Competitor Instructions – Automobile Technology

Competitor Competitor
Task
Name No

……………………………………………….. …………………….. B

Competitor Instructions

Task Engine Mechanical

Familiarization Time 5 minutes

Task Duration 85 minutes
Total Time 90 minutes

Marking Summary

Possible
Section
Mark
1. Preparation 100

2. Dismantling Cylinder Head 50

3. Dismantling Piston and Connecting Rod 50

4. Cylinder Bore and Piston Measurement 150

5. Crankshaft and Bearing Measurement 150

6. Assembling Piston and Connecting Rod 100

7. Assembling Cylinder Head, Front Case and Oil Pan 100

Task Total 700

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 Competitor Number on all forms
- Use appropriate tools and procedures
- Complete all instructions on the next page

Remarks : Engine 5 K (Toyota)

 Competitor Competitor
Task
Name No

B
…………………………………………………………. …………………

1. Perform diagnostic work according to the fault and fill in the report sheet

2. Prepare all necessity tools and equipment for measuring for measuring engine
components.

3. Perform measurement work according to the report sheet and justify the
result.
 Form 5 – Automobile Technology

Competitor Competitor
Task Marking Scale
Name No

……………………………………….. …………. B Engine Mechanical

Marking Summary

Possible Actual
Section
Mark Mark
1. Preparation 100

2. Dismantling Cylinder Head 50

3. Dismantling Piston & Connecting Rod 50
4. Cylinder Bore & Piston Measurement 150
5. Crank pin Crankshaft and Bearing Measurement 150
6. 100
Assembling Piston and Connecting Rod
7. Assembling Cylinder Head, Front Case and Oil Pan 100

Task Total 700

Time Keeping

Familiarization Competition Breaks

Start Start Start

Stop Stop Stop

Experts Signatures
1 2

……………………………………….. …………………………………………………..
 Competitor Competitor
Task Marking Scale
Name No

……………………………………….. …………. B Engine Mechanical

1. Preparation Yes No Actual Comments

1.1 Use workshop manual 10 0
1.2 Check all equipments 10 0
1.3 Check all instructions 10 0
1.4 Select the correct tools 15 0
1.5 Calibrate measuring tools 15 0
1.6 Use logical working procedure 15 0
1.7 Clean up the working area 10 0
1.8 Clean up tools and equipment 15 0
Sub-Total 100 0

2. Dismantling cylinder head Yes NO Actual Comments

2.1 Remove rocker cover 10 0

Remove cylinder head bolts in correct 30
2.2 0
order
2.3 Remove cylinder head gasket 10 0

Sub-Total 50 0
 Competitor Competitor
Task Marking Scale
Name No

B Engine Mechanical
………………………………………………… …………….

Dismantling piston and connecting

3. Yes No Actual Comments
rod
3.1 Remove connecting rod cap 15 0
3.2 Remove piston 20 0
3.3 Remove main bearing cap 15 0
Sub-Total 50 0

4. Cylinder Bore & Piston Measurement Yes No Actual Comments

4.1 Measure Outer Diameter Piston No. 1 20 0

4.2 Measure Inner Diameter Cylinder No. 1 50 0
Measure piston Oil Clearance Cylinder 20
4.3 0
No. 1
4.4 Measure Roundness Cylinder No. 1 20 0
4.5 Measure Cylindericity Cylinder No. 1 20 0
Measure Piston ring side Clearance No. 1 20
4.6 0
Sub-Total 150 0

Crankpin & Bearing Measurement

5. Yes No Actual Comments
( no.1 )
Measure Crank Pin Outer Diameter No. 1 40
5.1 0
Measure Crank Pin Bearing Inner 40
5.2 0
Diameter No.1
5.3 Measure Oil Clearance Crank Pin 20 0
5.4 Measure Crank pin roundness 20 0
5.5 Measure Crank pin taper 20 0
5.6 Measure Conecting rod & play 10 0
Sub-Total 150 0
 Competitor Competitor
Task Marking Scale
Name No

…………………………………….. B Engine Mechanical

…………..

Assembling piston & connecting

6. Yes No Actual Comments
rod

Assemble piston ring in correct setting 30 0

Assemble piston to cylinder blok 30 0
Assemble connecting rod & cap 20

cap

Lubricate components before assembling 20 0

Sub-Total 100 0

7. Assembling cylinder head Yes NO Actual Comments

7.1 Assemble cylinder head gasket 30 0

7.2 Lubricate cylinder head bolt 15 0
Assemble cylinder head bolts in correct 40
7.3 0 With torque
order
7.4 Assemble rocker cover 15 0
Sub-Total 100 0
 Competitor Report Sheet – Automobile Technology

Competitor Competitor
Task
Name No

………………………………………………… …………………… B

Report Sheet

ENGINE MECHANICAL
a) Piston

Description Specification Actual Serviceable Unserviceable

No. 1 Piston Outer Diameter

b) Cylinder bore

Description Specification Actual Serviceable Unserviceable

No. 1 Cylinder inner diameter A1:
B1:
C1:
A2:
B2:
C2:
Roundness Cylinder No.1
Cylindricity Cylinder No.1 A1:
B1:

c) Piston ring

Description Specification Actual Serviceable Unserviceable

Piston 1 Side clearance (No.
1 compression ring)
Piston 1 Side clearance (No.
2 compression ring)
Piston 1 End Gap (No. 1
compression ring)
Piston 1 End Gap (No. 2
compression ring)
d) Crank Pin

Description Specification Actual Serviceable Unserviceable

Connecting rod & play
No. 1 Crank pin journal A1:
Outer Diameter B1:
A2:
B2:
No. 1 Main Bearing Inner A1:
Diameter. B1:
A2:
B2:
Oil clearance (No. 1 cylinder)
Crankpin roundnes
Crankpin taper