DOCUMENT RESUME ED 098 402 CE 002 507

DOCUMENT RESUMEED 098 402AUTHORTITLEINSTITUTIONSPONS AGENCYPUB DATENOTEAVAILABLE FROMCE 002 507O'Brien, Ralph D.Engine Fundamentals: Automotive MechanicsInstructional Program. Block 2.Kentucky Univ., Lexington. Vocational EducationCurriculum Development Center.Kentucky State Dept. of Education, Frankfort. Bureauof Vocational Education.73115p.; For other curriculum guides in the series, seeCE 002 506-511Curriculum Development Center, Room 151, TaylorEducation Building, University of Kentucky,Lexington, Kentucky 40506 (Single copies only, 3.50)PLIts PRICELf,SCRIPTORSIDENTIFIERSMF- 0.75 HC- 5.40 PLUS POSTAGE*Auto Mechanics; Auto Mechanics (Occupation);Behavioral Objectives; Course Content; CourseDescriptions; *Curriculum Guides; *Engines;Industrial Arts; Instructional Materials; Job Skills;Lubricants; *Mechanics (Process); Post SecondaryEducation; Resource Materials; Secondary Education;Skilled Occupations; *Trade and Industrial Education;Vocational EducationKentuckyABSTRACTThe second of six instructional !locks in automotivemechanics, the lessons and supportive information in the documentprovide a guide for teachers in planning an instructional program inengine fundamentals at the secondary and postsecondary level. Thematerial, as organized, is a suggested sequence of instruction withineach block. Each lesson is stated in terms of a specific teachingobjective, teaching aids, references, and an outline of information.Upon successful completion of the 49 lessons, students viii be ableto: (1) describe the principle of converting fuel and heat tomechanical energy, (2) identify the basic types of power units usedfor motor vehicles, (3) briefly outline the historical development ofthe internal combustion piston engine and explain its operatingprinciples, (4) describe and relate the systems, parts, components,and mechanisms essential to the mechanical operation of modern pistonengines, (5) disassemble, examine, measure, adjust, align, refit,machine, and reassemble components and mechanisms from practiceengines, and (6) describe the purpose and functions of modern enginelubricating systems and relate the use of modern lubricants. Includedwith the course outline are transparency masters and a referenceguide listing related books, texts, and other publications. (M W)

AUTOMOTIVE MECHANICSINSTRUCTIONAL PR.OGI' AMBLOCK IIEngine FundamentalsPREPARED FORKentucky Industrial Education TeachersINCOOPERATIONWITHBureau of Vocational EducationState Department of EducationFrankfort, KentuckyD. O'Brien, Curriculum SpecialistCurriculum Development Center151 Taylor Education BuildingUniversity of KentuckyLexington, KentuckyRalph

("eine lindamental Upon successful completion of the forty-nine lessons in this block of work,students will be able to:1.Describe the principles of converting fuel and heat to mechanical energy.11.2.Identify the basic types of power units used for motor vehicles.3.Briefly outline the historical development of the internal combustion pistonengine and explain its operating principles.4.Describe and relate the systems, parts, components, and mechanisms essentialto the mechanical operation of modern piston engines.S.Disassemble, examine, measure, adjust, align, refit, macnine, and reassemblecomponents and mechanisms from practice engines.6.Describe the purpose and functions of modern engine lubricating systems andrelate the use of modern lubricants.

CONTENTS - BLOCK IIENGINE FUNDAMENTALSExternal CombustionExternal CombustionInternal CombustionInternal CombustionPiston Engines-Basic Operating PrinciplesTorque, Horsepower, RPM123456The Pi '.on Engine7Reciprocal to Rotary MotionEngine CyclesEngine Cycles89IntakeCompressionPowerExhaustFour-Stroke Cycle EngineEngine ClassificationsBasic Engine Design Depending on Cyclinder ArrangementsEngine Block, Head and Oil PanEngine Block, Head, and PanGasketsEngine GasketsRemoving and Replacing Cylinder HeadRod, Piston and Rings AssemblyConnecting Rod, Piston, and RingsCleaning and Inspecting Pistons and Rod AssembliesExamine, Measure, and Align Connecting Rod.Bearings (Precision Type Insert Bearings)Examining and Measuring BearingsUse of PlastigageCylinder'Wear Limits.Cylindey4Ridge, Cause and CorrectionCylinder Taper and RidgeMicrometerMicrometersMicrometer ReadingsMeasuring CylindersCrankshaft Function and Design CharacteristicsCrankshaftsCrankshaft InspectionCrankshaft.easuring i CrankshaftFlywheel Function and Design CharacteristicsEngine ComponentsCamshaft Function and DesignCam DesignCamshaft Drives and Timing GearsChecking Camshaft Bearing 363739404243444546474849505152545556

Crankshaft-Camshaft RelationshipValve Purpose and OperationCrankshaft, Camshaft, and ValveValve ConstructionValve ConstructionValve Systems.Valve Arrangements, I-Head, T-HeadValve Arrangements, L-Head, F-HeadValve TrainsValve System MechanismsValve SeatsValve SeatingRemoving Valves and SpringsFitting Valve SpringsPracticing Valve Grinding and Valve Seat GrindingValve Lifters - Function and TypeMechanical Valve LifterHydraulic Valve LifterExamining Valve LiftersValve RotatorsValve AdjustmentAdjusting Valve Tappets (With Engine Operating)Adjusting Valve Tappets (Engine Not Running)Purpose of Engine Lubricating SystemsThe Four Essential Functions of the Engine Lubricating SystemReaction Within Engine Crankcase Temperatures During Operation.Function and Construction of Oil Pumps and Oil Pressure ReliefValveLocation of Oil Pump in the EngineGear-Type Oil PumpInspecting a Gear Type Oil PumpInspecting a Rotor Type Oil PumpRotor-Type Oil PumpFiltration (Oil Filter Systems)Oil FilterSpin-On Oil FilterFull Flow Type System, Easy Change, Fran CorporationFull Flow Type System, Replaceable Cartridge, Fram Corporation.By-Pass Type System, Easy Change, Fran CorporationService Ratings of OilViscosity StandardsNew Engine Oil DesignationsEngine Oil DesignationsOil Pressure IndicatorsElectric Circuit Oil Pressure IndicatorOil Pressure Indicator, Bourdon 8899091.9293949596979899100101103104106107108109

INFORMATIONBloa:Lesson:Engine FundamentalsExternal CombustionBlockJobLessonTITeachin& Objective: Upon completion of this lesson, students will be able todiscuss the principles of external combustion.Teaching Aids:Reference:Transparency:- External Combustion, p. 11-2Encyclopedia Americana, Volume 10, 1969Outlihe of Informatim:1.The external combustion engine is a mechanical energy device that receivesits heat energy from fuel having been burned outside the engine cylinder.2.The steam engine is the most common application of converting externalcombustion heat energy to mechanical energy.3.Many fuels have been 11,ed to produce steam power, such as wood, oil, gasand kerosene. However, coal is most abundantly used.4.Once the major sorLce of mechanical power in the 20th century, the steamengine has virtually been replaced.a.Two types of steam engines-- Reciprocating (piston-type)-- Steam turbineb.The steam engine was used to power some production automobiles in theearly 1900's.-- Stanley, White, Locomobile

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INFORMATIONBlock;Lesson:Engine FundamentalsInternal CombustionBlockJobLesson11Teachin; Objictive: Upon completion of this lesson, students will be able to discussthe principles of internal combustion.Teaching Aids:References:Transparency:- Internal Combustion, p. 11-4Auto Mechanics Fundamentals, Stockel, Chapter 1"Gasoline as Automotive Fuel," Block IV, pp. IV-I, IV-2Outline of Information:1.The internal combustion engine is a device that converts potential energy(the heat energy contained in fuel) into kinetic energy (useful mechanicalenergy).a. All combustible materials contain heat energy, but only a few are suitableas fuel for infernal combustion engines.-- Gasoline, liquid petroleum gas, natural gas, methane are suitable.-- Gunpowder, dynamite are unsuitable.-- Kerosene and other grades and types of fuel oil are suitable forDiesel and turbine applications.b. The most common internal combustion engine for automotive application isthe four-stroke cycle piston engine.Gasoline is the most commonly-usedfuel.2.As the contained fuel burns, it expands, releases heat, and exerts the forceto initiate the kinetic energy.a. Explosive force in the cylinder pushes the piston creating the initialmovement in the mechanical energy train.b. The necessity of controlling the energy and motion has led to the modern,complicated automotive engine systems.

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INFORMATIONBlock:Lesson:Engine FundamentalsPiston Engines-Basic Operating PrinciplesBlockJobLessonIITeaching Objective: Upon completion of this lesson, students will be able todescribe the chemical and physical activities during the combustion process inthe internal combustion engine.Teaching Aids:References:Transparency:- Cleaner Exhaust Regulations, p. IV-133Auto Mechanics Fundamentals, Stockel, Chapter 1Automotive Mechanics, Crouse, Chapter 3Outline of Information:1.2.Atoms and moleculesa.When two or more atoms combine, molecules form.b.Chemical reactions cause molecules to form.c.Combustion is a chemical reaction in which oxygen combines withother elements.-- Chemically, oxygen is a very active element.d.During combustion the following chemistry occurs. (Refer toBlock IV, pp. IV-1 - IV-10)-- Atoms of oxygen and hydrogen combine to form water (H20).-- Atoms of oxygen and carbon combine to form carbon dioxide (CO2).-- Atoms of oxygen and carbon combine to form carbon monoxide (CO).Combustiona.During combustion, extreme temperature changes occur.-- Pressurization of gasses creates heat.-- The temperature of compressed air in a diesel engine canreach 1000 F.-- The resulting temperature from burning fuel in an enginecylinder is upwards to 6000 F.b.The rapid movement of molecules and the chemical changes Inducesthe following physical activities:-- Heat causes expansion of liquids and gases.-- Heat increases pressures of gases.-- Heat causes expansion of solids (metals).-- As heat effects pressure, it effects vacuum.

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INFORMATIONBlock:Engine FundamentalsLesson:BlockJobLessonThe Piston EngineIITeaching Objective: Upon completion of thislesson, students will be able todiscuss the relationship of work and power to theinternal combustion engineand trace the early development of the engine.Teaching Aide:References:Motion Picture:The ABC of the Automobile Engine, General MotorsTransparency:- Torque, Horsepower, RPM, p. 11-6Automotive Mechanics, Crouse, Chapter 3Fundamentals of Aircraft Piston Engine, Borden and Cake,Chapter 1putline of Information:1.The piston engine (also called reciprocating engine)is a member of theinternal combustion engine family of power plants.2.The piston engine produces power by burning fuel and convertingthereleased energy from force to controlled motion.a.Power is the rate at which work is doneb.Work is the application of force.Piston engines are the most common source of power in modern use.4.The early development of the internal combustion piston engine tookplace during the ninteenth century.a.England (1820) - experimentation with exploding hydrogento movea piston in a cylinderb.England (early 1800's) - piston engines burning illuminatinggasand air-- These engines were inefficient, heavy and sluggishc.France (1862) - Beau de Rw-hes developed the al:ignition,comAreasedfuel mixture theory and proposed the modern four-strokecyc/e.d.Germany (1876) - Nikolaus Otto built aid sold Otto SilentGas Engines.-- Otto used the four-stroke cycle which is referred to as the Ottocyclee.Germany (1886) - Gottlieb Daimler adapted the four-strokecycle enginefor liquid-fuel operation11-7