Automotive Technologies

Student Workbook

AURTTE004 - Inspect & Service Engines

TAFE - 2018

Version 3.0 09/2018

Acknowledgements

This Unit Guide has been prepared by TAFE Lecturers. It

is intended for TAFE students only.

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Name:

Student Workbook

AURTTE004
Inspect & Service Engines

©South Metro TAFE 1 V3.0 09/2018

Student Workbook Index

Description Page
Student Instructions 4
Assessment Information 5
Theory Questions
Questions 6

Learning Exercises
Vacuum gauge / engine condition readings 20
Engine cycle tables 21
W/shop manuals excercise 22
Tappet adjustment 23
Intake manifold pressure test 23
Oil pressure test 23
Compression test 24
Cylinder leak down test 24

©South Metro TAFE 2 V3.0 09/2018

Student Instructions
This Student Workbook contains all of the specific information, theory questions and
practical task instructions to prepare for the assessments in these units.

Refer to your lecturer for assessment dates and times.

The information required to complete the theory questions in this book can be found
from the following recommended sources:

 Automotive Mechanics 10th Edition (Textbook or eBook)

McGraw Hill Education, May and Simpson.

 Lecturer delivery
(Presentations, videos, handouts, demonstrations, class discussions)

 Further research
(Workshop manuals, textbooks, magazines, PC programs, websites, Apps, Industry
experience and contacts)

Refer to the recommended information source at the beginning of each theory question
section.

If you have any questions regarding the theory questions please ask.

The information required to complete the practical tasks in this book will be from a
combination of theory knowledge, experience, research and lecturer demonstration.

Practical tasks are covered at the rear of this workbook.

Student eLinks

SM TAFE My Campus Student Password Reset

©South Metro TAFE 3 V3.0 09/2018

Assessment Information

Student Learning Resources

Provided by South Metro TAFE
South Metro TAFE Student Workbook.
Computer access, internet access and student account with data storage.
Workshop manuals (hardcopy and electronic), applicable tools and equipment.
Required by student
Textbook or eBook - May and Simpson, Automotive Mechanics 9th Edition Volume 1.
Appropriate stationary and study equipment.
Appropriate work wear and PPE – trousers, work shirt, steel cap boots, safety glasses.
Electronic pdf reader is recommended. Eg. Your own laptop, tablet or e-Reader.

Assessment guidelines
Method Requirement
Written or verbal exam questions to assess aspects of competency that
Theory cannot be demonstrated during either practical task. Must answer all
correctly.
17 Questions with 2 Attempts
1st Attempt multiple choice, 2nd Attempt may require written responses
AURTTE004 Inspect and Service Engines
Practical
Task 1 Inspect and service an engine including replacing the engine oil and filters.

Practical
Inspect and service a different engine including replacing the engine oil and
Task 2
filters.

©South Metro TAFE 4 V3.0 09/2018

 Note

©South Metro TAFE 5 V3.0 09/2018

 AURTTE004 - Inspect & Service Engines

Safety and Environmental

1. What are some safety hazards that could cause personal injury when
working with the following:

a) Rotating and hot components

___________________________________________________________________
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___________________________________________________________________

b) Engine oils
___________________________________________________________________
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___________________________________________________________________

c) High energy ignition and charging systems

___________________________________________________________________
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___________________________________________________________________

2. How should fluids released from engines (e.g. Engine oil) be trapped,
stored and disposed of?

a) Trapping
___________________________________________________________________
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b) Storage
___________________________________________________________________
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c) Disposal
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Page 6 of 27
Engines

3. What are the strokes that make up the 4 stroke cycle in their correct
order?

_______________ _______________ _______________ ______________

4. How does the air actually get into the cylinder in the “intake” stroke?
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________

5. How is the fuel ignited in the following engines:

a) Diesel engine
___________________________________________________________________
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___________________________________________________________________

b) Petrol engine
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________

6. When does the spark actually spark, at what point in the 4 stroke cycle
does the spark plug actually fires = exactly?
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________

Page 7 of 27
 7. What does the crank shaft do in the engine?
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________

Label the components below

8. What does the term “TDC” mean?

___________________________________________________________________
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9. What does the term “BDC” mean?

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10. How many degrees of crankshaft rotation are there for one complete 4
stroke cycle?
___________________________________________________________________
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Page 8 of 27
 11. What is the purpose of the flywheel
___________________________________________________________________
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12. What is the function of the intake manifold on a petrol 4 stroke engine?
___________________________________________________________________
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13. What is the function of the exhaust manifold?

___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
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14. How is manifold vacuum created in a petrol engine?

___________________________________________________________________
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___________________________________________________________________

Pistons and Rings

15. What is the main purpose of the compression rings?

___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________

Page 9 of 27
Label the components below

16. What is the purpose of the oil rings?

___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________

Valves and Heads

17. What makes up the “valve train”

___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________

18. What does the cam shaft do in the engine?

___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________

19. What speed does the camshaft turn in relation to the crankshaft?
___________________________________________________________________
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Page 10 of 27
Label the components below

20. What are the piston and valves doing during valve overlap / on the rock?
Fill in the blanks using the words below.
 BDC, TDC, BBDC, BTDC
 Exhaust, Intake, Power, Compression
 Opening, Closing, Closed,

The piston is at ______ position and has just finished the ____________
stroke and about to start the ____________ stroke.
The exhaust valve is ______________ and the intake valve is
_______________.

21. At what stage are both valves of an engine closed?

___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________

22. What does valve overlap do for an engine

___________________________________________________________________
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Page 11 of 27
 23. What could happen to an engine if valve clearances are not set to
specification?

a) Clearance too tight

___________________________________________________________________
___________________________________________________________________
___________________________________________________________________

b) Clearance too loose

___________________________________________________________________
___________________________________________________________________
___________________________________________________________________

Lubrication

24. How is a 4 stroke engine lubricated?

___________________________________________________________________
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___________________________________________________________________
___________________________________________________________________

25. How is oil pressure created in a 4 stroke engine?

___________________________________________________________________
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Page 12 of 27
Fill in the missing blanks below

26. How is this oil pressure controlled?

___________________________________________________________________
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27. What is the most likely outcome from an oil pressure relief valve being
jammed open?
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Timing Belts

28. What does a “timing belt” actually do?

___________________________________________________________________
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Page 13 of 27
 29. When should an engine timing belt be replaced? (give two answers)
___________________________________________________________________
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Cooling Systems

30. What precautions should be observed when checking the coolant level
of a hot engine?
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________

31. How you would inspect a water pump whilst it was still on the engine?
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________

32. Briefly explain the purpose and operation of the oil cooler
___________________________________________________________________
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___________________________________________________________________

33. What are 2 ways of testing the condition of the coolant

___________________________________________________________________
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___________________________________________________________________

34. How would you know if a radiator hose needed to be replaced

___________________________________________________________________
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___________________________________________________________________

Emissions

35. What are the four emissions that come out of a tail pipe of a motor
vehicle that go into the atmosphere?
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________

Page 14 of 27
2 stroke engines

36. How many degrees of crankshaft rotation are there for one complete 2
stroke cycle?
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________

Fill in the missing blanks below

37. What are the three main ports in a 2 stroke engine

___________________________________________________________________
___________________________________________________________________
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___________________________________________________________________

38. Which component controls the opening and closing of the ports?
___________________________________________________________________
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Page 15 of 27
 39. What part does the crankcase play in operation of the 2 stroke petrol
engine?
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________

40. What is a reed valve and what function does it play in the operation of a
2 stroke engine?
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________

41. How are the engine parts of a petrol 2 stroke lubricated?

___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________

Diagnosis, Testing and Repairs

42. What does “power overlap” mean?

___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________

43. Which of these engine configurations has power overlap?

___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________

44. What are three (3) main checks or tests you could do on an engine to
check its “Internal condition”?
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________

Page 16 of 27
 45. What are some other “External” tests that can be done to check an
engines “Internal” condition?
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________

46. List at least one application for the following engines:

Two-stroke spark ignition engines________________________________________

Four-stroke spark ignition engines________________________________________

Four-stroke compression ignition engines__________________________________

47. When servicing an engine where can you locate the information listing
the types and applications of engine oils and filters?
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________

48. During post-service testing procedures for engines, what are 3 checks
you should include?
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________

Page 17 of 27
 49. In the table below, match the component identification with the
component function.

Cylinder block and head

Piston and connecting rod
Crankshaft
Valve train
Manifolds
Ports and reed valve

Component function

Connected to the cylinder head. Pipes The mechanism that opens and closes
or branches that carry air fuel mixtures the intake and exhaust valves.
or exhaust gases.
_______________________________
_______________________________

Transfers the force from the power A one way air valve located between
stroke to the big end journal of the the intake and crankcase only on two
crankshaft. stroke engines.

_______________________________ _______________________________

Converts reciprocating (up/down) The main engine parts which house the
motion to rotary motion. valves, cam shafts, crank shafts,
pistons and oil galleries.
_______________________________
_______________________________

Page 18 of 27
 50. In the table below, match the engine system with the appropriate
function.

Lubrication
Cooling system
Fuel system
Air system

Component function

This system pressurises and This system transfers heat from

controls the delivery of diesel or inside the engine to the surrounding
petrol to the engine outside air

_______________________________ _______________________________

This systems function is to provide This system reduces wear and

clean air and carry it to the cylinders friction, helps to cool the engine and
seal piston rings
_______________________________
_______________________________

Page 19 of 27
Vacuum gauge / engine condition readings

Page 20 of 27
Complete the table below

STROKES INTAKE COMPRESSION POWER EXHAUST

PISTON DIRECTION
 Up
 Down

INTAKE VALVE
POSITION
 Open
 Closed

EXHAUST VALVE
POSITION
 Open
 Closed

CYLINDER CONTENTS
 Air-fuel mixture
 Burning gas
 Burnt gas

CYLINDER VOLUME
 Increasing
 Compressing
 Decreasing

CYLINDER PRESSURE
 Above atmospheric
 Below atmospheric
 High
 Very high

Complete the chart below. Number 4 is completed as a guide.

(Find an example of an inline six cylinder firing order from the vehicle manual)

CYLINDER STROKE PISTON INLET VALVE EXHAUST

NUMBER POSITION VALVE

1
2
3
4 Intake T.D.C. Opening Closing
5
6

Page 21 of 27
Using a suitable workshop manual or equivalent, complete the following chart
that compares 2 different makes of vehicles.

Vehicle Chosen Vehicle Chosen

Number of cylinders

Valve Train
 OHC
 DOHC
 Push rod, etc
Valve clearance

Fuel System Type

Engine Capacity

Compression Ratio

Compression pressure

Engine Output in KW

Engine Torque

Ignition System type

Base Ignition Timing

What spark plugs are

fitted or recommended

Type and size of

Battery fitted

Cylinder head bolt

tension

Main Bearing bolt

tension

Big end bearing bolt

tension

Page 22 of 27
 Supplementary learning activities

Complete an engine tappet adjustment

Vehicle make/model Engine used
Number of
Firing order
cylinders
Intake
Valve clearance specification
Exhaust
Number of valves per cylinder
Type of valve train (e.g. pushrod, OHC, DOHC)

Measure intake manifold vacuum on an engine

Vehicle make/model Engine used
Ignition
Fuel system type
system type
Record of intake
manifold vacuum
measurements

Check engine oil pressure

Vehicle make/model Engine used
Engine oil
Engine oil level
condition
Oil pressure
specification
Recorded oil
At Idle: At 2500rpm:
pressure

Page 23 of 27
 Complete a compression test on an engine
Vehicle make/model Engine used
Number of
Firing order
cylinders
Manufacturers
specifications
Cylinder Dry Wet

1.

2.

3.

4.

5.

6.
Check spark plug
condition & gaps

Complete a cylinder leakage test on an engine (minimum 2 cylinders)

Vehicle make/model Engine
Number of
Firing order
cylinders
Recommended
readings
Cylinder leakage
Cylinder Cylinder leakage Pass Fail
percentage
Exhaust

Intake
1
Piston rings/Cylinder

Cooling system

Exhaust

Intake
2
Piston rings/Cylinder

Cooling system

Page 24 of 27
Page 25 of 27