AUTOMOBILE LKS WILAYAH KERJA 3

2019
TECHNOLOGY PROPINSI JAWA TIMUR

Competitor Name Competitor No Task

……………………………………………….. …………………….. D

ENGINE MECHANICAL

Familiarization Time
5 minutes
Task Duration
55 minutes
Total Time
60 minutes

Marking Summary

Possible Score
Section
Mark Record
Preparation (PPE Used, Safety and Health ...........
1. 100
Environment)

2. Dismantling Timing Chain 100 ...........

3. Dismantling Cylinder Head 100 ...........

4. Cylinder Bore Crankshaft and Piston Measurement 250 ...........

5. Assembling Cylinder Head 100 ...........

6. Assembling Timing Chain 250 ...........

7. Assembling Timing Chain Cover 100 ...........

Task Total 1000 ...........

Time Keeping

Familiarization Competition Breaks

Start Start Start

Stop Stop Stop

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AUTOMOBILE LKS WILAYAH KERJA 3
2019
TECHNOLOGY PROPINSI JAWA TIMUR

You are required to

- Observe occupational health & safety standards

- Only ask necessary questions
- Not speak to the public while competing
- Comply with Experts instructions
- Ensure Competitor Number on all forms
- Use appropriate tools and procedures
- Complete all instructions on the next page

Remarks : Engine 2NR-VE TERIOS/RUSH

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AUTOMOBILE LKS WILAYAH KERJA 3
2019
TECHNOLOGY PROPINSI JAWA TIMUR

Engine Mechanical Task Instraction

1. Perform dismantling timing chain

2. Perform dismantling cylinder head

3. Perform Dismantling a piston

4. Measure cylinder bore, piston and oil clearance of main journal. Fill the result
in the report sheet

5. Perform assembly piston

6. Perform assembly cylinder head

7. Perform assembly timing chain

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AUTOMOBILE LKS WILAYAH KERJA 3
2019
TECHNOLOGY PROPINSI JAWA TIMUR

Report Sheet
ENGINE MECHANICAL

a) Piston

Description Specification Actual Serviceable Unserviceable

Piston Outer Diameter ................... ................... ................... ...................

b) Cylinder bore

Description Specification Actual Serviceable Unserviceable

A1: .............
B1: .............
No. 1 Cylinder inner ...................
C1: .............
diameter
A2: .............

................... B2: .............

C2: .............

Max. Oval ................................ mm

Max. Taper ................................ mm

c) Measuring oil clearance main journal and Pin Journal No1 use plastic gauge

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AUTOMOBILE LKS WILAYAH KERJA 3
2019
TECHNOLOGY PROPINSI JAWA TIMUR

Description Specification Actual Serviceable Unserviceable

Oil clearance Main

journal No.1
.................... .................... .................... ....................

Oil clearance Pin

journal No.1
.................... .................... .................... ....................

d) Moment of the bold

1. Cylinder head bolds ......................... Nm
2. Cylinder head Cover bolds ......................... Nm
3. Timing chain cover bolt ......................... Nm
4. Pully bold ......................... Nm

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AUTOMOBILE LKS WILAYAH KERJA 3
2019
TECHNOLOGY PROPINSI JAWA TIMUR

Marking Summary

1. Preparation Yes No Actual Comments

1.1 Use proper workshop manual 15 0

1.2 Check all equipments 15 0

1.3 Check all instructions 15 0

1.4 Select the correct tools 15 0

1.5 Calibrate measuring tools 15 0

1.6 Use logical working procedure 10 0

1.7 Clean up the working area 5 0 Majun

1.8 Clean up tools and equipment 10 0

Sub-Total 100 0

2. Dismantling Timing Belt Yes NO Actual Comments

25
2.1 Remove Pulley Crankshaft 0
25
2.2 Remove Timing Chain Cover 0
25
2.3 Remove Timing Chain Tensioner 0
25
2.4 Remove Timing Chain 0

Sub-Total 100 0

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AUTOMOBILE LKS WILAYAH KERJA 3
2019
TECHNOLOGY PROPINSI JAWA TIMUR

3. Dismantling Cylinder Head Yes NO Actual Comments

Remove Cylinder Head Cover

3.1 20 0
bolts
3.2 Remove Cylinder Head Cover 15 0

3.3 Remove Cylinder Head Bolts 30 0

3.4 Remove Cylinder Head 20 0

3.5 Remove Cylinder Head gasket 15 0

Sub-Total 100 0

Cylinder Bore ,Piston,and oil

4. Yes No Actual Comments
Clearance Measurement
Select correct Outside
4.1 20 0
Micrometer
4.2 Calibrate Outside Micrometer 30 0

4.3 Measure diameter piston 40 0

4.4 Install Cylinder Bore gauge 30 0

Calibrate Cylinder Bore gauge
4.5 40 0
using Outside Micrometer
4.6 Measure diameter Cylinder Bore 30 0
Measure oil clearance main
4.7 30 0
journal No1 by plastic gauge
Tighten crankshaft bolt before
4.8 30 0
measure oil clearance
Sub-Total 250 0

5. Assembling Cylinder Head Yes No Actual Comments

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AUTOMOBILE LKS WILAYAH KERJA 3
2019
TECHNOLOGY PROPINSI JAWA TIMUR

5.1 Assamble Cylinder Head gasket 20 0

5.2 Assamble Cylinder Head 20 0

5.3 Lubricate Cylinder Head Bolts 20 0

5.4 Tighten Cylinder Head Bolts 40 0

Sub-Total 100 0

6 Assembling Timing chain Yes No Actual Comments

6.1 Position engine on TOP 1 30 0

6.2 Assemble Timing Chain 30 0

6.3 Assemble Tensioner 30 0

6.4 Turn Crankshaft 1,9 rotation 0

35
Loose Timing Chain Tensioner
6.5 30 0
Bolt

Turn Crankshaft until 2 rotation 30 0

6.6

Tighten Timing Chain Tensioner

6.7 30 0
Bolt
6.8 Turn Crankshaft 2 rotation 0
35

Sub-Total 250 0

7. Assembling Timing Belt Cover Yes NO Actual Comments

7.1 Assemble Cylinder Head Cover 15 0

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AUTOMOBILE LKS WILAYAH KERJA 3
2019
TECHNOLOGY PROPINSI JAWA TIMUR

7.2 Assemble Timing belt Cover 15 0

7.3 Tighten Cylinder Head Cover Bolts 25 0

7.4 Assemble Pulley Crankshaft 20 0

7.5 Tighten Pulley Crankshaft Bolt 25 0

Sub-Total 100 0

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