Dismantling Engine External Attachment Components 0.40 5.. Valve & Valve Mechanism Measurements 1.90 9 Assembling Piston, Connecting Rod and Crankshaft 2.70 12.. Dismantling Engine E
Trang 1Test Project Automobile Technology
TASK E – Engine mechanical
TP33_14VN_actual_M4
Submitted by:
Name:
Member Country: All Members
Trang 2Competitor Instructions - Automobile Technology
E Instructions to Competitor
Marking Summary
1 Health, Safety and House Keeping 1.10
2 Dismantling Engine External Attachment Components 0.40
5 Dismantling piston, connecting rod and crankshaft 1.80
6 Cylinder Bore and Piston Measurements 1.90
7 Crankshaft and Bearing Measurements 2.40
8 Valve & Valve Mechanism Measurements 1.90
9 Assembling Piston, Connecting Rod and Crankshaft 2.70
12 Assembling Engine External Attachment Components 0.30
Trang 3Skill 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
Trang 4Competitor Instructions - Automobile Technology
E
1 Prepare all necessary tools and equipment for measuring engine components
2 Disassemble and re-assemble the engine
3 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
Trang 5Skill 33 - Automobile Technology
Form 5 - Automobile Technology
Marking Summary
1 Health, Safety and House Keeping 1.10
2 Dismantling Engine External Attachment Components 0.40
5 Dismantling piston, connecting rod and crankshaft 1.80
6 Cylinder Bore and Piston Measurements 1.90
7 Crankshaft and Bearing Measurements 2.40
8 Valve & Valve Mechanism Measurements 1.90
9 Assembling Piston, Connecting Rod and Crankshaft 2.70
12 Assembling Engine External Attachment Components 0.30
Time Keeping
Familiarization Competition Breaks
Experts Signatures
Trang 6Competitor Name Country Code Task Marking Scale
1 Health, Safety and House Keeping Yes No Actual Comments
1.5 Calibrate measuring tools 0.20 0
1.6 Use logical working procedure 0.20 0
2 Dismantling engine external attachment components Yes No Actual Comments
2.3 Remove all ignition coils 0.10 0
3.1 Set timing mark in the correct position 0.20 0
3.3 Remove front crankshaft oil seal 0.10 0
3.5 Remove front timing cover 0.10 0
3.6 Remove timing chain tensioner 0.10 0
3.7 Remove timing chain slipper 0.10 0
3.8 Remove timing chain vibration damper 0.10 0
3.9 Remove crankshaft position sensor plate 0.10 0
Trang 7Skill 33 - Automobile Technology
4.1 Turn crankshaft counterclockwise to 40
4.2 Loosen camshaft caps uniformly 0.20 0
4.4 Remove camshaft together with VVTi 0.20 0
4.5 Loosen cylinder head bolts in correct order 0.30 0
4.6 Remove all cylinder head bolts 0.10 0
4.8 Remove cylinder head gasket 0.10 0
4.9 Remove one cylinder set of valves 0.20 0 (2 inlet & 2 exhaust valves)
5 Dismantling piston, connecting rod and crankshaft Yes No Actual Comments
5.4 Remove oil pump and drive chain 0.10 0
5.5 Loosen crankshaft balancer shaft assembly bolts in correct order 0.20 0
5.6 Remove crankshaft balancer assembly 0.10 0
5.7 Loosen all connecting rod bearing caps 0.20 0
5.8 Remove connecting rod bearing caps 0.20 0
5.9 Remove all pistons with connecting rods 0.20 0
5.10 Remove main bearing caps in correct order 0.20 0
Trang 8Competitor Name Country Code Task Marking Scale
6 Cylinder Bore & Piston Measurement Yes No Actual Comments
6.1 Set up bore gauge and micrometer 0.30 0
6.2 Correct usage of bore gauge 0.30 0
6.3 Correct usage of micrometer 0.30 0
6.6 Measure Piston ring side Clearance 0.30 0
6.7 Measure Piston ring end Gap 0.20 0
7 Crankshaft & Bearing Measurement Yes No Actual Comments
7.1 Set up of micrometer and dial gauge 0.30 0
7.2 Correct usage of micrometer 0.30 0
7.3 Correct usage of dial gauge 0.30 0
7.4 Correct usage of plastic gauge 0.30 0
7.5 Measure Main Journal Diameter 0.20 0
7.6 Measure Oil Clearance Main Journal 0.20 0
7.7 Measure Crank Pin Diameter 0.20 0
7.8 Measure Crank Pin Side clearance 0.20 0
7.9 Measure Oil Clearance Crank Pin 0.20 0
7.10 Measure crankshaft end play 0.20 0
Trang 9Skill 33 - Automobile Technology
8 Valve & Valve Mechanism Measurement Yes No Actual Comments
8.1 Set up of micrometer and vernier caliper 0.30 0
8.2 Correct usage of micrometer 0.30 0
8.3 Correct usage of vernier caliper 0.30 0
9 Assembling piston, connecting rod and crankshaft Yes No Actual Comments
9.1 Lubricate components before assembling 0.20 0
9.3 Install main bearing caps and tighten to torque in correct order 0.40 0 Torque
9.4 Install piston ring in correct setting 0.40 0 Torque
9.5 Install piston with connecting rod 0.20 0 Torque
9.6 Install connecting rod bearing caps and tighten to torque 0.40 0 Torque
9.7 Install crankshaft balancer assembly and tighten all bolts to torque in correct order 0.40 0
Trang 10Competitor Name Country Code Task Marking Scale
10.1 Install one cylinder set of valves 0.20 0
10.2 Install cylinder head gasket 0.10 0
10.4 Tighten and torque cylinder head bolts in correct order stage 1 0.30 0 Torque value 70 Nm
10.5 Turn 90order stage 2 0 cylinder head bolts in correct 0.30 0
10.6 Install camshafts in correct position 0.40 0
10.7 Install, tighten and torque camshaft caps in correct order 0.20 0
11.2 Install crankshaft position sensor plate 0.10
11.3 Install timing chain vibration damper 0.10 0
11.4 Install timing chain slipper 0.10 0
11.5 Install timing chain tensioner 0.10 0
11.6 Install front timing cover 0.10 0
11.7 Install crankshaft sensor 0.10 0
11.9 Install crankshaft damper 0.10 0
11.10 Set timing mark in the correct position 0.20 0
11.11 Turn engine two revolutions 0.10 0
12 Assembling engine external attachment components Yes No Actual Comments
Trang 11Skill 33 - Automobile Technology
Competitor Report Sheet - Automobile Technology
Report Sheet
ENGINE MECHANICAL
a) Piston (One Only)
Description Specification Actual Serviceable Unserviceable Piston No 1 - Diameter
b) Cylinder Bore No 1 (One Only)
Description Specification Actual Serviceable Unserviceable Cylinder Bore
A1:
B1:
c) Piston No 1 Compression Ring No 1 (One set only)
Description Specification Actual Serviceable Unserviceable Piston Ring Side clearance
(No 1 compression ring)
Piston Ring End Gap
(No 1 compression ring)
Trang 12d) Crankshaft (One Journal only)
Description Specification Actual Serviceable Unserviceable Crankshaft end play
Crankshaft Main Journal
Diameter
Oil clearance
e) Crank Pin (One Crankpin only)
Description Specification Actual Serviceable Unserviceable Connecting Rod
Side Clearance
Crank Pin Journal
Diameter
Oil clearance
( 1 cylinder)
f) Valve Mechanism (One set only)
Description Specification Actual Serviceable Unserviceable
Intake valve stem No.1
No.2 Exhaust valve stem
No.1 No.2
Valve spring
height
Intake No 1
No 2
Exhaust No 1
No 2
g) Camshaft
Description Specification Actual Serviceable Unserviceable
Cam Height (one only)