Test Project Automobile Technology TASK E – Engine mechanical TP33_14VN_actual_M4 Submitted by: Name: Member Country: All Members TP33_14VN_actual_M4_EN Copyright © ASEAN Skills Competition 2014 All rights reserved.6 Skill 33 - Automobile Technology Competitor Instructions - Automobile Technology Competitor Name Country Code Task E Instructions to Competitor Task Engine Mechanical Familiarization Time 15 minutes Task Duration hours Total Breaks 15 minutes Marking Summary Section Possible Mark Health, Safety and House Keeping 1.10 Dismantling Engine External Attachment Components 0.40 Dismantling Timing Belt 1.10 Dismantling Cylinder Head 1.60 Dismantling piston, connecting rod and crankshaft 1.80 Cylinder Bore and Piston Measurements 1.90 Crankshaft and Bearing Measurements 2.40 Valve & Valve Mechanism Measurements 1.90 Assembling Piston, Connecting Rod and Crankshaft 2.70 10 Assembling Cylinder Head 1.60 11 Assembling Timing Chain 1.20 12 Assembling Engine External Attachment Components 0.30 Task Total 10TH ASC, October 2014, Ha Noi, Viet Nam 18.00 Skill 33 - Automobile Technology You are required to - Observe occupational health & safety standards - Only ask necessary questions - Not speak to the public while competing - Comply with Experts instructions - Ensure Name on all forms - Use appropriate tools and procedures - Complete all instructions on the next page Remarks: Toyota Engine 2AZ - FE mounted on stand Make / Model : Toyota Camry 2.4 - Year 2007 10TH ASC, October 2014, Ha Noi, Viet Nam Skill 33 - Automobile Technology Competitor Instructions - Automobile Technology Competitor Name Country Code Task E Prepare all necessary tools and equipment for measuring engine components Disassemble and re-assemble the engine Perform measurement work according to the report sheet For cylinder bore and piston measurement perform in cylinder number one * Working procedures to follow according to workshop manual 10TH ASC, October 2014, Ha Noi, Viet Nam Skill 33 - Automobile Technology Form - Automobile Technology Competitor Name Country Code Task Marking Scale E Engine Mechanical Marking Summary Possible Mark Section Health, Safety and House Keeping 1.10 Dismantling Engine External Attachment Components 0.40 Dismantling Timing Belt 1.10 Dismantling Cylinder Head 1.60 Dismantling piston, connecting rod and crankshaft 1.80 Cylinder Bore and Piston Measurements 1.90 Crankshaft and Bearing Measurements 2.40 Valve & Valve Mechanism Measurements 1.90 Assembling Piston, Connecting Rod and Crankshaft 2.70 10 Assembling Cylinder Head 1.60 11 Assembling Timing Chain 1.20 12 Assembling Engine External Attachment Components 0.30 Task Total Actual Mark 18.00 Time Keeping Familiarization Competition Breaks Start Start Start Stop Stop Stop Experts Signatures 10TH ASC, October 2014, Ha Noi, Viet Nam Skill 33 - Automobile Technology Competitor Name Country Code Health, Safety and House Keeping Yes No 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 Check all equipment Check all instructions Select the correct tools Proper tools handling Calibrate measuring tools Use logical working procedure Prepare working area Prepare tools and equipment Clean up the test models 0.10 0.10 0.10 0.10 0.20 0.20 0.10 0.10 0.10 0 0 0 0 1.10 Sub-Total Dismantling engine external attachment components Yes No 2.1 2.2 Use workshop manual Remove valve cover 0.10 0.10 0 2.3 Remove all ignition coils 0.10 2.4 Remove all spark plugs 0.10 Sub-Total 0.40 Dismantling Timing Chain Yes No 3.1 Set timing mark in the correct position 0.20 3.2 Remove crankshaft damper 0.10 3.3 Remove front crankshaft oil seal 0.10 3.4 Remove crankshaft sensor 0.10 3.5 Remove front timing cover 0.10 3.6 Remove timing chain tensioner 0.10 3.7 Remove timing chain slipper 0.10 3.8 Remove timing chain vibration damper 0.10 3.9 Remove crankshaft position sensor plate 0.10 3.10 Remove timing chain 0.10 1.10 Sub-Total 10TH ASC, October 2014, Ha Noi, Viet Nam Task Marking Scale E Engine Mechanical Actual Comments Actual Comments Actual Comments Skill 33 - Automobile Technology Competitor Name Country Code Dismantling cylinder head Yes No 4.1 Turn crankshaft counterclockwise to 40 degrees from TDC 0.20 4.2 Loosen camshaft caps uniformly 0.20 4.3 Remove camshaft caps 0.10 4.4 Remove camshaft together with VVTi 0.20 4.5 Loosen cylinder head bolts in correct order 0.30 4.6 Remove all cylinder head bolts 0.10 4.7 Remove cylinder head 0.20 4.8 Remove cylinder head gasket 0.10 4.9 Remove one cylinder set of valves 0.20 Sub-Total 1.60 Dismantling piston, connecting rod and crankshaft Yes No 5.1 Loosen all oil pan bolts 0.20 5.2 Remove oil pan 0.10 5.3 Remove oil strainer 0.10 5.4 Remove oil pump and drive chain 0.10 5.5 Loosen crankshaft balancer shaft assembly bolts in correct order 0.20 5.6 Remove crankshaft balancer assembly 0.10 5.7 Loosen all connecting rod bearing caps 0.20 5.8 Remove connecting rod bearing caps 0.20 5.9 Remove all pistons with connecting rods 0.20 5.10 Remove main bearing caps in correct order 0.20 5.11 Remove crankshaft 0.20 1.80 Sub-Total 10TH ASC, October 2014, Ha Noi, Viet Nam Task Marking Scale E Engine Mechanical Actual Comments (2 inlet & exhaust valves) Actual Comments Skill 33 - Automobile Technology Competitor Name Country Code Cylinder Bore & Piston Measurement Yes No 6.1 Set up bore gauge and micrometer 0.30 6.2 Correct usage of bore gauge 0.30 6.3 Correct usage of micrometer 0.30 6.4 Measure Piston Diameter 0.20 6.5 Measure Cylinder Bore 0.30 6.6 Measure Piston ring side Clearance 0.30 6.7 Measure Piston ring end Gap 0.20 1.90 Sub-Total Crankshaft & Bearing Measurement Yes No 7.1 Set up of micrometer and dial gauge 0.30 7.2 Correct usage of micrometer 0.30 7.3 Correct usage of dial gauge 0.30 7.4 Correct usage of plastic gauge 0.30 7.5 Measure Main Journal Diameter 0.20 7.6 Measure Oil Clearance Main Journal 0.20 7.7 Measure Crank Pin Diameter 0.20 7.8 Measure Crank Pin Side clearance 0.20 7.9 Measure Oil Clearance Crank Pin 0.20 7.10 Measure crankshaft end play 0.20 2.40 Sub-Total 10TH ASC, October 2014, Ha Noi, Viet Nam Task Marking Scale E Engine Mechanical Actual Comments Actual Comments Skill 33 - Automobile Technology Competitor Name Country Code Task Marking Scale E Engine Mechanical Valve & Valve Mechanism Measurement Yes No 8.1 Set up of micrometer and vernier caliper 0.30 8.2 Correct usage of micrometer 0.30 8.3 Correct usage of vernier caliper 0.30 8.4 Measure inlet valve stem 0.20 Use Micrometer 8.5 Measure exhaust valve stem 0.20 Use Micrometer 8.6 Measure valve spring height 0.20 Use Vernier 8.7 Measure cam height 0.20 Use Micrometer 8.8 Measure camshaft bent 0.20 Use dial gauge Sub-Total 1.90 Actual Comments Assembling piston, connecting rod and crankshaft Yes No 9.1 Lubricate components before assembling 0.20 9.2 Install crankshaft 0.20 Torque 9.3 Install main bearing caps and tighten to torque in correct order 0.40 Torque 9.4 Install piston ring in correct setting 0.40 Torque 9.5 Install piston with connecting rod 0.20 Torque 9.6 Install connecting rod bearing caps and tighten to torque 0.40 Torque 9.7 Install crankshaft balancer assembly and tighten all bolts to torque in correct order 0.40 9.8 Install oil strainer 0.20 Torque 9.9 Install oil pan 0.30 Torque 2.70 Torque Sub-Total 10TH ASC, October 2014, Ha Noi, Viet Nam Actual Comments Skill 33 - Automobile Technology Competitor Name Country Code 10 Assembling Cylinder Head Yes No 10.1 Install one cylinder set of valves 0.20 10.2 Install cylinder head gasket 0.10 10.3 Install cylinder head 0.10 10.4 Tighten and torque cylinder head bolts in correct order stage 0.30 10.5 Turn 900 cylinder head bolts in correct order stage 0.30 10.6 Install camshafts in correct position 0.40 10.7 Install, tighten and torque camshaft caps in correct order 0.20 1.60 Sub-Total 11 Assembling timing chain Yes No 11.1 Install timing chain 0.10 11.2 Install crankshaft position sensor plate 0.10 11.3 Install timing chain vibration damper 0.10 11.4 Install timing chain slipper 0.10 11.5 Install timing chain tensioner 0.10 11.6 Install front timing cover 0.10 11.7 Install crankshaft sensor 0.10 11.8 Install water pump 0.10 11.9 Install crankshaft damper 0.10 11.10 Set timing mark in the correct position 0.20 11.11 Turn engine two revolutions 0.10 Sub-Total 1.20 12 Assembling engine external attachment components Yes No 12.1 Install valve cover 0.10 12.2 Install all spark plugs 0.10 12.3 Install ignition coils 0.10 0.30 Sub-Total 10TH ASC, October 2014, Ha Noi, Viet Nam Task Marking Scale E Engine Mechanical Actual Comments Torque value 70 Nm Actual Comments Actual Comments 10 Skill 33 - Automobile Technology Competitor Report Sheet - Automobile Technology Competitor Name Country Code Task Subject E Engine Mechanical Report Sheet ENGINE MECHANICAL a) Piston (One Only) Description Specification Actual Serviceable Unserviceable Actual Serviceable Unserviceable Piston No - Diameter b) Cylinder Bore No (One Only) Description Specification A1: Cylinder Bore B1: c) Piston No Compression Ring No (One set only) Description Specification Actual Serviceable Unserviceable Piston Ring Side clearance (No compression ring) Piston Ring End Gap (No compression ring) 10TH ASC, October 2014, Ha Noi, Viet Nam 11 Skill 33 - Automobile Technology d) Crankshaft (One Journal only) Description Specification Actual Serviceable Unserviceable Actual Serviceable Unserviceable Actual Serviceable Unserviceable Crankshaft end play Crankshaft Main Journal Diameter Oil clearance e) Crank Pin (One Crankpin only) Description Specification Connecting Rod Side Clearance Crank Pin Journal Diameter Oil clearance ( cylinder) f) Valve Mechanism (One set only) Description Specification No.1 Intake valve stem No.2 No.1 Exhaust valve stem No.2 No Intake No Valve spring height No Exhaust No g) Camshaft Description Specification Actual Serviceable Unserviceable Cam Height (one only) Camshaft Bent 10TH ASC, October 2014, Ha Noi, Viet Nam 12