%
C. Engine Block Diagnosis and Repair 18 26%
D. Lubrication and Cooling Systems Diagnosis and
Repair
9 13%
E. Fuel, Electrical, Ignition and Exhaust
Systems
Inspection and Service 8 11%
Total 70 100%
A.
General Engine Diagnosis (17 questions)
1. Verify the driver’s complaint and/or road test the vehicle;
determine necessary action.
2. Determine if
the no-crank, no-start, or hard starting condition is an ignition system,
cranking system, fuel system, or engine
mechanical problem.
3. Inspect the engine assembly for fuel, oil, coolant, and other
leaks; determine necessary
action.
4. Listen to engine noises; determine necessary action.
5. Diagnose the cause of excessive oil consumption, coolant
consumption, unusual engine
exhaust color, odor,
and sound; determine necessary action.
6. Perform engine vacuum tests; determine necessary action.
7. Perform cylinder power balance tests; determine necessary
action.
8. Perform cylinder compression tests; determine necessary action.
9. Perform cylinder leakage tests; determine necessary action.
B. Cylinder Head and Valve
Train Diagnosis and Repair (18 questions)
1. Remove cylinder heads, disassemble, clean,
and prepare for inspection according to
manufacturers’ procedures.
2. Visually inspect cylinder heads for cracks, gasket surface areas
for warpage, corrosion,
and leakage, and check passage condition.
3. Inspect and test valve springs for squareness, pressure, and
free height comparison;
replace as necessary.
4. Inspect valve spring retainers, rotators, locks, and valve lock
grooves.
5. Replace valve stem seals.
6. Inspect valve guides for wear; check valve guide height and
stem-to-guide clearance;
determine needed repairs.
7. Inspect valves; resurface or replace according to manufacturers’
procedures.
8. Inspect and resurface valve seats according to manufacturers’
procedures.
9. Check valve face-to-seat contact and valve seat concentricity
(runout).
10. Check valve spring installed
(assembled) height and valve stem height; service valve
and spring assemblies as necessary.
11. Inspect pushrods, rocker
arms, rocker arm pivots, and shafts for wear, bending,
cracks, looseness, and blocked oil passages; repair or replace
as required.
12. Inspect and replace
hydraulic or mechanical lifters/lash adjusters.
13. Adjust valves on engines
with mechanical or hydraulic lifters.
14. Inspect and replace
camshaft drives (includes checking gear wear and backlash,
sprocket and chain wear, overhead cam drive sprockets, drive
belts, belt tension,
tensioners, and cam sensor components).
15. Inspect and measure
camshaft journals and lobes.
16. Inspect and measure
camshaft bore for wear, damage, out-of-round, and alignment;
repair or replace according to manufacturers’ specifications.
17. Time camshaft(s) to
crankshaft.
18. Reassemble and install
cylinder heads and gaskets; replace and tighten fasteners
according to manufacturers’ procedures.
C. Engine Block Diagnosis and
Repair (18 questions)
1. Disassemble engine block and clean and
prepare components for inspection.
2. Visually inspect engine block for cracks,
corrosion, passage condition, core and
gallery plug holes, and surface warpage;
determine necessary action.
3. Inspect and repair damaged threads where
allowed; install core and gallery plugs.
4. Inspect and measure cylinder walls; remove
cylinder wall ridges; hone and clean
cylinder walls; determine need for
further action.
5. Visually inspect crankshaft for surface
cracks and journal damage; check oil passage
condition; measure journal wear; check crankshaft sensor
reluctor ring (where
applicable); determine necessary action.
6. Inspect and measure main bearing bores and cap alignment and
fit.
7. Install main bearings and crankshaft; check bearing clearances
and end play;
replace/retorque bolts according to
manufacturers’ procedures.
8. Inspect camshaft bearings for unusual wear;
remove and replace camshaft bearings;
install camshaft, timing chain, and gears; check end play.
9. Inspect auxiliary (balance, intermediate, idler, counterbalance,
or silencer) shaft(s)
and support bearings for damage and wear; determine necessary
action.
10. Inspect, measure, service,
repair, or replace pistons, piston pins, and pin bushings;
identify piston and bearing wear patterns that indicate
connecting rod alignment
problems; determine necessary action.
11. Inspect connecting rods
for damage, alignment, bore condition, and pin fit; determine
necessary action.
12. Inspect, measure, and
install or replace piston rings; assemble piston and connecting rod;
install piston/rod assembly; check bearing clearance and
sideplay; replace/retorque
fasteners according to manufacturers’ procedures.
13. Inspect, reinstall, or
replace crankshaft vibration damper (harmonic balancer).
14. Inspect crankshaft flange
and flywheel mating surfaces; inspect and replace crankshaft
pilot bearing/bushing (if applicable); inspect
flywheel/flexplate for cracks and wear
(includes flywheel ring gear); measure flywheel runout;
determine necessary action.
15. Inspect and replace pans, covers, gaskets, and seals.
16. Assemble engine parts using formed-in-place (tube-applied)
sealants or gaskets.
D. Lubrication and Cooling
Systems Diagnosis and Repair (9 questions)
1. Perform oil pressure tests; determine
necessary action.
2. Disassemble, inspect, measure, and repair
oil pump (includes gears, rotors, housing, and
pick-up assembly), pressure relief devices, and pump drive;
replace oil filter.
3. Perform cooling system tests; determine necessary action.
4. Inspect, replace, and adjust drive belts, tensioners, and
pulleys.
5. Inspect and replace engine cooling and heater system hoses.
6. Inspect, test, and replace thermostat, bypass, and housing.
7. Inspect coolant; drain, flush, and refill cooling system with
recommended coolant;
bleed air as required.
8. Inspect and replace water pump.
9. Inspect, test, and replace radiator, heater core, pressure cap,
and coolant recovery
system.
10. Clean, inspect, test, and
replace fan (both electrical and mechanical), fan clutch, fan
shroud, air dams and cooling related temperature sensors.
11. Inspect, test, and replace
auxiliary oil coolers.
E. Fuel, Electrical, Ignition,
and Exhaust Systems Inspection and Service (8 questions)
1. Inspect, clean or replace fuel and air
induction system components, intake manifold, and
gaskets.
2. Inspect, service or replace air filters, filter housings, and
intake ductwork.
3. Inspect turbocharger/supercharger; determine necessary action.
4. Test battery; charge as
necessary.
5. Remove and replace starter.
6. Inspect and replace positive crankcase ventilation (PCV) system
components.
7. Visually inspect and reinstall primary and secondary ignition
system components;
time distributor.
8. Inspect, service, and replace exhaust manifold.