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Classroom Manualby Jeffrey Rehkopf
Synopses & Reviews
This two book set–a Classroom Manual and a Workshop Manual–provides a current and deep technical discussion of engine rebuilding and repair. This revision, written by a new author, has greatly reorganized the Workshop manual to eliminate duplicate material and improve the correlation between the two books. Provides users with an excellent resource in preparation for ASE Certification tests. In addition to the latest information about lubricants, engine design, and manufacturing, the books cover the following key topics: OSHA safety self-inspection worksheets; Engine parts, operation, and construction; Engine physics and chemistry; cooling systems; intake and exhaust systems; Tools for engine rebuilding; Engine testing and diagnosis; Engine removal, disassembly, general inspection, and cleaning. For auto mechanic professionals, those preparing for the ASE Certification Exam, or for use as a reference tool for those seeking a good foundation in theory and repair of engines.
Table of Contents
INTRODUCTION TO AUTOMOTIVE ENGINE REPAIR.
1. Engine Operation and Construction.
Engine Operation. Major Engine Components. Cylinder Arrangement. Engine Displacement and Compression Ratio. Engine Structure. Engine Systems. The Ignition System. Engine-Ignition Synchronization. Other Engine Types.
2. Engine Physics and Chemistry.
Engine Physics. Engine Torque. Engine Horsepower. Chemistry and Combustion. Engine Operation and Air Pressure. Airflow Requirements. Air-Fuel Ratios. Introduction to Emission Control. Engine Design Effects on Emissions. Engine Mechanical Condition Effects on Emissions.
Cooling System Function. Engine Coolant. Cooling System Components. Engine Temperature Effects on Mechanical Wear.
4. Intake and Exhaust Systems.
The Intake System. The Intake Manifold. The Exhaust System.
5. Engine Lubrication.
Purposes of Engine Oil. Engine Oil Composition and Additives. Engine Oil Designations. Engine Oiling System and Pressure Requirements. Engine Lubrication Effects on Mechanical Wear.
6. Engine Materials and Manufacture.
Engine Materials. Metallurgy. Man-Made Materials. Manufacturing Operations. Material Treatments. Machining Operations. Materials and Machining Relationships.
7. Cylinder Blocks and Heads.
Materials and Construction. Cylinder Block Design. Cylinder Heads. Cylinder Head Attachment. Miscellaneous Engine Covers.
8. Valves, Springs, Guides and Seats.
Valves. Springs. Guides. Valve Guide Seals. Valve Seats. Valve, Spring, Guide, and Seat Relationships.
9. Camshafts, Camshaft Drives, and Valve Timing.
Camshafts. Camshaft Drives. Camshaft Design. Valve Timing. Reground Camshafts. Variable Valve Timing.
10. Lifters, Followers, Pushrods, and Rocker Arms.
Valve Lifters and Cam Followers. Pushrods. Rocker Arms.
11. Crankshafts, Flywheels, Vibration Dampers, and Balance Shafts.
Crankshafts. Flywheels. Flexplates. Vibration Dampers. Engine Balance.
12. Pistons, Rings, and Connecting Rods.
Pistons. Piston Rings. Connecting Rods. Piston Speed.
13. Engine Bearings.
Bearings and Friction. Bearing Types. Main and Connecting Rod Bearings. Camshaft Bearings. Plain Bearing Operation. Plain Bearing Materials.
14. Gaskets, Seals, Sealants, Fasteners, and Engine Mounts.
Gaskets. Seals. Adhesive, Sealants, Lubricants, and Cleaners. Fasteners. Engine Mounts.
15. ASE Sample Test.
AUTOMOTIVE ENGINE REPAIR AND REBUILDING SHOP MANUAL.
Personal Safety. Know Your Shop. Fire. Solvents and Chemicals. Right to Know Laws. Vehicle and Underhood Safety. Electrical Safety. Tool Safety. Machine Tool Safety. OSHA Safety Self Inspection Check List.
2. Tools for Engine Rebuilding.
General Hand Tools. Power Tools. Automobile Technician Tool Set.
3. Measurement, Measuring Equipment, and Specifications.
The Metric System. Measurement Tools. Fastener Torque. Manufacturers Specifications.
4. Engine Testing and Diagnosis.
Oil Consumption. Engine Oil Pressure. Basic Diagnostic Tests. Engine Noises. Replacement Parts, Subassemblies, and Engines.
5. Engine Repair in the Vehicle.
Servicing the Camshaft Drive. Valve Train Adjustment and Repair. Removing and Replacing the Cylinder Head. Cylinder Head Gasket Replacement. Servicing the Bottom End.
6. Engine Removal, Disassembly, General Inspection, and Cleaning.
Preparation. Disconnecting the Engine. Lifting the Engine. Inspect as You Go. Top End Disassembly and Inspection. Bottom End Disassembly and Inspection. Engine Cleaning.
7. Servicing Blocks.
Tolerances and Oil Clearances. Block Inspection. Main Bearing Bore Reconditioning. Deck Reconditioning. Cylinder Reconditioning. Lifter Bore Reconditioning.
8. Servicing Cylinder Heads.
Head Disassembly. Cleaning. Inspection. Head Resurfacing. Repairing Cracks and Damaged Threads. Repairing Damaged Threads. Internal Thread Replacement. Crack Detection. Crack Repair.
9. Servicing Valves and Guides.
Valve Inspection. Valve Repair. Valve Guide Repair. Valve Seat Reconditioning. Valve Testing and Assembly.
10. Servicing Camshafts, Lifters, Followers, Pushrods, and Rocker Arms.
Camshaft Service. Valve Lifter and Cam Follower Service. Pushrod Service. Rocker Arm and Shaft Service.
11. Servicing Crankshafts, Flywheels, and Engine Balancing.
Crankshaft Service. Flywheel and Flexplate Service. Engine Balancing.
12. Piston and Connecting Rod Service.
Separating Pistons and Rods. Reconditioning Pistons. Evaluating Connecting Rod Condition. Reconditioning Connecting Rods. Piston and Connecting Rod Reassembly.
13. Engine Assembly.
General Assembly Practices. Oil Pump Service. Assembly Preparation. Assembling the Block and Bottom End. Final Bottom End Assembly. Assembling the Top End.
14. Final Assembly, Installation, Break-in, and Delivery.
Final Assembly Procedures. Engine Pre-oiling. Engine Installation. Starting the Engine. Cycling the Engine. Returning the Vehicle to the Customer.
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