AUT
113-01M
CYLINDER BLOCK
SERVICE
Fall Semester 2008m,
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.
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!
Missing
more than 3 classes will drop your final grade one letter.
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 9, 2008
THERE IS NO GUARANTEE THAT
STUDENT PROJECTS/ MACHINE WORK WILL BE COMPLETED BY THE END OF THE SEMESTER!