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| Line 62: |
Line 62: |
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| − | == '''GATE 1''' == | + | == [[GATE 1]] == |
| | | | |
| − | === '''Dissection Plan''' ===
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| − | ----
| + | == [[GATE 2]] == |
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| − |
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| − | Given several factors, we decided that it would be most effective to start the dissection process as soon as possible and will have our first session the following Wednesday. Given the size and complexity of the product, we plan on completing the dissection in two parts over two weeks in the two lab hours on Wednesdays. This gives us two extra lab hours to complete the dissection in order to make up in case of any delays leading up to the second gate.
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| − |
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| − | Given that our Technical Experts have had prior experience with car engines and a strong knowledge of tools and hardware, they were able to write up an accurate list of tools required for the disassembly. They are as follows:
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| − |
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| − | * Socket Wrench Set with Sockets, Deep Sockets and Wrench Extensions.
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| − |
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| − | * Allen Keys.
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| − |
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| − | * Pulley Puller.
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| − |
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| − | * Valve Spring Compressor.
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| − |
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| − |
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| − | === '''The Product: Initial Product Assessment''' ===
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| − |
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| − |
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| − | ----
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| − |
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| − | '''Uses:''' The product that was given to our group for reverse engineering was a GM Vortec 4300 V6 Car Engine. The intended use of this model specifically is to drive cars although other types of internal combustion engines can be used for many other applications in industry and other vehicles. The product can be used for either home or professional use and its function is to convert the chemical energy from the fuel to mechanical energy that is used to drive the car.
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| − |
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| − |
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| − | '''Method of operation:''' The product works by igniting fuel and pressurized gas inside a chamber which then causes the combustible substances to push against the moving parts of the engine. Specifically, the fuel injectors allow a mixture of air and gasoline to enter the cylinder. The piston inside the cylinder then compresses the mixture which is then ignited by the spark plug causing the piston to shoot back out. The pistons move the camshaft which in turn drives the car. The energies used are purely chemical (i.e. contained in the air and gasoline) and are then converted into Heat and Mechanical Energy. While the intent is only to produce Mechanical Energy, Heat is a by-product of the inherent inefficiency. As explained above the operation of the engine allows it to convert Chemical Energy to Mechanical Energy and Heat (which is discharged through the exhaust and the surroundings of the engine itself). The product itself is not currently functioning, thus making it difficult to assess any of its problems.
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| − |
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| − |
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| − | '''Components:''' The model is a GM V6 engine with several components. These are:
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| − |
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| − | * Camshaft
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| − | * Crank
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| − |
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| − | * A timing chain
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| − |
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| − | * 2 Heads/ Valve covers
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| − |
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| − | * 6 Rods
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| − |
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| − | * 6 Pistons
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| − |
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| − | * 12 Lifters
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| − |
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| − | * 12 Rocker Arms
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| − |
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| − | * 12 Pushrods
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| − |
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| − | * 12 Valve Springs
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| − |
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| − | * Upper and Lower Air intakes
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| − |
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| − | * Oil Pump and Oil Pan
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| − |
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| − | * Throttle Body
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| − |
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| − |
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| − | '''Complexity:''' Looking at each of these individual parts, they are not in themselves complex, but on a whole, the engine can be said to be around a 5 on a scale of 10. The reason for this is that we have defined complexity as a whole on the basis of moving parts and the number of components. In order to judge complexity, we only compared it to other car engines and not to other larger engines used for other applications. For a better idea, the engine in a Lamborghini (which has 4 overhead cams, 12 cylinders and 4 valves per cylinder) would be placed at 10, whereas a carbureted 4-cylinder configuration (without multi-port fuel injection) would be placed at a 1.
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| − |
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| − |
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| − | '''Materials Analysis:''' The Materials used in the product are primarily Cast Iron, Cast Aluminum and Stainless Steel. Other materials include rubber for the timing chain and plastic for the covers on the Valve and Cylinder heads. Given our group’s prior knowledge on car engines, we estimate that there are no other significant materials in the engine.
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| − |
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| − |
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| − | '''End User Satisfaction:''' When comparing the product to other equivalents V6 motors of the mid 1990’s, the Vortec outclassed other engine models due to its high fuel efficiency and its sizeable 3.8L power. Thus, we can say that end users would be quite happy with the product as a whole. Given that it is in itself a component of a car and being used indirectly by the end user, we cannot comment on its ergonomics and its ease-of-use. The regular maintenance that the end user performs would be to change the oil every 3000 miles. This does not reflect the maintenance required on a car however, just the engine itself. Anything beyond the said oil change would require professional knowledge from a certified technician.
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| − |
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| − |
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| − | '''Alternatives to the product:''' When trying to find other alternatives to the product, we cannot limit the criteria to the engine alone as such information would not be useful. Factors such as cost would depend on specific cases depending on any modifications to the engine itself. Therefore, we can try and compare the alternatives from a user’s point of view i.e. by comparing the cars that incorporated the Vortec 4300 and comparing them to other models in the same power class of these cars.
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| − |
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| − | Various models (Chevy Astro Van, GMC Safari, GMC Jimmy, Chevy Blazer, Oldsmobile Bravada, etc) used the Vortec 4300. All of these vehicles were in the price range of $22,000 and $25,000. The alternatives were:
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| − |
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| − | * The Ford Explorer: $22,000
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| − |
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| − | * The Toyota 4runner: $25,000
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| − |
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| − | * The Mitsubishi Montero:$26,000
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| − |
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| − | * The Jeep Cherokee:$23,000
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| − |
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| − | * And the Nissan Pathfinder:$30,000
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| − |
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| − | As mentioned earlier, the Vortec 4300 outclasses these models in terms of fuel efficiency and power so it was also in comparison value for money to the end user. However, despite having a track record of very few reliability issues the Nissan Pathfinder has even less Reliability issues
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| − |
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| − |
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| − | ----
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| − | == '''GATE 2''' ==
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| − |
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| − |
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| − |
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| − | === '''Causes for corrective action''' ===
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| − |
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| − | ----
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| − |
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| − |
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| − | Overall, all of our goals were accomplished in good time. Individually, all of our members were able to contribute constructively and in a timely manner. Since the dissection required coordination with the other team (Group 18), we agreed on a Wednesday meeting time and was able to complete the dissection by the 26th. Problems arose as several members were ill but we were able to keep in contact and complete the dissection. Regrettably, we were not present for the last dissection session that took place on Monday however the steps have been included in our report nonetheless.
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| − |
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| − |
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| − | === '''Difficulty Key to Disassembly Process ''' ===
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| − |
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| − | ----
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| − |
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| − | Difficulty of the described step is expressed on a scale of 5 and can be expressed as:
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| − |
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| − | * '''Level 1'''
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| − | :* Requires small and/or simple tools (e.g. Screwdriver, Socket Wrench).
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| − | :* Requires minimal use of force.
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| − | :* Removed parts are small with few fasteners (e.g. Bolts).
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| − | :* Requires no more than one person to complete.
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| − |
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| − |
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| − | * '''Level 2'''
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| − | :* Requires small and/or simple tools.
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| − | :* Requires minimal use of force.
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| − | :* Removed parts are small or delicate usually with a numbers of fasteners.
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| − | :* Requires one person but also close attention.
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| − |
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| − |
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| − | * '''Level 3'''
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| − | :* May require slightly larger tools (e.g. Hammer/Mallet).
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| − | :* May require use of light force.
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| − | :* Removed parts may be complex but large and need attention to prevent damage.
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| − | :* Significant number of fasteners that require attention.
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| − | :* May require 2 individuals working side by side.
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| − |
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| − |
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| − | * '''Level 4'''
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| − | :* Requires use of larger and possibly specialized tools (e.g. Valve Spring Compressors).
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| − | :* Requires considerable use of force.
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| − | :* Parts removed are numerous and/or large and heavy making them difficult to move and store.
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| − | :* Requires 2 or 3 individuals working simultaneously.
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| − |
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| − |
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| − | * '''Level 5'''
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| − | :* Requires largest and specialized tools that require the use of force (e.g. Pulley Puller).
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| − | :* Requires most use of force (possibly involving more than one individual).
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| − | :* Removed parts are very large, with numerous fasteners and/or delicate parts.
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| − | :* Removed parts are heavy and hard to move.
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| − | :* Requires 3 people working simultaneously to complete the task or tasks.
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| − |
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| − | {| class="wikitable sortable" style="margin: 1em auto 1em auto" border="1"
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| − |
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| − | |-
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| − | ! Step No !! Instructions !! Difficulty !! Components Removed !! Picture
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| − | |-
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| − | |align="center"| 1
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| − | |align="center"|Remove throttle body bolts.
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| − | Remove throttle body.
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| − | |align="center"|Level 1
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| − | |align="center"|Throttle Body Bolts Throttle Body (1x)
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| − | ||[[Image:34first.jpg|center|thumb|100px]]
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| − | |-
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| − | |align="center"| 2
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| − | |align="center"|Remove upper intake manifold bolts.
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| − | Remove upper intake manifold.
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| − | |align="center"|Level 1
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| − | |align="center"|Upper Intake Manifold Bolts Upper Intake Manifold (1x)
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| − | ||[[Image:34second.png|center|thumb|100px]]
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| − | |-
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| − | |align="center"| 3
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| − | |align="center"|Remove MAF sensor bolts.
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| − | Remove MAF sensor.
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| − | |align="center"|Level 2
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| − | |align="center"|MAF Sensor Bolts
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| − | MAF Sensor (1x)
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| − | ||[[Image:34third.png|center|thumb|100px]]
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| − | |-
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| − | |align="center"| 4
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| − | |align="center"|Remove distributor bolts.
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| − | Remove distributor.
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| − | |align="center"|Level 2
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| − | |align="center"|Distributor Bolts
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| − | Distributor (1x)
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| − | ||[[Image:34fourth.png|center|thumb|100px]]
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| − | |-
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| − | |align="center"| 5
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| − | |align="center"|Remove intake manifold bolts.
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| − | Remove intake manifold.
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| − | |align="center"|Level 3
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| − | |align="center"|Intake Manifold Bolts
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| − | Intake Manifold(1x)
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| − | ||[[Image:34fifth.png|center|thumb|100px]]
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| − | |-
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| − | |align="center"| 6
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| − | |align="center"|Remove valve cover bolts.
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| − | Remove valve cover.
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| − | |align="center"|Level 2
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| − | |align="center"|Valve Cover Bolts
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| − | Valve Cover (1x)
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| − | ||[[Image:34sixth.png|center|thumb|100px]]
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| − | |-
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| − |
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| − | |align="center"| 7
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| − | |align="center"|Remove exhaust manifold bolts.
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| − | Remove exhaust manifold.
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| − | |align="center"|Level 2
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| − | |align="center"|Exhaust Manifold Bolts
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| − | Exhaust Manifold (2x)
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| − | ||[[Image:34seventh.png|center|thumb|100px]]
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| − | |-
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| − |
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| − | |align="center"| 8
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| − | |align="center"|Remove cylinder head bolts.
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| − |
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| − | Remove cylinder heads (x2).
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| − |
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| − | Steps for Cylinder Head Disassembly:
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| − | Remove rocker arm bolts,
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| − |
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| − | Remove rocker arms (x12)
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| − |
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| − | Remove pushrods (x12)
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| − |
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| − | Compress valve springs with spring compressor and remove retainers (x12).
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| − |
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| − | Release spring compressor and remove springs (x12)
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| − | and valves (x12).
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| − | |align="center"|Level 3
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| − | |align="center"|Cylinder Head bolts
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| − |
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| − | Cylinder Heads (2x).
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| − |
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| − | Rocker Arm Bolts.
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| − |
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| − | Rocker Arms (12x).
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| − |
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| − | Pushrods (12x).
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| − |
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| − | Retainers (12x).
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| − |
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| − | Springs (12x).
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| − |
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| − | Valves (12x).
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| − | ||[[Image:34-8.png|center|thumb|100px]]
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| − | [[Image:34-8A.png|center|thumb|100px]]
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| − | [[Image:34-8B.png|center|thumb|100px]]
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| − | |-
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| − |
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| − | |align="center"| 9
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| − | |align="center"|Remove lifter cover bolts
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| − | Remove lifter covers (x2)
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| − | |align="center"|Level 1
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| − | |align="center"|Lifter Cover Bolts
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| − | Lifter Covers (2x)
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| − | ||[[Image:34nine.png|center|thumb|100px]]
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| − | |-
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| − |
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| − | |align="center"| 10
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| − | |align="center"|Remove lifters (x12)
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| − | |align="center"|Level 1
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| − | |align="center"|Lifters (12x)
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| − | ||[[Image:34ten.png|center|thumb|100px]]
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| − | |-
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| − |
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| − | |align="center"| 11
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| − | |align="center"|Remove water pump bolts.
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| − | Remove water pump.
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| − | |align="center"|Level 3
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| − | |align="center"|Water Pump Bolts
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| − | Water Pump (1x)
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| − | ||[[Image:34eleven.png|center|thumb|100px]]
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| − | |-
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| − |
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| − | |align="center"| 12
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| − | |align="center"|Remove oil pan bolts,
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| − | Remove oil pan
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| − | |align="center"|Level 1
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| − | |align="center"|Oil Pan Bolts
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| − | Oil Pan (1x)
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| − | ||[[Image:34twelve.png|center|thumb|100px]]
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| − | |-
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| − |
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| − | |align="center"| 13
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| − | |align="center"|Remove oil transfer bolts.
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| − | Remove oil transfer.
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| − | |align="center"|Level 2
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| − | |align="center"|Oil Transfer Bolts
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| − | Oil Transfer (1x)
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| − | ||[[Image:34-13.png|center|thumb|100px]]
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| − | |-
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| − |
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| − | |align="center"| 14
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| − | |align="center"|Remove oil pickup/pump bolts,
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| − |
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| − | Remove oil pickup/pump.
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| − |
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| − | (the pickup and pump are a single assembly)
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| − | |align="center"|Level 3
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| − | |align="center"|Oil Pickup Bolts
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| − | Oil Pickup and Pump Assembly (1x)
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| − | ||[[Image:34-14.png|center|thumb|100px]]
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| − | |-
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| − |
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| − | |align="center"| 15
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| − | |align="center"|Remove connecting rod nuts from connecting rod bolts.
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| − |
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| − | Remove back of connecting rod (x6).
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| − |
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| − | Remove piston (x6).
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| − |
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| − | Remove piston rings from piston (x12).
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| − | |align="center"|Level 4
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| − | |align="center"|Connecting rod nuts and bolts.
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| − |
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| − | Connecting Rod Backings (6x).
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| − |
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| − | Pistons (6x).
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| − |
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| − | Piston Rings (12x).
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| − | ||[[Image:34-15.png|center|thumb|100px]]
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| − | |-
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| − |
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| − | |align="center"| 16
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| − | |align="center"|Remove outer crank pulley bolts.
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| − |
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| − | Remove outer crank pulley.
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| − |
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| − | Remove crank pulley with a pulley puller tool.
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| − |
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| − | Remove timing cover bolts.
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| − |
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| − | Remove timing cover.
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| − |
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| − | Remove timing gear bolts.
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| − |
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| − | Remove timing gear and timing chain.
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| − |
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| − | Remove camshaft cover bolts.
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| − |
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| − | Remove camshaft.
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| − |
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| − | Remove crank retainer bolts.
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| − |
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| − | Remove crank retainers (x4).
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| − |
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| − | Remove crank.
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| − | |align="center"|Level 5
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| − | |align="center"|Crank Pulley Bolts
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| − | Outer Crank Pulley (1x).
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| − |
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| − | Timing Cover Bolts.
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| − |
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| − | Timing Cover (1x).
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| − |
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| − | Timing Gear bolts.
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| − |
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| − | Timing Gear (1x).
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| − |
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| − | Timing Belt (1x).
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| − |
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| − | Camshaft Cover Bolts.
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| − |
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| − | Camshaft (1x).
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| − |
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| − | Crank Retainer Bolts.
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| − |
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| − | Crank Retainers (4x).
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| − |
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| − | Crankshaft (1x).
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| − | ||[[Image:34-16A.png|center|thumb|100px]]
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| − | [[Image:34-16B.png|center|thumb|100px]]
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| − | [[Image:34-16C.png|center|thumb|100px]]
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| − | |-
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| − | |}
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| − |
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| − | ----
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| | | | |
| | ==[[GATE 3]]== | | ==[[GATE 3]]== |
| | | | |
| − |
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| − | ----
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| | | | |
| | ==[[GATE 4: CRITICAL PROJECT REVIEW]]== | | ==[[GATE 4: CRITICAL PROJECT REVIEW]]== |
Throughout the project the single biggest tool used for communication by Group 34 was the online message board. Keith Billanti established an account at
. The group members then created accounts and kept in touch effectively with the use of this message board. Most of the data for final submission was discussed and transferred from one member to next with the use of this message board. The image on the right shows a screen-cap of the board.
