Medium Heavy Vehicle Diesel Engine 1
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1 Medium Heavy Vehicle Diesel Engine Student/intern information: Name Class Vehicle used for this activity: Year Make Model Odometer VIN Learning Objective / Task (Fuel Supply System) Check fuel level and condition; determine needed action. Perform fuel supply and return system tests; determine needed action. Inspect fuel tanks, vents, caps, mounts, valves, screens, crossover system, supply and return lines, and fittings; determine needed action. Inspect, clean, and test fuel transfer (lift) pump, pump drives, screens, fuel/water separators/ indicators, filters, heaters, coolers, ECM cooling plates, and mounting hardware; determine needed action. Inspect and test low pressure regulator systems (check valves, pressure regulator valves, and restrictive fittings); determine needed action. Check fuel system for air; determine needed action; prime and bleed fuel system; check primer pump NATEF Reference Number 2007 NATEF Priority Level G1-1 P-1 G1-2 P-1 G1-3 P-1 G1-4 P-1 G1-5 P-1 G1-6 P-1 Recommended Resource Materials CDX Automotive program CDX etextbook Technical service bulletins, shop manuals, and any other information applicable to the specific vehicle or components you are working on Class notes Materials Required Vehicle with possible engine concern Vehicle manufacturer s workshop manual Manufacturer-specific tools depending on the concern Vehicle lifting equipment if applicable For every task in Diesel Engines, the following safety task must be strictly enforced: Comply with personal and environmental safety practices associated with clothing; eye protection; hand protection; proper lifting practices; hand tools; power equipment; proper ventilation; and the handling, storage, and disposal of fuels/chemicals/materials in accordance with federal, state, and local regulations. Some Safety Issues to Consider Diagnosis of this fault may require test driving the vehicle on the school grounds or on a hoist, both of which carry severe risks. Attempt this task only with full permission from your supervisor/instructor and follow all the guidelines exactly. Medium Heavy Vehicle Diesel Engine 1
2 Caution: If you are working in an area where there could be brake dust present (may contain asbestos, which has been determined to cause cancer when inhaled or ingested), ensure you wear and use all OSHAapproved asbestos protective/removal equipment. Lifting equipment such as vehicle jacks and stands, vehicle hoists, and engine hoists are important tools that increase productivity and make the job easier. However, they can also cause severe injury or death if used improperly. Make sure you follow the manufacturer s operation procedures. Also make sure you have your supervisor/instructor s permission to use any particular type of lifting equipment. Comply with personal and environmental safety practices associated with clothing; eye protection; hand tools; power equipment; proper ventilation; and the handling, storage, and disposal of chemicals/materials in accordance with federal, state, and local regulations. Always wear the correct protective eyewear and clothing and use the appropriate safety equipment, as well as fender covers, seat protectors, and floor mat protectors. Make sure you understand and observe all legislative and personal safety procedures when carrying out practical assignments. If you are unsure of what these are, ask your supervisor/instructor. Performance Standard 0 No exposure: No information or practice provided during the program; complete training required 1 Exposure only: General information provided with no practice time; close supervision needed; additional training required 2 Limited practice: Has practiced job during training program; additional training required to develop skill 3 Moderately skilled: Has performed job independently during training program; limited additional training may be required 4 Skilled: Can perform job independently with no additional training Task Check fuel level and condition; determine needed action. G Check the fuel level(s). 2. Draw off a sample of the fuel and have it tested for its condition. 3. Discuss the findings with your instructor NATEF Reference Number: G1-1 Task Perform fuel supply and return system tests; determine needed action. G Reference the manufacturer s workshop manual and perform fuel supply and return system tests; determine needed action. Medium Heavy Vehicle Diesel Engine 2
3 2. Using the manufacturer s recommended tools and gauges, perform fuel supply and return system tests. 2. Check the coolant temperature cold: 3. Discuss the findings with your instructor NATEF Reference Number: G1-2 Task Inspect fuel tanks, vents, caps, mounts, valves, screens, crossover system, supply and return lines, and fittings; determine needed action. G Inspect the fuel tanks. a. Inspect the surface of the fuel tank for any signs of structural damage. i. Any signs of structural damage: Yes: No: 2. Check the fuel tank cap and vents. a. Inspect the fuel tank cap/vents for any signs of damage or blockage. i. Any signs of damage/blockage: Yes: No: 3. Check the fuel tanks mounts. a. Inspect the fuel tank mounts for any signs of structural damage or loose bolts. i. Any signs of structural damage: Yes: No: Medium Heavy Vehicle Diesel Engine 3
4 b. Are fuel tank mounting bolts correctly torqued to the manufacturer s specifications or leaking from any of the structural damaged areas? i. Manufacturer s recommended torque setting: ft-lbs (Nm) ii. Have the mounting bolts been torqued to specifications? Yes: and to ft-lbs (Nm) No: iii. If no, detail why these mounts have not been torqued to specifications: 4. Inspect the fuel tanks valves. a. Inspect the fuel tank valves for any signs of malfunction. i. Any signs of malfunction: Yes: No: 5. Inspect the fuel tank screens. a. Inspect the fuel tank screens for any signs of damage. i. Any signs of damage: Yes: No: 6. Inspect the fuel tank cross-over pipes system. a. Inspect the fuel tank cross-over pipe system for any signs of damage. i. Any signs of damage: Yes: No: 7. Check the fuel supply and return lines and fittings. a. Inspect the fuel supply and return lines and fittings for any signs of damage or deterioration. i. Any signs of damage/deterioration: Yes: No: Medium Heavy Vehicle Diesel Engine 4
5 8. Discuss the findings with your instructor NATEF Reference Number: G1-3 Task Inspect, clean, and test fuel transfer (lift) pump, pump drives, screens, fuel/water separators/indicators, filters, heaters, coolers, ECM cooling plates, and mounting hardware; determine needed action. G Reference the manufacturer s workshop manual and inspect, clean, and test the fuel transfer (lift) pump; determine needed action. 2. Following the instructions in the workshop manual, inspect, clean, and test the fuel transfer (lift) pump. 3. Reference the manufacturer s workshop manual and inspect and clean the pump drives and screens; determine needed action. 4. Following the instructions in the workshop manual, inspect and clean the fuel/water separators/indicators. a. Locate the fuel filter water trap, if fitted. i. Is there water visible in the water trap fuel bowl? Yes: No: ii. If yes, place a drain container under the sediment bowl of the filter and remove. iii. Clean the sediment bowl and dry Medium Heavy Vehicle Diesel Engine 5
6 5. Reference the manufacturer s workshop manual and inspect and clean the filters, heaters, coolers, ECM cooling plates, and mounting hardware. 6. Discuss the findings with your instructor NATEF Reference Number: G1-4 Task Inspect and test low pressure regulator systems (check valves, pressure regulator valves, and restrictive fittings); determine needed action. G Reference the manufacturer s workshop manual and inspect and test the low pressure regulator systems (check valves, pressure regulator valves, and restrictive fittings). a. Use the manufacturer s specified tooling and gauges. b. Carry out the inspection and testing. i. Meets the manufacturer s specifications: Yes: No: ii. If no, list your recommendations for any rectifications: 2. Discuss the findings with your instructor NATEF Reference Number: G1-5 Task Check fuel system for air; determine needed action; prime and bleed fuel system; check primer pump. G Reference the manufacturer s workshop manual and check the fuel system for air. Medium Heavy Vehicle Diesel Engine 6
7 2. Reference the manufacturer s workshop manual and prime and bleed the fuel system; check the primer pump. 3. Discuss the findings with your instructor NATEF Reference Number: G1-6 Medium Heavy Vehicle Diesel Engine 7
Medium Heavy Vehicle Diesel Engine 1
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