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COURSE SYLLABUS

1.

TITLE OF COURSE:

AUTOMOTIVE MACHINING

 

PREFIX/NUMBER:

ASE 165

CREDIT HOURS:

2 CR. (1L/1.5 LBV)

2.

PREREQUISITE:

None

3.

RESOURCES NEEDED:

 

 

TEXT:

 

SUPPLIES:

Basic tools and uniform shirts

4.

COURSE DESCRIPTION:

Offers instruction in machining processes on the automotive engine using up-to-date machines to recondition connecting rods, bore engine blocks, machine heads for replaceable guides and seats.  Brake drum and disc machining is also discussed.

5.

COURSE GOAL:

 

6.

COURSE OBJECTIVES:

 

By the end of the course, students will:

 

(A)

Bore an engine block to a specified size.

  (B) Rigid hone the block for proper piston clearance
  (C) Disassemble con rod and piston assembly using the BP10 pin press with the Sunnen piston press board.
  (D) Use the Sunnen hone process to recondition connecting rods' big bore ends to factory specifications.
  (E) Use the hone to recondition connecting rods' smaller bore ends to factory specifications.
  (F) Check and align all con rods for bend and twist to factory specifications.
  (G) Reassemble piston and rod assemblies using the Sunnen rod heater.
  (H) Reface valves to factory specifications using the Sioux valve machine.
  (I) Cut valve stem ends to factory specifications.
  (J) Chamfer valve stem ends to factory specification.
  (K) Using the Kansas Instrument Valve Shop, machine integral valve guides to.
  (L) Use the Kansas Instruments Valve Shop to machine heads with integral valve seat to accept replaceable valve seat inserts.
  (M) Using the Kansas Instruments Valve Shop with 3-way cutter to cut both the intake and exhaust seats to factory specifications.
  (N) Use the AAMCO Brake Lathe to machine a brake drum to factory specifications.
  (O) Use the AAMCO Brake Lathe to machine a brake disc to factory specifictions.

7.

EVALUATION PROCEDURES:

 

(A) There will be a written exam after each unit and a final, during the 7½ week term, during class time, and on announced dates.  All will be weighted equally, except the final will count double.

 

(B) There may be unannounced “pop” quizzes throughout the 7½  week term, which will also be weighted equally to other exams.

 

(C) Routine evaluations will be made on an individual basis by the instructor during each lab session.

 

(D) There will be a lab final (performance) exam.  The score on this exam will be entered twice (doubled) when computing your final grade.

 

(E) Grading will be weighted--30% of your grade for written assignments, 40% of your grade for lab assignments, 30% of your grade for tests. One grade point value will be deducted from total grade percentage for every hour absent.

 

 

Grading Scale
Raw Score Range

Letter Grade

 

 

90 to 100

A

 

 

80 to 89

B

 

 

70 to 79

C

 

 

60 to 69

D

 

 

0 to 59

F

Written Assignments
30%

Lab  Assignments
40%

Tests
30%

Attendance

50/50
50/38
50/50

50/38
50/50
50/38

100/90
100/70
100/90

One point will be deducted from total grade percentage for each hour absent

150/138

150/126

300/250

Special Remarks:

1.

All announced examinations will be made up of multiple choice, completion and short essay type questions and will be given during regular class periods. Make-up exams will only be given if prior arrangements have been made.

2.

Attendance:  College policy states that students may be dropped from enrollment when absent 20% of the scheduled class meetings.  If enrolled from the beginning of the term, 15 hours will usually constitute 20% of a four-credit semester course which meets five hours per week.  Reinstatement procedures are described in the PCC catalog.

3.

Tardy Policy:  A student who is late three times (enters classroom after the instructor has taken roll) will be charged with one full absence unless the student can provide valid reasons for one or more of these tardies.

4.

Assignments/Missed Exams:  It is the student's responsibility, whether present or absent, to obtain all material presented and to complete all course assignments.  If prior arrangements are made or extenuating circumstances exist, makeup of tests may be allowed.  Late homework papers will not be accepted unless those same extenuating circumstances exist.  Makeup of quizzes is to be at the instructor's discretion.

8.

COURSE OUTLINE:

I. Engine Disassembly, General Inspection, Cleaning
    A.  Inspect As You Go
    B.  Top End  Disassembly and Inspection
    C.  Bottom End Disassembly and Inspection
    D.  Engine Cleaning
II. Repairing Cracks and Damaged Threads
    A.  Removing Broken Fasteners
    B.  Repairing Damaged Threads
    C.  Internal Thread Replacement
    D.  Crack Detection
    E.  Crack Repair
III. Servicing Blocks
    A.  Tolerances and Oil Clearances
    B.  Block Inspection
    C.  Main Bearing Bore Reconditioning
    D.  Deck Reconditioning
    E.  Cylinder Reconditioning
    F.  Lifter Bore Reconditioning
IV. Servicing Crankshafts, Flywheels, Pistons, and Rods
    A.  Crankshaft Service
    B.  Piston and Connecting Rod Service
    C.  Flywheel and Flexplate Service
V.   Engine Balancing
    A.  Balancing Precautions
    B.  Balancing Reciprocating Weight
    C.  The Bob Weight
    D.  Balancing Rotation Weight
VI. Servicing Cylinder Heads and Manifolds
    A.  Head Reconditioning
    B.  Head Resurfacing
    C.  Valve Testing and Assembly
VII. Servicing Camshafts, Lifters, Pushrods, and Rocker Arms
    A.  Camshaft Service
    B.  Valve Lifter and Cam Follower Service
    C.  Pushrod Service
    D.  Rocker Arm and Shaft Service
VIII. Safety and Operating Procedures for Machine Room Equipment
    A.  VanNorman Boring Bar
    B.  Sunnen Honing Machine
    C.  Sioux Valve Machine
    D.  Kansas Instrument Valve Shop
    E.  AAMCO Brake Lathe

9.

METHODS OF INSTRUCTION:

 

To be successful in this course, students are expected to participate in discussions, readings, in-class writing, and peer review activities. The instructor may assign point values to such activities.

10.

ACADEMIC INTEGRITY:

 

The very nature of higher education requires that students adhere to accepted standards of academic integrity. Therefore, Pueblo Community College has adopted a policy of academic conduct as described in the Student Handbook. Violation of academic integrity may be defined to include the following: cheating, plagiarism, falsification and fabrication, abuse of academic materials, complicity in academic dishonesty, and personal misrepresentation. It is the student’s responsibility to be aware of the behaviors that constitute academic dishonesty. Sanctions for violating the standards of academic integrity may include warning, probation, suspension, and/or failure of the course or assignment at the discretion of the instructor.

11.

ADA NOTICE:

 

Students who have a documented disability may be eligible to receive accommodations for this class. Please contact the Disability Resources Center at 549-3446 for further information.