AUT
113-01M
CYLINDER BLOCK
SERVICE
Fall Semester
2009
16 WEEK
COURSE
Phone: (703)257-6676(vm) 257-5328 portable ph. Email gphares@nvcc.edu
Office hours: M
0700-1630
Web
www.nvcc.edu/home/gphares
T 0830-1800
W0930-1800
R1000-1600
F0700-1530
TEXT: Automotive Engine Repair &
Rebuilding, Chek-Chart 4th Edition,
2005
CONTENT:
AUT-113-Cylinder Block
Service (3 cr.)
Studies basic cylinder block
reconditioning, including boring, installing cylinder sleeves, line boring and
deck resurfacing. Includes repair techniques for damaged
block and cylinder head castings to include cold welding, brazing, welding and
epoxy. Students study design and
performance characteristics, as well as the use of various types of
equipment. In the machine shop
laboratory, the student practices using the various types of equipment for
re-manufacturing cylinder blocks.
This course will provide the student with a thorough knowledge of the design and performance characteristics of the cylinder block assembly, the inspection and measurement techniques necessary to determine what overall operations are required, and the machining skill to completely remanufacture a cylinder block to equal or better factory specifications.
COURSE
OBJECTIVES:
Upon completion of this course the student will be able
to:
a.
Develop a thorough knowledge of the design and performance of
various
cylinder block materials and types, with particular emphasis on modern 4,
6 and V8 engines.
b.
Develop skills in the
operation of various machine shop tools and equipment required to remanufacture
cylinder blocks including:
1.
Cylinder block boring and
honing
2.
Milling block
decks
3.
Removal and replacement of
cam bearings
4.
Line boring of main bearing
journals
5.
Rust and scale removal from
water passages
6.
Removal and replacement of
cylinder block core plugs
7.
Chasing
threads
8.
Measurement
9.
Sleeve
installation
10.
Crack and thread
repairs
MAJOR TOPICS TO BE
INCLUDED
A. Introduction: cleaning and
inspection
B.
Measurement
C.
Cylinder boring with Rottler boring bar
D. Sleeve fitting and
installation
E.
Cylinder honing by hand and
also by Sunnen CK-10
F.
Line boring main bearing
journals
G. Crack detection and
repair
H. Bolt hole re-tapping and
thread repair
I.
Freeze plug removal and
replacement
J.
Tapping and cleaning oil
gallery ports
K. Block
designs
L.
Metallurgy of block
materials
M.
Milling operations using the
SV Blockmaster
N. Cylinder wall / surface
finishes
O. Piston and ring
designs
P.
Head
plates
Q. Removal and installation of
cam bearings
GENERAL:
Study the entire text,
specific readings will be assigned; however, students are responsible for both
the classroom and shop texts.
STUDENT
HANDBOOK:
Students should review the
Student Handbook, especially the sections about “Rights and
Responsibilities”, “Student
Conduct”, and “Student
Dishonesty”. Students should also
read the Information Technology Student/Patron Ethics Agreement and NVCC
Computer Use Agreement in the student handbook. If you have any questions or need
clarification, please ask. Students
found cheating will receive a 0 for the activity. The use of electronic devices during
class will not be tolerated such as cell phones, pagers, PDAs, Ipods, laptop computers, unless authorized through the
special needs assistance program.
STUDENT
ASSISTANCE:
Students who have special
needs or require accommodations need to inform the instructor and the Counseling
Dept. Please let me know by
the end of the second class/lab period.
Quizzes:
Expect a quiz at the
beginning of each class. Additional
quizzes may be given at any time.
In the event that you miss a quiz, you must contact me to take a
make-up. Make-ups may be out of
class written assignments or in class presentations.
ATTENDANCE:
Regular attendance is
strongly recommended. The quizzes,
tests, and laboratory contract are the basis of your grade, missing class or lab
will effect your ability to pass the course. Let me know if you will not be able to
make class by leaving a message on my answering machine, or send me an
email!
Missing more than 3 classes
will result in a F for the
course.
CLASS START/END
TIMES:
Class begins at a 6:00 pm
and end at 10:40 pm on Tuesday nights. In the event I am delayed more
than 10 minutes beyond the beginning of class, students are instructed to
contact the Science and Technology division secretary located in Colgan Hall ext. 6604/6605 for
directions.
INCLEMENT WEATHER
POLICY:
The
college policy for canceling classes due to inclement weather is not campus
specific. The decision to cancel
classes for the entire college is made early in the morning for daytime classes
and in the afternoon for evening classes (separate decisions). This information is available on local
radio and TV stations as well as NOVANET.
Phone 330-3770 (
COURSE
WITHDRAWAL:
In
the event you are unable to complete the course requirements and you wish to
withdrawal, YOU ARE RESPONSIBLE FOR COMPLETING THE NECESSARY FORMS
available at the Admissions & Records office to obtain a "W" grade. Failure to do so on
you part is a failing grade for the course.
COURSE
REQUIREMENTS:
1.
Achieve a passing average in the quizzes.
2.
Achieve a passing average in the midterm and final exam.
3.
Complete the lab contract.
GRADES: Lab Contract
30%
A = 91-100
Quizzes & class participation 30%
B = 81-90
Final 20% D = 61-70 Total 100% F = Below 61
Final Exam
Date: Tuesday December 8,
2009
THERE IS NO GUARANTEE THAT
STUDENT PROJECTS/ MACHINE WORK WILL BE COMPLETED BY THE END OF THE
SEMESTER!