Automotive Machining
and Engine Repair

The engine rebuilding and machining content of this text bridges the gap that typically exists between textbook coverage and service manuals used by technicians. Information in this book is presented from the view of a machine shop serving automotive technicians. Emphasis is placed upon “how to” information and procedures, however appropriate attention is given to theory – especially in difficult to understand areas. An ideal book to help students prepare for certification examinations in both engine repair and automotive machining areas.

Click on the cover to view a PDF of the table of contents.

AERA currently uses this book in conjunction with its Engine Machinist Online Training and Certification program. For more information about this program, go to

Available exclusively from AERA. To purchase the most current edition, visit the AERA online store.


Information included in the book

18 Chapters, over 450 pages

1) Shop Safety and Hazardous Waste Management, 2) Fundamentals of Machining, 3) Measuring Tools, 4) Fasteners, 5) Engine Theory, 6) Engine Diagnosis, 7) Engine Disassembly, 8) Cleaning Engine Parts, 9) Inspecting Valve Train Components, 10) Inspecting Engine Block Components, 11) Crack Detection and Repair, 12) Reconditioning Valve Train Components, 13) Reconditioning Engine Block Components, 14) Resurfacing Cylinder Heads and Blocks, 15) Engine Balancing, 16) Engine Assembly, 17) Preparing Performance Engines, 18) Engine Installation.

Review Questions and Key

Review questions are featured at the end of each chapter to ensure the material covered is understood. Answer key is included after the last chapter. A list of topics for further study are also included.

Appendix Reference Tables

Torque Recommendations, Pipe Plug Torque Recommendations, Torque Conversions, Decimal Equivalents, Tap Drill Sizes, Helicoil Drill Sizes, English-Metric and Metric-English Conversions, Conversion Factors.

About the Author

Gary Lewis began his interest in all things mechanical at an early age repairing his old cars and fabricating farm equipment. He gained formal training in an apprenticeship machining aircraft engine parts. After accumulating a few more years experience, he returned to college and earned Baccalaureate and Master's degrees from California State University San Jose.

While in his senior year at CSU San Jose, Mr. Lewis accepted a part time teaching assignemt in machine tools at De Anza College in Cupertino, California. In 1969, he was hired full time and began building nationally recognized programs in Machine Tool and Automotive Technologies at De Anza College. He has also consulted in developing programs at other colleges and for private industry.

In 1972, following his love of engines, Mr. Lewis began developing an Automotive Machining program at De Anza. With this assignment, he learned that he had to develop his own teaching materials with an appropriate mix of machining and engine technologies. Other materials at the time were either entirely academic or limited to parts replacement and assembly. Slowly, the materials developed for instruction in this program accumulated to become the current textbook.

In 1985, he gained recognition for presenting to the Automotive Engine Rebuilders Association process technology that he developed for stress relieving and straightening aluminum cylinder heads. This process had been developed over time beginning in the mid-70s coinciding with huge increases in import overhead cam engines. Since the presentation in 1985, the process has become a standard for the industry.

Available exclusively from AERA.
To purchase the most current edition of this book, visit the AERA online store.

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