Engine Mechanics Course

Lesson 1 • Workshop Safety and Tool Basics

Establishes safe work practices, personal protective equipment, and proper tool handling. Safety compliance is a prerequisite for all hands-on lab sessions.

Lesson 2 • Major Engine Components Overview

Identifies and describes every primary engine part and its function. Builds the component vocabulary needed for all subsequent chapters.

Lesson 3 • History and Engine Classifications

Traces engine development from early combustion designs to modern variants. Provides context for understanding why specific configurations exist.

Lesson 1 • Two-Stroke Cycle Comparison

Contrasts two-stroke port timing and power delivery with the four-stroke cycle. Clarifies trade-offs in power density, emissions, and lubrication.

Lesson 2 • Intake and Compression Strokes

Explains air-fuel mixture entry and compression mechanics in detail. Connects valve timing to mixture quality and compression ratio outcomes.

Lesson 3 • Power and Exhaust Strokes

Analyzes ignition timing, combustion expansion, and exhaust gas evacuation. Shows how power output is generated and waste gases are expelled.

Lesson 1 • Compression and Leak-Down Testing

Teaches compression test procedures and leak-down analysis to locate internal faults. Results guide decisions on ring, valve, and gasket condition.

Lesson 2 • Precision Measurement Instruments

Covers micrometers, calipers, dial indicators, and bore gauges for engine work. Accurate measurement is the foundation of all machining and assembly decisions.

Lesson 3 • Oscilloscope Use for Engine Signals

Applies oscilloscope waveform analysis to ignition, sensor, and actuator signals. Waveform interpretation extends diagnostic capability beyond code readers.

Lesson 4 • Oil Analysis and Fluid Inspection

Explains how oil condition, viscosity, and contamination reveal internal wear. Fluid analysis complements mechanical testing for complete engine assessment.

Lesson 1 • Oil Pressure Diagnosis and Service

Teaches mechanical oil pressure testing and interpretation of low-pressure causes. Connects bearing clearance, pump wear, and viscosity to pressure readings.

Lesson 2 • Overheating Diagnosis and Prevention

Identifies causes of overheating including air locks, head gasket failure, and blockage. Systematic diagnosis prevents repeat failures and engine damage.

Lesson 3 • Engine Lubrication System Design

Maps oil flow from sump through pump, galleries, and bearings back to the pan. Understanding flow paths is essential for diagnosing pressure and wear issues.

Lesson 4 • Cooling System Components and Flow

Describes coolant circulation through the water pump, radiator, thermostat, and passages. Proper flow understanding supports accurate overheating diagnosis.

Lesson 1 • Port Fuel Injection Systems

Details injector operation, fuel rail pressure, and ECU pulse-width control. Connects sensor inputs to injector timing and duration decisions.

Lesson 2 • Direct Injection System Mechanics

Examines high-pressure fuel pumps, injector placement, and spray strategies in GDI engines. Highlights carbon buildup risks unique to direct injection.

Lesson 3 • Fuel System Diagnosis and Testing

Applies pressure, volume, and electrical tests to isolate fuel delivery faults. Systematic testing reduces misdiagnosis and unnecessary parts replacement.

Lesson 4 • Air Filtration and Intake Design

Covers air filter types, intake manifold geometry, and airflow measurement sensors. Intake restriction and design directly affect volumetric efficiency.

Lesson 1 • Spark Plug Inspection and Service

Teaches reading plug condition as a diagnostic window into combustion quality. Proper gap setting and torque ensure reliable ignition performance.

Lesson 2 • Ignition System Fundamentals

Explains coil energy storage, primary triggering, and secondary voltage delivery to plugs. Establishes the electrical foundation for all ignition diagnostics.

Lesson 3 • Ignition Timing and Advance Systems

Covers base timing, centrifugal advance, and ECU-controlled spark timing strategies. Correct timing maximizes power while preventing detonation.

Lesson 4 • Engine Control Unit Inputs and Outputs

Maps ECU sensor inputs, actuator outputs, and control strategies for fuel and ignition. Understanding ECU logic enables accurate fault isolation.

Lesson 1 • Piston, Ring, and Connecting Rod Service

Evaluates piston skirt clearance, ring end gap, and rod bearing clearance against specifications. Correct clearances ensure proper sealing and load distribution.

Lesson 2 • Engine Removal and Teardown Procedures

Covers safe engine removal, labeling, and systematic disassembly to prevent damage. Organized teardown preserves component identity for accurate inspection.

Lesson 3 • Crankshaft Inspection and Bearing Fitting

Measures journal diameter, taper, and surface finish to determine grind requirements. Proper bearing selection and crush ensure correct oil film thickness.

Lesson 4 • Cylinder Block and Bore Inspection

Measures bore diameter, taper, and out-of-round to determine machining requirements. Block integrity determines whether boring, honing, or replacement is needed.

Lesson 5 • Engine Assembly and Break-In Procedures

Sequences final assembly steps, torque specifications, and initial start-up protocols. Proper break-in establishes ring seal and bearing surfaces for long service life.

Lesson 1 • Volumetric Efficiency and Airflow

Analyzes how port shape, valve size, and intake design affect cylinder filling. Volumetric efficiency is the primary lever for naturally aspirated power gains.

Lesson 2 • Engine Tuning and Calibration

Introduces ECU calibration tools, fuel and ignition map editing, and dyno verification. Data-driven tuning maximizes power while protecting engine reliability.

Lesson 3 • Emissions Compliance in Performance Builds

Addresses how performance modifications interact with emissions control requirements. Builds awareness of compliance obligations when modifying engines for road use.

Lesson 4 • Turbocharging and Supercharging Systems

Explains compressor maps, boost control, and intercooling for forced induction engines. Forced induction multiplies power output but requires supporting system upgrades.