Lesson Plan
Instructor: Steve Metaxas Date: November 28, 2024
Course: 843-476 Unit: 8
Chapter 60: Engine Reassembly, Installation, and Break-In
Chapter Objectives
Recall the general rules for proper engine reassembly.
Install an oil pump and oil pan.
Install and torque a cylinder head assembly.
Install lifters or cam followers.
Install exhaust and intake manifolds.
Install a camshaft housing cover.
Install an overhead camshaft.
Install valve and camshaft covers.
Complete final engine assembly.
Install the engine into the vehicle.
Perform proper engine start-up and break-in.
Materials, Equipment, and Supplies
Needed for this lesson:
Safety Notes
There are no specific safety notes that apply to this lesson. General shop safety precautions should always
be observed.
Demonstration
Show students the engine parts and tools clean, laid out, and aligned properly. Explain that parts must
be reinstalled in their correct places to leave proper clearance.
Show students the procedure for installing a head gasket and cylinder head.
Demonstrate the proper way to install and torque head bolts. Stress that both the parts and the engine
must be clean.
Show students how to check for warpage on the intake manifold sealing surfaces and the exhaust
manifolds.
Demonstrate the proper way to install an intake manifold gasket, including proper bolt tightening.
Show students how to install a camshaft housing.
Demonstrate how to install push rods and rocker arms.
Demonstrate how to adjust the valve train clearance in a valve train with hydraulic lifters both with the
engine running and the engine off.
Show students how to install a valve cover gasket.
Explain to students the difference between installing an engine with and without the transmission or
transaxle.
Show the students how to prepare the engine for installation.
Show students how to make sure an engine is reinstalled properly and all fluids are refilled.
Evaluation
Have students identify a camshaft with one-piece bearings and two-piece bearings.
1
Lesson Plan
Have your students retrieve and interpret trouble codes on an engine with a known problem.
Students should know the difference between valve train clearance adjustment with mechanical lifters
and valve train clearance adjustment on OHC engines.
While closely supervising, have the students install the engine. Make sure they follow the proper
procedures and observe all safety precautions.
Have students replace an oil pump. Give students credit for completing the task, including following
proper safety procedures.
Have students replace an oil pan. Give students credit for completing the task, including following proper
safety procedures.
Have students check the engine thermostat. Grade them on properly and accurately measuring the
engine’s temperature.
Have students paint an engine. Grade them on completing the task, including following proper safety
procedures.
Have students install any remaining components on the engine and prepare the engine for installation.
Make sure the students properly complete all necessary tasks.
Have students understand the requirements for final engine assembly. Grade the students by their
ability to know when to install external engine parts, such as the engine sensors, actuators, brackets,
engine mounts, flywheel, clutch, torque converter, and oil filter.
Instructional Resources
Textbook/eBook: Chapter 60
Instructor Resources: Chapter 60 Instructor’s Presentation for PowerPoint
Other instructional resource:
Resources for Practice and Application
eBook Drill and Practice: Vocabulary Activities
Textbook/eBook: Chapter 60 Activities
Textbook/eBook: Chapter 60 Review Questions
Textbook/eBook: Chapter 60 ASE-Type Questions
Workbook: Chapter 60–Chapter Review and Critical Thinking
Related job(s) in the Shop Manual
Other resource:
Assessment
ExamView Assessment Suite
Chapter 60 Pretest
Chapter 60 Posttest
Chapter 60 Exam
Other assessment:
Additional Notes
Other notes:
