| I. | ENGINE REPAIR | |
| A. | General Engine Diagnosis; Removal and Reinstallation (R & R) | |
| 1 | Identify and interpret engine concern; determine necessary action. | P-1 |
| 2 | Research applicable vehicle and service information, such as internal engine operation, vehicle service history, service precautions, and technical service bulletins. | P-1 |
| 3 | Locate and interpret vehicle and major component identification numbers (VIN, vehicle certification labels, and calibration decals). | P-1 |
| 4 | Inspect engine assembly for fuel, oil, coolant, and other leaks; determine necessary action. | P-1 |
| 5 | Diagnose engine noises and vibrations; determine necessary action. | P-2 |
| 6 | Diagnose the cause of excessive oil consumption, unusual engine exhaust color, odor, and sound; determine necessary action. | P-2 |
| 7 | Perform engine vacuum tests; determine necessary action. | P-1 |
| 8 | Perform cylinder power balance tests; determine necessary action. | P-1 |
| 9 | Perform cylinder compression tests; determine necessary action. | P-1 |
| 10 | Perform cylinder leakage tests; determine necessary action. | P-1 |
| 11 | Remove and reinstall engine in a late model front-wheel drive vehicle (OBDI or newer); reconnect all attaching components and restore the vehicle to running condition. | P-1 |
| 12 | Remove and reinstall engine in a late model rear-wheel drive vehicle (OBDI or newer); reconnect all attaching components and restore the vehicle to running condition. | P-3 |
| I. | ENGINE REPAIR | |
| B. | Cylinder Head and Valve Train Diagnosis and Repair | |
| 1 | Remove cylinder head(s); visually inspect cylinder head(s) for cracks; check gasket surface areas for warpage and leakage; check passage condition. | P-2 |
| 2 | Install cylinder heads and gaskets; tighten according to manufacturer's specifications and procedures. | P-1 |
| 3 | Inspect valve springs for squareness and free height comparison; determine necessary action. | P-2 |
| 4 | Replace valve stem seals on an assembled engine; inspect valve spring retainers, locks, and valve grooves; determine necessary action. | P-2 |
| 5 | Inspect valve guides for wear; check valve stem-to-guide clearance; determine necessary action. | P-3 |
| 6 | Inspect valves and valve seats; determine necessary action. | P-3 |
| 7 | Check valve face-to-seat contact and valve seat concentricity (runout); determine necessary action. | P-3 |
| 8 | Check valve spring assembled height and valve stem height; determine necessary action. | P-3 |
| 9 | Inspect pushrods, rocker arms, rocker arm pivots and shafts for wear, bending, cracks, looseness, and blocked oil passages (orifices); determine necessary action. | P-2 |
| 10 | Inspect hydraulic or mechanical lifters; determine necessary action. | P-2 |
| 11 | Adjust valves (mechanical or hydraulic lifters). | P-1 |
| 12 | Inspect camshaft drives (including gear wear and backlash, sprocket and chain wear); determine necessary action. | P-2 |
| 13 | Inspect and replace timing belts (chains), overhead camdrive sprockets, and tensioners; check belt/chain tension; adjust as necessary. | P-1 |
| 14 | Inspect camshaft for runout, journal wear and lobe wear. | P-2 |
| 15 | Inspect camshaft bearing surface for wear, damage, out-of-round, and alignment; determine necessary action. | P-3 |
| 16 | Establish camshaft(s) timing and cam sensor indexing according to manufacturer's specifications and procedures. | P-1 |
| I. | ENGINE REPAIR | |
| C. | Engine Block Assembly Diagnosis and Repair | |
| 1 | Disassemble engine block; clean and prepare components for inspection and reassembly. | P-2 |
| 2 | Inspect engine block for visible cracks, passage condition, core and gallery plug condition, and surface warpage; determine necessary action. | P-2 |
| 3 | Inspect internal and external threads; restore as needed (includes installing thread inserts). | P-2 |
| 4 | Inspect and measure cylinder walls for damage, wear, and ridges; determine necessary action. | P-2 |
| 5 | Deglaze and clean cylinder walls. | P-2 |
| 6 | Inspect and measure camshaft bearings for wear, damage, out-of-round, and alignment; determine necessary action. | P-3 |
| 7 | Inspect crankshaft for end play, straightness, journal damage, keyway damage, thrust flange and sealing surface condition, and visual surface cracks; check oil passage condition; measure journal wear; check crankshaft sensor reluctor ring (where applicable); determine necessary action. | P-2 |
| 8 | Inspect and measure main and connecting rod bearings for damage, clearance, and end play; determine necessary action (includes the proper selection of bearings). | P-2 |
| 9 | Identify piston and bearing wear patterns that indicate connecting rod alignment and main bearing bore problems; inspect rod alignment and bearing bore condition. | P-3 |
| 10 | Inspect and measure pistons; determine necessary action. | P-2 |
| 11 | Remove and replace piston pin. | P-3 |
| 12 | Inspect, measure, and install piston rings. | P-1 |
| 13 | Inspect auxiliary (balance, intermediate, idler, counterbalance or silencer) shaft(s); inspect shaft(s) and support bearings for damage and wear; determine necessary action; reinstall and time. | P-2 |
| 14 | Inspect or replace crankshaft vibration damper (harmonic balancer). | P-3 |
| 15 | Assemble the engine using gaskets, seals, and formed-in-place (tube-applied) sealants, thread sealers, etc. according to manufacturer's specifications. | P-2 |
| I. | ENGINE REPAIR | |
| D. | Lubrication and Cooling Systems Diagnosis and Repair | |
| 1 | Perform oil pressure tests; determine necessary action. | P-1 |
| 2 | Inspect oil pump gears or rotors, housing, pressure relief devices, and pump drive; perform necessary action. | P-2 |