Name: _____________________________ Hour: _______ Date: _______

Engine
Technology

Fall 2007

Mr. Ubersox

www.waunakeeteched.com

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Name: _____________________________ Hour: _______ Date: _______

Engine Technology Syllabus

Welcome to the Engine Technology class. This course will provide you with a
wealth of basic knowledge about various metals and metal technology that will
give you an opportunity to gain more knowledge about metals and metal
processes to help prepare you for your future and possibly a career!

Responsibility
It is the responsibility of the instructor to maintain a safe learning environment in
the classroom and lab so those students who want to learn have the opportunity
to do so. A teacher can only facilitate learning. It is the responsibility of the
student to complete all the assignments and activities to the best of their ability.

Teacher/Student Relationship
I am a teacher who believes that a strong student/teacher relationship is
necessary in order for a student to get the most out of a course. In that, I am
saying that I care about what you think and how you feel. I have dedicated my
life to education and helping young individuals learn. I will meet you half way in
your learning. My door is always open, my e-mail is available 24-7, and my
phone is set up with voice mail.
Contacting Mr. Ubersox
Phone: 849-2275
E-mail: rubersox@waunakee.k12.wi.us
Prep hours: 3A and 4B
Rules
Students are expected to follow all school rules in addition to the following
classroom rules.
1. Be in your seat when the bell rings. The instructor will dismiss you…NOT
THE BELL.
2. Follow lab safety rules.
3. Bring all materials to class. NO BACKPACKS ALLOWED!
4. Sit in your assigned seat daily.
5. Raise your hand to talk. Do not interrupt others.
6. Follow directions the first time they are given.

Consequences Rewards
• Stay after class • Praise
• Come in before or after school • Positive notes home
• Asked to leave lab • Pride Club
• Detention/behavioral contract • Student of the month

Policies and Procedures

Daily procedure/Class Period: Students should enter the room and look at the
white board for the plan of the day. Once the bell rings, students should remain
in their seats until otherwise instructed. Students should expect a daily 10 point
quiz based on the previous day’s topic(s) at the beginning of each class. At the

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Name: _____________________________ Hour: _______ Date: _______

end of class the instructor dismisses students AFTER proper cleanup has been
performed and inspected.

Attendance/Tardy: Attendance and timeliness is important…especially in classes

that are potentially preparing you for a future career! Students who are tardy to
class and unexcused may lose 10% off of the lab for the day. If students have 3
or more unexcused tardies, it will be referred to the office.

Leaving the Classroom: The purple pass is for emergencies only and may not be
used during the first 30 minutes nor the last 15 minutes of class.

Materials: Students should bring to class a three ring binder (or a folder and
paper), a writing utensil, their class handbook, and their textbook.

In the Lab/Shop: Students must follow directions and all safety precautions. No
one will be allowed to work in lab without a signed safety contract and a grade of
90% or higher on the safety quiz. Any student not following directions and safety
measures may be given a warning at the discretion of the teacher or asked to
leave the lab immediately, resulting in no credit for the lab. All injuries must be
reported to the teacher. After a lab, it is essential that students clean up their lab
area before they are dismissed.

Late Work: Worksheet type assignments are only accepted on the due date for
full credit. Late work will be accepted with a 40% reduction of the points (D).
Late labs are given credit based on the discretion of the instructor.

Emergency Alerts: There are signs posted by the door and at the front of the
room stating where the class needs to go in the event of a fire, tornado, or bomb
threat. The procedures for these events might be practiced later in the year.

Miscellaneous: No soda, juice, or food allowed in the classrooms or labs.

Grading Scale
The Waunakee Technology and Engineering Department is on a 10 point grading
scale. The grading breakdown is as follows:
100% - 90% A
89% - 80% B The top and bottom 2 percent
79% - 70% C of each grade category
69% - 60% D becomes the + and - grades
Below 60% F

Quarter Grades
Worksheets 5 points each
Quizzes 10-20 points each
Activities vary
Quarter Test 50 points

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Name: _____________________________ Hour: _______ Date: _______

Semester Grades
The semester grade will be based on the following break down.

1st Quarter Grade 25%

2nd Quarter Grade 25%
Average of Quarter Grades 25%
Final (may be project or test) 25%

You should be prepared to open your mind in Engine Technology. You will learn
some things that the general public does not understand. I expect that you will
work hard and always try your best. If you do this, you will learn a lot and have a
lot of fun in the process.

If you are in the need of differentiation please let me know. You are encouraged
to seek additional help whenever needed. I will be in the school district everyday
from 7:30 a.m. to 3:30 p.m. (at least). Feel free to stop in before or after school
or by appointment during my preparatory hours.

I’m looking forward to a great semester! - Mr. Ubersox

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Name: _____________________________ Hour: _______ Date: _______

Engine
Technology

Work sheets
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Name: _____________________________ Hour: _______ Date: _______

Engine Technology Worksheet 1

1) Give a brief description of:

A) Engine: _________________________________________
B) Motor: _________________________________________
2) What are the two different combustion types of engines and what is the
difference between them?
_______________: ___________________________________
_______________: ___________________________________
3) Give an example of an external combustion engine.
___________________
4) Name the two most common fuels used by internal combustion engines.
A) ______________ B) __________________
5) Name the five ways small engines may be classified.
A) ___________________
B) ___________________
C) ___________________
D) ___________________
E) ___________________
6) What are two types of ignitions used in engines?
A) ___________________
B) ___________________
7) What is the stroke of an engine?
____________________________________________________
8) How many strokes may a small gasoline engine have to complete the four
events of a operating cycle? (2 answers)
A) _______
B) _______
9) Name the different types of cylinder designs used in small engines.
A) ____________
B) ____________
C) ____________
D) ____________
10) Why is the shaft orientation significant?
____________________________________________________

11) What are the two ways a cooling system can work on an engine? (Name
and briefly describe)
A) _________________________________________________
B) _________________________________________________
12) Why must an engine have a cooling system?
____________________________________________________

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Name: _____________________________ Hour: _______ Date: _______

Engine Technology Worksheet 2

1) Alcohols and ethers are added to gas to _____________ the octane level.

2) What are the four strokes of a four stroke engine (in order) and what happens
during each stroke?
A) ______________ - _________________________________
B) ______________ - _________________________________
C) ______________ - _________________________________
D) ______________ - _________________________________

3) What are the three main moving parts of a piston engine?

A) ______________ B) _____________ C) ______________

4) ___________________ keeps all engine parts in alignment.

5) Name the two most common types of metal used in an engine.

A) __________________ B) ____________________

6) The cylinder block contains _________________ which are designed for

efficient air circulation.

7) The _________________ converts the up and down movement of the piston

to a more useful rotary motion.

8) What two things do the rings on the piston do?

A) _________________________________________________
B) _________________________________________________

9) Intake and exhaust ports work differently in 2 stroke and 4 stroke engines.
Explain the difference.
2 stroke - __________________________________________
4 stroke - __________________________________________

10) The _____________ gear is always twice as large as the ______________

gear.

11) The camshaft has _________ which lift the _________ which lift the valves.

12) The valve __________ old each valve firmly against the seat.

13) The flywheel has four distinct purposes. They are:

A) _______________________________________________
B) _______________________________________________
C) _______________________________________________
D) _______________________________________________

14) Write in your own words how an engine works by describing the

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Name: _____________________________ Hour: _______ Date: _______

function of each of its basic parts.

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Name: _____________________________ Hour: _______ Date: _______

Engine Worksheet 3
4 stroke engines

1) Name the 8 main moving parts of a four stroke engine.

A) ______________ E) 2 ____________
B) ______________ F) 2 ____________
C) ______________ G) 2 ____________
D) ______________ H) ______________

2) A four stroke engine includes ___ strokes per cycle.

3) A stroke is the piston’s movement from __________ to __________.

4) ______ strokes occur during each revolution of the crankshaft.

5) The piston travels _________ during the intake stoke.

6) A ______________ is created during the intake stroke and atmospheric

pressure forces air through the ________________.

7) The intake valve (is) (is not) subjected to as much temperature as the
exhaust valve.

8) The _______________ stroke is created by the piston moving upward in the

cylinder. The valves are closed during this stroke.

9) ____________ and ____________ rings seal for the compression of the

engine.

10) The compression ratio is the difference in ___________________

___________________________________________________.

11) At the end of the compression stroke) the ______________ jumps the spark
plug gap and ____________ the air/fuel mixture.

12) The exhaust stroke removes gases from the ______________ when the
____________ rises and pushed the burnt gases out.

13) The exhaust valve transfers heat through the ____________ to the cylinder
block.

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Name: _____________________________ Hour: _______ Date: _______

Engine Worksheet 4
2 stroke engines

1) A mixture of ________ and ________ lubricates a two-stroke

engine.

2) It takes _____ revolution(s) of the crankshaft to complete one two-stroke

cycle.

3) The number of moving parts in a two-stroke engine is _______ than that of a

four-stroke engine.

4) The two-stroke engine burns a mixture of _______, ______, and air.

5) As the piston moves ______, the crankcase pressure drops and the
__________ port is exposed.

6) Atmospheric pressure is greater than the crankcase pressure and forces ___
through the carburetor and into the ____________.

7) As the piston moves ________ it compresses the mixture in the crankcase

and forces the mixture through the __________ port.

8) As the piston travels back up, it compresses the mixture in the cylinder to
about _______ its original volume.

9) At top dead center (TDC) a _______ ignites the mixture and forces the piston
back down.

10) As the piston moves down, the ________ port is exposed.

11) Complete exhausting of burnt gases takes place when __________ ports are
opened.

12) When the exhaust system is designed correctly, it will scavenge all gases in
combustion chamber. Some systems use _________ waves to create
_______ pressure that prevents the incoming mixture from leaving with the
exhaust.
13) There are many advantages of 2 and 4 stroke engines. Name four
advantages of each.

2 stroke A) __________________________________________
B) __________________________________________
C) __________________________________________
D) __________________________________________

4 stroke A) __________________________________________
B) __________________________________________

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Name: _____________________________ Hour: _______ Date: _______

C) __________________________________________
D) __________________________________________

14) Some of the uses of 2 and 4 stroke engines are similar. Name four machines
that are powered with either 4 or 2 stoke engines.

2 stroke A) ______________4 stroke A) _____________

B) ______________ B) _____________
C) ______________ C) _____________
D) ______________ D) _____________

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Name: _____________________________ Hour: _______ Date: _______

Engine Worksheet 5

1) Engines are ranked by their ______________ and their ______________.

2) The diameter of a cylinder is called the __________.

3) The ____________ is the up or down movement of the piston.

4) _______________________ is the total volume of space in the cylinder as the piston

moves from ________ to _________.

5) The area of the bore is found by using the formula ___________________.

6) The piston displacement or cubic inch displacement formula is as follows:

7) A) Find the area of a cylinder bore of 4 inches.

B) Find the piston displacement of the same engine if the stroke length is 5 inches.

C) Find the total C.I.D. (cubic inch displacement) if the engine had eight cylinders.

8) The ___________________________ is a measurement of the difference between total

cylinder volume when the piston is at ________ compared to the remaining volume at
________.

9) If a small engine had a BDC of 9 in.3 and a TDC of 1 in.3, what would the
compression ratio be?

10) A ________ is the pushing or pulling of one body on another and can be measured in
__________, ___________, and ____________.

11) _____________ is force per a given unit of area.

12) Force times distance equals __________.

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Name: _____________________________ Hour: _______ Date: _______

Engine Worksheet #6
Valves and Timing

1) What type of valves are found in four stroke engines?

_____________

2) What directly pushes on the valves to open them?

_____________ or _____________

3) What indirectly opens the valves?

_______________

4) What is the purpose of the valve guides?

__________________________________

5) The valve spring assembly includes 2 __________, 2 _________, and 2

_____________ for each cylinder.

6) A _____________________ is used to squeeze the valve spring to allow for

removal of the retainer.

7) When valves get worn out they could have:

A) ________________________________
B) ________________________________
C) ________________________________
D) ________________________________
E) ________________________________
F) ________________________________

8) What can be done to valves that show wear on their faces? _____
__________________________________________________

9) When valve springs wear out the can lose _____________ or become
________.

10) Two types of valve guides are:

A) ___________________________
B) ___________________________

11) Why do valve guides wear out so much? ______________________

____________________________________________________

12) The major purpose of the valve seat is to dissipate _________.

13) If a valve seat is burned or worn, what two things can be done?
A) ______________________ B) ____________________

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Name: _____________________________ Hour: _______ Date: _______

14) Valve seats are usually ground to ____ or ____.

15) Why must there be a gap between the valve stem and the tappet? __
____________________________________________________

16) What happens if the valve stem/tappet clearance is too small? _____
____________________________________________________

17) How is the valve stem/tappet clearance adjusted?

A) _____________________ B) _____________________

18) A) What should be done to new or good used valves when overhauling
an engine? ____________
B) Why do some manufacturers not recommend this procedure? ___
_________________________________________________

19) When oil is burned onto a hot exhaust valve, it causes a varnish deposit
buildup which results in a ________________.

20) The camshaft is designed to ______________________.

21) The camshaft gear is always _________ the size of the crankshaft gear.

22) Explain how an easy start mechanism releases some compression for easy
starting. __________________________________________________
_________________________________________________________

23) What is the slight back and forth movement called on the crankshaft and why
is it used? ______________________________________
____________________________________________________

24) How can crankshaft end play be reduced?

A) ___________________ B) ___________________

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Name: _____________________________ Hour: _______ Date: _______

Engine Worksheet 7

1) The crankshaft converts ___________________ or back and forth motion of

the piston into _______________ or circular motion.

2) The crankshaft can do three types of things, they are:

A) _____________________________________
B) _____________________________________
C) _____________________________________

3) A crankshaft can/can not be made up of more that one piece.

4) The parts of a crankshaft include:

A) ______________________________
B) ______________________________
C) ______________________________
D) ______________________________
E) ______________________________

5) Th purpose of the main bearings is to ________________________

____________________________________________________.

6) Crankcase seals prevent leakage of _______ and can be made from

________________, __________________, or ______________.

7) The ________________ is designed to ______________________

______________________________.

8) The camshaft gear is exactly ________ the size of the crankshaft gear which
gives us a ratio of _________.

9) Camshaft and crankshaft gears are aligned correctly when the camshaft
timing mark is lined up with the crankshaft ____________.

10) What is the purpose of the automatic compression release on a small

engine? _____________________________________________

11) The basic concept of the automatic compression release is to release part of
the __________________ by lifting the ___________ valve.

12) Explain how the automatic compression release works.

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Name: _____________________________ Hour: _______ Date: _______

Worksheet 8

1) The purpose of the connecting rod is to ______________________

____________________________________________________.

2) The lower end of the connecting rod can be _____________ or

_____________.

3) Two types of bearings used at the bottom of the connecting rod are
A) _______________________ B) _____________________

4) If the connecting rod cap is split, it can be put back together in ____ way.

5) The purpose of the piston pin is to __________________________

____________________________________________________.

6) The piston pin is held in place by ______________________ or

______________________.

7) The top of the piston is called the ____________ and is subjected to most of
the _____________ from the combustion of the mixture.

8) In a 2 stroke engine, a piston head may be ____________________

____________________________________________________.

9) In a 4-stroke engine, a piston head may have three different shapes. They
are:
A) _______________ B) _______________ C) ___________

10) The ______________________________ holds the rings in place while the

_________ are the metal areas between them.

11) The piston moves up and down hundreds/thousands/millions of times per

minute.

12) A piston is made from A) ________________ B) ___________.

13) A piston might need to serviced when:

A) _______________________________________
B) _______________________________________
C) _______________________________________

14) The purpose of the piston rings is to ________________________.

15) 2 stroke engines have _____________________ rings while 4 stroke engines

have ______ rings.

16) The rings are usually made of cast __________ or ____________.

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Name: _____________________________ Hour: _______ Date: _______

17) Name the two types of piston rings and explain what each does.
A) _________________________________________________
B) _________________________________________________

18) The ring end gap is the ______ in the ring that permits __________
____________________________________________________.

19) In four stroke engines the rings are called ____________________ because
they _________________________________________.

20) In two stroke engines the rings are called ____________________ because
they are held in place so that the rings do not ___________
____________________________________________________.

21) Most piston to cylinder clearances are between _______ and ______.

22) If the cylinder is too big a _________ will be heard inside the cylinder
because the piston is tilting. This will do damage to the ________ and the
______________.

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Name: _____________________________ Hour: _______ Date: _______

Worksheet 9

1) ___________________________________ can be performed on aluminum

bore cylinders, cast iron cylinders, or cylinders with cast iron inserts.

2) A new cylinder has a pattern that is called a ___________________

______________.

3) __________________ is caused by a foreign object and does not usually

affect engine wear or performance.

4) ______________________ is caused by abrasive particles entering the

cylinder along with the fuel/air mixture.

5) Severe __________________ damage might happen if the piston pin snap

ring is missing allowing the piston pin to come in contact with the cylinder
wall.

6) __________________ lubrication can cause wear from the metal to metal

contact in the cylinder.

7) Severe galling may happen when the piston skirt and other parts of piston
look to be acceptable, but some aluminum parts are welded to the cylinder or
in other spots gouged out. Three reasons this might happen include:
A)
B)
C)

8) To decide whether a cylinder should be resized, one must ______________

the bore of the cylinder.

9) When measuring the bore of a cylinder, two tools are used. They are:
A)
B)

10) Automatic transmission fluid (______) is used to lubricate the grinding stones
when re-sizing a cylinder bore.

11) Measure the cylinder bore diameter at ______ points to make sure the boring
diameter is correct.

12) The last .001” of re-sizing of a cylinder should be used to put a _____
____________ pattern into the cylinder.

13) To effectively clean the cylinder and engine, one only needs to use a
conventional wash tank. T/F

14) Resizing is ___________________ and cost _______________.

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Name: _____________________________ Hour: _______ Date: _______

Worksheet 10
Carburetion

1) The purpose of a carburetor is to ___________________________

____________________________________________________.

2) A carburetor must ______________ the fuel and mix it with air.

3) The three basic steps in a carburetor are:

A) ___________________________________________
B) ___________________________________________
C) ___________________________________________

4) The amount of air needed for combustion is far greater/less than the amount
of fuel required.

5) To start an engine, ________ pounds of air is needed for every 1 pound of

gas.

6) A _______________ is referred to as any pressure less than atmospheric

pressure.

7) __________________________________ is the total weight of air molecules

above the earth.

8) Bernoulli’s Principle states that as the _______________________

____________________________________________________.

9) A _______________ is a restriction in a passage. When there is a restriction

in a passage, air moves faster/slower through the passage and the pressure
___________.

10) Three types of carburetors include:

A) ___________________________
B) ___________________________
C) ___________________________
11) A __________ is a small sealed vessel inside the fuel bowl and its purpose is
to maintain a ________________________________.

12) A _________________ is a round disk that is used when starting a cold

engine.

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Name: _____________________________ Hour: _______ Date: _______

13) The ____________ is a round disk that is located after the main fuel nozzle.
It has three main purposes that include:
A) ______________________________________________
B) ______________________________________________
C) ______________________________________________

14) The ________________ connects the throttle to the governor.

15) Carburetors have load adjustment screws or jets that allow for ____
____________________________________________________.

16) The ____________________________ is set up so that when an engine

accelerates it will not slow down or stall.

17) The reservoir for fuel in the acceleration system is called an

_________________________.

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Name: _____________________________ Hour: _______ Date: _______

Worksheet 11
Carburetors Continued

1) An ___________________________ retards fuel flow to the engine at part throttle to

cut down on _______________________.

2) When the engine is idling, the throttle is closed/open and the ______
_____________ allows just enough air/fuel to keep the engine running.

3) At _____________________ the engine is at full speed and power.

4) Speed and power are __________________ related to the amount of air/fuel mixture
allowed into the cylinder. This means that the more air/fuel that enters the cylinder,
the faster/slower and more/less powerful the engine will be.

5) The primer is the _______________________________________

____________________________________________________.
It produces air pressure in the ___________________ which forces fuel up the
nozzle.

6) A __________________________ carburetor does not have a float system and a

______________ controls the fuel intake.

7) A throttle control that is the sole control for the throttle valve that has a mechanical
linkage or flexible cable is called a _____________
________________.

8) Manual throttles can be found on:

A) __________________________
B) __________________________
C) __________________________

9) A governor provides _________ and ________ speed regardless of the load on the
engine.
10) Three main functions of governors are:
A) _______________________________________________
B) ________________________________________________
C) _________________________________________________

11) Name and describe the three types of governors:

A) _______ - ________________________________________
B) _______________ - _________________________________
C) _______________ - _________________________________

12) A governor has _____________ and _______________.

13) Hunting is when ________________________________________.

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Name: _____________________________ Hour: _______ Date: _______

Worksheet 12
Fuel Injection and Air Filters

1) Carburetors became very complicated for two main reasons:

A) _______________________________________
B) _______________________________________

2) The fuel injector is an ____________________ controlled valve.

3) A fuel injector is able to open and close many times per __________.

4) Because of fuel injectors, when we step on the throttle we are really

regulating the _________ intake.

5) The purpose of an air filter is to ___________________________

____________________________________________________.

6) Air filters have three basic designs which are:

A) ___________________________________
B) _____________
C) ___________________________________

7) An _____ wetted filter can/cannot be reused.

8) A ________ filter is designed to be _____________________ after use.

9) A ___________________________ filter contains both foam and pleated

paper.

10) When removing a filter the carburetor is __________________.

11) The steps in servicing a filter include:

A) ______________________________________________
B) ______________________________________________
C) ______________________________________________
D) ______________________________________________
E) ______________________________________________

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Name: _____________________________ Hour: _______ Date: _______

12) Label the three types of dual element filters.

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Name: _____________________________ Hour: _______ Date: _______

Worksheet 13
Ignition #1

1) Ignition provides _______________________________________

____________________________________________________.

2) A high rate of spark must be delivered through an ignition system. At 3600

rpm, the number of sparks per minute would be
A) 4 stroke - _________
B) 2 stroke - _________

3) The __________________ unit produces current without an outside source of

electricity.

4) An __________ is the smallest particle of an element that can exist.

5) A ________________ is a __________________ charged particle.

6) An electron is a _________________ charged particle.

7) The number of electrons is equal/more/less than the number of protons in an

atom.

8) _____________________ are materials that allow electrons to move from

atom to atom and three examples are:
A) __________________________
B) __________________________
C) __________________________

9) ______________________ are materials in which electrons cannot move

easily from atom to atom and three examples include:
A) __________________________
B) __________________________
C) __________________________

10) Amperage (Amps) measures the ____________________________

_________________________________________________.

11) ____________ is the measurement of the force that causes electrons to flow.

12) _____________ is the measurement of the resistance to electron flow.

13) Ohm’s law can be used to show the relationship between amps, volts, and
ohms. The formula is:

14) Most molecules have/do not have magnetic force.

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Name: _____________________________ Hour: _______ Date: _______

15) Three molecules that have magnetic force include:

A) __________________
B) __________________
C) __________________

16) _____________________________________ discovered electricity could be

produced from magnetism.

17) When current flows through a coil, a ________________________

__________________ is produced.

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Name: _____________________________ Hour: _______ Date: _______

Worksheet 14
Ignition Systems #2
Spark plugs

1) An ______________________ _______________ operates like a

transformer in that it __________ __ or ____________ _______ current or
voltage.

2) ____________________ is the transfer of electricity by brining a charged

object near another object without touching it.

3) In a small engine, as the current passes through the primary coil, it is induced
to the ____________ coil in which the voltage is increased/decreased as the
amperage is increased/decreased.

4) The coil is necessary so that the _____________ is high enough to “push”

the electricity across the spark plug ________.

5) Spark plugs affect:

A) _______________________________
B) _______________________________
C) _______________________________

6) The terminal nut may be ______________ or ________________

by a neoprene boot.

7) The insulator is usually made of __________________ material.

8) The ribs of the insulator prevent ________________ which is when

the current travels down the ________________ of the spark plug.

9) The _______________ ________________ carries the high

voltage to the spark plug gap.

10) A “hot” plug is one in which the heat has to travel less/a greater distance than
a “cold” plug.
11) The heat from combustion is conducted through the spark plug. If the
temperature of the insulator nose exceeds 1750 degrees F, ______-
_________ will occur. If the insulator tip drops below 700 degrees F, the plug
may ___________.

12) The reach of the spark plug is the __________ of the threads and is
determined by the cylinder head _________.

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Name: _____________________________ Hour: _______ Date: _______

13) There are four types of electrodes. Fill in the names of each type below.

14) The spark symbol tells us 5 things about the spark plug. They include:
A) _______________________________
B) _______________________________
C) _______________________________
D) _______________________________
E) _______________________________
F) _______________________________

15) Spark plugs can be re-_________, however because of their affordability,

most people just by new plugs.

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Name: _____________________________ Hour: _______ Date: _______

Worksheet 15
Ignition Systems (3)

1) Three types of ignitions include:

A) __________________________
B) __________________________
C) __________________________

2) A ________________ is a device that opens and closes a circuit.

3) An example of a mechanical switch used in small engines is _____________

___________.

4) An __________________ switching device may also be used in a small engine.

This switch is activated by an ________________ charge.

5) The purpose of the condenser is to __________________________

____________________________________________________.

6) The condenser absorbs most of the energy from the coil and prevents
__________ ___________.

7) The advantages of electronic ignitions include:

A) _________________________________________
B) _________________________________________
C) easy starting
D) _________________________________________
E) _________________________________________
F) automatic; no adjustments needed
G) _________________________________________
H) improves __________________________________

8) On the CDI electronic ignition, the only moving parts are the _______________
on the flywheel.

9) __________________ ______________ (AC) changes direction 60 times per

second whereas ________________ _____________ (DC) continues in the
same direction.

10) A _________________ changes AC to DC.

11) In a battery ignition system, there must be a __________________ to replenish

the battery.

12) Sulfuric acid and _____________ water is used in a dry cell battery.

13) A 12V battery has _____ separate cells that produce about _____ V per cell.

28
Name: _____________________________ Hour: _______ Date: _______

Engine
Technology

Lab Sheets
29
Name: _____________________________ Hour: _______ Date: _______

Lab 1
Engine Basics
Directions: Answer the following questions after the instructor has given you
your engine.

Basics
1) Engine manufacturer: ________________________

2) Model number: ____________________________

3) Type number: ____________________________

4) Code number: ____________________________

5) What date was this engine manufactured? _________________________

6) Look over the engine. Are their any parts missing? If so list them (you may need
the instructor’s help).

7) Check the engine for oil and gas. If there is not oil in the engine, put the
appropriate amount in. The engine will also need gasoline in order to start. Only put
a small amount in the gas tank.

Primary systems
8) After the instructor shows you how to check for spark, use a partner and a c-
clamp to clamp the engine to a secure surface. Check you own engine for spark. Is
there ignition (a spark) for this engine? Yes No

9) Using a compression tester check the compression of the engine and write your
finding in the blank. ________psi.

10) “Good” compression for this type of engine is about 65 psi. Does your engine
have “good” compression? Yes No

If not, what are three reasons why this engine might not have good compression?
(Hint: Check page 2 in the compression section of the repair manual.)
A) _______________________________________________________
B) _______________________________________________________
C) _______________________________________________________

11) Another way to check an engine (mostly for performance measures) is to check
the amount of leakage. After watching the demonstration from the instructor, use the

30
Name: _____________________________ Hour: _______ Date: _______

leakage tester to test the leakage on your engine and record the measurement.
_________% of leakage. (Remember to lock the piston at top dead center!)

12) Make sure there is gas and oil in the engine and try to start the engine. Is there
carburetion (mixture of fuel and gas)? If then engine does not start, take out the
spark plug and check to see if it is damp. Yes No

List whether each primary system works or not.

Ignition: Yes No

Compression: Yes No

Carburetion: Yes No

31
Name: _____________________________ Hour: _______ Date: _______

Lab 2
st
1 steps of disassembly

Directions: Inspect your engine more closely while starting to take it apart. It
is very important that you following the directions in the lab to ensure that the
engine will run when you are finished.

The following steps should be done AFTER the primary systems have been
checked. These items should be done in this order:

1) Basics
Wipe all dirt off of engine
Drain the oil into appropriate container
Remove spark plug
Remove shroud (shield or blower housing) from engine
Remove air filter
Remove gas tank WITHOUT DISCONNECTING THE
CARBURETOR LINKAGE!!!! LEAVE THE CARBURETOR ON
THE GAS TANK!
Drain gas from gas tank into appropriate container
Remove the muffler
Remove valve chamber cover (breather)
STOP…Help someone else finish if you are done.

2) Flywheel and magneto

Check and record the armature gap __________. Record the

tolerance for the armature gap from the manual _________. Is this
within the tolerance according to the manual? Circle Yes or No

Remove the magneto.

Remove the starter clutch and flywheel nut
Remove the flywheel. DO NOT LOOSE THE KEY!!!
What are the four functions of a flywheel?
_______________________________________
_______________________________________
_______________________________________
_______________________________________
STOP… Help someone else finish if you are done.

32
Name: _____________________________ Hour: _______ Date: _______

Lab 3
Steps of Disassembly
Compression System

Directions: The following should only be followed after a compression test has
been performed. It is very important that the directions are followed in the lab
to ensure that the engine will run when finished. Listen to the instructor and
then follow the steps below.

1) Cylinder Head and Cylinder

Use a 3/8” socket to loosen the head bolts. ALWAYS
NOTE THE POSITION OF THE DIFFERENT CYLINDER HEAD SCREWS
SO THAT THEY MAY BE PROPERLY REASSEMBLED AS THEY ARE NOT
ALWAYS THE SAME LENGTH. Break all of them loose first and then
remove them.

Remove the cylinder head. What type of metal is it made of?

___________

Look at the cylinder head. Is it darkened in color? _______

What is (would) this material (be) called? _____________
What causes this to happen? ___________________

Rotate the crankshaft by hand. Does the piston move up and

down? _______ If it didn’t, what could be the problem?
_______________________________________________

2) Measure the stroke of this engine. _______________

Measure the bore of the engine. (Take 6 measurements...2 at the top, 2 in

the middle, and 2 at the bottom each perpendicular to each other)
Top __________ ___________
Middle __________ ___________
Bottom __________ ___________

Check the max and min dimensions for cylinder bore in the manual.
____________ max ____________min

Is this cylinder worn out? ________ How can you tell?

_______________________________________________

Average the numbers together ___________. Using this number find the
cubic inch displacement of this engine
CID = (3.14 x Bore2 x Stroke) x Number of Cylinders
4

33
Name: _____________________________ Hour: _______ Date: _______

Find the compression ratio of this engine

Compression Ratio = Volume BDC
Volume TDC

= Stroke Volume + Head Volume

Head Volume

34
Name: _____________________________ Hour: _______ Date: _______

Lab 4
Steps of Disassembly
Compression System - Valves
Directions: The following should only be followed after a compression test has been
performed. It is very important that the directions are followed in the lab to ensure
that the engine will run when finished. Listen to the instructor and then follow the
steps below.

1) How can you determine which valve is the intake and which is the
exhaust in regards to the size of the valves? ___________
__________________________________________________

2) Remove the breather element.

Position the piston at TDC of the compression stroke. Use a feeler

gauge to measure the valve clearance (the gap between the valve
stem and the tappets).

Intake clearance: __________ Spec clearance: _________

Exhaust clearance: ________ Spec clearance: _________

3) Use a valve spring compressor to remove the springs and pins, collars,
or retainers.

Clean the valves with a wire wheel. Also check for pitting.

Put the valve in the drill press chuck and turn it on. This will show
whether the valve is warped or bent.

4) Identify the type of valve guides are used in this engine. (Inserts or
Integral) Use the correct plug gauge to check for excessive wear on
the valve guides.

Identify the valve seats used in this engine.

(Inserts or Integral)

5) Carefully measure the valve margin. _______________

If the margin was smaller than this size (______) it would have to be
replaced.

35
Name: _____________________________ Hour: _______ Date: _______

Lab 5 Discussion Guide

What is the side to side movement called in a crankshaft?

Why is it necessary?

What is the measuring tool called that measures endplay?

How can endplay be adjusted?

36
Name: _____________________________ Hour: _______ Date: _______

Lab 6
Steps of Disassembly
Compression System – Piston and Connecting Rod

Directions: The following should only be followed after a compression test has been
performed. It is very important that the directions are followed in the lab to ensure
that the engine will run when finished. Listen to the instructor and then follow the
steps below.

1) Examine the connecting rod. Is it split? __________ Is there an extra

device (locking plate) on the bottom of the connecting rod to ensure it will not
come loose during operation? _______

2) Mark the sump side of the piston and connecting rod to ensure they are put
back in the same direction in which they were removed. Ask the instructor to
help you find the marks on the connecting rod to help line up the cap during
re-assembly.

3) If there is a ridge at the top of the cylinder, remove it with 400 grit sand paper
or steel wool to prevent damage to the piston rings upon removal.

4) Bend down the locking plate at the bottom of the connecting rod. Remove
the cap screws. Are they ¼” coarse or ¼” fine threads? _________ When
reassembling the end of the connecting rod, what torque should be put on the
screws? ________ In. Lbs.

5) Push the piston out of the top of the cylinder. Is there any damage to the:
A) PTO end journal ________ Describe

B) Flywheel end journal _______ Describe

C) Crankpin Journal _________ Describe

6) Measure the journals of the crankshaft, compare them to the spec reject sizes, and
decide whether or not this crankshaft should be replaced.
Actual Reject Replace (Y/N)
PTO Journal
Flywheel Journal
Crankpin Journal

7) Inspect the cylinder. Is it scored? ______________

8) Inspect the piston. What are the two top rings (look in the manual)?
________________ rings What is the bottom ring? ___________ ring

9) Secure the piston gently in a vice. Check the piston ring land wear (look in
manual if unsure on how) and record the measurements for each land.

37
Name: _____________________________ Hour: _______ Date: _______

If a _______ in thick feeler gauge can be inserted, the piston is worn and
should be replaced.

Actual measurements:
Top land ______ Middle land _______ Bottom land ______

CAREFULLY remove the top ring. Look in the manual and match this ring up
with and appropriate diagram in the manual. Remove the other two rings and
sketch a cross sectional view of each ring next to its piston ring land. (Keep
in mind there is a top and bottom to these rings.)
Top Ring Cross Section -

Middle Ring Cross Section –

Bottom Ring Cross Section -

10) Place the compression ring into the cylinder approximately 1” down. Make
sure it is level and measure the end gap in the ring. Repeat this for the oil
rings. Replace them if needed.

Actual End Gap Reject End Gap Replace (Y/N)

Top Compression ring
Middle Compression Ring
Bottom Oil Ring

What may cause the end gap to be larger than the specs (what two things may
be worn)?
A) _____________________________________________________
B) _____________________________________________________

11) Carefully remove the ring (snap ring or “C” ring) holding the piston pin in
place with a needle nose pliers. Keep track of the small parts. Gently tap the
piston pin out to separate the piston from the connecting rod. Measure the
piston pin diameter. __________What is the rejection size? ________
Should it be replaced? ____________

12) How would the clearance of the piston pin and the pin bore (hole that pin sits
in) be determined? _______________________________________
__________________________________________________________
Bore diameter = ________________
Formula =
Piston pin and piston pin bore clearance = ______________

38
Name: _____________________________ Hour: _______ Date: _______

Lab 7
Steps of Disassembly
Crankshaft Wear – Using Plastigage
Directions: It is very important that the directions are followed in the lab to ensure
that the engine will run when finished. Listen to the instructor and then follow the
steps below.

13) Determine the clearance between the connecting rod bearing surface and the
crankpin by using a 1” piece of plastigage. Lay the plastigage on the bearing
surface of the connecting rod, parallel to the crankshaft. Place the
connecting rod and cap on the crankshaft and tighten the bolts to the correct
torque (which is ________ inch pounds).

2) Now take the cap back off of the connecting rod. The plastigage will be
flattened. Is it equally flattened or is it tapered?______________ If it was
tapered, what would that mean? ________________________________

3) Use the plastigage wrapper to determine which strip most closely matches
the flattened plastigage. What is the measured clearance of the connecting
rod bearing surface and the crankpin? ___________________ Any
clearance over .003” indicate excessive wear.

39
Name: _____________________________ Hour: _______ Date: _______

Lab 8
Steps of Disassembly
Carburetor, Air Filter, and Parts Ordering
Directions: It is very important that the directions are followed in the lab to ensure
that the engine will run when finished. Listen to the instructor and then follow the
steps below.

1) Use the manual to identify the type of carburetor on your engine. ____________ Is
this an up draft, down draft, or cross draft carburetor? ___________________

2) Carefully remove it from the gas tank. DO NOT REMOVE THE LINKAGE.
ALSO BE VERY CAUTIOUS AS TO WHICH WAY THE DIAPHRAM IS PLACED
ON THE CARBURETOR.
Use carburetor cleaner to clean out all spray out all passages of the carburetor.

3) Remove the cover of the air cleaner and remove the filter element. Explain how it
traps dirt from entering the engine. __________________________________
________________________________________________________________
(According to the manual (Black cover!), this element should be cleaned every
_______ hours)

4) There are four steps to cleaning the foam air filters. Follow the steps in the black
manual to clean it. If it is a paper element, show it to the instructor to see if it needs
to be replaced.

Disassembly is complete! Now the parts need to be ordered for this engine. Ask the
instructor for the phone so that you can call in your parts. You will need:

Manufacturer’s Name: ________________

Model Number: ______________________
Type: ______________________________
Code: ______________________________

The phone number for parts is: 849-4101

You also might find it helpful to list the items that need to be ordered below.

If any of the lab measurements have turned up rejected parts. Ask instructor for help
on this.

40
Name: _____________________________ Hour: _______ Date: _______

E-Parts
Purpose: Mechanics very rarely use magazines to look up engine parts. The
either use software or the Internet to look up needed parts and information. This
activity will require you to look up engine parts using the Briggs and Stratton E-
parts online network.

Directions: Use the Briggs and Stratton network to find the given parts for our
classroom engine.

Type in: www1.briggsnetwork.com

Login: voed_schools
Password: briggs

Click on Quick Links at the top of the page.

Click on Web-Based Parts Look-Up System.

Enter the required Model and Type numbers.

Look up the following part numbers that need to be replaced in the engine. (This
usually includes all gaskets, worn parts, and replaceable parts due to regular
maintenance.) You must look up five parts for the engine. If five parts do not need
to be replaced, look up the alternate part number for the following:

Part name or Alternate Part Number Price

Head gasket

Air Filter

Sump Gasket

Flywheel Key

Flywheel

Go back to the network home web site (www1.briggsnetwork.com/main_Frame.asp)

and click on Dealer Support. This is where the mechanic finds the updated price for
each part. Find the price for each part above by clicking on Parts and 2004 Master
Price List. Then choose how you would like to view the file (view online makes it
easy.

Hand in this sheet when you are finished.

41
Name: _____________________________ Hour: _______ Date: _______

Parts Ordering Sheet

Fill out the name and part number of the needed part.
Use http://www1.briggsnetwork.com/ to find Briggs part numbers
Give this sheet back to the instructor to get your parts ordered.

Brand: _____________________________
Model: _____________________________
Type: _____________________________
Code: _____________________________

Part Name Part Number

Other comments:
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________

Parts ordered on: ________________

Parts ordered from: Carl F. Statz and Sons or _____________________

42
Name: _____________________________ Hour: _______ Date: _______

To get into briggsnetwork.com with Vo-ed ID

Username is always the 6- digit ID number

Password: is the first two letters of the school name and the last 3 numbers of the ID
backwards followed by bs.

Example: Perfect School ID 123456

This schools password would be pe654bs

You may get a prompt that says your password is expired. You simply change it to
something you can remember. You will be required to change it every 90 days. You
will need to keep track of the password as it is encrypted.

43
Name: _____________________________ Hour: _______ Date: _______

Winterizing a Small Engine

Directions: Students must instruct a parent (of opposite sex) in the steps
required to winterize a small engine. The students have gone through
research in class to determine these steps. They may use any materials from
class (text book, hand outs, etc.) to help them explain the tasks at hand.

Put a date in the blank next to the steps as they are completed. The students will

get this sheet back for their records.

1) Manufacturer Name: _______________________

2) Do you have, or can you find the manual for this engine? _________

3) List all important numbers for the engine (model, series, type, etc.)
___________________________________________________________
___________________________________________________________
___________________________________________________________

4) ________ Clean the engine and remove all debris.

5) ________ Change the oil (and oil filter if needed).

6) ________ Winterize the gas by emptying most of the tank and running the
engine until it is out of gas. You may also use Stabil, but realize that gasoline
may seep into gaskets and make them brittle over time.

7) ________ Make sure the carburetor is empty (if you chose to use Stabil.

8) _______ Check/change the air filter.

9) _______ Check/change the spark plug and lubricate the top of the
piston.

10) _______ If the engine is hooked to a battery, take it out and store it in a
“room temperature” environment. If this is not possible, many people put a
piece of wood under the battery to keep a barrier between it and the concrete
to help prevent the battery from becoming too cold. The battery may need to
be charged periodically throughout the winter to get the longest life out of it.

44
Name: _____________________________ Hour: _______ Date: _______

Engine
Technology

Appendix
45
Name: _____________________________ Hour: _______ Date: _______

Standard Tiny-Tach™ — Installation Instructions

The Tiny-Tach™ meter can be mounted in the desired location using either sheet metal screws or by
using double sided tape. For best results when using tape, be sure to clean off any dirt, grease and
oil from the desired mounting location using a suitable solvent such as denatured alcohol.

Find a suitable route to run the pick-up wire to the spark plug wire. It is not critical how the wire is
routed. It can be put into existing wire harnesses or wrapped around and taped to metal supports.
Caution: Keep wire clear of extremely hot engine parts such as the muffler, etc. Wire damage (cuts
or burns) will cause the wire to short and your Tiny-Tach™ will stop working. Wire damage is not
under warranty.

The red wire should be wrapped around a section of the spark plug wire using 3-4 turns. Please be
certain you do not wrap the red wire too close to the spark plug that engine vibration will allow it to
come into direct contact with the metal portion of the spark plug. Most engines have a spark plug
cap and will prevent this from happening. After the connections are made, any excess wire can be
coiled up and taped to a convenient area.

46
Name: _____________________________ Hour: _______ Date: _______

Operating Instructions for Gasoline Tiny-Tachs™

When the engine is started, the display will indicate the RPM of the engine. When the engine is shut
down, the display will switch to run time, initially in minutes and then switching to hours once the
total reaches 60 minutes.

Models with a Reset Function

The RESET indicator on the label surface is a pressure point that can be pushed at any time to reset
the total hours. When pushed, the meter will go through a self test and display all the segments to
ensure everything is OK. If you need to record your hours, do so before resetting your Tiny-Tach.™

Standard Tiny-Tach™— Operating Instructions

When the engine is started, the display will indicate the RPM of the engine. When the engine is shut
down, the display will switch to run time, initially in minutes and then switching to hours once the
total reaches 60 minutes.

Models with a Reset Function

The RESET indicator on the label surface is a pressure point that can be pushed at any time to reset
the total hours. When pushed, the meter will go through a self test and display all the segments to
ensure everything is OK. If you need to record your hours, do so before resetting your Tiny-Tach.™

47
Name: _____________________________ Hour: _______ Date: _______

Frequently Asked Questions

1. What is the update time? 2.5 seconds for the original gas Tiny-Tach™ and 1/2 second for
commercial Tiny-Tach.™

2. How do you hook it up? You have two wires at the engine. The red wire (antenna wire)
wraps 3-4 times around the plug wire. The white wire has a lug to put under a bolt head for
ground.

3. How is the tach powered? A 3 volt lithium battery is used for the original gas Tiny-Tach™
and the commercial unit. The commercial unit requires additional outside power such as a
9-volt battery hook up.

4. How long does the battery last? The lithium battery life is estimated at 5+ years. With
external power applied to the commercial unit, the internal battery recharges as power
goes to the unit extending the battery life. Both tachs are warranted against defects (but
not wire damage) for a period of one year from date of purchase.

5. How many models are there? There are 3 different modes of the original Tiny-Tach™
relating to how the engine cylinder fires:
o 2C for 1x per revolution (typically for Briggs, Honda and Kohler type engines);

o 1C for cylinders firing 2x per revolution (2 cylinder personal watercraft such as

Seadoos typically fire this way); and
o 4C for cylinders firing every other revolution (typically K series Kohler engines)

o The commercial unit, CTT-S, can be programmed for different firing sequences.

6. Will the Tiny Tach work on multi-cylinder engines? Yes. Some multiple cylinder engines
require a filter to cut out electric noise. The filtered "X" models are made to order for you.
Call for information if you have a multi-cylinder engine.

7. Do you make a model for resetting the hours? Yes, it is called an R, instead of an NR.

8. Why does my 2C tach read double on my two cylinder engine? It can be one of two
reasons, It can be picking up the other cylinder signal or your engine fires each plug 2
times/rev. Note: Some single cylinder engines do this also, i.e. ATVs.

9. Can you lengthen the wire (all models)? No. You must send your tach to us and we can
lengthen the coaxial wire here.

10. Why does my 1-c tach read 1/2 time on a 2 cylinder engine? You need to attach the
wires to BOTH cylinders. Make sure you use only 3 wraps with the wire.

48
Name: _____________________________ Hour: _______ Date: _______

Small Engines
Calculations/Engine performance Chapter 5

Technical Math Assignment Sheet #1 Calculate Work

Calculate the following problems using the formula for work.

Work = Force X Distance

1. Two men push a 300 pound weight a distance of 50 feet along a

warehouse floor. The force necessary to slide the weight is 110 pounds.
How much is accomplished?

2. How much work is accomplished if it takes 92 pounds of force to move a

400 pound object 44 feet?

3. It takes 49 pounds of force to move a 92 pound box 60 feet across the

floor. How much work is accomplished?

49
Name: _____________________________ Hour: _______ Date: _______

Assignment Sheet #2 – Calculate Horsepower

Calculate the following problems using the formula for horsepower.

HP = F x D________________
Time (seconds) x 550

1. A 200 pound man climbs a 40 foot flight of stairs in 20 seconds. How

much horsepower does he develop performing the feat?

2. A 1000 pound weight is moved a distance of 60 feet across the floor. The
force necessary to move the weight is 200 pounds and the time required
to accomplish this is one minute. How much horsepower is required to
perform this task?

3. A man pushes a 400 pound weight a distance of 10 feet along the loading
dock. The force required to move the weight is 500 pounds. The task is
completed in 5 seconds. How much horsepower is produced?

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Name: _____________________________ Hour: _______ Date: _______

Other
Documents

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