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

3 hours

Total Breaks

15 minutes
Marking Summary
Section

Possible
Mark

1.

Health, Safety and House Keeping

1.10

2.

Dismantling Engine External Attachment Components

0.40

3.

Dismantling Timing Belt

1.10


4.

Dismantling Cylinder Head

1.60

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

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


2


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

3


Skill 33 - Automobile Technology
Competitor Instructions - Automobile Technology

Competitor Name

Country Code

Task
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.

10TH ASC, October 2014, Ha Noi, Viet Nam

4


Skill 33 - Automobile Technology
Form 5 - Automobile Technology
Competitor Name

Country Code

Task

Marking Scale


E

Engine
Mechanical

Marking Summary
Possible
Mark

Section
1.

Health, Safety and House Keeping

1.10

2.

Dismantling Engine External Attachment Components

0.40

3.

Dismantling Timing Belt

1.10

4.


Dismantling Cylinder Head

1.60

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

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

1

2

10TH ASC, October 2014, Ha Noi, Viet Nam

3

4

5



Skill 33 - Automobile Technology

Competitor Name

Country Code

1.

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
0
0
0
0
0

1.10

0


Sub-Total

2.

Dismantling engine external
attachment components

Yes

No

2.1
2.2

Use workshop manual
Remove valve cover

0.10
0.10

0
0

2.3

Remove all ignition coils

0.10

0


2.4

Remove all spark plugs

0.10

0

Sub-Total

0.40

0

3.

Dismantling Timing Chain

Yes

No

3.1

Set timing mark in the correct position

0.20

0


3.2

Remove crankshaft damper

0.10

0

3.3

Remove front crankshaft oil seal

0.10

0

3.4

Remove crankshaft sensor

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

3.10

Remove timing chain

0.10

0

1.10

0

Sub-Total

10TH ASC, October 2014, Ha Noi, Viet Nam

Task

Marking Scale

E

Engine Mechanical

Actual


Comments

Actual

Comments

Actual

Comments

6


Skill 33 - Automobile Technology

Competitor Name

Country Code

4.

Dismantling cylinder head

Yes

No

4.1


Turn crankshaft counterclockwise to 40
degrees from TDC

0.20

0

4.2

Loosen camshaft caps uniformly

0.20

0

4.3

Remove camshaft caps

0.10

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

4.7

Remove cylinder head

0.20

0

4.8

Remove cylinder head gasket


0.10

0

4.9

Remove one cylinder set of valves

0.20

0

Sub-Total

1.60

0

5.

Dismantling piston, connecting rod
and crankshaft

Yes

No

5.1

Loosen all oil pan bolts


0.20

0

5.2

Remove oil pan

0.10

0

5.3

Remove oil strainer

0.10

0

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

5.11

Remove crankshaft

0.20

0

1.80

0


Sub-Total

10TH ASC, October 2014, Ha Noi, Viet Nam

Task

Marking Scale

E

Engine Mechanical

Actual

Comments

(2 inlet & 2 exhaust valves)

Actual

Comments

7


Skill 33 - Automobile Technology

Competitor Name


Country Code

6.

Cylinder Bore & Piston Measurement

Yes

No

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

6.4

Measure Piston Diameter

0.20

0

6.5

Measure Cylinder Bore

0.30

0

6.6

Measure Piston ring side Clearance

0.30

0

6.7


Measure Piston ring end Gap

0.20

0

1.90

0

Sub-Total

7.

Crankshaft & Bearing Measurement

Yes

No

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

2.40

0

Sub-Total

10TH ASC, October 2014, Ha Noi, Viet Nam

Task

Marking Scale

E

Engine Mechanical

Actual

Comments


Actual

Comments

8


Skill 33 - Automobile Technology
Competitor Name

Country Code

Task

Marking Scale

E

Engine Mechanical

8.

Valve & Valve Mechanism
Measurement

Yes

No

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

8.4

Measure inlet valve stem

0.20

0


Use Micrometer

8.5

Measure exhaust valve stem

0.20

0

Use Micrometer

8.6

Measure valve spring height

0.20

0

Use Vernier

8.7

Measure cam height

0.20

0


Use Micrometer

8.8

Measure camshaft bent

0.20

0

Use dial gauge

Sub-Total

1.90

0

Actual

Comments

9.

Assembling piston, connecting rod
and crankshaft

Yes


No

9.1

Lubricate components before assembling

0.20

0

9.2

Install crankshaft

0.20

0

Torque

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

9.8

Install oil strainer

0.20

0

Torque

9.9

Install oil pan

0.30

0

Torque


2.70

0

Torque

Sub-Total

10TH ASC, October 2014, Ha Noi, Viet Nam

Actual

Comments

9


Skill 33 - Automobile Technology
Competitor Name

Country Code

10.

Assembling Cylinder Head

Yes

No


10.1

Install one cylinder set of valves

0.20

0

10.2

Install cylinder head gasket

0.10

0

10.3

Install cylinder head

0.10

0

10.4

Tighten and torque cylinder head bolts in
correct order stage 1


0.30

0

10.5

Turn 900 cylinder head bolts in correct
order stage 2

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


1.60

0

Sub-Total

11.

Assembling timing chain

Yes

No

11.1

Install timing chain

0.10

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

11.8

Install water pump

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

Sub-Total

1.20

0

12.

Assembling engine external
attachment components

Yes

No

12.1

Install valve cover

0.10


0

12.2

Install all spark plugs

0.10

0

12.3

Install ignition coils

0.10

0

0.30

0

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. 1 - Diameter
b) Cylinder Bore No. 1 (One Only)
Description

Specification

A1:
Cylinder Bore

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)

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
( 1 cylinder)
f) Valve Mechanism (One set only)
Description

Specification

No.1


Intake valve stem

No.2
No.1

Exhaust valve stem

No.2
No. 1

Intake

No. 2

Valve spring
height

No. 1

Exhaust

No. 2

g) Camshaft
Description

Specification

Actual


Serviceable Unserviceable

Cam Height (one only)
Camshaft Bent

10TH ASC, October 2014, Ha Noi, Viet Nam

12