ENGINE REPAIR (A1)

ASE TASK LIST

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.