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AUTOMOTIVE
ENGINES
Diagnosis, Repair, and Rebuilding
EIGHTH EDITION
TIM GILLES
Professor Emeritus
Santa Barbara City College
Santa Barbara, CA
Australia Brazil Mexico Singapore United Kingdom United States
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Automotive Engines: Diagnosis, © 2019, 2015 Cengage Learning
Repair, and Rebuilding, 8th edition WCN: 02-300
Tim Gilles Unless otherwise noted, all content is © Cengage.
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Notice to the Reader

Publisher does not warrant or guarantee any of the products described herein or
perform any independent analysis in connection with any of the product information
contained herein. Publisher does not assume, and expressly disclaims, any obligation
to obtain and include information other than that provided to it by the manufacturer.
The reader is expressly warned to consider and adopt all safety precautions that might
be indicated by the activities described herein and to avoid all potential hazards. By
following the instructions contained herein, the reader willingly assumes all risks in
connection with such instructions. The publisher makes no representations or war-
ranties of any kind, including but not limited to, the warranties of fitness for particular
purpose or merchantability, nor are any such representations implied with respect to
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this material.
Printed in the United States of America

Print Number: 01 Print Year: 2017
DEDICATION
The completion of this book was made possible with the help of a great many indi-
viduals. Automotive Engines is dedicated to them and especially to my parents for the
inspiration, and to my wife, Joy, and children, Jody and Terri, without whose help the
book would not have been completed. Special appreciation is due to my wife, Joy, who
has managed the organization of the art package, spending countless hours developing
and organizing all the spreadsheets, captions, photos, and sketches, making certain
they are in their correct locations—a substantial task.
This book is also dedicated to four important mentors: Lloyd Corliss, my first
automotive teacher, who shared his love of engines and whose integrity and example
inspired me to become an automotive teacher; Roger Aylesworth, who became a big
brother to me while I worked in his automotive business and who shared, by example,
his attitude that, with knowledge, a good mechanic can fix just about anything; and
Bob Barkhouse, another big brother and good friend. Bob is a retired automotive
teacher and the author of a very fine best-selling textbook on the upper end of engines.
His example is one of generosity. He has been a big help and an inspiration to me and
countless other teachers. My good friend and mentor, Joe Schuit, began helping the
engine-rebuilding students at Santa Barbara City College shortly after he retired from
his automotive machine shop business. Joe was an inventor with a gifted mind for
automotive engines and an enthusiasm that was contagious. He always had something
new and valuable to share from his vast library of knowledge and experience.
Contents
Dedication ● iii
Preface ● ix
About This Book ● ix
Features of the Text ● xi
About the Author ● xiv
ASE Certification Tests ● xv
Acknowledgments ● xvi
SECTION 1
Engine Construction, Diagnosis, Disassembly, and Inspection
1
CHAPTER 1 Engine Operation 2

Simple Engine ● Four-Stroke Engine Operation ● Cylinder Arrangement ● Valvetrain ● Cylinder
Block ● Front-Wheel Drive ● Engine Classifications ● Combustion Chamber Designs ● Direction of
Crankshaft Rotation ● Firing Order ● Engine Cooling ● Spark and Compression Ignition ● Putting It All
Together ● High-Performance Engine Trivia ● Study Questions ● ASE-Style Review Questions
CHAPTER 2 Engine Shop Safety 25

General Shop Health and Safety ● Shop Cleanliness ● Fire Prevention ● Tool and
Equipment Safety ● Lifting Equipment ● Other Shop Equipment Safety ● Cautions with
Caustic Bases ● Hazardous Materials and Environmental Safety ● Hazard Communication
Standards ● Safety Data Sheets ● Hazardous Materials Common to the Automotive
Industry ● Cleaning Solvent Safety Precautions ● Skin Care Safety Precautions ● Breathing
Safety ● Study Questions
CHAPTER 3 Diagnosing Engine Problems 53

Diagnosing Problems Before a Repair ● Oil Consumption ● Oil Leaks ● Fuel Mixture
Problems ● Compression Loss ● Engine Noises ● Oil Pressure Problems ● Cooling System
Problems ● Electronic Failures/Engine Damage ● Study Questions ● ASE-Style Review Questions
CHAPTER 4 Engine Removal, Disassembly, Inspection,

and In-Chassis Repairs 96
Service Information ● Service Literature ● Service Records ● Engine Removal ●
Front-Wheel Drive Engine and Transaxle Removal ● Rebuild or Replace? ●
vi Contents
Engine Disassembly ● Ordering Parts ● Major Engine Repair—Engine in the Vehicle ●
Study Questions ● ASE-Style Review Questions
CHAPTER 5 Cleaning the Engine 153

Cleaning Methods ● Cleaning the Inside of the Engine ● Study Questions ●
ASE-Style Review Questions
CHAPTER 6 Measuring 170

Metric System ● Measuring Tools ● Precision Measuring Tools ● Study Questions ●
ASE-Style Review Questions ● Micrometer Practice
SECTION 2
The Breathing System
187
CHAPTER 7 Cylinder Head: Parts and Service 188

Cylinder Heads ● Head Identification ● Head Disassembly ● Carbon Removal ●
Crack Inspection ● Crack Repair ● Valve Guide Inspection ● Valve Guide Repair ●
Reaming Valve Guides ● Valve Guides and Seals ● Resurfacing Heads ● Study
Questions ● ASE-Style Review Questions
CHAPTER 8 Cylinder Head: Springs, Valves, and Valve Seats 225

Generic Specifications and Guidelines ● Valve Springs ● Pushrods ● Rocker Arms ●
Valves and Valve Service ● Valve Seats and Service ● Reassembling the Head ●
CHAPTER 9 Camshafts, Lifters, Timing Belts, and Chains 269

Camshaft ● Controlling Camshaft End Thrust ● Valve Lash (Clearance) ● Valve Lifters ●
Hydraulic Lifters and Lash Adjusters ● Hydraulic Lifter Operation ● Valve Timing ●
Roller Cam and Lifters ● Cam Drives ● Timing Chains and Belts ● Timing the Cam to the Crank ●
Timing Belts ● Timing Belt Replacement ● Study Questions ● ASE-Style Review Questions
SECTION 3
Cylinder Block Assembly
311
CHAPTER 10 Cylinder Block: Inspection and Service 312
Cleaning the Block ● Oil and Water Plugs ● Oil Jet Cooling ● Aligning Dowels on the
Back of the Block ● Main Bearing Caps and Registers ● Main Bearing Bore Alignment ●
Decking the Block ● Inspecting Cylinder Bores ● Deglazing Cylinders ● Reboring
Cylinders ● Honing Cylinders to Size ● Chamfering the Cylinder ● Cylinder Sleeves ●
Lifter Bores ● Final Block Preparation ● Cam Bearings ● Study Questions ●
Contents vii
CHAPTER 11 Crankshaft, Bearings, and Engine Balancing 346

Crankshaft Design ● Crankshaft End Thrust ● Checking Crankshaft Condition ● Other
Crankshaft Modifications ● Checking Bearing Clearance ● Crankshaft Design and Engine
Balance ● Engine Balancing ● Study Questions ● ASE-Style Review Questions
CHAPTER 12 Pistons, Rings, and Connecting Rods 386

Pistons ● Piston Rings ● Piston Pins ● Connecting Rods ● Study Questions ●
CHAPTER 13 Lubrication 424

Oil Pressure ● Oil ● Engine Oil ● Engine Oil Licensing and Certification ● Oil Additives ●
Changing Engine Oil ● Oil Pumps ● Priming the Lubrication System ● Oil Filter ●
Replacing the Oil Filter ● Crankcase Ventilation ● Study Questions ● ASE-Style Review Questions
CHAPTER 14 Cooling System 459

Types of Cooling Systems ● Cooling System Parts ● Cooling System Circulation ● Coolant Pump ●
Accessory Belts ● Thermostat ● Thermostat Bypass ● Radiators ● Cooling System Pressure Cap ●
Radiator Fan ● Coolant ● Coolant Service ● Study Questions ● ASE-Style Review Questions
SECTION 4
Engine Repair and Reassembly
503
CHAPTER 15 Engine Hardware: Fasteners, Thread Repair, and Gaskets 504

Characteristics of Fasteners ● Bolt Stretch ● Torque and Friction ● Drill Bits ● Taps, Threads,
and Dies ● Repairing Broken Fasteners and Damaged Threads ● Automotive Tubing Repair ●
Gaskets ● Gasket Sealers ● Seals ● Study Questions ● ASE-Style Review Questions
CHAPTER 16 Reassembly and Starting 558

Warranty ● Reassembly ● Completion of Assembly ● Engine Installation ● Ignition System
Installation and Timing ● Engine Starting and Break-In ● Final Inspection and Cleaning ●
SECTION 5
Engine Power and Performance
599
CHAPTER 17 Engine Breathing: Intake and Exhaust Systems 600

Intake Manifolds ● Plastic Intake Manifolds ● Cylinder Head Modifications to Improve Airflow ●
Exhaust Systems ● Study Questions ● ASE-Style Review Questions
viii Contents
CHAPTER 18 Turbochargers and Superchargers 620

Supercharging and Engine Power ● Aftercooler/Intercooler ● Belt-Driven Superchargers/Blowers ●
CHAPTER 19 Producing Power: Valve Timing,

Power, and Torque Measurement 640
Camshaft and Engine Performance ● Checking Camshaft Timing ● Camshaft Phasing,
Lobe Centers, and Lobe Spread ● Variable Valve Timing ● Active Fuel Management ●
Power and Torque ● Measuring Torque and Horsepower ● Dynamometer Safety
Concerns ● Study Questions ● ASE-Style Review Questions
Supplemental Test Questions and Answers ● 677

Appendix ● 685
Glossary ● 696
Index ● 702
Preface
ABOUT THIS BOOK procedures. The lubrication and cooling systems are
also covered. Section 4 deals with final reassembly
It is often said that engines never change. Although
and starting the engine. Gaskets and miscellaneous
large changes are not the norm, the internal combus-
repair procedures are covered in this section as well.
tion engine (ICE) is constantly evolving. When the
Section 5 covers engine power and performance,
first edition of this text was being written in 1980,
including intake and exhaust systems, turbochargers
futurists were questioning whether the four-stroke
and superchargers, varying valve timing, and measur-
cycle engine would still be around in 20 years. The
ing power and torque.
long history of this well-proven engine has shown
continuous small refinements, and ICEs still power
most of today’s vehicles. Compared with the engines New to This Edition
that powered the muscle cars of 1980, today’s engines
are more refined, lighter, and offer improved perfor- This eighth edition of Automotive Engines has been
mance and durability. updated and refined to reflect changes in the market-
Automotive Engines, Eighth Edition, provides the place. The seventh edition was produced in a four-
reader with the comprehensive knowledge needed to color design for the first time with many new and
repair and rebuild these automotive engines. The most updated photos and illustrations. This has been a tre-
complete book of its kind, it takes a generic, rather mendous improvement. An emphasis on photos and
than product-specific, approach. The text provides art anticipates the needs of those with different learn-
all of the need-to-know information in an easy-to- ing styles and encourages student interest in reading
understand format. Much effort has gone into orga- the related text. New color photos and illustrations
nizing this book to make it easily readable, like a story. have been added to this eighth edition to continue
To facilitate learning, all items related to a given topic improving this project.
are included within a single chapter. Appropriate for The design and engineering of the internal com-
entry-level as well as more experienced technicians bustion engine is continuing to evolve, with enhance-
and machinists, this text also provides opportunities ment of high-performance sport compact cars and
for the reader to develop critical diagnostic and prob- vehicle restoration accounting for a substantial part
lem-solving skills. of the industry.
Here is a listing of some of the highlights:
Organization of This Edition ■■ The updated high-performance Section 5 includes

three chapters with updated information on engine
This text is divided into five sections and is designed
breathing, including intake and exhaust manifolds,
so that the student can begin working in the shop
turbocharging, supercharging, high-performance
right away. Section 1 covers engine construction,
camshafts, and variable valve timing.
disassembly, inspection, and parts ordering. Diag-
nosis techniques, both before and after disassembly, ■■ Up-to-date information on cooling and lubrica-
are covered in detail. Also included are repair proce- tion systems is included in this edition of the text.
dures that can be performed while the engine is still Engines last far longer than they did 25 years ago.
in the vehicle. Tools and equipment procedures, as Maintenance is important to vehicle owners; cool-
well as safety issues, are covered throughout. Section ing system failures that result in serious engine
2 deals with the valvetrain, cylinder head repair, cam- damage must be avoided.
shafts, and cam drives. Section 3 discusses the cylin- ■■ Metric micrometer reading has been expanded in
der block assembly with a focus on lower-end repair Chapter 6.
ix
x Preface
■■ New or updated case histories highlight real- This book is used in schools that teach NATEF
world situations, providing more critical thinking A-1 (Engine Repair). Coverage emphasizes procedures
practices. that would be performed in a typical automotive facil-
■■ Vintage Engines additions help put newer technol- ity that does engine repairs. The book is also used in
ogies in historical perspective by offering interest- schools that teach in-depth engine machining pro-
ing facts about older technologies while separating cesses. One of my challenges as an author is to present
them from the core text, along with accompanying machining tips in a way that will benefit all students
photographs. who study the book. Instructions on the use of a par-
ticular machine are avoided; they are available in video
form or in the online pdf manual for the machine.
Use of the Text The primary aim of the text is to provide a student
A goal of Automotive Engines is to fill the needs of with adequate preparation for entry-level employment
many, merging commonplace and vintage content with emphasis on the ASE A1 Engines area, including
with the latest high-tech information. Some schools ASE test preparation.
have smaller engine course offerings, whereas oth-
ers have large programs with classes of long enough
duration to complete the entire text. Some instruc- To the Student
tors assign certain chapters, leaving others to be cov- Restoration and improvement is a very popular auto-
ered in an introductory course. Others use some of motive technology area and you should be prepared to
the chapters in a prerequisite introductory engines capitalize on that interest. Most cities and towns have
course, saving others for an advanced engine- residents who can afford to spend money on their cars
rebuilding course. For instance, Chapter 9 covers all and light trucks. You will need a good understanding
of the camshaft-related items that would be needed of performance and vintage material to be successful
for an entry-level automotive apprentice, whereas the in this field. Additionally, you need a good grounding
Engine Power and Performance Chapters, 17, 18, and in the broad area covering four-stroke cycle engine
19, consist of more advanced technical material for basics if you are to be successful as an engine diagnos-
aspiring engine machinists and high-performance tician. During engine diagnosis and disassembly, the
specialists. text gives an emphasis to analyzing worn and dam-
There are many new and updated photos of aged parts. The aim is to improve your diagnostic
engine disassembly and reassembly on newer vehicles. ability and develop a method of approaching things
Students need to learn to diagnose an engine during in an inquisitive manner. Get into the habit of asking
disassembly so they can assess its suitability for repair yourself, “What caused this to happen?” You will want
prior to spending a lot of money and wasting a lot of to take measures so it does not happen again. This
time. Analyzing unusual wear or part failure will also can be applied to more advanced topics as you further
help them correct problems so they do not recur. your automotive studies.
The camshaft chapter emphasizes timing belt ser- You will also find that learning about automotive
vice, including cam lobe position identification, so internal combustion engines will prepare you for work
you can be sure you are doing the right thing. This in the heavy-duty market. Working on heavy trucks
is something all good technicians should know, but or on marine engines is not that much different than
many do not. working on cars. The principles are the same.
Features of the Text
Learning the theory, diagnosis, and repair procedures

for today’s complex engines can be challenging. To
guide readers through this material, a series of features
are included that will ease the teaching and learning
processes.
CHAPTER 1
Objectives ▶ Engine Operation
Each chapter begins with a list of objectives. The
objectives state the expected outcome that will result CONTENTS
Front-Wheel Drive
Engine Cooling
Spark and Compress
ion
Simple Engine
Engine Classifications
from completing a thorough study of the contents of Four Stroke Engine
Operation
Combustion Cham
ber Designs
ft
Ignition
Puttin g It All Toge ther
Direction of Cranksha High-Performance
Engine
the chapter.
nt
Cylinder Arrangeme
Rotation Trivia
Valvetrain
Firing Order
Cylinder Block
ld be able to:
this chapter, you shou
Upon completion of
OBJECTIVES n • Expla in various engine class
ifications and
ustio
iples of internal comb
• Explain the princ systems.
engin e oper ation .
by
58 SECTION I Engin ustion engine parts
e Construction, Diagnosis, Disas
sembly, and Inspe
• Identify internal comb
name.
SIMPLE ENGINE
ction
Leaking V-Type Inta
ke Man ifold Gasket a piston,
engine has a cylinder,
Intake manifold vacu
ports from the lifter
um can draw oil into Crankcase Pressure INTRODUCTION s are pow- A simple reciprocating
a crankshaft. The cylin
der can
the intake Normally, there is obiles and light truck connecting rod, and n can
-valley area under a slight vacuum in Most of today’s autom rocat ing a and the roun d pisto
manifolds (FIGURE some intake One possible reaso the ted four-stroke recip be compared to a cann
on
of the cylin-
find. A smoke test
3.8). This is a
tough n for excessive oil leaka crankcase. ered by a spark-igni type was built in 1876 a cannonball. The end
is a good way of findi problem to tive crankcase venti ge is a posi-
engine. The first engin e of this be comp ared to n, which
manifold leak. A cran ng an intake This can cause press
lation (PCV) valve
that is plugged. Germ any. Thus , it was named the seale d with a cylin der head. The pisto
king vacuum is anot by Nicolaus Otto in der is , is con-
test for internal air her way to ure
low rpm. Crankcase to build up in the crankcase at pared to previous inter
nal der wall by piston rings and a
sembled. These proc
leaks before the engi
ne is disas- pressure can resul Otto-cycle engine. Com using the same amount is sealed to the cylin by a connecting rod
chapter. When remo
edures are covered
later in this
internal oil consump
tion, too.
t in increased ns
combustion engine desig engine weighed less, ran nected to the crankshaft
ving an intake man Otto’s four- strok e
nt pisto n pin (also called a wrist pin). n to retur n
visually inspect for ifold of fuel, ceme s the pisto
the possibility of prev , always red less cylinder displa This arrangeme nt allow maki ng cont inuo us
gasket leakage. ious intake much faster, and requi later,
horsepower. A few years to the top of the cylin
der,
V-type engines equi NOTE to produce the same a moto rcycle and then a
pped with an exha red
recirculation (EGR ust gas this engine design powe d use
) valve
experience oil-fouling on the intake manifold often
The operation of the r engine designs in limite
of the spark plugs that
in Chapter 13. PCV valve is cover
ed in detail horseless carriage. Othe the rotar y (Wankel), two- Vintage Engines
de
est to the EGR valve
. This is caused when are clos- in modern autos inclu on (diesel) engines.
ressio n igniti Otto has been
manifold warps or the intake stroke, and comp
ustion engine, a Although Nicolaus inter-
the al comb tion of the four-stroke
the gasket with one manifold gasket fails. Replace In a spark-ignit ed intern
d in a cyl- credited with the inven h inventor
designed for high To see if the PCV and fuel is compresse e in 1876, the Frenc
applications. -temperature valve is working prop precise mixture of air izes easily nal combustion engin the concept
erly: be of a type that vapor Rochas developed
■■ Pinch the line that inder. The fuel must a flam- Alphonse Beau de d for a patent but
leads to it, or cove anol, or ethan ol) or 1862. He applie
14 years earlier in
the PCV valve with
your thumb.
r the end of (such as gasoline, meth or natural gas). When the ed taxes so the Frenc
h govern-
ne did not pay the requir
■■ With computer idle mable gas (such as propa re is burned, it pushes a pis- te his patent.
speed adjust disab ment did not valida
PCV valve is good
, idle speed should
led, if the compressed air-fuel mixtu action turns a crankshaft,
This
drop. ton down in a cylinder.
Blocking the flow of (FIGURE 1.1).
Intake
the air-fuel mixture. air to the PCV valve enric which powers the car
manifold hes
gasket
Intake
manifold
REMEMBER: 2
Manifold A leaner air-fuel mixtu
vacuum Oil re means a highe
r idle speed.
Lifter-valley area 7/27/17 2:47 PM
dd 2
SHOP TIP 67480_ch01_hr_001-024.in
Here is another simple

in the crankcase: test to see if there are
(a) any leaks
●■
Remove the hose from
the valve cover to the
air cleaner side). air cleaner (at the
●■
With the engine idling,
put your thumb over
for a couple of secon the end and wait
ds. If the crankcase
working correctly, vacuu ventilation system is
m should be felt in the
hose.
Shop Tips
Oil leaks
Intake
valve
in here
Be sure to check for
a restricted filter
◀
in the breather line or a kink
from the valve cove
Found throughout the chapters, these tips cover things

cleaner. This can resul r to the air
Gilles.
Lifter t in oil leakage caus

valley
case pressure. ed by crank-
Photo courtesy of Tim
(b)
(b)
Vintage Engines
If oil is leaking from
commonly performed by experienced technicians.
FIGU the breather hole
RE 3.8 Oil can of a mechanical
faulty manifold gaske be drawn into the intake manifold fuel pump, be sure
to inspect for
t. past a excessive crankcase
pressure.
67480_ch03_hr_053-09
5.indd 58
7/27/17 2:59 PM
xi
xii Features of the Text
Safety Notes and Cautions ▼ Key Terms ▼

Safety is a major concern in any automotive shop, so Each chapter ends with a list of the terms that were
safety notes and cautions are listed throughout to focus introduced in the chapter. These terms are highlighted
the reader’s attention on important safety information. in the text upon first use.
ing System
266 SECTION II The Breath
stment
Valve Clearance Adju ters, the valve clear-
bucket adjus
On OHC heads with the adjust-
using special tools so
ance can be adjusted replaced as
can be removed and
ment discs, or pucks, outsid e edges of two buckets.
One tool fits on the
needed.
Vintage Engines
two buck-
the camshaft holds the
▼ Prying the tool against
ets down against sprin
g pressure while the
other tool
the
Gilles.
aft and lifts the disc from
reaches around the camsh rubber-tipped blowgun can
Photo courtesy of Tim

). A
bucket (FIGURE 8.116
These text boxes place newer technologies in histori- be used, as show n in FIGURE 8.117, to
from trapped oil that tends

release the disc
to hold it against the bucke
the procedure for adjus
t.
ting Notch
Chapter 16 describes
cal perspective by offering interesting facts about older valve lash on engines
on the rocker arm or
with an adjus tmen
cam follower. Be sure
t provision
to readjust
e has
-tipped blowg
FIGURE 8.117 A rubbering disc from its bucket.
adjust
un can be used to
seated, when the engin remove a lash pad
technologies while separating them from the core text. the valves after they have erature.
been run at opera ting temp
Vintage figures are also included within the boxes.

KEy TERMS solvent test
low-carbon steel valve lash
carbon-manganese steel medium-carbon steel
induction hardened valve spring inserts
proud surface
integral seats runout
interference angle
Case Histories ▼
STUDy QUESTION
S
of valve seating press
ure.
6. List three sources
These true stories describe automotive situations 1. List three tests made
a.
on valve springs. a.
b.
encountered by the author and others. They provide b.

c.
", and
c.
7. Repairs to what part
of the head must be
the seats?
com-
ble in 0.015", 0.030

the reader with insight into the critical thinking skills 2. VSI shims are availa
0.060" sizes. True or false?
a harde ned
pleted prior to refinishing
8. What are the name s of the three valve seat angles?
d most often have
necessary to diagnose automotive engine problems. 3. Which valve woul
tip?
a.
b.
a. Intake c.
t1 "
b. Exhaust ion the valve seat abou 32
9. To correctly posit which
of the part of the valve d
that of a 458 valve face,
4. What is the name from the outer edge
excessive metal is groun angle would you grind
?
becomes too thin when
from the valve face? a. 308
usua lly
are integ ral seats
5. By what proce ss b. 608
hardened?
31 7/27/17 6:13 PM
pection ty
, and Ins Safe
s, Dis assembly S hop
tion, Diagnosi ine
e Construc 00001 dd 266 Eng
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sp
MANUF t “P”
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eventually published ch n . Wh the b o
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s p o th re d e
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it
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manufac ke of vehic dealership and
cov 2
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each ma gas droppe up. The The re e a ligh
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year for icians in le. Every F
Plant . s
the techn l of vehic ys of Assembly tally leaned atch fire lways u
for use by e year and mode the da Z c a
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detail. In c
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service op and trucks, when le Production in . (se
s new vehic bus
simple car n, many to go wi
th tube
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popu deale le from so for someth
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FIGURE
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their ve ers.
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et publish olution is
aftermark mputer rev from some
Tim
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ts
microfich uncom-
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rature pro s become LED
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service lite computers and ha c film card that is

ring.
by sti
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rep is a sm der. Many
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of
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aracter an ). char- amm ld be
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eighth ch cter (FIGURE 4.3 of ea ch prov
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meaning n ap line rs it
tenth chara e manual for the 2.1
3A Gaso and neve lean floo line so mperatu he flash
er aso west te lode. T
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vic c as-
turer’s ser t make of car. FIG
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gaso
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t th a n g
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tha poin oint is th ignite or ns that liq erature
acter for Front locations. s. Liqpors r use ash p
Neve higher fl ’s flash hich can This me any tem e. The
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serial num
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n might 4.4 Eng
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as a ble liquid pors, w 8C). almost n gasolin f the
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VIN code auto ther, it are he op. ma va 8F (2 ors at r tha is one
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es ajor caushes fire. Re vapors s in the shitch,
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If the engin le. Some manufac ch as the valve co
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not be avail at various places
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a re po
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ed . ed into produc l lab will e diese ines te to gaso
att ach the tag
Vehicles d emission contro n to the technici
an you point of sel eng ng or faili ontribu around
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pan. Do not los e
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gaso are so ey can by a sp t have b e ha
sa ie
flash ns why d tte smoki ills can workin an be.
c g l
or oil ser under-hoo es useful informa . On other enta
en have a examples that air, so th ignited ires th ght.
a
le sp c ccid
Blocks oft 4.4 shows several al gives the loca- b a so ig a re e d to s it . A
giv ta e re c lin u
This label w h se th
URE manu than can be ctrical shop li re accep tube. T less gaso me u
Care clean le beco how dan ith your tal.
gero mou
them. FIG ations. The service engine. y d a
The otor, ele droppe p lights a plastic nt bulb. ●
ughly n. Peop ignore soline w can be fa
Gilles.
o
number loc de for a particular the m ed, or a s of sho sed in andesce tio to
situa en begin siphon the lun
ga gs
co
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tion of the d lo
cross wo kin ulb enc roof in
c th
and t attemp soline in
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Do n ing of g
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uses disc l syste r or the .O
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a l Fire prevente the ele h as the cable firstrk e
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ta e
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FIGURE arou nator. D ). This nch com cable. er y bloc older ve
batt can be ble som
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UR
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hen gro re, e fi nd c 17
(FIG rring w and the ctrical fi le so th e grou lly turn
8/7/
3:16 PM
7/27/17 th
occu t” cable an ele as possib oving ccidenta
“ ho is st rem t a
a ere fa no
If th cted as antage to fan can
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onn
disc Another tric coo r it.
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67480_ch04
31
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2.in
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0_ch
6748
Features of the Text xiii
Notes ▼
Throughout the text, notes are included to call atten- ste m
athing Sy
II The Bre
tion to need-to-know information. 266 SECTION

justmen
t
ar-
rance Ad adjusters, the valve clejust-
Valve Clea th bucket so the ad
heads wi al tools as
On OHC adjusted using speci oved and replaced
be ts.
ance can or pucks, can be reme edges of two bucke -
ment discs, ou tsid o buck
fits on the lds the tw tool
s.
of Tim Gille
On e too l shaft ho
needed.
Ase-Style Review Questions
inst the cam re while the other the
▶ too l aga
Prying the ainst spring pressu lifts the disc from
tesy
ets down
ag shaft and blowgun c
can
Photo cour
und the cam er-tipped
reaches aro URE 8.116). A rubb 17, to release the dis t. Notch
bucket (FIG wn in FIGURE 8.1 it against the bucke g
Each appropriate chapter concludes with ten ASE- be use d, as sho
ed oil that
from trapp 16 describes the
tends to ho ld
e for adjus
procedur t provision
tin
ped blowg
un can be
rubber-tip c from its bucket
.
used to
adjustmen 8.117 A
style review questions to help the reader prepare for Chapter st dis
en gin es with an er. Be sure to readju s FIGURE
a lash pad
adjusting
on ha
valve lash er arm or cam follow , when the engine remove
on the rock er they have seated e.

aft ur
the ASE Certification Exam. the valves operating temperat
been run
at
t
solvent tes
MS valve lash
KEy TER
steel
low-carbon g inserts
el carbon ste
el valve sprin
nganese ste medium-
Study Questions ▶
carbon-ma
induction
hardened
integral sea
ts
proud surfa
runout
ce
e angle
interferenc
At the end of each chapter, there are 15 study ques- ting press
ure.
of valve sea
NS
tions of varying types. The questions provide an STUDy
QUESTIO
lve springs.
6. List thr
a.
ee sources
de on va
opportunity for reinforcement and review of key con- 1. List thr
a.
ee tests ma b.
c.
rt of the
head mu
st be com-
to what pa ing the seats?
7. Repairs
cepts presented in the chapter. b.
c.
ailable in
0.015", 0.0
30", an d
pleted pr ior to ref
the name
inish
s of the thr
ee valve sea
t angles?
ims are av false? 8. What are

2. VSI sh or ed
es. True have a ha
rden
0.060" siz a.
most often
valve would b.
3. Which 1
out 32"
c. lve seat ab
tip? ion the va valve face, which
Instructor Resources a. Int ak

b. Exhaus
e
t
me of the
valve tha
part of the is ground
tal
t
from the
ctly posit
9. To corre outer edge of a
angle would
you grind
?
458
is the na when excessive me

4. What
An Instructor Companion Website is available to from the
too thin
becomes lve face?
va
are integ
ra l se ats
us ua lly
a. 308
b. 608
at proc ess
instructors at login.cengage.com and includes the fol- 5. By wh
hardened
?
lowing components: an electronic Instructor’s Guide 7/27/17

6:13 PM
with answers to all end-of-chapter questions, Word

files of all end-of-chapter questions, Cengage Testing, 67480_ch08
_hr_225
-268.indd
266
Powered by Conero(R), with hundreds of questions for

quizzes or exams, chapter presentations in PowerPoint
for each chapter of the text, an Image Gallery with hun-
dreds of illustrations to support in-class presentations,
der Block: Ins
pection
and Servi
ce 337
a NATEF AST/MAST correlation grid connecting the
10 Cylin
CHAPTER
meter of
chapter content with the most current A1 task list, and
NOTE inside dia
e plu g.
l 1 8 " smalle
tha
r than the
Select a too tool that is too sm
A driving t is
all can dis
too tight
tort the
will get stu
ck in
ck. The cor
e
electronic job sheets to guide students through com-
the cor
plug, cau
sin g
g
it
wh
to leak; one driven into the blo
en the plug is
the core plu FIGURE 10.57
in
wa s ins talled inc
orrectly by
mon engine diagnosis and repair procedures.
plug shown er sealing
lip.
pounding
on its out
Additional teaching materials are available for
teachers at http://timgilles.com/.
Gilles.
tesy of Tim
Photo cour
Gilles.
tesy of Tim
prior to
opening
the core
MindTap for Automotive Engines: Diag-

ting sealer on
10.54 Put
Photo cour
FIGURE ation.
coreplug install
ly
nosis, Repair, and Rebuilding, 8th Edition

talled incorrect
g was ins
s core plu
10.57 Thi er sealing lip.
FIGURE out
ng on its
by poundi
MindTap for Automotive Engines provides a customized

learning experience with relevant assignments that will
Gilles.
tesy of Tim
s.
of Tim Gille
help students learn and apply concepts while it allows

Photo cour
tesy
Photo cour
sure to use
a brass 10.58 The
FIGURE nt depths.
se core plu
gs are the
same dia
meter but
instructors to measure skills and outcomes with ease.
MindTap for Automotive Engines meets the needs
g. Be ere
core plu have diff
ve in the
10.55 Dri the tool.
FIGURE avoid damaging
hammer
to of h
Outside Flush wit 20"
of today’s automotive classroom, shop, and student.

0.0
block block or
concave
Within the MindTap, faculty and students will find a

Outside
of block
0.020"
Plug
variety of engaging activities including videos, anima-
minimum
Chamfer Before
Correct
installation
Incorrect
installation tions, matching exercises, and gradable assessments.
e plug unt
il its lips
are past
the
installation
FIGURE
10.59 Ins
talling an expans
ion plug.
MindTap also offers students the opportunity to prac-
10.56 Ins
FIGURE the block.
chamfer
in
tall the cor
tice diagnostic techniques in a safe environment while
strengthening their critical thinking and troubleshoot-
12:40 AM
8/2/17
ing skills with the inclusion of diagnostic scenarios

from Delmar Automotive Training Online (DATO).
337
-345.indd
_hr_311
67480_ch10
About the Author
Tim Gilles has authored and coauthored several of the California Automotive Teachers (CAT) and as
textbooks. He recently retired from the Automotive a board member and election committee chair of the
Technology Department at Santa Barbara City Col- North American Council of Automotive Teachers
lege, after having been a teacher for 38 years. He holds (NACAT). He has been a frequent seminar presenter
a Master of Arts degree in Occupational Education at association conferences. Tim was a longtime mem-
from Chicago State University and a Bachelor of Arts ber of the California Community College Chancellor’s
degree in Industrial Arts from California State Uni- Trade and Industry Advisory Committee. He has been
versity, Long Beach. He has held the industry certi- active in industry associations and groups, including
fications of ASE Master Engine Machinist and ASE AERA, ARC, ASCCA, and IATN, and served several
Master Automotive Technician. terms as education representative on the board of the
Tim has been active in professional associations for Santa Barbara Chapter of the Independent Automo-
many years, serving as president and board member tive Professionals Association (IAPA).
xiv
ASE Certification Tests
The National Institute for Automotive Service Excel- provides a technician with a means of showing a pro-
lence (ASE) certifies automotive technicians in eight spective employer that he or she has a validated train-
specialty areas of automotive and light truck repair. ing background. The practice tests at the end of the
The engine repair certification test is A1. Tests are chapters in this text provide examples of the types of
given on the Internet at proctored centers during eight questions that will be found on the ASE A1 test on
months of the year. For more information, check the Engine Repair. There is also a bank of sample ASE
following URL: http://www.ase.com/Tests/ASE-Certi- Engine test questions and explanations of the correct
fication-Tests/Certification-Testing.aspx. answers included at the back of this book.
To become certified in one of the specialty areas,
you must correctly answer between 60% and 70%
of the questions, depending on the difficulty of the
particular test. To become a Master Auto Technician,
AERA Engine Rebuilding and Machining
you must pass all eight tests. To receive certification, Certificate Program
you must also have at least 2 years of automotive work For many years, ASE and AERA developed and
experience and submit a reporting form to ASE. Your administered an Engine Machinist test series. The last
automotive education can count for one of those administration of these tests was in November 2010. In
years. If you do not have the work experience, you can the absence of ASE machinist certification following
still take the tests. ASE will provide you with the test 2015, AERA has offered a comprehensive online self-
results and will certify you as soon as your experience paced training program leading to diploma-quality
requirement is met. certificates in Cylinder Heads and Engine Machinist.
Many employers ask for ASE certification when Contact AERA at http://www.aera.org/ or phone
they advertise a job opening. ASE certification 815-526-7600 for more information.
xv
Acknowledgments
The author and publisher would like to offer special Jim Brandon
thanks to the following reviewers for their comments, Linn State Technical College
criticisms, and suggestions on the eighth and prior Linn, MO
editions of this text.
David Christen
Eighth edition reviewers: University of Northwestern Ohio
Lima, OH
David R. Christen
Instructor Earl Comer
University of Northwestern Ohio University of Northwestern Ohio
Lima, OH Lima, OH
Jonathan Couch Kenneth P. Dytrt
Owner: Couch’s Automotive Racing Services Pennsylvania College of Technology
Competition Williamsport, PA
Engine Builder/Automotive Educator
Dimitri Elgin
Klein Forest High School
D. Elgin Cams
Houston, TX
Redwood City, CA
Gerard Egan
Gary Engberg
Associate Professor/Department Head
Northeast Metro Technical College
Wake Tech Community College
White Bear Lake, MN
Raleigh, NC
Paul Gagnon
Vincent LaVerdi
Central Maine Community College
Instructor
Auburn, ME
Alfred State College
Wellsville, NY Dave Hagen
AERA Engine Builders Association
Tim LeVan
Crystal Lake, IL
Instructor, College of Applied Technologies
University of Northwestern Ohio John Kraemer
Lima, OH Western Iowa Tech Community College
Sioux City, IA
Stanley D. Martineau
Utah State University Norman Laws
Price, UT Professor Emeritus
Chicago State University
Reviewers of earlier editions:
Larry Leavitt
Henry Baboolal
Pennsylvania College of Technology
University of Northwestern Ohio
Williamsport, PA
Lima, OH
Tim LeVan
Steve Bertram
Palomar College
Lima, OH
San Marcos, CA
xvi
Acknowledgments xvii
Wilmer Martin Jason Spohr

Automotive Training Center Pasadena City College
Pasadena, CA
Gary McDaniel
Metropolitan Community College–Longview Bill J. Steen
Lee’s Summit, MO Yuba College
Marysville, CA
J. C. Mitchell
Gaston College Forrest J. Stewardson
Mayo Technical College
Joseph Moore
Southern Maine Community College Don Sykora
South Portland, ME Morton College
Cicero, IL
Ted Nicoll
Central Missouri State University John Thorp
Illinois Central College
Jason Norris
Peoria, IL
Pasadena City College
Pasadena, CA Christopher VanStavoren
Pennsylvania College of Technology
Jerry Norris
Williamsport, PA
Southeast Community College
Milford, NE Walter Varella
Trident Technical College
Joe Polich
North Charleston, SC
President Production Engine Rebuilders Association
Bob Warnke
Fred Raadsheer
Hutchinson Technical College
British Columbia Institute of Technology
Vancouver, BC Michael White
Richard Rackow
Lima, OH
Moraine Valley Community College
Palos Hills, IL
The author would also like to thank the mem-
Robert D. Raduechel
bers of the AERA for the tremendous job they do in
Modesto Junior College
sharing technical information through their orga-
Modesto, CA
nization. AERA associate members from industry
Butch Reilly and manufacturing have been extremely helpful
Spokane Community College in providing illustrations and technical help. Dave
Spokane, WA Hagen, AERA Technical Support Manager, has
Chuck Rockwood made countless helpful suggestions for improve-
Ventura College ment of this and earlier editions of Automotive
Ventura, CA Engines.
The author would especially like to thank his
Charles Romack Cengage Learning team—Mary Clyne, Cheri Plasse,
Southern Illinois University and Larry Main for their exceptional effort and
Jerry Rosenquist dedication in bringing this revision to publication.
Fel-Pro/Federal-Mogul Thanks are also due to Katie McGuire, my product
manager. Katie has very capably managed this eighth
Raymond K. Scow Sr edition revision of Automotive Engines. She has been
Truckee Meadows Community College an advocate of excellence throughout this project
Gary Semerdjian and others she has worked on with me. The quality
Santa Barbara City College of this project would be substantially less without
Santa Barbara, CA her participation.
SECTION 1
Engine Construction, Diagnosis,
Disassembly, and Inspection
OVERVIEW
Automotive Engines is a book about the diagnosis, repair, and rebuilding of
engines in modern automobiles and light trucks. Section 1, comprising the
first six chapters, introduces the reader to the internal combustion engine.
Chapter 1 provides a brief overview of engine construction and operation.
Safety and shop equipment are covered next in Chapter 2. Chapter 3 deals
with engine problem diagnosis that can be performed before engine repair
while the engine is still running. The chapter has been designed so that it can
be used as a reference while studying the rest of the text. Problems are listed
alphabetically throughout the index at the back of the book. Chapter 4 covers
engine removal, disassembly, inspection, and diagnosis of internal engine
parts wear. Also covered are in-chassis repairs—those that can be done on
an engine without removing it from the vehicle. The final two chapters in this
section deal with engine cleaning and measuring after disassembly.
CHAPTER
1
Engine Operation
CONTENTS
Simple Engine Front-Wheel Drive Engine Cooling
Four Stroke Engine Engine Classifications Spark and Compression
Operation Combustion Chamber Designs Ignition
Cylinder Arrangement Direction of Crankshaft Putting It All Together
Valvetrain Rotation High-Performance Engine
Cylinder Block Firing Order Trivia
OBJECTIVES Upon completion of this chapter, you should be able to:

• Explain the principles of internal combustion • Explain various engine classifications and
engine operation. systems.
• Identify internal combustion engine parts by
name.
INTRODUCTION SIMPLE ENGINE

Most of today’s automobiles and light trucks are pow- A simple reciprocating engine has a cylinder, a piston,
ered by a spark-ignited four-stroke reciprocating a connecting rod, and a crankshaft. The cylinder can
engine. The first engine of this type was built in 1876 be compared to a cannon and the round piston can
by Nicolaus Otto in Germany. Thus, it was named the be compared to a cannonball. The end of the cylin-
Otto-cycle engine. Compared to previous internal der is sealed with a cylinder head. The piston, which
combustion engine designs using the same amount is sealed to the cylinder wall by piston rings, is con-
of fuel, Otto’s four-stroke engine weighed less, ran nected to the crankshaft by a connecting rod and a
much faster, and required less cylinder displacement piston pin (also called a wrist pin).
to produce the same horsepower. A few years later, This arrangement allows the piston to return
this engine design powered a motorcycle and then a to the top of the cylinder, making continuous
horseless carriage. Other engine designs in limited use
in modern autos include the rotary (Wankel), two-
stroke, and compression ignition (diesel) engines. Vintage Engines
In a spark-ignited internal combustion engine, a Although Nicolaus Otto has been
precise mixture of air and fuel is compressed in a cyl- credited with the invention of the four-stroke inter-
inder. The fuel must be of a type that vaporizes easily nal combustion engine in 1876, the French inventor
(such as gasoline, methanol, or ethanol) or a flam- Alphonse Beau de Rochas developed the concept
mable gas (such as propane or natural gas). When the 14 years earlier in 1862. He applied for a patent but
compressed air-fuel mixture is burned, it pushes a pis- did not pay the required taxes so the French govern-
ton down in a cylinder. This action turns a crankshaft, ment did not validate his patent.
which powers the car (FIGURE 1.1).
Intake Exhaust
valve valve
Intake
Combustion port
Piston
Combustion
chamber Exhaust
Up-and-down port
motion
FIGURE 1.3 Valves seal off the valve ports.
Crankshaft
FIGURE 1.1 A piston forces a crankshaft to turn. Cylinder head
rotary motion of the crankshaft possible. Because

of the powerful impulses on the piston as the
fuel is burned in the cylinder, a heavy flywheel is
bolted to the rear of the crankshaft ( FIGURE 1.2).
The weight of the flywheel blends the power Head gasket
impulses together into one continuous motion of
the crankshaft.
The cylinder head has one combustion cham-
ber for each cylinder (FIGURE 1.3). An intake valve
port allows a mixture of air and fuel to flow into
the cylinder, and an exhaust valve port allows the
burned gases to flow out. Each port is sealed off by Engine block
a poppet-style valve. The head is sealed to the cyl-
inder block with a head gasket (FIGURE 1.4). The FIGURE 1.4 A head gasket seals the head to the block.
opening of the valves is controlled by the camshaft
(FIGURE 1.5).
FOUR-STROKE ENGINE
OPERATION
A stroke is the movement of the piston from TDC
(top dead center) to BDC (bottom dead center), or
from BDC to TDC. There are four strokes in one
four-stroke cycle of the engine. They are called the
intake stroke, compression stroke, power stroke, and
exhaust stroke.
Photo courtesy of Tim Gilles.
■■ Intake Stroke. Gasoline will not burn unless it is

mixed with the correct amount of air. It is very
Flywheel explosive when 1 part is mixed with about 15 parts
of air. Shortly before the piston reaches TDC, the
FIGURE 1.2 A flywheel is installed at the end of the crank- intake valve begins to open. As the crankshaft
shaft. This is a Buick opposed engine from the early 1900s. turns, it pulls the rod and piston down in the
4 SECTION I Engine Construction, Diagnosis, Disassembly, and Inspection
Camshaft Intake valve

open
Cam follower
Air-fuel
mixture
Valves
Timing
belt
Crankshaft
Intake stroke
FIGURE 1.6 The air-fuel mixture is drawn into the cylinder.
FIGURE 1.5 The opening of the valves is controlled by the

camshaft. Both valves
closed
cylinder toward BDC (FIGURE 1.6). This action

creates a low-pressure void that is filled by atmo-
spheric air pressure and fuel through the open Air-fuel
intake valve. About 10,000 gallons of air is drawn mixture
in for every 1 gallon of fuel supplied by the fuel
system. The ideal mixture (called stoichiometric)
for the combined purposes of engine performance,
emission control, and fuel economy is about 14.7:1
(at sea level). Crankshaft
Older vehicles had carburetors and newer
vehicles manufactured since the mid-1980s have Compression stroke
fuel injection systems with computer controls.
The computer monitors the oxygen content in the FIGURE 1.7 The air-fuel mixture is compressed as the piston
vehicle’s exhaust and then adjusts the fuel supply moves up in the cylinder.
to provide the correct amount of fuel and air for
each intake stroke.
As the crankshaft continues to turn, the piston moves toward TDC, both of the valves are closed
begins to move back up in the cylinder and the as the mixture is compressed to about 1 8 of the
intake valve closes. volume it occupied when the piston was at BDC.
■■ Compression Stroke. The piston moves up in In this case, the compression ratio is said to be
the cylinder, compressing the air-fuel mixture 8:1 (FIGURE 1.8). If the mixture is compressed
(FIGURE 1.7). If you light a puddle of gasoline to 112 its original volume, the compression ratio
on fire in open air, it does not produce power. If is then 12:1.
it is confined in a cylinder, however, usable power ■■ Power Stroke. As the piston approaches TDC on its
can be produced. Compressing the mixture of compression stroke, the compressed air-fuel mix-
air and fuel into a smaller area makes it easier ture becomes very explosive (FIGURE 1.9). When
to burn. The compression stroke begins at BDC the ignition system generates a spark at the spark
after the intake stroke is completed. As the piston plug, the fuel ignites. The air-fuel mixture burns,
Volume before Volume after Both valves

compression: 480 cc compression: 60 cc closed
1
2
3 TDC
4
5
6
7
8
BDC
Compression ratio: 8 to 1
Crankshaft
FIGURE 1.8 Compression ratio is a comparison of the volume
of the air space above the piston at BDC and at TDC. In this
Power stroke
example the compression ratio is 8:1.
FIGURE 1.10 The air-fuel mixture ignites, pushing the piston
down.
PSI 14.7
1408F
PSI 1000
8508F
Blowby
FIGURE 1.9 The air-fuel mixture heats up as it is compressed.
but it must not explode. As the mixture burns, it

expands, forcing the piston to move down in the
cylinder until it reaches BDC (FIGURE 1.10). The
action of the piston turns the crankshaft to power FIGURE 1.11 Blowby into the crankcase is leakage of gases
the car. The power stroke is sometimes called the past the piston rings. It starts in the combustion chamber in
expansion stroke. gasoline and diesel engines.
Some leakage of gases past the rings occurs
during the power stroke. This leakage, called
blowby, causes pressure in the crankcase exhaust valve ( FIGURE 1.12 ). A few degrees
(FIGURE 1.11). Blowby starts in the combustion after the piston passes TDC, the exhaust valve
chamber in both gasoline and diesel engines. closes. The entire four-stroke cycle repeats
itself, starting again as the piston moves down
■■ Exhaust Stroke. As the piston nears BDC on the
on the intake stroke.
power stroke, the exhaust valve opens, allowing
the spent gases to escape. Because the burning The four-stroke cycle is considerably more com-
gases are still expanding, they are forced out plicated than this simple explanation. When the
through the open exhaust valve. As the crank- engine is running, the timing of the opening and clos-
shaft continues to turn past BDC, the piston ing of the valves actually determines when each stroke
moves up in the cylinder, helping to push the effectively begins. Valve timing is discussed in much
remaining exhaust gases out through the open greater detail in Chapter 9.
Exhaust valve
open
(a) Courtesy of BMW of North America, LLC

Crankshaft (a)
Exhaust stroke
(b) Courtesy of Daimler Chrysler Corporation. Image used with

FIGURE 1.12 The exhaust valve opens and exhaust gases
escape as the piston comes up.
CYLINDER ARRANGEMENT
Automobile and light truck engines have three,
four, five, six, eight, or more cylinders. C
ylinders
are arranged in one of three ways: in-line, in
a “V” arrangement, or opposed to each other
permission.
(FIGURE 1.13). In-line six-cylinder and V6 engines (b)
are shown in FIGURE 1.14.
The V arrangement is popular with designers FIGURE 1.14 (a) Section view of an in-line six-cylinder
when an engine has more than four cylinders because engine. (b) Section view of a V8 engine.
this design can be considerably shorter in length.
Vintage Engines
In the first half of the 20th Century,
before the jet age, airplane engines had cylinders
arranged in a radial arrangement. (see figure below.)
V-type In-line
Opposed A radial engine from a vintage airplane.
FIGURE 1.13 Cylinder arrangements.
A completely assembled V-type engine typically

Rocker arm
weighs less than an in-line engine with the same num-
ber of cylinders. Pushrod
V-type engines have connecting rods from two Spring
cylinders on opposite sides of the engine that share
one crankpin (see Chapter 11). This allows the engine
block to have fewer supports for the crankshaft main
bearings. An in-line six-cylinder engine might have Valve
Lifter
seven main bearings; a V6 block is shorter and will
typically have only four main bearings. A V8 block
will usually have five main bearings.
VALVETRAIN
Cam lobe
One complete four-stroke cycle requires the crank-
shaft to rotate two times. Two 360° crankshaft revolu- (a)
tions means the crankshaft travels a total of 720° to
complete one cycle. During these two revolutions, Camshaft
each cylinder’s intake and exhaust valves open once.
The valves are opened by the camshaft, commonly Lobe
called the “cam,” which is considered the “heart” of
the engine. The cam has lobes that are off-center and Camshaft
push against the valvetrain parts, causing the valves to follower
Lash adjuster
open at precise times (FIGURE 1.15). Valve
The camshaft controls the rate at which the spring
engine breathes. Its design can be for best opera-
tion at maximum power and high speed, or for fuel
economy and best low-speed operation. A produc-
tion engine is an engine produced at the factory.
Production engines are a compromise between
these two concerns, and this is the reason many
late-model vehicles use variable valve timing. Chap-
ter 19 deals with different “cam grinds” and variable
valve timing in detail.
Camshafts can be located either in the block
Valve Water jacket
(see FIGURE 1.15a) or in an overhead cam cylinder
head (see FIGURE 1.15b). One or more camshafts Cylinder head
are driven via crankshaft rotation using one of sev-
(b)
eral combinations, including gears or sprockets and
chains or belts. The crank must turn twice for every FIGURE 1.15 A cam lobe forces the valve open. (a) The
one turn of the cam, so there are half as many teeth c am-in-block design uses pushrods to open valves. (b) In the
on the crank drive as there are on the cam drive overhead cam design, the camshaft is located in the cylinder
head.
(FIGURE 1.16).
Vintage Engines CYLINDER BLOCK

A V-type engine uses a carburetor The cylinder block is an intricate casting that includes
more efficiently than an in-line engine. This is oil galleries as well as jackets for coolant, which are
because the intake manifold runner lengths are commonly called water jackets. Cylinder blocks are
more equal (see Chapter 17). made of cast iron or aluminum, cast into a mold. Many
engine blocks today are made of aluminum with iron
Cam
sprocket
Gear drive
FIGURE 1.18 Sand casting cores.
Crank liner that will provide the shape for the outside sur-
sprocket face of the engine block. The mold is supported at
several points around the outside of the core box; the
supports will leave core holes in the finished block.
Glue binders and a hardener hold the grains of sand
Belt drive together. They are mixed with the sand and blown into
Chain drive an iron master mold. Next a gas is injected to cure the
sand into a hard core mold.
FIGURE 1.16 There are half as many teeth on the crank drive Most of today’s blocks are made of aluminum
as there are on the cam drive. alloy. When iron liners are used in aluminum blocks,
they are inserted into the cylinder block core. They are
heated before the pour to help them bond to the mol-
ten aluminum. Oil gallery areas of the core are coated
with talcum powder to prevent sand from sticking to
the aluminum during the pour. Otherwise, the sand
might contaminate engine lubricating oil.
Molten aluminum is poured into the mold at
Iron sleeves 1,500°F. The mold cavity is filled from the bottom to
prevent oxidation when the molten aluminum con-
tacts air. If the mold was filled from the top, alumi-
num oxide would contaminate the pour. Following the
pour, the aluminum casting is placed for a few hours in
an oven for heat treating to strengthen the block. This
process also bakes the binder that holds the sand mold
FIGURE 1.17 An aluminum block with cast iron sleeves.
together, loosening the sand. Then a robot rotates and
vibrates the casting to expel the loose sand. The cast-
ing is rough machined before sending it to another
cylinder bore liners called sleeves (FIGURE 1.17). This plant that does the finish machining and assembly.
allows for the weight savings provided by aluminum,
coupled with the durability and trueness of cast iron
in the cylinder bore area. Some aluminum blocks do Lost Foam Casting
not have iron sleeves because aluminum cylinder wall In another casting process, lost foam casting (LFC),
surfaces can be made very hard. a foam mold pattern, is “lost” or burned up as it is
There are different casting processes for engine replaced by molten metal during the pour. General
parts, including sand and foam. Motors first experimented with LFC in 1982 and since
then has refined the process for use in casting blocks,
heads, and crankshafts. GM’s now-defunct Saturn
Sand Casting line used this process since its beginning in 1990 and
The sand casting process uses a zircon sand mold made GM has been routinely casting aluminum heads and
up of several sections, called cores (FIGURE 1.18). The blocks in its other divisions using LFC since 1999.
mold is suspended in a container, or core box, with a With conventional sand casting, oil galleries must be
machined in the block casting. With LFC, the oil gal-

leries and coolant passages can be cast into the part. Gussets for strength
Foam also provides a more accurate casting compared
to sand casting. The completed casting is smoother in
appearance and there are no parting lines. The mold
is often made in pieces, which are fastened together
using hot-melt glue to make up the finished model.
These more intricate castings are possible because the
pattern does not need to be removed as was the case
with sand castings.

The LFC pattern is made of expendable polysty-
rene beads, otherwise known as Styrofoam. Patterns
are made by injecting the beads into a die and then
Core plugs
superheating them with steam to bond them together
and form the finished mold. The foam pattern is
coated with a refractory coating, which smoothes the FIGURE 1.19 Core plugs.
surface of the pattern. Gates and risers are attached to
the pattern to allow for the pouring and venting of the
molten metal. Unlike the conventional sand casting V-Type Cylinder Banks
process, which uses binders to hold the sand together, On V-type blocks, cylinders are cast in two rows called
LFC uses dry, unbonded sand that is poured around left and right banks.
and into the internal passages in the pattern. The sand
is vibrated and compacted to thoroughly fill the voids
around the pattern. During the pour, the molten metal
replaces the pattern as it vaporizes. When the finished
NOTE
casting has cooled and become solid, the unbonded
sand is dumped out. It can be reused, unlike conven- The location of the left and right banks is determined
when viewing from the transmission end of the engine.
tional casting sand, which requires disposal.
A typical passenger car engine today uses a cast
aluminum cylinder block with cast iron cylinder
sleeves. The sleeves are ground to size on the outside V8 blocks are cast with the cylinder banks sepa-
diameter (O.D.), chilled, and pressed into machined rated by a 90° angle. V6 blocks have either 60° or 90°
holes in the aluminum block. This allows the iron lin- between banks. There are also unusual engine designs,
ers to dissipate heat into the aluminum casting and such as Volkswagen’s V6, which has 15° between banks.
water jackets. The inside diameter (I.D.) of the cast There are big block and small block engine designs.
iron sleeves is bored and honed to approximately Smaller, lighter blocks are more popular in passen-
1.5 mm thick when finished, providing an excellent ger cars because of their fuel efficiency. Some intake
wear surface for the piston rings. manifolds cover the area between the heads known as
the valley (FIGURE 1.20), whereas others use covers
and a separate intake plenum.
Core Plugs and Gussets A complete block assembly with the entire val-
Gussets to add strength are cast in strategic positions vetrain (cylinder heads and related parts) included is
on the block. Core holes in the block and head(s) are called a long block.
closed off with core plugs (FIGURE 1.19). Core plugs
are usually made of steel or brass, although rubber
and copper expandable plugs are available, too. Brass Short Block and Long Block
core plugs are superior because they do not rust. Brass The cylinder block assembly (without the heads
plugs are not used in new cars because of their extra installed) is called a short block. The short block
cost and because new engines are filled with cool- includes the crankshaft, piston and rod assembly, and
ant, which prevents rust. Core plugs are sometimes all bearings. On pushrod engines, the camshaft, tim-
referred to as expansion plugs, welsh plugs, freeze ing sprockets, and timing chain are also part of the
plugs, or soft plugs. short block (FIGURE 1.21).
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And now we will finish by saying a few words concerning the
plump chubby-cheeked one.
His name was Santiago Morcillo. He was a native of Leon, had no
parents, and was one of those quiet beings whom it is difficult to
rouse, either through anger or pleasure. When anything unpleasant
happened, he said only, “God’s will be done,” and if he had reason to
feel pleased, showed it only by a smile or by going to church to thank
God for the favors which he bestowed on him. His father’s conduct
had been disorderly, and he left but few unencumbered possessions,
his affairs being in confusion, but the good-natured Santiago did not
mind this. He was quite the opposite of his father and, by force of
work, economy and shrewdness, he recovered what was lost, and
even improved his condition so far that finally he was free from debt
and in easy circumstances. Until then he had never thought of
women, and when he did, he said,
“I shall take a rest now. It would be folly to begin a dangerous
experiment immediately. My mother was a very virtuous woman, but
all women are not alike.”
The good Morcillo was not only economical, but somewhat
avaricious, and it occurred to him to use the influence of his relatives
to obtain some sort of office, and with this object in view he had
come to the court at Madrid. One morning he went to mass at St.
Joseph’s Church, and standing near the entrance, and turning aside
to let a caballero pass, he saw Doña Estrella, who was kneeling in
prayer, her virgin lips moving in religious fervor, and her eyes raised
to Heaven with a most sweet and tender expression. For the first
time Señor Santiago felt a vivid impression, and involuntarily he
made a somewhat impious comparison between the sublime young
girl and an angel. He was always timid in the presence of women,
but this being was not a woman, she was a cherub. Being a good
Catholic, the hidalgo instantly repented of his sinful attention to
worldly affairs, and turning his back upon the young lady, began to
repeat his prayers; but he was unable to forget the cherub with the
blue eyes, and ten minutes later, moved by an irresistible attraction,
he turned and looked again. He saw her a second time, and felt his
heart beating. When the mass was over, the good Morcillo could
contain himself no longer. He turned quickly round and looked for
her. The mother was very near her daughter, and in front, one behind
the other, were her two sisters. However, in the crowd it was not
easy to see that the four belonged together, and besides, the hidalgo
had no eyes for any except the fair one. He tried to get nearer to her,
but every one rose at the same moment, and he again lost sight of
her for a few moments. He tried his best to force a way for himself
through the crowd, but, being quite confused, he paid no attention as
to where he planted his feet, and many of the faithful accosted him
roughly, while others threw themselves against him and prevented
his getting out. The poor fellow was almost suffocated, crushed and
choking. He could hardly breathe, and perspired freely, while his face
became livid. His stoutness was his great misfortune, and he missed
the lady.
“Is it possible that I have fallen in love?” he asked himself when he
got into the street.
He could not forget the fair face, and began to think the matter
over with as much calmness as he could muster in his
embarrassment. Having met such an angel of a woman, why should
he not marry her? A bachelor’s life was very nice, but only up to a
certain age. He went to mass the next day, and again he saw
Estrella, and lost her in leaving the church. At last, on the day when
our story begins, Morcillo, like the others, discovered by accident the
residence of the charming maiden. He saw her on the balcony.
Nothing else happened, but, feeling sure that he was in love, and
that his will power was not strong enough to resist his passion, he
made up his mind to go on with his wooing, and not to stop, unless
this marvelous being with the face of an angel should prove to be a
demon, which was, of course, impossible.
Now we know the three hidalgos, who did not resemble each other
in the slightest degree.
(To be continued.)
QUATRAIN.
To dash irradiant on the barren shore
The wave is born; the lark to sing and soar;
To traffic with the sun upsprings the tree—
Man only has no certain destiny.
—H. C. H.
EXTRACTS FROM THE LOG OF THE
“RITA”
BEING A DISCONNECTED ACCOUNT OF THE DOINGS OF SOME
ARTISTS ON A SUMMER CRUISE....
“First day out. We can scarcely realize we have left behind the heat, the noise,
and the dust of the city for three weeks. Far to the north, overhung by clouds
of noisome smoke, our late prison is gradually sinking from sight. Only the
tallest spires and houses can be seen. As the distance grows greater our
hearts grow lighter, and dance in unison with the leaping waves. The day is a
miracle of light and color,—
and
we’re
a happy
crew!”
“Came
very
near
being
wrecked
last night. Even the moon was full—but that fact saved the lives of all on
board. Spike made a sketch this morning that will explain better than words.”
“The fashionable portrait painter’s man and girl flirting on the shore turned
out to be rather clever devices for frightening crows. He has been advised to
consult an oculist.”
“Fuzzie-Wuzzie and the Languid Aquarellist got together in the forecastle to

hatch a scheme to get possession of the champagne. Nick, the Nipper, woke
up and heard the conversation. He called to Mock-a-Hi. Hi took in the situation
at a glance, and skewered Fuzzie and the Aquarellist with his prize finger-nail
(with which he does his etchings), and thus the villains were balked. The
conspirators had been eating Anti-Puncture, so that when Hi withdrew his nail,
none of the wind came out of their tires. There was little blood and much wine
spilled over this affair. The Skipper instantly had the schemers put in irons,
and Nick, the Nipper, was allowed to torture them in their helpless condition
with a few of his songs and imitations, as a reward for his vigilance.”
“To-day we took on board a small party of guests, several ladies being
among the number. The finished style in which our fashionable portrait painter
received the latter excited general admiration. There is very little doubt but
that he will be promoted to be Assistant Skipper, with a cook’s pay.”
“The Skipper complained this evening of “feeling queer in the head,” and
the Duke made unkindly reference to the moon (which is known to have a
peculiar influence in certain cases), but got “sat on” for his inopportune display
of wit. Fuzzie’s allusion to the banquet in the cabin last night was perhaps
more truly explanatory.”
“Sailing
close to
shore,
—and enjoying the
beautiful glimpses of
field and wood seen
through the golden
haze of a summer
afternoon.
What a
glorious
land!”
“The Languid Aquarellist is singing the national anthem. Perhaps he is

being unconsciously stirred by all these
wondrous
beauties of
nature.”
“Here
Truthful
Freddie
—sits by the hour, in
the golden evening
glow, dreaming of—what ?”
“Salad
day.
Before seven o’clock this morning Curly and the Duke had caught enough
crabs to supply the mess of a man-of-war. The salad—prepared by the Duke,
of course—was pronounced excellent in technique, although somewhat after
the manner of Bouguereau, being extremely smooth and delicate.
But this
can be
forgiven
in a
salad.”
“Late this afternoon we passed a sailing party homeward-bound. As they
passed, quite close, Spike, with his ever-ready pencil, transferred several of
the most conspicuous members to paper.”
“For his marvelous success in mixing salads, the Duke, who studied the
culinary art in Paris and Rome, has been made Second Mate.”
“Three days out. The Languid Aquarellist insisted this morning on going
ashore and shooting ducks—wild ones. After he had almost decimated a
farmer’s prize flock of pekins (without noticing their barnyard confidence in
man)—he was promoted by the Captain for excellent gunnery, and the
addition to the yacht’s stores.”
“Tomson, (of the Barber’s-Own School), spent the entire afternoon trying to
convince Miss ⸺ that his own peculiar method of painting is the acme of art.
Miss ⸺ seemed delighted with his efforts, and thinks his pictures are “just
lovely.” She wants him to attempt an imaginary portrait of the sea serpent.
Owing to the ceaseless motion of the boat, Tomson’s pictures are decidedly
impressionistic.”
—“And then Bill Weatherbones gave us his version of the great naval
combat at Santiago, in which he took a very prominent part. ‘I tole yer how it
wuz,’ Bill began; ‘it wuz dis way, sur. I wuz a-settin’ on de aft hatch a-smokin’ a
cigar Bill Sampson giv’ me, an’ Bill an’ Winnie Schley wuz a-workin’ out a little
game wid de cards. Bill t’rowed down his papes an’ sed,—
“I
aint
got
no
luck,
I got to shake yuse fellers. Mc. he’s sent me de wire to go over an’ chin dat
man Shafter, wot’s runnin’ de army push, an’ make him git a move on hisself.”
“Don’t go, Bill,” sez I, “send one o’ de gang, it’s too hot fer yer, wot’s de good
yer workin’?” “Dem aint me orders,” sez Bill, den turnin’ to Winnie Schley, he
giv’ him de stern look, an’ sed, “Winnie, yer do de stunts here till I gets back
wid meself, an’ if de Spaniels tries ter get out de bottle squirt de guns on ’em.”
“I’m on,” sez Winnie, an’ he giv’ me de wink, “if de farmers shows up I shoots.”
Den de Admiral he gits in his little ya’t an’ sails off. Winnie den piped up de
grog all eround, an’ de game went on ag’in. I aint much stuck on de game de
navy push puts up, it’s on de squar’, an’ so I set dere gappin’ an’ feedin’ me
face, while de boys plays. All of a sudding I seen over dere where de guy
Hobson sinked de Merrymac some smoke. I wunk t’ meself, but didden say
nothin’ to break de boys up, but soon Winnie Schley looked up an’ seen it.
“Hully gee!” he yelled, “de blokes is a-chasin’ out,” an’ he grabbed a bunch o’
flags an’ did de signal act o’ his life. He worked dose flags till he looked like a
skirt dancer. De udder ships looked like a back yard wid de clothes-line full of
red-flannel shirts from de wavin’ de guys put up. “Git dem guns loaded,” yelled
Schley, “yuse blokes look lively, dere.” Boom! busted out one o’ de big guns,
an’ de noise it knock de win’ outten me works. It hit de Spaniel an’ turned him
bottom upwards; when he come up ag’in he shot his gun at us, but it wuz half
a mile too high. Schley he rung out de joyous laugh. “Dere optics aint no
good,” sez he, den he lets anudder ball go at him dat went clean t’rough him
an’ hit anudder ship two miles off an’ sunk it in a minnit. Den up comes
anudder Spaniel, an’ I seen⸺’”
“The steering gear is a little rattled: a puff of wind blew a lock of Mate
Fuzzie-Wuzzie’s hair into the wheels, and instantly the vessel swung round.
The engine was stopped, and in the excitement that ensued, a case of
champagne was almost lost overboard. We had to run backward for a mile
and a-half to disengage Fuzzie’s hair from the machinery. Fuzzie has been
reduced.”
“Spike’s interest in the war has grown to be a matter of serious
inconvenience to all on board. He has literally covered the yacht with
Military
and
Naval
cartoons.
The boat will certainly have to be re-painted. This morning he came on deck
with a drawing he did sometime during the night, which represents Uncle Sam
admonishing Spain to stop kicking the “yaller dorg”—Cuba. It’s not half bad,
but his claim of it’s being the best yet made on the war is a little strong. He
has been so busy admiring it all day he has not thought to make any others—
and we have had time to breathe.”
“We
came
to
anchor
this evening near the wreck of the “Two Sisters,” in the vicinity of which—on
the shore—was situated a dog-pound, containing some two hundred canines
awaiting execution.... We enjoyed a night of delightful rest.”
“The Skipper went out on his bicycle gig to take a survey of the harbor, but the
roadway was running so high he found it difficult to make any headway,
and had to return to the yacht.”
“Curly has been pronounced unfit for the duties of an able-bodied seaman,
and has been handed over to the Duke for treatment. It is suspected he is
afflicted with some curious, and hitherto unknown, form of love. Yesterday the
Duke administered a very carefully prepared shrimp salad, but it failed utterly
to bring about the desired results. He’s still very pensive, and seems to wish to
be alone. Grave symptoms indeed. Ever since our last visit ashore, when he
was seen walking through the fields with a tall, willowy creature of undeniable
attractiveness, he has been very dejected and apathetic.
We shall
try
keel-hauling
as a
last resort,
—but trust it will not be necessary.”
“The last glimpse of the glorious old Bay, and the last day afloat. The cruise
has been one of continuous delight, but we can not but regret the end has
come, and we must tread the bricks of uninteresting streets instead of the
swaying deck of the Rita. But, as Bill Weatherbones would say, “Wot’s de
use? Man aint born to be happy,
—an’
dats
straight.”
THE END

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Automotive Service Inspection Maintenance Repair 5th

Automotive Service: Inspection, Maintenance, Repair

Advanced Automotive Fault Diagnosis Automotive

Automotive maintenance & light repair Second Edition

Social Media for Knowledge Sharing in Automotive Repair

Small engines and outdoor power equipment : a care &

Combustion Engine Diagnosis Model based Condition

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Product Director: Matthew Seeley

Senior Content Developer: Mary Clyne

To learn more about Cengage Learning, visit www.cengage.com

Notice to the Reader

Printed in the United States of America

they are in their correct locations—a substantial task.

inspired me to become an automotive teacher; Roger Aylesworth, who became a big

CHAPTER 1 Engine Operation 2

CHAPTER 2 Engine Shop Safety 25

CHAPTER 3 Diagnosing Engine ­Problems 53

CHAPTER 4 Engine Removal, Disassembly, Inspection,

Front-Wheel Drive Engine and Transaxle Removal ● Rebuild or Replace? ● ­

Engine Disassembly ● Ordering Parts ● Major Engine Repair—Engine in the Vehicle ● ­

Study Questions ● ASE-Style Review Questions

CHAPTER 5 Cleaning the Engine 153

ASE-Style Review Questions

CHAPTER 6 Measuring 170

ASE-Style Review Questions ● Micrometer Practice

CHAPTER 7 Cylinder Head: Parts and Service 188

CHAPTER 8 Cylinder Head: Springs, Valves, and Valve Seats 225

CHAPTER 9 Camshafts, Lifters, Timing Belts, and Chains 269

CHAPTER 11 Crankshaft, Bearings, and Engine Balancing 346

CHAPTER 12 Pistons, Rings, and Connecting Rods 386

ASE-Style Review Questions

CHAPTER 13 Lubrication 424

CHAPTER 14 Cooling System 459

CHAPTER 15 Engine Hardware: Fasteners, Thread Repair, and Gaskets 504

CHAPTER 16 Reassembly and Starting 558

CHAPTER 17 Engine Breathing: Intake and Exhaust Systems 600

Exhaust Systems ● Study ­Questions ● ASE-Style Review Questions

CHAPTER 18 Turbochargers and Superchargers 620

Study Questions ● ASE-Style Review Questions

CHAPTER 19 Producing Power: Valve Timing,

Supplemental Test Questions and Answers ● 677

Organization of This Edition ■■ The updated high-performance Section 5 includes

Learning the theory, diagnosis, and repair procedures

Here is another simple

Found throughout the chapters, these tips cover things

Lifter t in oil leakage caus

Safety Notes and Cautions ▼ Key Terms ▼

Photo courtesy of Tim

from trapped oil that tends

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Vintage figures are also included within the boxes.

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tion to need-to-know information. 266 SECTION

CHAPTER 1 Engine Operation 2

CHAPTER 2 Engine Shop Safety 25

CHAPTER 3 Diagnosing Engine Problems 53

CHAPTER 4 Engine Removal, Disassembly, Inspection,

Front-Wheel Drive Engine and Transaxle Removal ● Rebuild or Replace? ●

Engine Disassembly ● Ordering Parts ● Major Engine Repair—Engine in the Vehicle ●

CHAPTER 5 Cleaning the Engine 153

CHAPTER 6 Measuring 170

CHAPTER 7 Cylinder Head: Parts and Service 188

CHAPTER 8 Cylinder Head: Springs, Valves, and Valve Seats 225

CHAPTER 9 Camshafts, Lifters, Timing Belts, and Chains 269

CHAPTER 11 Crankshaft, Bearings, and Engine Balancing 346

CHAPTER 12 Pistons, Rings, and Connecting Rods 386

CHAPTER 13 Lubrication 424

CHAPTER 14 Cooling System 459

CHAPTER 15 Engine Hardware: Fasteners, Thread Repair, and Gaskets 504

CHAPTER 16 Reassembly and Starting 558

CHAPTER 17 Engine Breathing: Intake and Exhaust Systems 600

Exhaust Systems ● Study Questions ● ASE-Style Review Questions

CHAPTER 18 Turbochargers and Superchargers 620

CHAPTER 19 Producing Power: Valve Timing,