QR Questions for Internal Engine Combustion Task 1 – Time the Engine, Remove the Headbolts and Head 1- Why do we time the engine up before stripping it down? 2- What way do we fit the cambelt? 3- If you don’t time the engine up correctly (one or two teeth out), what could happen? 4- What is the purpose of the tensioner and how do you check the operation of the tensioner? 5- After you have fitted the cambelt, what should you do next? 6- What connects the crankshaft and crankshaft pulley, and also turns them together? 7- How many turns does the crankshaft and camshaft turn on one revolution? 8- What is the firing order? 9- What does TDC mean? 10- Should you refit an old cambelt? Task 2 – Remove two inlet and two exhaust valves, carry out measurements on the valves and springs 1- What is the tool called that removes the valves? 2- Name all of the components of the valve assembly? 3- Why do we have a washer at the bottom of the valve? 4- How many measurements do we do on the valve stem? 5- What sort of temperature can the exhaust reach? 6- What is the purpose of the valve stem seal? 7- Why do we check the valve stem guide? Should it be bigger or smaller that the valve? 8- What is the bottom tip of the valve called? 9- What can happen to the valves if the belt breaks? 10- What is the purpose of the rockers? Task 2 – Remove the Camshaft and carry out all measurements 1- What are the tools that are needed to check the camshaft? 2- What does DTI stand for? 3- Why is it important to place the DTI Gauge at 90 degrees? 4- Why do we need to check the camshaft? 5- Where on the camshaft do we measure? 6- What is meant by the term ‘lift’? 7- What can cause damage to the lobes? 8- How many turns does the camshaft turn in one revolution of the engine? 9- On the Cam lobes, what are the maximum and minimum measurements? 10- What tools do you use to measure the Camshaft? Task 3 – Checking for Head Damage 1- Why is it important to check for warpage on the head? 2- Where can the head warp? 3- If the head warps, what can you do? 4- What is the purpose of the combustion chamber? 5- Why do we have a head gasket? 6- What PSI does the head gasket need to be able to take/withstand? 7- What is the head gasket made of? 8- When checking the head, what is the maximum distortion you are aloud? 9- When tightening the head bolts below, what order do you need to do them in? (Need to go to the QR Code, Slide Number 13 and look at the picture) 10- What torque do you torque the head bolts to? Give all readings. Task 2 – Remove the Pistons and carry out all measurements 1- Why do we mark the pistons before we remove them? 2- What is the purpose of the oil jet in the conrod? 3- On the SI engine, name the three pistons rings, explain what order they are in and what their job is? 4- What sort of temperature does the piston get to? 5- Name the parts of the piston? (Go to Slide Number 50 on the QR Code) 6- What is the purpose of the grudeon pin? 7- If the timing is out, and the piston is travelling to TDC, and the valve is open, what could happen to the piston? 8- Why do we use this piece of equipment? (Go to Slide Number 51 on the QR Code) 9- Why do we turn the engine over after we have fitted a piston? 10- Why do we use the wooden part of the hammer to knock the piston in, and not the metal part? Task 2 – Remove the Crankshaft and carry out all measurements 1- What is the purpose of the woodruff key? 2- How many times does the crankshaft turn in one revolution? 3- What is the purpose of the flywheel? 4- Label the parts of the crankshaft? (Go to Slide Number 31 of the QR Code) 5- How do you check for oil clearance? 6- What is the purpose of the shells? 7- Why do we have holes in the journals? 8- If you place the shells in the wrong way, what could happen? 9- In Slide 24 you are using a Micrometer. What are you checking? 10- Where would you find the rear main seal? Task 2 – Carry out all measurements on the Block 1- What can happen to the block if it overheats? 2- How many places do you check in the cylinder? 3- What does the term ovality and tapered mean? 4- How do you get ovality and tapered? 5- What should you do to the cylinder before fitting the piston and why? 6- Label the block? (Go to Slide Number 31 on the QR Code) 7- Why do we have frost plates on the engine? 8- What is the tool called to measure the bore? 9- Why do we horen the bore when we are rebuilding the engine? 10- What is the purpose of the thrust washers, and which way do you refit them? Task 5 – Remove the Oil Pump and Strip it down 1- What is the purpose of the baffle plate in the sump? 2- How is the oil pump driven? 3- What is the purpose of the relief valve? 4- When the pump is stripped down, what are you looking for? 5- How does the gear pump work? 6- If the gauze filter is blocked, what would happen? 7- If the bolts are not tightened to the correct torque setting on the oil pick up pipe, what could happen? 8- If you have filled the car up with too much oil, what could happen to the engine? 9- What sort of seal is fitted to the oil pump? 10- What torque should you torque the oil pump end plate to? Task 7 – Check and Adjust the Valve Clearances (Tappets) 1- Why do we have tappet clearance? 2- How do you adjust tappets? 3- Should you adjust the tappets when they are hot or cold? Task 8 – Check the operation of the Thermostat 1- What is the purpose of a thermostat? 2- How does the thermostat work? 3- How do you test a thermostat? 4- Explain the terms Conduction, Convection and Radiation? 5- What temperature should the thermostat open at? 6- What two ways can you test the operation of the thermostat in the car? 7- If the thermostats stayed closed, what could happen? 8- Why do we have a gasket fitted? 9- When do you know if the water pump is leaking? 10- A customer complains that the temperature is not getting hot. You have to replace the thermostat, which takes 1 hour. You also replace the coolant. The hourly rate is $89.00 per hour, the coolant is $20 a litre and you use 1.5 litres. What is the total price you will charge, including 15% GST? Task 8 – Remove and Refit Core Plug 1- What are the three ways of heat travel? 2- Why is a core plug fitted to the engine? 3- Why should you not knock the core plug inwards? 4- What are the two different types of core plugs? 5- How do you remove both of the different types? 6- Why do we have water jackets? 7- A customer comes into your garage, and one of the front core plugs is leaking. You have to replace it. You have to remove the exhaust manifold. Two of the exhaust studs broke. You drain the coolant, remove and fit the core plug, replace the coolant and fit a new exhaust gasket. The core plug costs $55.75, the Exhaust Gasket is $120.89, the Exhaust Downpipe Gasket is $55.60, and Coolant is $65.00. Removing the exhaust and replacing the broken studs takes 2 hours labour, fitting the core plug and replacing the coolant takes 1.5 hours, and the road test in 0.5 hours. Your garage charges $84.00 per hour. What is the total cost including 15% GST? 8- What is the block made of? 9- When measuring the block with a straight edge, what is the maximum warpage you can have? 10- How do you know what size core plug to fit? What tools must you use? Task 8 – Carry Out Engine Tune using a timing light and multimeter 1- What is the purpose of using a timing light? 2- What does ATDC, BTDC, ABDC, BBDC mean? 3- How does the coil work? 4- What is the purpose of contact points? 5- How do you test the operation of the coil? 6- How do the points open and close? 7- Why do we have a ballast resistor? 8- If you leave the ignition on, what could happen to the coil? Task 8 – Carry out Electrical test on a glow plug circuit and carry out a compression test 1- What is the purpose of a glow plug? 2- Draw a glow plug circuit? Task B1 – Check coolant and carry out test coolant compression test 1- Why do we have coolant? 2- Can you mix coolant? 3- If one ball is floating, what temperature can it drop down to before it starts to freeze? 4- What percentage of coolant to water should you have? 5- What happens if you only replace it with coolant? 6- What temperature does water freeze and boil? 7- Why do we need to pressurise the cap? 8- What should you check if the pressure is dropping on the pressure tester? 9- Why is it important to release the pressure before removing the tester? 10- If you check the water in your radiator, and it is rusty coloured, what does that mean? 11- If you are replacing the anti-freeze, what do you do with the old anti-freeze? Task B2 – Carry out Oil Pressure test 1- Why do we need to carry out an oil pump pressure test? 2- If the warning light comes on, what does this mean? 3- How does the warning light circuit work? 4- What is the purpose of the pump? 5- How is oil graded? 6- What are the two reasons we have oil in the car? 7- A customer comes into your garage, and is complaining of the oil warning light flashing. You have done your check (pressure test), and found that it is a faulty pressure switch. This costs $72.58. You also carried out an oil and filter change. The Oil costs $49.75 and the Filter costs $36.20. There is labour of 1.5 hours, and your garage charges $74 per hour. What is the price to charge the customer, including 15% GST? 8- Make a pie chart of the readings of the oil pressure on idle when cold, and when hot. It also has to include when the engine is idling at 2000rpm cold, and hot. Go to the following link. Download it and place your answer here. (Go to Slide 16 on the QR Codes for this) 9- What could cause too higher oil pressure? 10- What is the purpose of the oil filter? Task 8 – Timing a Diesel Pump Have to request access Task – Carry out Engine compression test, and leak down test 1- What is the purpose of doing a compression test? 2- What is the purpose of doing a leak down test? 3- If you don’t set the cylinder to TDC, what could happen when doing a leak down test? 4- Why do we put oil in the cylinder when carrying out a compression test? 5- What is the firing order on a four stroke four cylinder? 6- How do you know what cylinder is on the ignition stroke? 7- If you put oil in the cylinder on the compression test, and the PSI does not increase, what is the problem? 8- Should you do a compression and leak down test when it is hot or cold? 9- In Slide 15, you need to work out the total Kpa %. Use Slide 16 for help.

Vehicle Tech

Hi guys Vehicle Tech MUST BE FINISHED BY 10th Sep which only gives you 11 days. On the 11th Sept there will be a ASSESSMENTs YOU MUST BRING PENS, CALCULATOR OVERALLS AND BOOTS

Remember
The Engineering module must be done by the 19th June, Also the two  revision assessments and word finder must be placed on your blog. Also all job cards must be filled out and returned to the lecturer