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COURSE OF STUDY

AUTOMOTIVE TECHNICIAN (P-119-1)


MODULE 03: PETROL ENGINE REPAIR
Module Synopsis
This module is developed for students to acquire knowledge and skills in petrol engine repair. At the end of this module trainees will be able to :
 conduct engine compression test
 conduct engine top overhaul
 check oil pressure relief valve
 check radiator unit
 check thermostat functioning
 check water pump functioning
 check cooling fan functioning
 conduct cooling system pressure test
 check engine air filter
 check ignition timing
 conduct lubrication system pressure test

Module Objectives:
Carry out petrol engine repair using car service manual, hand tools set, special tools, measuring tools, timing light, tachometer, valve grinding
paste, valve grinding stick, compression gauge, oil filter wrench, oil funnel, lubrication oil, oil filter opener, waste oil receiver, top set gasket, radiator,
pressure tester, thermometer, personal protection equipment, oil filter, air filter, hose, radiator pressure cap, water coolant and multimeter so that
engine compression test conducted, cylinder head assembly removed, engine cylinder head assembly examined, cylinder head assembly installed,
oil pressure relief valve, radiator unit, thermostat functioning, water pump functioning and cooling fan functioning checked, cooling system pressure
test conducted, engine air filter and ignition timing checked, and lubrication system pressure test conducted in accordance with manufacturer’s
specification.

Module Content
Task No
03.03 Determine engine condition
03.02 Rectify engine lubricating system
03.01 Rectify engine cooling system
03.04 Carry out engine top overhaul

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DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE

1. Conduct engine 1.1 Engine types and 6 Lecture 1. Knowledge (D)


compression test classifications
 Internal combustion 2. Performance (A & C)
 External combustion  Construction of engine
 2 stroke - V type
 4 stroke - In line type
 Rotary - Opposite type
1.2 Engine construction  Determine engine
 V type component.
 In line type  Test engine
 Opposite type compression
1.3 Engine main components  Record compression
 Cylinder head test result
 Cylinder block  Disconnect battery
 Oil sump terminal
1.4 Principles of engine  Drain water coolant
operation  Remove external
1.5 Purpose of compression test attachment
1.6 Types of compression  Unfasten cylinder head
gauge bolts
 Analog  Remove cylinder head
 Digital from engine
1.7 Procedure in conducting  Dismantle cylinder
engine compression test head components
 Dry test  Clean cylinder head
 Wet test and components
 Running test

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20
DELIVERY ASSESSMENT
STEPS KNOWLEDGE PERFORMANCE HRS
MODE MODE
1.1 Determine type of engine 9 Demonstration and  Inspect cylinder head
 Internal combustion Observation - Bend
 External - Cracks
combustion - Surface (flatness)
 2 stroke  Inspect cylinder head
 4 stroke components
 Rotary - Valve mechanism
1.2 Determine construction of - Hydraulic lifter
engine - Rocker
1.3 Determine engine mechanism
cylinder head assembly - Cam shaft bearing
component such as  Measure cylinder
 Cylinder head head components
 Valve  Inspect for oil
 Bucket tappet leakage
 Cam shaft  Inspect oil pressure
 Rocker arm relief valve
 Valve spring  Inspect oil pressure
 Rocker finger relief valve
 Rocker cover  Change oil pressure
1.4 Test engine compression switch
 Dry test  Inspect for water
 Wet test leakage
 Running test  Inspect condition of
1.5 Interpret compression radiator hoses
test result  Inspect condition of
 Refer engine radiator pressure cap
specification  Inspect condition of
expansion tank
Attitude/Safety:
 Handle compression gauge
with care

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DELIVERY ASSESSMENT
STEPS KNOWLEDGE PERFORMANCE HRS
MODE MODE

2. Remove cylinder 2.1Function and types of 4 Lecture  Inspect radiator


head assembly cylinder head assembly condition
 Hemispherical - Upper tank
 Bathtub - Lower tank
 Wedge - Core
2.2 Construction of cylinder - Fin
head  Flush radiator
2.3 Cylinder head materials  Detach thermostat
 Cast iron  Test thermostat
 Aluminum alloy  Fix thermostat
2.4Locations of cylinder head  Inspect thermostat
components such as housing from leakage
 Rocker mechanism  Remove water pump
 Valve mechanism  Make water pump
2.5 Procedure to remove gasket
cylinder head assembly  Install water pump
2.6 Method to unfasten  Detach cooling fan
cylinder head bolts  Test cooling fan
2.1 Disconnect battery 9 Demonstration and  Fix cooling fan
terminal Observation  Assemble cylinder
2.2 Drain water coolant head components
2.3 Take out external  Torque cylinder head
attachment assembly bolts
2.4 Unfasten cylinder head  Fix timing belt/chain
bolts  Adjust timing belt
2.5 Take out cylinder head tension
from engine

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DELIVERY ASSESSMENT
STEPS KNOWLEDGE PERFORMANCE HRS
MODE MODE

2.6 Dismantle cylinder head  Adjust valve


components clearance/bleed
 Rocker mechanism hydraulic
 Valve mechanism  Test water pump from
leakage
Attitude/Safety:  Detach engine air
 Follow procedure to filter
unfasten cylinder head  Clean engine air filter
bolts  Fix engine air filter
 Disconnect negative cable  Fix battery terminal
from battery  Confirm engine
lubrication oil level
 Inspect oil leakage
3. Examine engine 3.1 Method of checking 6 Lecture  Inspect water coolant
cylinder head cylinder head leakage
assembly 3.2 Method of cleaning cylinder  Inspect engine from
head components abnormal noise
3.3 Types and usage of - Knocking
measuring tools such as - Humming
 Micrometer - Pinking
 Vernier caliper  Adjust ignition timing
 Dial gauge indicator  Adjust engine idling
 Filler gauge speed
 Straight edge  Test lubrication
 Valve spring tester pressure system
 Hydraulic lifter tester  Interpret test result
3.4 Procedures of valve
lapping

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DELIVERY ASSESSMENT
STEPS KNOWLEDGE PERFORMANCE HRS
MODE MODE

3.1 Clean cylinder head and 9 Demonstration and


components Observation
3.2 Inspect cylinder head
 Bend
 Cracks
 Surface (flatness)
3.3 Inspect cylinder head
components
 Valve mechanism
 Hydraulic lifter
 Rocker mechanism
 Cam shaft bearing
3.4 Use measuring tools
3.5 Measure cylinder head
components
 Tear and wear
 Bend
 Run out
3.6 Lap cylinder head valve
3.7 Test valve seat from leak

Attitude/Safety:
 Patient when lapping valve
 Meticulous when measure
cylinder head components

24
DELIVERY ASSESSMENT
STEPS KNOWLEDGE PERFORMANCE HRS
MODE MODE

4. Install cylinder 4.1 Procedures of assembling 2 Lecture


head assembly cylinder head components
4.2 Types of cylinder head
gasket
 Carbon
 Metal
 Silicon
4.3 Method of tightening
cylinder head bolts
4.4 Valve timing diagram
4.5 Types of timing belt
tensioner
 Auto
 Manual

4.1 Assemble cylinder head 12 Demonstration and


components Observation
4.2 Torque cylinder head
assembly bolts
4.3 Fix timing belt/chain
4.4 Adjust timing belt tension
4.5 Adjust valve clearance or
bleed hydraulic
4.6 Fix external attachment

Attitude/Safety:
 Meticulous when adjust
valve clearance

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DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE

5. Check lubrication 5.1 Function of lubrication 4 Lecture


system system
components 5.2 Layout and function of
lubrication system
components such as
 Oil filter
 Oil pump
 Oil sump
 Oil main gallery
 Oil pressure regulator
 Oil cooler
 Oil sensor
 Oil pressure switch
 Oil pressure relief valve
5.3 Types and function of
engine lubrication oil
5.4 Operational flow of
lubricant
5.5 Construction and operation
of engine oil cooler
5.6 Construction and operation
of oil pressure relief valve
5.7 Circuit diagram of oil
pressure switch

5.1 Determine location of 6 Demonstration and


lubrication system Observation
components
5.2 Interpret operational flow
of lubricant

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DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
5.3 Inspect for oil leakage
5.4 Apply procedure to
change oil pressure
switch
 Test oil pressure
switch
 Remove oil pressure
switch
 Replace oil pressure
switch
 Fix and tighten oil
pressure switch
according to
specifications

Attitude/Safety:
 Avoid spilling oil on floor
 Handle oil pressure
gauge with care

6. Check radiator unit 6.1 Principles of cooling 4 Lecture


system
6.2 Types of cooling system
 Air
 Liquid
6.3 Layout of cooling system
components

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DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
6.4 Function of cooling system
components such as
 Water pump
 Thermostat
 Radiator
 Radiator fan
 Radiator hose
 Radiator cap
 Expansion tank
 Belt
 Temperature sensor
 Temperature gauge
 Water jacket
6.5 Types of radiator
 Down flow
 Cross flow
6.6 Construction of radiator
 Radiator core assembly
 Inlet/outlet pipe
 Inlet/outlet tank
 Gasket
 Filler neck
6.7 Checking radiator unit
method
6.8 Types of coolant
 Anti freeze
 Anti corrosion
6.9 Purpose of flushing
radiator
6.10Techniques to flush
radiator

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DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
6.1 Determine location of 4 Demonstration and
cooling system Observation
components
6.2 Inspect for water leakage
6.3 Inspect condition of
radiator hoses
6.4 Inspect condition of
radiator pressure cap
6.5 Inspect condition of
expansion tank
6.6 Inspect radiator
assembly condition
 Upper tank
 Lower tank
 Core
 Fin
6.7 Flush radiator

Attitude/Safety:
 Meticulous when handling
hot water
 Wear PPE
7. Check thermostat 7.1 Function, operation and 1 Lecture
functioning types of thermostat
 Single stage
 Two stage
7.2 Thermostat opening
specifications
7.3 Procedures to remove
thermostat
7.4 Method to test thermostat

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DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE

7.1 Detach thermostat 3 Demonstration and


7.2 Test thermostat Observation
functioning using hot
water
7.3 Read thermometer
7.4 Fix thermostat
7.5 Inspect thermostat
housing from leakage

Attitude/Safety:
 Meticulous when
handling hot water

8. Check water pump 8.1 Function and types of water 2 Lecture


functioning pump
8.2 Construction and operation
of water pump
 Water pump impeller
 Water pump housing
 Water pump bearing
8.3 Procedures of removing
and installing water
8.4 Procedures of checking
water pump functioning

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DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
8.1 Determine type of water 12 Demonstration and
pump Observation
8.2 Detach water pump
8.3 Inspect water pump from
noise
8.4 Make water pump gasket
8.5 Install water pump
8.6 Refill water coolant
8.7 Test water pump from
leakage

Attitude/Safety:
 Meticulous when
installing water pump
9. Check cooling fan 9.1 Types of cooling fan 2 Lecture
functioning  Manual fan
 Electric fan
9.2 Construction of cooling fan
 Fan motor
 Fan blade
9.3 Procedure to remove
cooling fan
9.4 Method to check cooling
fan functioning 9.1 Determine type of 2 Demonstration and
cooling fan Observation
9.2 Detach cooling fan
9.3 Test cooling fan
functioning
9.4 Fix cooling fan

Attitude/Safety:
 Keep hands away from
moving fan

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DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
8.1 Determine type of water 12 Demonstration and
pump Observation
8.2 Detach water pump
8.3 Inspect water pump from
noise
8.4 Make water pump gasket
8.5 Install water pump
8.6 Refill water coolant
8.7 Test water pump from
leakage

Attitude/Safety:
 Meticulous when
installing water pump
DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE

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DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
8.1 Determine type of water 12 Demonstration and
pump Observation
8.2 Detach water pump
8.3 Inspect water pump from
noise
8.4 Make water pump gasket
8.5 Install water pump
8.6 Refill water coolant
8.7 Test water pump from
leakage

Attitude/Safety:
 Meticulous when
installing water pump
10. Conduct cooling 10.1 Purpose of cooling system 1 Lecture
system pressure pressure test
test 10.2 Procedures of testing
cooling system pressure
10.3 Types of cooling system
pressure tester
10.4 Operation of cooling
system pressure tester
10.5 Cooling system pressure
specifications

10.1 Operate cooling system 2 Demonstration and


pressure tester Observation
10.2 Pressurize cooling
system
10.3 Interpret test result

Attitude/Safety:
 Meticulous when

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DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
8.1 Determine type of water 12 Demonstration and
pump Observation
8.2 Detach water pump
8.3 Inspect water pump from
noise
8.4 Make water pump gasket
8.5 Install water pump
8.6 Refill water coolant
8.7 Test water pump from
leakage

Attitude/Safety:
 Meticulous when
installing water pump
11. Check engine air 11.1 Purpose of engine air filter 1 Lecture
filter 11.2 Types of engine air filter
 Paper element
 Oil bath
11.3 Operation of engine air
filter
11.4 Procedures of cleaning air
filter
11.5 Method of checking
engine air filter

34
DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
11.1 Detach engine air filter 3 Demonstration and
11.2 Clean engine air filter Observation
11.3 Fix engine air filter

Attitude/Safety:
 Meticulous when cleaning
air filter
 Wear dust mask

12. Check ignition 12.1 Procedures of starting an 2 Lecture


timing engine
12.2 Engine operating
temperature
12.3 Inspect engine from
abnormal noise
 Knocking
 Humming
 Pinking

12.1 Fix battery terminal 4 Demonstration and


12.2 Confirm engine Observation
lubrication oil level
12.3 Confirm coolant oil level
12.4 Start engine for
warming up
12.5 Ensure engine is at
normal operating
temperature
12.6 Inspect oil leakage
12.7 Inspect water coolant
leakage

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DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
12.8 Inspect engine from
abnormal noise
 Knocking
 Humming
 Pinking
12.9 Adjust ignition timing
12.10 Tune up engine idling
speed

Attitude/Safety:
 Connect positive battery
first

13. Conduct 13.1 Procedures of testing 1 Lecture


lubrication system lubrication pressure
pressure test
13.1 Install oil pressure test 3 Demonstration and
gauge Observation
13.2 Test lubrication
pressure system
13.3 Interpret lubrication
pressure reading
13.4 Off engine

Attitude/Safety:
 Meticulous when
installing oil pressure test
gauge

36
DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
Core Abilities

01.04 Analyze Information


01.05 Utilize the internet to locate and gather information
03.08 Develop and maintain c cooperation within work group
04.01 Organize own work activities
04.02 Set and revise own objectives and goals
04.03 Organize and maintain own workplace
04.04 Apply problem solving strategies
04.05 Demonstrate initiative and flexibility

NOTE ON ASSESSMENT MODE:


A : Practical; B : Project; C : Oral; D : Written; E : Others

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Selected References and Audio Visual Materials
REFERENCES AUDIO VISUAL MATERIALS

1. Anthony E.Schwaller (2004) Total Automotive Technology, 4th


Edition-Delmar Learning, New York USA, ISBN: 1-4018-2476-5

2. Ed May (2003) Automotive Mechanic Vol 2 7th Edition, Mc Graw-


Hill Australia ISBN: 0074712969

Tools, Equipment and Materials


ITEMS RATIO (Equipment : Trainees)
1. Service manual 1:5
2. Hand tools set 1:5
3. Special tools 1:5
4. Measuring tools 1:5
5. Timing light 1:5
6. Tachometer 1:5
7. Valve grinding paste As required
8. Valve grinding stick 1:5
9. Replacement parts As required
10. Lubricant and fluids As required
11. Fender cover 1:5
12. Compression gauge 1:5
13. Oil can 1:5
14. Seat cover 1:5
15. Oil filter wrench 1:5
16. Oil funnel 1:5
17. Lubrication oil As required
18. Oil filter opener 1:5
19. Dust mask 1:1

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20. Waste oil receiver 1:5
21. Top set gasket 1:5
21. Radiator pressure tester 1:5
22. Thermometer 1:5
23. Personal protection equipment 1:1
24. Oil filter 1:5
25. Air filter 1:5
26. Hose 1:5
27. Radiator pressure cap 1:5
28. Water coolant As required
29. Multimeter 1:5

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