Automotive Engine/Block & Cylinder Head Machining Combo Program Objectives

The program objective of Automotive Engine/Block & Cylinder Head Machining is to qualify the student as an automotive block and cylinder head machinist. Although the actual machining process will be the emphasis of the program, a thorough education on theory of operation of the modem automotive engine will be presented along with the role of the cylinder head to the complete assembly. Performance modifications effect on power, longevity, and airflow characteristics will be highlighted in all courses of this program.

This program is intended for the mechanically inclined student with a desire to work in the automotive industry.

The program will include both classroom and hands-on lab instruction.

One semester credit hour for each fifteen (15) hours of classroom contact plus appropriate outside preparation or the equivalent: or one semester credit hour for each thirty (30) hours of laboratory work plus appropriate outside preparation: or one semester credit hour for not fewer than forty-five (45) hours of shop instruction (contact hours) or the equivalent.

Single subjects making up this program are not offered individually. See the Equipment List Addendum for a complete list of machines used in the Automotive Engine/Block & Cylinder Head Machining-Certificate program.

Gainful Employment Disclosure – Automotive Engine/Block & Cylinder Head Machining-Certificate

101 WORK PRACTICES, TOOLS, AND SAFETY

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This course provides a general introduction to the industry work environment including customer relations, work orders, build-sheets, and parts acquisition. Introduction to, and familiarization with the use of precision measurement and specialized, as well as, basic hand tools required will also be covered. Special emphasis is placed on both personal and shop safety due to the nature of potentially hazardous equipment.

102 MACHINIST MATH AND MEASUREMENT INSPECTION

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The procedures of careful inspection and precise measurement technologies is taught. Combining this information, with the proper applications, formulas, and machinist math will be covered to provide a solid basis for successful production and high performance engine assembly procedures.

103 PRINCIPLES AND THEORIES OF THE INTERNAL COMBUSTION ENGINE

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This course starts with exploring the basic theory and concepts of internal combustion engine operation. The course then moves into more specific and complex areas including torque, air flow, volumetric efficiency, operating cycles, and horsepower.

104 DESIGN, FUNCTION, AND COMPOSITION OF ENGINE BLOCK COMPONENTS

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The individual components … their function, design, and material composition, and the differences will be covered. This will allow a clearer understanding of the relationship of the individual pieces to each other and the assembly as a whole. Production and performance variations will also be discussed.

105 DISASSEMBLY, INSPECTION, AND CLEANING PROCEDURES

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The student learns the techniques of thorough examination and evaluation during disassembly to correctly diagnose engine failure, potential problems, and component replacement. Cleaning methods for both cast iron and aluminum are covered, including the impact of current environmental concerns. Additionally, crack detection methods and casting repairs are also covered.

106 OPERATION OF MACHINING EQUIPMENT

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The student learns the set-up and operation procedures of the machining equipment. He will also learn the procedures used to complete the machining of block and component parts. The differences between standard and high performance applications will be highlighted.

107 ENGINE BLOCK AND COMPONENT MACHINING

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Actual hands-on block and component machining will be accomplished by each student as they become proficient with all machining operations. Machined components will be carefully checked for accuracy. These pieces will become part of each student’s course project

108 ENGINE BLOCK BLUEPRINTING

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Blueprinting; the art of producing maximum capable horsepower, torque, volumetric efficiency, and R.P.M. through precise component assembly relationships will be taught. The effects of camshaft selection, degreeing, and valve timing in relation to cylinder pressure will be studied. Students will learn the real mystery of high performance.

109 ENGINE BLOCK ASSEMBLY AND DYNAMOMETER TESTING

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The primary focus of this course is mastering the art of assembling precisely machined components into a complete, operating engine block. Upon completion, the student will run his engine project on a Superflow Dynamometer for evaluation. Changes and adjustments will be made to demonstrate their effects on power output.

201 WORK PRACTICES, TOOLS, AND SAFETY

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This course provides a general introduction to the industry work environment including customer relations, work orders, build-sheets, and parts acquisition. Introduction to, and familiarization with the use of precision measurement and specialized, as well as, basic hand tools required will also be covered. Special emphasis is placed on both personal and shop safety due to the nature of potentially hazardous equipment.

202 MACHINIST MATH AND MEASUREMENT INSPECTION

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The procedures of careful inspection and precise measurement technologies are taught. Combining this information, with the proper applications, formulas, and machinist math will be covered to provide a solid basis for successful production and high performance engine assembly procedures.

203 PRINCIPLES AND THEORIES OF THE INTERNAL COMBUSTION ENGINE

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This course starts with exploring the basic theory and concepts of internal combustion engine operation. The course then moves into more specific and complex areas including torque, air flow, volumetric efficiency, operating cycles, and horsepower.

204 DESIGN, FUNCTION, AND COMPOSITION OF CYLINDER HEAD COMPONENTS

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The course explores the hows and whys of the many components of the cylinder head assembly and their relationship to each other.The function and various material compositions of cylinder head castings and components will also be covered. Standard and high performance differences will be discussed.

205 DISASSEMBLY, INSPECTION, AND CLEANING PROCEDURES

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This course covers the proper procedure of head disassembly and careful inspection to determine any causes of failure, repairs needed, and component replacement. Cleaning methods, crack detection, repair, and associated environmental issues, for both aluminum and iron heads will also be discussed.

206 OPERATION OF MACHINING EQUIPMENT

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The student learns the set-up and operation procedures of machining equipment. He will also learn the procedures used to complete the machining of cylinder heads and component parts. A discussion of high performance and production differences will complete this section.

207 CYLINDER HEAD AND COMPONENT MACHINING

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Actual hands-on cylinder head and component machining will be accomplished by each student as they become proficient with all machining operations. Machined components will be checked closely for accuracy. These pieces will become part of each student’s course project.

208 CYLINDER HEAD BLUEPRINTING

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Students are exposed to the art of creating maximum efficiency and horsepower through precision component assembly relationships. Combustion chamber sizing and compression ratios will be discussed. Students will also study cylinder head performance secrets.

209 CYLINDER HEAD ASSEMBLY

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Correct assembly procedures of the precisely machined components into a complete cylinder head is covered in detail. Evaluation and testing of complete assemblies will reveal the relationship of changes to performance.

210 CYLINDER HEAD PORTING

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Students will explore flow characteristics of various head designs and the resultant effects of change. Proper techniques of porting, when it should be used, and actual hands-on experience will illustrate methods and levels of air flow improvement.

212 PERSONAL DEVELOPMENT AND CAREER PLANNING

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The student is prepared to enter the job market by teaching the importance of personal appearance, conduct, and attitude. Job search, application, and interview are also covered. A brief discussion on career goal orientation and job placement assistance available from the School of Automotive Machinists completes the course.

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