Engine Builder Team Contest This is a team contest to give students the opportunity to develop and show their talents of teamwork and engine building skills. Scope of Contest A team of five students will compete in a written contest at the region level. Each team member will take an exam consisting of 30 multiple choice ASE/NATEF type questions on Engine Repair and Diagnosis. The team member scores will then be averaged to determine the overall team score. The team with the highest average will represent that region at the state hands-on contest. The state contest will put eight teams (one team from each region) in a head-to-head engine builder shootout. Students will disassemble and reassemble a 350 Chevrolet engine. The teams will be judged on sportsmanship, quality of work, use of safe work practices, professionalism, as well as the finished product. Clothing Requirements:

Region contest: Students will dress in an appropriate manner to stay within the spirit of the event. Students should be neatly dressed, with shirt tucked in and pants at the waist. Hats will not be allowed. State contest: Khaki type pant (no jeans), pullover solid color collared shirt (team should all be the same color); black or brown leather work shoes, and safety glasses with side shields or goggles. (Prescription glasses can be used only if they are equipped with side shields. If not, they must be covered with goggles.) Baseball style hats will be allowed at this event, but must be worn with bill facing the direction of travel. No hats will be worn backwards. Work

shoes/boots meeting ANSI Specifications or rubber soled, oil resistant shoes. Eligibility: Open to active SkillsUSA GA members enrolled in a CTAE Transportation Logistical Support program with entry-level skills for the occupational objective. Team members can be from different schools as long as they are served by the same automotive program. (Example: Students from South Effingham High School and Effingham County High School that attend Effingham College and Career Academy would be eligible to compete as a team.) Teams cannot be built from students that attend high schools that are served by different instructors. (Example: Peach County High School, Dodge County High School, and Hutchings Career Center cannot build a team. Each school has its own instructor; therefore each school would have a team.) Safety Requirement:

Both the instructor and the contestant certify by agreeing to enter this contest that the contestant has received instruction and has satisfactorily passed an examination on the safe use of all tools. Further they agree that Skills USA, the Skills USA Championships Technical Committee and judges are released from all responsibility relating to personal injuries resulting from their use. Contestants will be removed from competition if proper training has not been provided and/or they are using the equipment in an unsafe manner.

Equipment and Materials:

Supplied by host school:

1. All necessary service publications for the contestants (this will be sent prior to the contest to the host school)

2. All necessary information and furnishings for judges and technical committee (this will be sent to the host school)

Supplied by Contestant:

� Safety glasses

� All necessary tools and equipment for the contest. No power tools will be used!

Skill/Test Region Contest: The region contest will consist of a 5 member team. Each team member will take an exam consisting of 30 multiple choice ASE/NATEF type questions. Each individual exam will be scored and then averaged for the overall team score. The team with the highest average will then represent their region at the state hand-on engine builder contest. If the first place team is unable to represent that region then the second place team will be the representative. The members taking the exam must be the same students that compete in the hands on contest. State Contest: General Rules for Disassembly/Reassembly

The state contest will consist of a 5 member team from each region for a total of eight teams. There will be 4 team members allowed to work as assemblers of the engine with one member of the team who must remain behind the table to act as a support person to keep parts, tools, and specification sheets in order. This is a timed event which the best score after penalties will deem the winner. Students will start with a Lemans style start from the back of the parts/tools table and enter assembly/disassembly area from the left end. At this point students will begin to disassemble their engine. All parts, with the exception of the crankshaft, must be removed and placed on the parts table before reassembly. These are the parts that must be removed from assembly:

� Carburetor � Intake � Spark plugs � Headers � Cylinder heads (valves/valve springs do not have

to be removed) � Valve train (pushrods, lifters, etc…) � Camshaft, timing chain and cam sprocket � Oil pump � Pistons and connecting rods (rings do not have to

be removed from pistons) � Distributor and wires � All tin (oil pan, timing cover, valve covers, air

cleaner) � Harmonic balancer

All members should them move to the back of the parts table around the left end for the judge to check assembly to determine if disassembly is complete. Once checked the team should proceed with reassembly. All parts must be reinstalled in proper manner and in the correct location (Example: number eight piston should be in number eight hole). All fasteners must be torqued to manufactures specifications. Torque wrench must be set by team member and checked by the judge prior to torqueing the fasteners. Correct torque sequence must be followed or a time penalty will be added to the final score. Penalties will also be added for improper torqued fasteners. Valve Adjustment Before the engine is completely assembled, the valve train must be properly adjusted. The following components and any other components that must precede them in reassembly should be installed before beginning the valve adjustment. Cylinder heads, valve train, timing chain, damper, and damper turning tool should be installed. Valves can only be properly adjusted when the lifter is resting on the camshafts base circle. Improper valve adjustment will result from adjusting the valve while the lifter is on the camshaft lobe or lobe ramp. Use the following guide to insure the lifter is resting on the camshafts base circle before valve adjustment. With the #1 piston at TDC (top dead center) on the compression stroke you may adjust the following valves: Intake Valves- #1, #2, #5, #7

Exhaust Valves- #1, #3, #4, #8 Now rotate the engine clockwise 360 degrees. The #1 piston should again be at TDC, only this time it’s the exhaust stroke. Coincidently the #6 piston is now at TDC on the compression stroke. You may adjust the following valves: Intake Valves- #3, #4, #6, #8 Exhaust Valves- #2, #5, #6, #7 Use the following procedure to adjust the valve. You will start with the rocker arm nut loose. Slowly tighten the rocker arm nut with one hand while rotating the pushrod back and forth with your other thumb and index finger until you feel a slight drag. At this point there should be no valve lash (extra clearance). Now turn the rocker arm nut an additional 3/4 turn. Now the valve is properly adjusted. Disassembly 1) All components to be placed on table, no engine components on floor (subject to venue). Tools can be placed on floor while in use, but cannot remain there during competition. 2) Torque wrenches cannot be placed on floor at any time during the event, but can be held by a team member or placed in /on a padded tray or returned to the work bench.

3) Rotating torque will be determined by judge at the beginning of disassembly. (Reassembly torque must be within 25 % of original spec.) 4) Air cleaner - must be removed from carburetor separately. 5) Distributor and spark plug wires can be taken off as an assembly. 6) Headers and gaskets (headers must be removed as separate procedure before head comes off). Hand wrench only tool permitted for this procedure 3/8" 6 or 12 pt. No ratchet wrenches. 7) Spark plugs must be removed before heads come off engine. 8) Oil filter must use filter wrench to loosen. 9) Water pump. NO removal sequence. 10) Intake manifold (see de torque sheet, sheet can be used as referenced during event). 11) Remove balancer - before removal you must remove the adaptor before removing with puller. Balancers have been honed to aid in fitting. Once balancer has been removed, engine can only be turned over the following ways. (1) With crank socket (2) balancer installed with crank bolt and adaptor bolted to balancer. Time penalty will be 10 minutes each occurrence. 12) Heads - fasteners must be removed in de torque sequence one side at a time. (See sheet, once again can be used during event). Number one (1) head bolt has been replaced with stud. The nut size is 1/2" 12 pt. Torque value is the same.

13) Rocker arms, balls, nuts, (Individual Rocker arm, ball, and nut may be removed as an assembly) push rods, and lifters must be removed individually and placed in holder (supplied or approved holder) before heads come off. Both sides of engine can be worked on at this time, but heads must come off one side at a time. Penalty minutes will be assessed if rocker arms, push rods, and lifters are mixed up and not in place in holder or assembled incorrectly. 14) Pistons - block will remain in upright position deck up oil pan side down. Removal and install of all components will be made with engine in this position. 15) Remove oil pan. No removal sequence 16) Oil pump and drive. 17) Timing chain cover (remember oil pan must be off or loose in front before removing) - timing chain - cam gear - crank gear can remain on crankshaft; gear has been honed to slide to aid procedure. 18) Rod bolt protectors must be used. When a rod cap is loosened, that rod/piston assembly must be removed from block before proceeding to the next assembly. No multiple removals of rod caps or nuts will be permitted. A 5 minute penalty each rod and piston assembly that is loosened before a single assembly is removed. Holders must be placed on table to complete disassembly process, cannot remain in work area, but can be brought to engine for disassembly. 19) Gaskets from engine must be placed on table. If timing chain cover gasket and or water pump gaskets rip, stick or are damaged use the new supplied gaskets. All components are to be placed on table (i.e. clean work area).

20) All students to return behind table / workstation using LEFT side when disassembly is complete - judges to check area, ONLY THE TIME KEEPER can call students to return to work. If time keeper judge does not call students back immediately, this means tools or components are still in work area (team’s responsibility to police area). 21) Instructor / coaches can observe from behind the table, but cannot physically be involved with disassembly or reassembly. They cannot coach or direct but can be there only to observe. They are not allowed to talk to and/or give signals/signs to the contestant. ASSEMBLY 22) Piston and rod assembly, along with crank journal, must be oiled prior to assembly during reassembly process. 23) Lifters - must use installation lube before installing (supplied). Also must be in proper bores, penalty if not. 24) Oiling of head bolts - pistons - bearings can be performed by second student during assembly process only and must be called out to judge. 25) Torque wrenches cannot be placed on floor at any time during event, but can be held by team member, placed in padded tray or returned to table.

26) No speed wrenches or “t” handles can be used for reassembly of the following components, intake manifold, headers, spark plugs, carburetors, rocker arm nuts, rod bolt nuts, water pump bolts, timing gear bolts, dampener bolt and adapt. 27) Engine must remain with decks up, oil pan side down during reassembly. 28) Bolts & Nuts. All bolts must be hand started then tightened to spec. No loading of nuts or bolts into sockets. A 2 minute penalty for each fastener. 29) Approved speed wrenches or t-bars may be used to run head bolts down before two step torque procedure. 30) Oiling of engine components can only be done during reassembly process and must be called out to judge. 31) Pistons reinstalled one piston at a time using ring compressor, band type or plier’s type must be used. No speed sleeves, rod bolt protectors must be used. You must oil pistons before ring compressor use. 32) Rings must be clocked before reassembly and called out to judge, penalty if not. Rings: no bent/damaged rings will be allowed to be installed in engine. If you damage a ring, you must remove piston and remove damaged ring. Rings must be spaced 180 before installation, show judge. 33) No multiple loading of pistons in ring compressors before reassembly. When reassembly starts, student at table may ready one piston/rod assembly at a time. Rod journals must be oiled and called out to judge.

34) Rod nuts must be torqued to spec. Click type torque wrench to be used "must be shown to judge before use". If not, penalty will be assessed. Two step on rod nut torque. Penalty if not shown and called out to judge.

35) Proper installing and tightening of pistons and rods. Rods must be torqued in two (2) steps 15 lbs. and 30 lbs. Install one (1) piston and rod at a time per crank journal (example #1 and #2 is one journal) Crank journal must be in the down position for that set of pistons and rods. Install rod caps and snug nuts proceed to next journal #3 and #4, then #5 and #6 then #7 and #8. Each time the crank is rotated it must be called out to judge. There will be a 1 minute penalty will be for the first time and a warning issued, a 2 minute penalty for the second time, a 3 minute penalty for the third time, and a 4 minute penalty for the fourth time the crank is turned without calling “JUDGE ROTATING CRANK”. Once all rod caps are installed and nuts tightened the torque procedure may begin. At the beginning of the install call out to judge. 36) Cam gear and timing chain installation #1 piston must be up in TDC position. Timing marks with chain installed must be dot to dot (see fig. #7). There is a 3 minute penalty not showing judge dot to dot. 37) Proper torque specs on timing gear bolts, torque wrench shown to judge before use. 38) Install oil pump, torque to spec, show judge torque wrench. 39) Install timing chain cover and oil pan, use gaskets supplied. Torque bolts to specifications and show judge torque wrench. Must use tightening pattern in spec sheets supplied in packet. 40) Install balancer torque to spec, show judge torque wrench. Install adapter on balancer, torque to specifications and show judge torque wrench. 41) Install oil filter - lube gasket, show judge, hand tight. 1 Minute penalty if gasket not lubed.

42) Install water pump. Must use gaskets - torque to spec-x pattern. Show judge torque wrench before use. 43) Install heads, both sides can be installed at the same time but only one side can be torqued at a time. Two step on bolt torque. Torque wrench must be shown to judge for both torque specs. Tighten in sequence. 44) Head bolts can be placed in heads and oiled - show judge. If bolt/bolts fall from head fastener must be wiped clean - re-oiled - show judge procedure. 45) Lifters & lifter guides - push rods - rocker arms - balls and nuts, must use lube on components (supplied). Roller lifters are used. Torque bolts to specifications and show torque wrench to judge. Rocker arm adjustment (see adjustment sheet in packet, may be used at table during event). 46) Penalty minutes will be assessed if lifters and rocker arms are mixed up and not in place in holder or assembled incorrectly.

47) Reinstall spider and torque to specifications. 48) Install intake with gaskets and cork seals at end of manifolds, use correct torque sequence and specifications. You must use 12 point box end 6" to 8" wrench, hand tightened in proper sequence. If judge can loosen with their fingers they will assess a 3 minute time penalty. No other tool will be permitted. 49) Install headers with gaskets, hand start bolts, tighten by hand with wrench using sequence center out. A 3/8” 6 point combination wrench is only tool permitted. No ratchet wrenches. No other tool will be permitted. 50) Install spark plugs, dab of anti-seize on threads (supplied) show judge before install. Torque spark plugs to100 inch pounds. Show judge torque wrench before use. 51) Install carburetor tighten carburetor. Nuts in x-pattern, hand tight. Hand wrench only. 52) Air cleaner - install wing nut hand tight. TIME ADDED PENALTIES Unsportsmanlike conduct - actions detrimental to the current and future of this event (by students and or Instructors) will be reviewed and assessed by the engine builder judges with the possibility of team being disqualified.

*penalty minutes are for each occurrence 53) Students using speed wrench where not permitted Will be stopped by judge and permitted to use Proper tool / tools with a 10 minute penalty. 54) Dropping of torque wrench, mishandling, throwing or tossed in / on tray or bench - 5 minutes each occurrence during the timed competition anywhere in competition area. 55) Dropped carburetor - 15 minutes - each occurrence 56) Dropped water pump - 10 minutes - each occurrence 57) Dropped intake - 15 minutes - each occurrence 58) Dropped head - 15 minutes - each occurrence 59) Dropped head gasket - 1 minute - each occurrence 60) Dropped piston - rod assy. - 15 minutes - each occurrence 61) Dropped bearing halves - 2 minutes - each occurrence 62) Dropped rod cap w/bearing - 3 minutes - each occurrence 63) Dropped distributor - 10 minutes - each occurrence 64) Damage to distributor cap - 1 minute – each occurrence 65) Dropped spark plugs - 2 minutes - each occurrence

66) Dropped headers - 15 minutes - each occurrence 67) Dropped lifters - 3 minutes (each lifter) - each occurrence 68) Dropped rocker arms - balls - push rods - 1 minute each - each occurrence 69) Dropped oil pump and drive - 5 minutes each occurrence 70) Dropped oil filter - 3 minutes - each occurrence 71) Dropped air cleaner - 5 minutes each occurrence 72) Dropped valve cover - 5 minutes each occurrence 73) Dropped oil pan - 5 minutes each occurrence 74) No drop penalty for fasteners 75) Removing balancer without puller - 10 minutes - each occurrence 76) Not showing judge torque wrench - 3 minutes each fastener - each occurrence 77) Not two stepping torque - 3 minutes each occurrence 78) Improper removal procedure - 5 minutes each component - each occurrence 79) Improper torque sequence - 15 minutes each component 80) Rotating torque out of spec - 30 minutes each occurrence 81) Stripped threads - 3 minutes each fastener - each occurrence

82) Stripped spark plug holes - 15 minutes each cylinder - each occurrence 83) Missing washer - 1 minute - each fastener 84) Missing head bolt washer - 5 minutes each fastener 85) Loose hand tight fasteners - 1 minute each fastener

86) Distributor out of time 180 degrees - 10 minutes - each occurrence 87) 1 minute penalty if distributor is loose 88) One tooth either advanced or retard - 4 minutes - each occurrence 89) Improper firing order - 3 minutes per wire - each occurrence 90) Damaged timing chain cover - 15 minutes - each occurrence 91) Loading of fastener into socket and not hand starting - 2 minutes - each fastener 92) Removal of multiple rod caps without piston/rod assembly - 15 minutes each occurrence –judge will stop procedure if multiple occurrences arise, but will assess minimum (1) 15 minute penalty 93) Broken rings - 15 minutes each ring - each occurrence 94) Lifters installed in incorrect bores - 1 minute - each occurrence 95) Rocker arms installed incorrectly (i.e. intake on exhaust valve) - 30 seconds for each occurrence and a 3 minute penalty for each one out of adjustment 96) No oiling or lubing of components - 2 minutes each component - each occurrence 97) Language - offending student will be pulled from competition for 5 minutes. Student from table cannot replace. You will be one student down for penalty time - each occurrence

98) Students under engine - not allowed, can reach under from all four sides, but cannot go into safety area. Judge will tap student once and call out to coach. After that - 3 minutes for each occurrence. It is the coach’s job to watch students in safety area. 99) Not showing judge ring clocking - 2 minutes each piston 100) Missing engine component - 3 minutes - each component 101) At the end of reassembly when all students return behind table / workstation judge will end time. 102) Students cannot come back out to work on engine or retrieve tools. 103) Work area must be clean. A time penalty will be 1 minute for each tool or engine component left out and 1 minute for each engine component worked on. 104) If instructor / coach omits or "takes the hit" on a procedure, there will be a minimum of 50 minutes penalty.

105) If an infraction occurs that is not listed, it will be taken under review. 106) All rules and penalties have been reviewed to ensure the event is conducted in a manner that is as fair as possible for all competitors. If a circumstance occurs that has not been covered in the above rules and procedures, all rules and procedures will fall under the term "EIRI" meaning “except in rare instances” - to indicate the likelihood that such a determination may be made. Minimum penalty will be 2 minutes. 107) Unsportsmanlike conduct - actions detrimental to the Current and future of this event (by students and or Instructors) will be reviewed and assessed by executive staff.

Judges will be watching!

FASTENER HEAD SIZES and TORQUE Specs 108) Air cleaner wing nut - hand tight 109) Carburetor nuts 1/2" wrench hand tighten using x-pattern

110) Intake manifold bolts 3/8" 12pt hand tight - see reference 111) Valve cover “t” handles hand tight X pattern 112) Dist. Hold down nut 9/16" 6pt hand tight 113) Header bolts 3/8" 6pt hand tight inside out 114) Balancer / Crank adaptor. Bolts 9/16" 6pt @) 100 inch pounds. 115) Head bolts 1/2" 6pt and One (1) 1/2" 12pt nut @) Two (2) step - 25 foot pounds then 50 foot pounds. 116) Water pump bolts 9/16" 6pt. 25 ft.pt. - x-pattern 117) Timing chain cover 3/8" 6pt.@ 50 inch pounds. See reference (bolt) 118) Balancer bolt --5/8" 6pt. @ 50 foot pounds. 119) Oil pan nuts a) 7/16" 6pt. @75 inch pounds. b) 1/2" 6pt. @ 100 inch pounds. (see reference) 120) Rod nuts 9/16" 6pt. Two (2) steps A) @15 foot pounds. B) @ 30 foot pounds. 121) Oil filter hand tight ONLY 122) Rocker arm nuts 9/16" 6pt. 123) Spark plugs 5/8" 6pt. @ 100 inch pounds. 124) Oil pump nut 5/8" 6 pt. @ 50 foot pounds.

125) Cam bolts 1/2" 6pt. @ 100 inch pounds. 126) Roller lifter spider hold down bolts 1/2" 6 pt. @ 100 inch pounds. 127) Oil filter must use strap wrench for removal. 128) All fasteners that are hand tight are to be tightened with a 6" or 8" wrench. "NO ratchet wrenches." THIS FORMAT IS A GUIDE TO PREVENT MAJOR ASSEMBLIES FROM COMING OFF TOGETHER, (E.G. CARBURETOR AND MANIFOLD). YOU ARE ENCOURAGED TO TRAIN YOUR STUDENTS AS YOU SEE FIT. No removal sequence for the following: oil pan bolts water pump bolts header bolts timing cover bolts carburetor bolts/nuts valve cover bolts

Correct sequence for header to spark plugs: (1) Remove plug wires (2) Remove headers (3) Remove spark plugs. Reverse procedure for assembly. Remember torque specs and sequences for plugs and headers.