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(A1) Engine Repair Task Sheets by ASE area

General

Research vehicle service information, including fluid type, vehicle service history, service precautions, technical service bulletins and recalls, including vehicles equipped with advanced driver assistance systems (ADAS).

Technical Service Bulletins

Microsoft Word

PDF

Vehicle Safety Certification Label

Microsoft Word

PDF

Automated and Connected Vehicle ID

Microsoft Word version

Fillable PDF version

Engine Lubrication Specifications

Microsoft Word version

Fillable PDF version

Retrieve and record DTCs, OBD monitor status, and freeze frame data; clear codes and data when directed.

Connecting Rod Specification/Measurement

Microsoft Word version

Fillable PDF version

Cylinder Block Specification/Measurement

Microsoft Word version

Fillable PDF version

Retrieve DTCs, Monitor Status & Freeze Frames

Microsoft Word version

Fillable PDF version

Retrieving OBD II Diagnostic Trouble Codes

Microsoft Word version

Fillable PDF version

Verify operation of the instrument panel engine warning indicators.

Engine Cooling System Identification

Microsoft Word version

Fillable PDF version

Oil Temperature and Pressure Switches

Microsoft Word version

Fillable PDF version

Inspect engine assembly for fuel, oil, coolant, and other leaks; determine needed action.

Install engine covers using gaskets, seals, and sealers as required.

Valve Cover Gasket Replacement

Microsoft Word version

Fillable PDF version

Verify engine mechanical timing.

Timing Belt/Chain Replacement

Microsoft Word version

Fillable PDF version

Inspect, remove and replace engine mounts.

Block Thread Inspection and Correction

Microsoft Word version

Fillable PDF version

Identify service precautions related to service of internal combustion engine of a hybrid vehicle.

Hybrid Electric Vehicle Safety Precautions

Microsoft Word version

Fillable PDF version

Remove and reinstall engine on a newer vehicle equipped with OBD; reconnect all attaching components and restore the vehicle to running condition.

Hybrid Electric Vehicle Safety Precautions

Microsoft Word version

Fillable PDF version

Cylinder Head and Valve Train

Identify cylinder head and valve train components and configurations.

Cylinder Head and Valve Train Components

Microsoft Word version

Fillable PDF version

Remove cylinder head; inspect gasket condition; install cylinder head and gasket; tighten according to manufacturer’s specification and procedure.

Remove Cylinder Head(s) and Inspect

Microsoft Word version

Fillable PDF version

Clean and visually inspect a cylinder head for cracks; check gasket surface areas for warpage and surface finish; check passage condition.

Cleaning and Crack Detection

Microsoft Word version

Fillable PDF version

Cylinder Head Flatness Measurement

Microsoft Word version

Fillable PDF version

Inspect valve actuating mechanisms for wear, bending, cracks, looseness, and blocked oil passages (orifices); determine needed action.

Adjust valves (mechanical or hydraulic lifters).

Inspect and replace camshaft and drive belt/chain; includes checking drive gear wear and backlash, end play, sprocket and chain wear, overhead cam drive sprocket(s), drive belt(s), belt tension, tensioners, camshaft reluctor ring/tone-wheel, and valve timing components; verify correct camshaft timing.

Timing Belt/Chain Replacement

Microsoft Word version

Fillable PDF version

Inspect valve springs for squareness and free height comparison; determine needed action.

Valve Spring Squareness and Free Height

Microsoft Word version

Fillable PDF version

Replace valve stem seals on an assembled engine; inspect valve spring retainers, locks/keepers, and valve lock/keeper grooves; determine needed action.

Valve Stem Seal Replacement

Microsoft Word version

Fillable PDF version

Inspect valve guides for wear; check valve stem-to-guide clearance; determine needed action.

Valve Guide Specifications and Measurement

Microsoft Word version

Fillable PDF version

Inspect valves and valve seats; determine needed action.

Check valve spring assembled height and valve stem height; determine needed action.

Valve Spring Assembled Height

Microsoft Word version

Fillable PDF version

Inspect valve lifters and hydraulic lash adjusters; determine needed action.

Inspect and/or measure camshaft for runout, journal wear and lobe wear.

Inspect camshaft bearing surface for wear, damage, out-of-round, and alignment; determine needed action.

Camshaft Bearing Surface Inspection

Microsoft Word version

Fillable PDF version

Engine Block Assembly

Identify engine block assembly components and configurations.

Diesel Engine Identification

Microsoft Word version

Fillable PDF version

Gasoline Engine Identification

Microsoft Word version

Fillable PDF version

General Engine Specification

Microsoft Word version

Fillable PDF version

Remove, inspect, and/or replace crankshaft vibration damper (harmonic balancer).

Crankshaft Vibration Damper

Microsoft Word version

Fillable PDF version

Disassemble engine block; clean and prepare components for inspection and reassembly.

Inspect engine block for visible cracks, passage condition, core and gallery plug condition, and surface warpage; determine needed action.

Cleaning and Crack Detection

Microsoft Word version

Fillable PDF version

Cylinder Block Specification/Measurement

Microsoft Word version

Fillable PDF version

Inspect and measure cylinder walls/sleeves for damage, wear, and ridges; determine needed action.

Perform deglazing and cleaning of cylinder walls.

Inspect and measure camshaft bearings for wear, damage, out-of-round, and alignment; determine needed action.

Camshaft Bearing Surface Inspection

Microsoft Word version

Fillable PDF version

Camshaft Bearing Inspection

Microsoft Word version

Fillable PDF version

Inspect crankshaft for straightness, journal damage, keyway damage, thrust flange and sealing surface condition, and visual surface cracks; check oil passage condition; measure end play and journal wear; check crankshaft position sensor reluctor ring (where applicable); determine needed action.

Inspect main and connecting rod bearings for damage and wear; determine needed action

Identify piston and bearing wear patterns that indicate connecting rod alignment and main bearing bore problems; determine needed action.

Piston and Bearing Wear Patterns

Microsoft Word version

Fillable PDF version

Inspect and measure piston skirts and ring lands; determine needed action.

Piston Inspection and Measurement

Microsoft Word version

Fillable PDF version

Determine piston-to-bore clearance.

Inspect, measure, and install piston rings.

Inspect auxiliary shaft(s) (balance, intermediate, idler, counterbalance and/or silencer); inspect shaft(s) and support bearings for damage and wear; determine needed action; reinstall and time.

Auxiliary and Balance Shafts

Microsoft Word version

Fillable PDF version

Assemble engine block.

Lubrication and Cooling Systems

Identify lubrication and cooling system components and configurations.

Engine Cooling System Identification

Microsoft Word version

Fillable PDF version

Engine Lubrication Specifications

Microsoft Word version

Fillable PDF version

Lubrication & Cooling System Components

Microsoft Word version

Fillable PDF version

Perform engine oil and filter change; use proper fluid type per manufacturer specification; reset maintenance reminder as required.

Perform cooling system pressure and dye tests to identify leaks; check coolant condition and level; inspect and test radiator, pressure cap, coolant recovery tank, heater core, gallery plugs: determine needed action.

Engine Cooling System Inspection

Microsoft Word version

Fillable PDF version

Identify causes of engine overheating.

Identify the Cause of Engine Overheating

Microsoft Word version

Fillable PDF version

Radiator Testing with an Infrared Pyrometer

Microsoft Word version

Fillable PDF version

Inspect, replace, and/or adjust drive belts, tensioners, and pulleys; check pulley and belt alignment.

Accessory Drive Belt Inspection

Microsoft Word version

Fillable PDF version

Inspect and test coolant; drain and recover coolant; flush and refill cooling system; use proper fluid per manufacturer specifications; bleed air as required.

Identify types of water pumps (belt driven, chain driven, and electric). Inspect, remove, and replace water pumps.

Remove, inspect, and replace thermostat and gasket/seal.

Remove and replace radiator.

Inspect and test fan(s), fan clutch (electrical or mechanical), fan shroud, and air dams; determine needed action.

Engine Fan Inspection and Testing

Microsoft Word version

Fillable PDF version

Cooling Fan and Related Inspections

Microsoft Word version

Fillable PDF version

Perform oil pressure tests; determine needed action.

Inspect auxiliary coolers; determine needed action.

Inspect, test, and replace oil temperature and pressure switches and sensors.

Oil Temperature and Pressure Switches

Microsoft Word version

Fillable PDF version

Inspect oil pump gears or rotors, housing, pressure relief devices, and pump drive; perform needed action.