Workbook M3

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WorkBook
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1. Contents
1.1. Lesson Plan 1
1.1.1. Types of Car Engines- The Basics
Here’s how you can identify the car engine type of your car, just by having a look at the layout
of the cylinders.
1. VEE
When looking at the engine from the front side, this arrangement will be like the alphabet ‘V’.
Every cylinder will be facing outwards and will be driving a common crankshaft at the base.
Expect this sort of engine in all those premium and high-performance cars, as it allows
squeezing in more cylinders. Also, the space consumed by the cylinders is quite compact as
compared to other engines.
2. INLINE
You will see all the cylinders arranged in a line. They will be facing in the upward direction
which is usually perpendicular to the car. This sort of configuration in the engines can be seen
in the wide variety of small and hatchback cars. The arrangement of the cylinder is simply
straight in these engines.
3. STRAIGHT
Looking at the arrangement of the cylinders in this engine, you will notice that the positioning
is done parallel to the car. All those premium cars like BMW use this type of car engines with
such cylinder positioning.
4. VR and W
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Developed by the Volkswagen group, it uses the exact same principle for all those V engines.
VR and W engine’s cylinder has a very narrow space between them. And, space is so narrow
that these cylinders are like squished together in one block. It is at the base that W
configuration joins two banks of VR engines. Manufacturers rarely use this engine and
configuration in any of the modern cars. Cars like Bentley Mulsanne use it though.
5. BOXER
And, then comes the boxer which is even called as Flat. These horizontally opposed engines
use the cylinders that are simply laid down on their side in two banks. But, the two cylinders
don’t face each other, in fact, they are placed pointing away from each other. Well, this allows
the gravity to stay at the low level, which simply adds to the benefit of handling. Want to know
which cars are actually using this layout in their cars? Well, brands like Porsche use this sort of
arrangement of cylinders in their vehicles.
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1.1.2. How Vin’s number works
Vehicle Identification Numbers (VINs) are unique identification sequences on every car
manufactured in the United States and many other countries. These numbers are sort of like a
fingerprint for a car. They help to keep track of problems, ownership changes, and deter theft.
In this article, we'll find out where to find your car's VIN, what the numbers mean and how you
can use VINs to help prevent theft or learn about the history of a used car.
A VIN is a 17-character sequence containing both numbers and letters. It is affixed to every car,
truck or trailer made in the United States after 1981. No two cars built within 30 years of each
other can have the same VIN. The Motor Vehicle Records database tracks information on a
VIN, such as when the car was inspected, when it changed ownership and if it was involved in a
serious crash, rollover or flood.
On most cars, you can find the VIN on the dashboard on the driver's side, and it's visible
through the windshield from outside the car. It is usually on a sticker or plate on the inside of
the driver's side door or on the frame sill where the door closes. The VIN is sometimes printed
inside the glove compartment, and it's usually on the car's title and/or on insurance
documents.
Each character in a VIN has a specific meaning, and the VIN is broken up into sections. The first
section identifies the manufacturer of the vehicle, and uses the first three digits:
The first digit identifies the nation of origin
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The second digit identifies the manufacturer of the vehicle
The third digit identifies a division within the manufacturer or a general vehicle type
The next five digits, four through eight, describe the vehicle
 The fourth digit might contain a code that represents the vehicle's weight, horsepower
or both.
 The fifth digit often identifies the platform of the vehicle, such as van, pickup truck,
trailer, sedan, et cetera.
 The sixth digit can be a special code used by the manufacturer, or it might identify the
specific model of the vehicle, such as Corvette, Durango or Mustang.
 The seventh digit can be used to identify body type, such as four-door, two-door,
hatchback or convertible.
 The eighth digit is used for information about the engine, such as number of cylinders
and engine displacement.
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1.1.3. OBD
The Check Engine Light turning on is usually a topic car owners try to avoid talking too much
about. It can be quite intimidating to see that little light on your vehicle’s dashboard suddenly
illuminate, but in reality, it is not something that should paralyze you in fear right away. By
preparing yourself with a little automotive knowledge, a helpful tool, and general background
information on what this light is actually trying to tell you, you will not only gain more peace of
mind, you will also develop a closer relationship to your vehicle.
Diagnostic trouble codes (DTC) are automotive computer codes stored by the on-board
computer diagnostic system (OBD) in your vehicle. There are literally hundreds of different
codes a Check Engine Light can represent. While that sounds daunting, with a little patience,
tackling basic diagnostics will give you useful knowledge about your vehicle and will also allow
that Check Engine Light to do what it is really supposed to do: be your guide.
There are two acronyms to be aware of when it comes to discovering more about Check
Engine Lights. These two acronyms are OBD and DTC.
 Tip: OBD codes refers to nearly the same thing as DTC codes, therefore you will often
hear them used interchangeably in the automotive industry. OBD codes are most
frequently referred to as OBD-II, which has been the code type since 1996.
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Unfortunately, obvious and helpful vehicle symptoms do not always accompany an illuminated
Check Engine Light. Since there are hundreds of possible OBD codes, there are also hundreds
of possible reasons for the light, including:
 Computer output circuit issues

 Emissions controls issues
 Fuel and air metering systems problems
 Ignition system faults
 Speed control and idle problems
 Transmission issues
This is why it is important for someone who does not have a lot of automotive knowledge to
not assume what a code means. When your Check Engine Light comes on, you should get it
checked out quickly by a certified mechanic. If the engine light comes on due to a serious
concern, you risk damaging your car further by not repairing the issue right away.
 Warning: If the Check Engine Light comes on and flashes, it indicates a very serious
concern. Find a safe place to stop, turn off your car, and have it diagnosed and
repaired before you continue to use it.
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1.1.4. Fuse Box
Power Centers are all about power. Not horsepower but routing electrical power through the
various circuits and accessories in the vehicle's electrical system. Think of the Power Center as
a fuse box on steroids. And because it is the heart of the entire electrical system, you can use it
as a handy access point for checking circuit voltages, resistance and continuity.
Compared to the random locations of fuses and relays throughout the electrical system in
older vehicles (those built up until the mid- to late-1980s), the Power Center is a welcome
improvement. With most of the relays and fuses grouped together inside one or two plastic
boxes, and labelled so you can identify the fuses and relays inside, the Power Center provides
a great place to start your electrical diagnosis.
Many vehicles may also have a separate fuse panel inside the vehicle (usually under the
instrument panel or under a side kick panel) that holds fuses for lower amperage electrical
accessories and circuits such as radio, power seats, windows, power outlets, horn, interior
lights, etc. But most of the high amperage circuits are routed through the power center rather
than the smaller interior fuse panel.
The power center is located in the engine compartment. It is usually a large rectangular plastic
box with a removable cover. If you can't find it, refer to your vehicle owner’s manual for its
location.
When you open the cover on the power center, you will see various fuses and relays that
protect and control the electrical circuits in your vehicle. The fuses and relays are usually
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identified on the inside of the power center cover. If not, you will have to refer to your owner’s
manual or the vehicle service literature to figure out which fuses and relays are associated
with which electrical circuits in your vehicle.
1.1.5. What do fuses do
Fuses are circuit protection devices. Up until the 1980s, most vehicles used snap-in style fuses
with a short piece of wire inside a hollow glass tube. In newer vehicles (1980s and up), blade-
style transparent plastic fuses are used (both "mini" and "maxi" sizes). With both styles, the
wire inside the fuse is designed to melt if the current passing through the fuse exceeds its
rated amperage. When the fuse "blows," it opens the circuit and stops the flow of current to
protect the circuit from dangerous overloads that might otherwise damage components or
start a fire.
Mini-fuses are typically used for circuits that normally handle no more than 20 to 30 amps.
Maxi-fuses are typically used for circuits that carry higher amp loads (40 to 120 amps). The
number on the fuse is its maximum amp rating. Most fuses are the push-in spade type, but
some larger capacity fuses may be bolt-in.
A blown fuse can be identified by visually inspecting the fuse. This may require removing the
fuse from its holder. If the wire inside the fuse is broken, the fuse has failed and must be
replaced with one that has the exact same amperage rating as the original.
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Warning: Never substitute a fuse with a higher amp rating as doing so may result in circuit
damage or a fire! Also, never remove or install a fuse when a circuit is on.
1.2. Lesson Plan 2
Tools
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1.3. Lesson Plan 3
1.3.1. Main components of an engine
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1.3.2. Engine crossword
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1.4. Lesson Plan 4:
1.4.1.Verbs for mounting and dismounting an engine
Verb Opposites Definition

Assemble
Attach
Bend
Bolt
Charge
Check
Connect
Cut
Dry
Fill
Fix
Flatten
Glue
Grease
Grip
Hit
Hook
Inflate
Inspect
Install
Keep
Lift
Link
Loosen
Lubricate
Measure
Mend
Place
Press
Protect
Pull
Push
Put
Raise
Reduce
Release
Remove
Repair
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Verb Opposites Definition

Replace
Rotate
Screw
Secure
Slide
Stretch
Strike
Tighten
Turn on
Can you think of any other technical verbs?
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1.4.2. Verbs for mounting and dismounting an engine.
Title the different actions
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1.5. Lesson Plan 5
1.5.1 Cooling System main components
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1.5.2 . Symptoms of Cooling System Failure
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1.6. Lesson Plan 6
1.6.1 Main Parts of the lubrication system
Identify and name the parts of the lubrication system :
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1.6.2. The lubrication system reading comprehension
1.The lubricating oil performs the following functions in an engine:
 The oil lubricates moving parts to minimize wear by sealing the clearances between
moving parts such as bearings, shafts, etc. Thus, the parts move on layers of oil, and
not in direct contact with each other, which reduces power loss in the engine.
 The oil obtains heat from the moving parts of the engine which is transferred into the
cooler oil in the oil pan. Therefore, the oil performs the function of a cooling agent.
Some engines have oil nozzles which spray oil at the underside of the pistons, thereby
removing heat from the pistons.
 The oil fills the clearances between rotating journals and the bearings. When heavy
loads are abruptly placed on the bearings, the oil acts as a cushioning agent, which
reduces the wear on bearings.
 The oil creates a seal between the walls of the cylinder and the piston rings, thereby
reducing exhaust gas blowby.
 The oil performs the function of a cleaning agent by picking up dirt particles and taking
them to oil pan. Larger particles are retained at the bottom while smaller particles are
filtered out by oil filters.

2.Parts And Operation Of Lubricating System
 Oil Pump: The gear-type oil pump has a pair of meshing gears. The spaces between the
teeth are filled with oil when the gears unmesh. The oil pump obtains oil from the oil
pan and sends oil through the oil filter to the oil galleries and main bearings. Some oil
passes from the holes in the crankshaft to the rod bearings. Main bearings and rod
bearings are lubricated adequately to achieve their desired objectives. In the rotor
type oil pump, the inner rotor is driven and drives the outer rotor. As the rotor
revolves, the gaps between the lobes are filled with oil. When the lobes of the inner
rotor move into the gaps in the outer rotor, oil is forced out through the outlet of
pump. An oil pump can also be driven by a camshaft gear that drives the ignition
distributor or by the crankshaft.
 Oil Pan: Oil also flows to the cylinder head through drilled passages that make up the
oil gallery, lubricates camshaft bearings and valves, and then returns to oil pan. Some
engines have grooves or holes in connecting rods, which provide extra lubrication to
pistons and walls of cylinders.
 Oil Cooler: Oil cooler prevents overheating of oil, by flow of engine coolant past tubes
carrying hot oil. The coolant picks excess heat and carries it to the radiator.
 Oil Filter: The oil from oil pump flows through oil filter before reaching the engine
bearings. The oil filter retains the dirt particles and allows only clean filtered oil to
pass.
3.Characteristics of Lubricants
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A lubricant is a substance introduced between moving surfaces to reduce friction. It may also
transports foreign particles line small metal particles and carbon from the moving part to the
oil sump. The lubrication oil has a very important property of reducing friction and is known as
lubricity (Slipperiness).
A good lubricant possesses the following characteristics:

 High boiling point
 Low freezing point
 High viscosity index
 Thermal stability
 Hydraulic stability
 Corrosion prevention
 High resistance to oxidation
Summarise your learnings here. Write your answers in the spaces provided.
1. List down the various functions of a lubrication system.
2. Name the parts and main functions of the lubrication system.
3. What characteristics should a good lubricant possess?
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1.7. Lesson Plan 7
Video comprehension
Check for the meaning of the following vocabulary:
Plunger:
Clog:
Bearings:
Worn out:
Knock:
Drip off:
Bushing:
1. What is the main responsibility of the oil pump?
2. Can you identify some of the components of the oil pump?
3. Can you name some of the components through which the oil flows after leaving the
oil pump?
4. What is the mission of the oil strainer located in the oil pickup tube?
5. What is the main objective of the oil filter bypass valve.
1. What does the rod control ring do?
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1.8. Lesson Plan 8
Engine belts
What kind of belts are these?
Do you know the differences between them?
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Diferences between a Serpentine belt and a Timing belt:
• A serpentine belt does more work than a timing belt. Timing belts synchronize the
movement of the crankshaft and the camshaft while the serpentine belt transmits
mechanical power which drives the air conditioner, water pump, alternator, etc.
• The serpentine belt can be seen coiled like a snake around engine accessories while
the timing belt is not visible because it is covered.
• A timing belt is expensive while a serpentine belt is cheap.
• If a serpentine belt breaks while your engine is on the move, it is only those things that
it powers that will stop working like the water pump, AC etc. If the timing belt breaks
while you are driving, your piston, valve and cylinder head will be damaged.
• The breakdown of the serpentine belt is cheaper to handle while repairing the
damages caused by a faulty timing belt can cost a fortune.
• You may need to change your engine if the timing belt breaks but if the serpentine belt
brakes, it will not lead to engine replacement.
• When it comes to servicing, the serpentine belt usually needs regular servicing while
the timing belt is serviced once in a while.
• To replace a serpentine belt is easy because it is outside of the engine. A timing belt
needs more work to be replaced because it is covered.
• The most important thing to a timing belt is that its timing must be accurate without
variation while the serpentine belt must be sturdy enough to bear its load without
slipping.
• The serpentine belt also differs from the timing belt in their respective life expectancy.
Since the former bears more load and is exposed, it is likely to damage easily.
• Some vehicles can use more than one drive belt but a timing belt is always just one.
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1.9. Lesson Plan 9
Intake systems
1.9.1 With the help of internet, try to answer the following questions using your own words:
a) What is an Intake System?
b) Components of an Intake System
c) How Does an Intake System Work?
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1.10. Lesson Plan 10
Engine Mounts.
a) Reading Activity: What are engine mounts and And why you should replace them.
Just like their name explains, engine mounts have the role of keeping the
power plant in place inside the engine bay. They are usually a component that
has rubber and metal, and they are screwed into the engine block and various
parts of the body to ensure that things do not move more than intended.
Motor mounts vary in shape, size, and appearance because they have to suit
different engine layouts, but they all function on the same principles. Just like
other components, engine mounts are made to provide a a balance of multiple
characteristics to suit the general population.
Automakers have the technology to make performance dedicated motor

mounts, but doing so will make the cars fitted with them uncomfortable at idle
or at various rpm ranges.
Because of that reason, motor mounts are softer than they could be, and they
tend to act like “cushions” that do their best to absorb vibrations and unwanted
movement.
The reason for engine mounts
As the throttle is applied, the engine shifts around the bay, and engine mounts
have the role of dampening this phenomenon. Depending on engine design,
engine mounts might have to absorb more or fewer vibrations. If that wouldn't
happen, the vehicle would shake like a washing machine operating on full
power during the spin cycle.
Unfortunately for performance enthusiasts, stock engine mounts are not even
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close to the level of rigidity desired from a sports car. Because of this, some of
the torque generated by the engine is lost in the form of vibrations that are
absorbed by motor mounts. However, if they were to be replaced with all-
metal units, other elements of the vehicle would be affected.
If engine mounts would not be as soft as most of them are designed to be, the
response of the power plant could be improved, especially when pulling away
from idle. The behavior of the car when going from consistent throttle
application to max throttle could also see an improvement after the change.
Some automakers have employed engine mounts with liquid in them, which have a
moving coil that makes them softer or harder depending on predetermined settings.
The respective coil operates magnetorheological fluid, which does the whole magic
with the help of an electromagnet.
Other active engine mounts have a vacuum-operated valve that controls the fluid
differences between two chambers, and adjusts it according to throttle operation. The
1990 Honda Accord had an active engine mount system, and its role was to increase
comfort at idle and at revs close to 1,000 rpm.
Some active engine mounts are configured to produce a vibration counter at a

particular frequency, which covers up the known vibration pattern of the power plant.
Active engine mounts used to be available only on premium cars that are not that
affordable, but volume automakers employ them these days as well.
Fortunately for performance enthusiasts, aftermarket engine mounts are available for
a variety of cars. Some of them are offered in different levels of rigidity, which is a
solution that was designed to satisfy a broad range of needs and applications. Some
customers will want to have their daily drivers to get slightly stiffer engine mounts,
while others will seek a dedicated solution for track toys.
Replacing engine mounts
The common symptoms of a failed engine mount involve increased engine noise, and
perceivable power plant vibrations in the passenger compartment. Usually, the rubber
parts of the engine mounts fail, especially when exposed to years of fluctuations. In
the case of liquid-filled engine mounts, their failure is similar, but the causes behind it
might be different.
In both instances, an engine that has broken mounts will make more noise in first or
reverse gears. Other signs include noticeable vibrations at idle, which get more intense
when the engine is started cold.
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Replace your engine mounts soon after you encounter any of these symptoms,
because they might translate into problems with the transmission mounts. In extreme
circumstances, you cannot exclude the complete failure of engine mounts, which will
lead to damaging the engine and engine compartment.
Regardless of the automobile you drive, the decision to fit uprated engine mounts
should bring a performance enhancement. If you start off with classic motor mounts
and want to drive your car on the track, you are bound for a massive improvement
with the use of quality aftermarket components that come with upgraded
specifications.
Enthusiasts who have fitted uprated engine mounts claim that their cars now have
improved throttle response, along with better acceleration. In cars with rear-mounted
engines, a handling improvement is also expected, because even the smallest
movements of the power plant can be felt in dynamic driving conditions, and this
upgrade should make the vehicles that get it more predictable and stable.
b) Try to summarize the information of the text we have just read in 5 sentences:
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1.11. Lesson Plan 11:
Oil sump gasket replacement
With the following key words, write the correct process for an oil sump gasket
replacement. Include a minimum of 5 steps and the tools required for the task.
Key words:
Seal oil pan pumped

lifting gasket tightened
draining joint bolts

fitted
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1.12. Lesson Plan 12
The Exhaust System
1.12.1 Reading Comprehension Activity
How Do Exhaust Systems Work?

Before learning about the ins and outs of exhaust systems, you should familiarize
yourself with how your engine generates power. First, fuel and oxygen get sucked
into your engine's cylinders. The fuel/oxygen mix gets ignited by a spark plug,
causing a small explosion inside the cylinder - a phenomenon known as
combustion. Combustion provides the energy and torque needed to turn your
wheels and move forward. Each explosion also creates a cloud of waste gases that
would choke your engine if it stayed in the cylinders. The exhaust system's job is to
get rid of these gases as quickly and efficiently as possible. Whether you install
a onto your truck or bolt an exhaust from Borla to your 'Vette, this is a crucial
system when it comes to maximizing your vehicle's power and performance.
Exhaust Manifolds/Headers
The exhaust gas left behind after combustion gets pushed out of the cylinders by
your engine's pistons, where it travels into your exhaust manifolds. Manifolds are
bolted onto your engine head, with a piece of pipe attached to each cylinder. These
pipes collect the gas from multiple cylinders and combine it into a single exit pipe
called a collector. Stock exhaust manifolds are usually made from heavy cast iron
and, while they're designed to cut costs and occupy little space, they don't expel
gas very efficiently. Performance enthusiasts and racers typically swap out their
manifolds for performance headers.
Aftermarket manifolds like Borla and Pacesetter are designed to provide better
exhaust flow than stock manifolds. They're typically built using mandrel bends for
more efficient flow and are available in a variety of materials and finishes. You can
also build a set of headers to your own specifications with weld-together pipe kits.
Headers are available in a range of finishes and materials, including nickel-chrome
plated mild steel, 409 stainless steel, and ceramic-coated steel. Brands like
Gibson and Doug Thorley give you several material options within the same design,
so you can choose the perfect header for your performance needs and budget.
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The exhaust gas that collects in the headers moves on to a straight pipe known as a
head pipe. The head pipe is the first section of exhaust piping and connects your
headers to the rest of your exhaust system. The head pipe is also where you'll find the
catalytic converter, the next step in your exhaust system.
Catalytic Converters
The combustion in your engine generates a lot of ugly and dangerous chemicals
including carbon monoxide, nitrogen oxide, and
hydrocarbons, to name a few. One way to battle these
pollutants and clean up your emissions is by utilizing a
catalytic converter. Also known as a cat converter or catcon,
your catalytic converter is packed with platinum and
palladium-coated ceramic beads or honeycomb, known as a
catalyst. When the pollutants in your exhaust hit the
ceramic catalyst, it sets off a chemical reaction that converts the oxides and
hydrocarbons into oxygen, nitrogen, carbon dioxide, and water vapor. Cat converters
significantly clean up your exhaust gas, making the planet - and your local emissions
tester - happy.
Cat Back Exhaust Systems
After your exhaust gas passes through the catalytic converter the fun really begins. The
rest of the exhaust from this point out is considered a Cat-Back exhaust system. The
term "Cat-Back" means every part of the system after the catalyst. The Cat Back
includes the pipes connecting the converter to the muffler, the muffler itself, and the
final tail pipe. The diameter, bends, and design of the exhaust pipes and muffler all
determine the efficiency and effectiveness with which exhaust gas is scavenged from
your engine. Plus, most performance exhausts like those from Banks are crafted from
high-quality stainless steel.
Mufflers
If your exhaust system ended at the catalytic converter, your vehicle would be
obnoxiously loud and noisy - far from the high-performance growl you know and love.
As their name implies, mufflers reduce the noise coming out of your exhaust to less-
than-deafening levels. They are generally built with a resonating chamber that utilizes
carefully-placed baffles and chambers to cause harsh sound waves to cancel each
other out. Performance mufflers also use their resonating chambers to amplify and
tune the exhaust note to a more pleasing, aggressive, or deep sound. They're available
with a wide range of inlet and outlet configurations, so you can get dual-output looks
without having to spring for a complete dual exhaust system.
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Tail Pipes & Exhaust Tips
The tail pipe and tip make up the last section of your exhaust system. Even this far
away from the engine, the diameter and bend of your tail pipe can affect how well
your vehicle gets rid of exhaust gas.
Instead of just having a metal pipe sticking out the rear of the vehicle, many tailpipes
are fitted with an exhaust tip. Exhaust tips are generally made from high-quality steel
and come in a bright, polished chrome finish for head-
turning looks. Tips are available in a wide range of designs
and shapes including angle-cut and triangular, and can
have straight or rolled edges. Chrome exhaust tips are
usually a wider diameter than the tail pipe, which gives
one last reduction in pressure for improved flow and adds
a nice look to your vehicle's rear end.
EXERCISES:
1. Answer the following questions:
a) Can you explain why racers prefer headers to manifolds?
b) What is the main function of a catalytic converter?
c) What is a Cat Back and what does it include?
d) What are the main characteristics of a tail pipe that affect how well your
vehicle gets rid of exhaust gasses?
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2. Match the underlined words of the text with their meaning:
a) Provided with a layer or covering of something:

b) To eliminate or discard:
c) a steady, continuous stream or supply of something:
d) all the details or facts that you need to know in order to deal with
a complicated situation, process etc.
e) to make an exchange:
f) to stop the breath of (someone) by squeezing or blocking the windpipe;
strangle:
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2. Workshop Activities
UF1 - Practice 0:
2.1. Vehicle 1:
Vehicle Data
Brand: Model: Type: QR
NIV: Engine: Horsepower:
Km: Fuel Tank: Colour:
Date of Manufacture: Euro: Fuel:
2.1.1. Electric power system diagram. (Drawing or Link to OneDrive describing how many
schemes there).
Photo or diagram of the power system.
2.1.2. Location of the socket eobd.

Location of the EOBD diagnostic socket.
2.1.3. Fuse and relay of auxiliary systems.

Maintenance indicator reset procedure.
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2.1.4. Specifications of Maintenance:

2.1.4.1. Setting maintenance indicator:
2.1.4.2. Car battery disconnection.

Car battery disconnection procedure.
2.1.4.3. Initialization of the keys:

Initialization of the keys and backup process.
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2.2. Vehicle 2:
Vehicle Data
NIV: Engine: HorsePower:
schemes there).


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2.3. Vehicle 3:
Vehicle Data
schemes there).


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2.4. Vehicle 4:
Vehicle Data
schemes there).


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2.5. Vehicle 5:
Vehicle Data
schemes there).


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2.6. Vehicle 6:
Vehicle Data
schemes there).


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2.7. Vehicle 7:
Vehicle Data
schemes there).


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2.8. UF1 - Practice 1: Engine Parts Measurements.
2.8.1. Engine specifications

ENGINE PARTS MESUREMENTS
Engine specification
Engine
Cycle
Nº Cylinders
Engine Layout
Cylinder Diameter
Stroke
Cylinder displacement
Compression Ratio
Engine power Cv / Rpm
Max Torque Kgm/rpm.
Observations
*It will be mandatory to add all the tightening torques used in practice
2.8.2. Engine Block – Cylinders

CYLINDERS (Bore gauge)
LONGITUDINAL Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4
Upper zone
Middle zone
Lower zone
TRANSVERSAL
Upper zone
Middle zone
Lower zone
CYLINDER DIÁMETER
(OEM mesurement/real mesurement)
Observations
The verification of the lubrication and refrigeration lines must be carried out
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2.8.3. Crankshaft

CRANKSHAFT
1 2 3 4 5
CRANK PIN DIAMETER
MAIN CRANK JOURNAL DIAMETER
SHELL BEARING THICKNESS
THRUST BEARING THICKNESS
MAIN CRANK JOURNAL GAP
(PLASTIGAUGE)
CRANKSHAFT AXIAL MOVEMENT
FLYWHEEL WARPAGE
Observations
*The verification of the bushes in three points (ends and central part) must be carried out
2.8.3.1. Plastigage Mesurements:
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2.8.4. Piston
ENGINE PART MEASURMENTS

PISTONS
PISTON 1 PISTON 2 PISTON 3 PISTON 4
Piston Diameter
Piston to Cylinder Free play/ Gap
Piston / Gudgeon Pin Diameter
Gudgeon Pin Hole Diameter
Piston Pin / Piston hole Freeplay
Piston Weight
Weight difference ( Lightest to heaviest)
Type of connection Piston/Connecting Rod
Observations
2.8.4.1. Piston diameter Measurement
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2.8.5. Piston Rings

PISTON RINGS
1 2 3 4 5 6
AXIAL MOVEMENT
UPPER COMPRESSION RING
LOWER COMPRESSION RING
OIL SCRAPER RING
PISTON RING GAP
UPPER COMPRESSION RING
LOWER COMPRESSION RING
OIL SCRAPER RING
Observations
* The Piston Rings should be removed with the appropriate tool (Piston Ring extractor).
2.8.6. Connecting Rods

CONNECTING RODS
CON-ROD 1 CON-ROD 2 CON-ROD 3 CON-ROD 4
CON-ROD SMALL END DIAMETER
CON-ROD BIG END DIAMETER
CON-ROD WEIGHT
WEIGHT DIFFERENCE ( LIGHTEST AND HEAVIEST)
BIG END SHELL BEARING THICKNESS
FREEPLAY CON-ROD/CRANKSHAFT
FREEPLAY CON-ROD/ GUDGEON PIN
Observations
*The deformation of the connecting rod must be verified by aligning the centers
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2.8.6.1. Rod Length Measurement
2.8.7. Cylinder Head Assembly

CYLINDER HEAD ASSEMBLY
1 2 3 4
COMPRESSION CHAMBER VOLUME
DIÁMETRO ALOJAMIENTO ÁRBOL DE
LEVAS
HYDRAULIC TAPPET DIAMETER
TAPPET HOLE DIAMETER
FREEPLAY TAPPET/ CYLINDER HEAD
CONDITION CYLINDER HEAD GASKET
CONDITION VALVE GUIDE
Observations
*The flatness of the stock with the ruled bar must be carried out. The combustion chamber in some cases is not housed in the cylinder head
(piston)
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2.8.8. Valves

VALVES
1 2 3 4 5 6 7 8
VALVE FACE DIAMETER(D)
VALVE STEM DIAMETER (d)
VALVE FACE ANGLE (α)
SPRING LENGTH
FREEPLAY VALVE/ VALVE
GUIDE
Observations
*One valve should be ground for each group component, checking for correct grinding with prussian blue.
2.8.8.1. Valves Measurements
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2.8.9. Camshafts

CAMSHAFTS
1 2 3 4
CAMSHAFT JOURNAL
DIAMETER
CAMSHAFT JOURNAL WEAR
CAM LIFT mm
Observations
2.8.9.1. Camshaft Measurements
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2.9. UF2: Sensors and Actuators
2.9.1. Sensor 1:
SENSOR :
VISUAL STATE
BRAND AND REFERENCE
NUMBER OF PINS
LOCATION IN THE VEHICLE
VERIFICATIONS
How it should be verified.
How it should be disassembled from the vehicle
Observations: Explain how the verification has been carried out and whether it should be repaired or replaced.
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2.9.2. Sensor 2:
SENSOR:
VISUAL STATE
BRAND AND REFERENCE
NUMBER OF PINS
VERIFICATIONS
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2.9.3. Sensor 3:
SENSOR:
VISUAL STATE
BRAND AND REFERENCE
NUMBER OF PINS
VERIFICATIONS
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2.9.4. Sensor 4:
SENSOR:
VISUAL STATE
BRAND AND REFERENCE
NUMBER OF PINS
VERIFICATIONS
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2.9.5. Actuator 1:
ACTUATOR:
VISUAL STATE
BRAND AND REFERENCE
NUMBER OF PINS
VERIFICATIONS
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2.9.6. Actuator 2:
ACTUATOR:
VISUAL STATE
BRAND AND REFERENCE
NUMBER OF PINS
VERIFICATIONS
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2.9.7. Actuator 3:
ACTUATOR:
VISUAL STATE
BRAND AND REFERENCE
NUMBER OF PINS
VERIFICATIONS
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2.9.8. Actuator 1:
ACTUATOR:
VISUAL STATE
BRAND AND REFERENCE
NUMBER OF PINS
VERIFICATIONS
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UF3
2.10. Cooling system reparation.
2.10.1. Objective:
 Check all the following elements of the cooling system (radiator, Thermocontact,
thermostat, coolant, Expansion vessel and sleeves).
2.10.2. Vehicle Data.
Vehicle Data
2.10.3. Technical Data.

Information of the cooling system.
2.10.4. Procedure of work.

Description and disassembly precautions:
2.10.5. Check-up.
Diagnosis of the elements:
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2.11. Lubrication system reparation and Check.
2.11.1. Objective:
 Removal and verification of the following items: oil engine, oil filter and engine oil
cooler.
Vehicle Data

Information of the lubrication system.

2.11.5. Check-up.
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2.12. Engine belts replacement (Accessory and timing belt).
2.12.1. Objective:
Removal and verification of the following items: Accessory belt and timing belt.
Vehicle Data
2.12.3. T
Date of Manufacture: Euro: Fuel: echni
cal
Data.
Information of the engine belts.

2.12.5. Check-up.
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2.13. Air intake system disassembly and check.
2.13.1. Objective:
 Remove, clean, repair and analyse all the elements air intake until the entrance to the
engine.
 Use of the air leak machine.
Vehicle Data
NIV: Engine: Horsepower: 2.13.3. T
Km: Fuel Tank: Colour: echni
cal
Date of Manufacture: Euro: Fuel: Data.
Infor
mation of the air intake system.

2.13.5. Check-up.
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2.14. Motor support replacement.
2.14.1. Objective:
 Disassembly, analysis and assembly of the motor supports one by one.
Vehicle Data
Km: Fuel Tank: Colour: 2.14.3. T
echni
Date of Manufacture: Euro: Fuel: cal
Data.
Information of the Motor supports.

2.14.5. Check-up.
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2.15. Oil sump gasket restitution.
2.15.1. Objective:
 Remove and replace the crankcase gasket and the rocker cover gasket.
Vehicle Data
Km: Fuel Tank: Colour: 2.15.3. T
echni
Date of Manufacture: Euro: Fuel: cal
Data.
Information of the crankcase gasket and the rocker cover gasket.

2.15.5. Check-up.
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2.16. Exhaust system disassembly and return.
2.16.1. Objective:
 Disassemble, analyse and assemble all the elements of the exhaust system of the
vehicle.
Vehicle Data
2.16.3. T
cal
Data.
Information of the exhaust system.

2.16.5. Check-up.
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2.17. Supercharger restitution. (DIESEL)
2.17.1. Objective:
 Learn the procedure, tools and PPE necessary to disconnect the turbo from the motor
support.
Vehicle Data
2.17.3. T
cal
Data.
Information of the supercharger (Turbo) system.

2.17.5. Check-up.
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2.18. Catalyst and exhaust restitution. (Gasoline)
2.18.1. Objective:
 Learn the procedure by which is achieved by changing both the catalyst and the
exhaust pipe in a current vehicle, knowing the necessary tools, the corresponding ipe
and trying to design a plan of work and subsequent recycling system.
Vehicle Data

Information of the Catalyst and exhaust system.

2.18.5. Check-up.
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2.19. Cleaning of injectors and fuel pressure regulator check. (Gasoline)
2.19.1. Objective:
 Learn the procedure by which petrol injectors that require cleaning using the
ultrasonic cleaning machine are left in working order again.
 Check-up fuel pressure regulator.
Vehicle Data

Information of the fuel injection system.

2.19.5. Check-up.
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2.20. Disassembly, Assembly and calibration of inlet throttle valve.(Gasoline)
2.20.1. Objective:
 Learn the method by which the Basic setting of the inlet throttle valve is performed
using the diagnosis machine.
Vehicle Data
2.20.3. T
cal
Data.
Information of the inlet throttle valve system.

2.20.5. Check-up.
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2.21. Filter and fuel pump replacement. (Gasoline)
2.21.1. Objective:
 Learn and perform systematic replacement of the electric fuel pump and filter.
Vehicle Data
2.21.3. T
cal
Data.
Information of the fuel pump and filter.

2.21.5. Check-up.
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2.22. EGR valve Repair. (DIESEL)
2.22.1. Objective:
 Learn the procedure for which is changed the egr valve, check its performance and the
associated solenoid valve.
Vehicle Data
2.22.3. T
cal
Data.
Information of the EGR system.

2.22.5. Check-up.
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2.23. Repair faulty ignition system elements.
2.23.1. Objective:
 Learn to replace the damaged elements of a motor after checking the elements.
 Gasoline Engine: spark plug wires, spark plugs, speed sensor, detonation sensor.
 Diesel Engine. Heaters (glow plugs), cables heaters and heater relay.
Vehicle Data

Information of the ignition system.

2.23.5. Check-up.
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1.1.1. Types of Car Engines- The Basics

1.1.2. How Vin’s number works

The first digit identifies the nation of origin

The second digit identifies the manufacturer of the vehicle

 Computer output circuit issues

1.1.4. Fuse Box

1.1.5. What do fuses do

1.2. Lesson Plan 2

1.3. Lesson Plan 3

1.3.1. Main components of an engine

1.3.2. Engine crossword

1.4. Lesson Plan 4:

1.4.1.Verbs for mounting and dismounting an engine

Verb Opposites Definition

Verb Opposites Definition

Can you think of any other technical verbs?

1.4.2. Verbs for mounting and dismounting an engine.

Title the different actions

1.5. Lesson Plan 5

1.5.1 Cooling System main components

1.5.2 . Symptoms of Cooling System Failure

1.6. Lesson Plan 6

1.6.1 Main Parts of the lubrication system

Identify and name the parts of the lubrication system :

1.6.2. The lubrication system reading comprehension

1.The lubricating oil performs the following functions in an engine:

A good lubricant possesses the following characteristics:

1. List down the various functions of a lubrication system.

2. Name the parts and main functions of the lubrication system.

3. What characteristics should a good lubricant possess?

1.7. Lesson Plan 7

Check for the meaning of the following vocabulary:

1. What is the main responsibility of the oil pump?

2. Can you identify some of the components of the oil pump?

5. What is the main objective of the oil filter bypass valve.

1. What does the rod control ring do?

1.8. Lesson Plan 8

What kind of belts are these?

Do you know the differences between them?

Diferences between a Serpentine belt and a Timing belt:

• A timing belt is expensive while a serpentine belt is cheap.

1.9. Lesson Plan 9

a) What is an Intake System?

b) Components of an Intake System

c) How Does an Intake System Work?

1.10. Lesson Plan 10

Automakers have the technology to make performance dedicated motor

Some active engine mounts are configured to produce a vibration counter at a

Replacing engine mounts

1.11. Lesson Plan 11:

Oil sump gasket replacement

Seal oil pan pumped

draining joint bolts

1.12. Lesson Plan 12

The Exhaust System

1.12.1 Reading Comprehension Activity

How Do Exhaust Systems Work?

Cat Back Exhaust Systems

Tail Pipes & Exhaust Tips

1. Answer the following questions:

a) Can you explain why racers prefer headers to manifolds?

b) What is the main function of a catalytic converter?