ENGINE REPAIR (A1)

NATEF TASK LIST

The following tasks have been determined by the National Automotive Technicians Education Foundation (NATEF), a part of the National Institute for Automotive Service Excellence (ASE), to be included in the teaching of this subject area. Priority one (P-1) items are the most important followed by P-2 and P-3 items.

· 95% of P-1 must be taught

· 80% of P-2 must be taught

· 50% of P-3 must be taught

For every task in Engine Repair, the following safety requirement must be strictly enforced:

Comply with personal and environmental safety practices associated with clothing; eye protection; hand tools; power equipment; proper ventilation; and the handling, storage, and disposal of chemicals/materials in accordance with local, state, and federal safety and environmental regulations.

A. General Engine Diagnosis; Removal and Reinstallation (R & R)

P-1:

1. Verify and interpret engine concern; determine necessary action.

2. Perform engine vacuum tests; determine necessary action.

3. Perform cylinder power balance tests; determine necessary action.

4. Perform cylinder compression tests; determine necessary action.

5. Perform cylinder leakage tests; determine necessary action.

P-2:

1. Inspect engine assembly for fuel, oil, coolant, and other leaks; determine

necessary action.

P-3:

1. Diagnose engine noises and vibrations; determine necessary action.

2. Diagnose the cause of excessive oil consumption, unusual engine exhaust color, odor, and sound; determine necessary action.

3. Remove engine (front-wheel drive); prepare for disassembly.

4. Reinstall engine (front-wheel drive).

5. Remove engine (rear-wheel drive); prepare for disassembly.

6. Reinstall engine (rear-wheel drive).

B. Cylinder Head and Valve Train Diagnosis and Repair

P-1:

1. Adjust valves (mechanical or hydraulic lifters).

2. Inspect and replace timing belt(s), overhead cam drive sprockets, and tensioners;

check belt tension; adjust as necessary.

3. Verify camshaft(s) timing according to manufacturer’s specifications and procedure.

P-2:

1. Remove cylinder head(s); inspect cylinder head(s) for cracks; check gasket surface

areas for warpage and leakage; check passage condition.

2. Install cylinder heads and gaskets; tighten according to manufacturer’s specifications and procedures.

3. Inspect valve spring retainers, locks, and valve grooves.

4. Resurface valves; perform necessary action

5. Resurface valve seats; perform necessary action.

6. Check valve spring assembled height and valve stem height; service valve and spring assemblies as needed.

7. Inspect pushrods, rocker arms, rocker arm pivots and shafts for wear, bending, cracks, looseness, and blocked oil passages (orifices); perform necessary action.

8. Inspect hydraulic or mechanical lifters; replace as needed.

9. Inspect camshaft drives (including gear wear and backlash, sprocket and chain wear) replace as necessary.

P-3:

1. Remove cylinder wall ridges.

2. Inspect and measure camshaft bearings for wear, damage, out-of-round, and

alignment; determine necessary action.

3. Inspect crankshaft for surface cracks and journal damage; check oil passage condition;

measure journal wear; determine necessary action.

4. Identify piston and bearing wear patterns that indicate connecting rod alignment and

main bearing bore problems; inspect rod alignment and bearing bore condition.

5. Inspect, repair or replace crankshaft vibration damper (harmonic balancer).

6. Inspect auxiliary (balance, intermediate, idler, counterbalance or silencer) shaft(s);

inspect shaft(s) and support bearings fro damage and wear; determine necessary

action; reinstall and time.

C. Engine Block Assembly Diagnosis and Repair

P-1:

1. Inspect internal and external threads; restore as needed (includes installing thread inserts).

2. Deglaze and clean cylinder walls.

3. Prime engine lubrication system.

P-2:

1. Inspect and replace pans, covers, gaskets, and seals.

2. Inspect engine block for visible cracks, passage condition, core and gallery plug condition, and surface warpage; determine necessary action.

3. Inspect and measure cylinder walls for damage and wear; determine necessary action.

4. Inspect and measure main and connecting rod bearings for damage, clearance, and

endplay; determine necessary action (includes the proper selections of bearings).

5. Inspect, measure, and service pistons and pins; determine necessary action.

6. Inspect, measure, and install piston rings.

7. Reassemble engine components using correct gaskets and sealants.

P-3:

1. Remove cylinder wall ridges.

2. Inspect and measure camshaft bearings for wear, damage, out-of-round, and

alignment; determine necessary action.

3. Inspect crankshaft for surface cracks and journal damage; check oil passage condition; measure journal wear; determine necessary action.

4. Identify piston and bearing wear patterns that indicate connecting rod alignment and main bearing bore problems; inspect rod alignment and bearing bore condition.

5. Inspect, repair or replace crankshaft vibration damper (harmonic balancer).

6. Inspect auxiliary (balance, intermediate, idler, counterbalance or silencer) shaft(s); inspect shaft(s) and support bearings for damage and wear; determine necessary action; reinstall and time.

D. Lubrication and Cooling Systems Diagnosis and Repair

P-1:

1. Perform oil pressure tests; determine necessary action.

2. Perform cooling system, cap, and recovery system tests (pressure, combustion leakage, and temperature); determine necessary action.

3. Inspect, replace, and adjust drive belts, tensioners, and pulleys.

4. Test coolant; drain and recover coolant; flush and refill cooling system with recommended coolant; bleed air as required.

5. Perform oil and filter change.

P-2:

1. Inspect and replace engine cooling and heater system hoses.

2. Inspect, test, and replace thermostat and housing.

3. Inspect, test, remove, and replace water pump.

4. Remove and replace radiator.

5. Inspect, and test fans(s) electrical or mechanical), fan clutch, fan shroud, and air dams.

6. Inspect, test, and replace oil temperature and pressure switches and sensors.

P-3:

1. Inspect oil pump gears or rotors, housing, pressure relief devices, and pump drive; perform necessary action.

2. Inspect auxiliary oil coolers; replace as needed.