internal combustion engines

engine tech

Torque Settings (mazda 323 b6)

1.Cylinder head bolts = Tighten: 30 Nm Tighten: 55 Nm Tighten: 76-81 Nm 2.Rocker cover bolts = Tighten: 5-9 Nm 3.Camshaft pulley bolt = Tighten: 49-61 Nm 4.Spark plugs = Tighten: 15-23 Nm 5.Fly wheel bolts = Tighten: 100 Nm 6.Sump drain bolts = Tighten: 30-45 Nm 7.Sump bolts = Tighten: 10 Nm 8.Main bearing bolts = Tighten: Stage 1: 27 Nm Stage 2: 54-59 Nm 9.Big end bearing bolts = Tighten: Stage 1: 25 Nm Stage 2: 50-54 Nm 10.Intake manifold to cylinder head bolts = Tighten: 20-25 Nm 11.Crankshaft pulley bolt = Tighten: 108-128 Nm

Electrical Questions (Part 1)

1)How many protons and electrons are there ? 29 of each 2)What dose EMF mean ? electro motor force 3)What is Resistance measured in ? ohms 4)What are the four factors to determine resistance ? material used, length of conductor, size of conductor, temperature of conductor 5)What is the purpose of a Resistor ? to cause a voltage drop 6)What is conventional current ? positive to negative 7)Which way does the electrons flow in electron current flow ? negative to positive 8)What is the term Ground ? connecting the battery to the chassis 9)Draw ohm's law triangle ? 10)How can you stop static electric shocks ? make sure there is a ground 11)What is the purpose of a Battery ? to store voltage 12)What device recharge the Battery ? the altinator recharges the battery (volts/amps) 13)What is the purpose of the ALT warning light ? to know the altinator is charging 14)What are the PPE for testing a battery and the SOP ? overalls, boots, wing guard, ruber gloves, safety glasses, 15)What is the battery fluid called ? electrolite 16)What are the three main components to test a battery ? hydromitor, multimetre, load tester

electrical module

Engineering Module

Vehicle Torque Settings

Specs for 1989 nissan skyline r31 rb30e

1) Engine sump drain plug = 29-39 Nm

2) Engine fly wheel bolts = 142-152 Nm

3) Rocker cover bolts = 2 - 4 Nm

4) Spark plugs = 20-29 Nm

5) Sump  = 5-7 Nm

H&S part 5

What does SOP mean?     Safety Operation Procceedures

When using any fixed machinery what should be done before you use it?  knowing where the cut off switch is, have atleast a 1metre space around the machine so you can move away safely.

How can you avoid danger?     Follow the correct SOP

What is the speed limit around the campus?     5kmph

When lifting a heavy object incorrectly what can happen to the person?   can damage your spine. pull ligaments

What does OOS mean and how can you prevent it?    Occupational Overuse Syndrome: follow SOP's and lifting procceedures

Write down the nine ACTIONS of lifting and moving any heavy object
bend knees and keep back straight, make sure there are no wires or anything you could trip over before lifting

H&S part 3

all students must wear appropriate ppe in the work shop.
keep work area clean and tidy. (in workshop or classroom).
be on time (punctuality).
S.O.P.'s
no running in the workshop
know the fire and evacuation procceedure's

H&S part 2

in the event of a fire activate the fire alarm and tell your tutor then procceed to the front carpark to the assembly point and inform your tutor that you are out safely.

fire wardens wear a bright orange vest.

Tyres, windows, flexi brake pipes, torquing wheel studs

TYRES
205 = tyre width
60 = tyre wall hight
R = tyre construction
15 = rim size
97 = laod capacity per tyre
Q = speed rating

tyres are made up of the following ingredients:
Rubber (natural and synthetic) 38%
Fillers (carbon black, silica, carbon chalk) 30%
Reinforcing materials (steel, rayon, nylon) 16%
Plasticisers (oils and resins) 10%
Chemicals for vulcanisation (sulphur, zinc oxide, various chemicals) 4%
Chemicals for antioxidants to counter ozone effects and material fatigue 1%
Miscellaneous 1%

WINDOWS

The difference between the front windscreen and the rest of the windows is Auto glass is designed and manufactured for optimum safety in the event of a crash. Your windshield is made of laminated safety glass. The side and rear windows are made of tempered glass. Laminated safety glass is two pieces of glass with a layer of vinyl sandwiched between, so it will stay intact in a collision. Tempered glass has been treated to make it much stronger than other glass of the same thickness. If it breaks, it is designed to shatter into small pieces.

 BRAKE FLEXI HOSE

The reason for flexi hoses on our brakes is so that while the car is driving the brake lines are able to withstand the bumps in the road.

TORQUING WHEEL STUDS 

The reason we use a torque wrench on the wheel studs is to ensure they are at the maximum tightness without stretching the bolts and to ensure the wheels will not fall off.

Health and Safety exercise

Health and Safety exercise, you need to read the booklet and fill in the missing words

The Law


Both the employer, Unitec Institude of Technology and its students have statutory obligations under the health and -safety in employment act 1992 and all its amendments.

Employer Duties Include:


To take all practicable steps to:
 Provide a safeworking environment
provide procedures for dealing with emergencies
Provide facilities for staff that include toilets and rest rooms, also first aid facilities.
Employees receive appropriate training in all matters

Students Duties include


Taking responsibility for yousafety and health at work
ensuringthat your action or inaction does not harm others
Reporting all or near hits to your supervisor as soon as possible after the event.

Hazards


To help reduce the health and safety risks in our workshop we need you to report any hazards that you may identify that have the potential to cause injury or serious harm
Report the problem to your supervisor immediately so that the risk can be analysed and preventative action taken
Who is your Health and safety representative: Rob Humphreys

industry practice