Medium Heavy Vehicle Diesel Engine 1

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Winifred Miller
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Medium Heavy Vehicle Diesel Engine Student/intern information: Name Class Vehicle used for this activity: Year Make Model Odometer VIN Learning Objective / Task (Air Induction and Exhaust Systems)

Inspect exhaust manifold, piping, mufflers, and mounting hardware; repair or replace as needed.

Inspect and test exhaust gas recirculation (EGR) system including EGR valve, cooler, piping, filter, electronic sensors, controls, and wiring; determine needed action.

1 Medium Heavy Vehicle Diesel Engine Student/intern information: Name Class Vehicle used for this activity: Year Make Model Odometer VIN Learning Objective / Task (Air Induction and Exhaust Systems) Inspect intake manifold, gaskets, and connections; replace as needed. Inspect, clean, and test charge air cooler assemblies; inspect aftercooler assemblies; replace as needed. Inspect exhaust manifold, piping, mufflers, and mounting hardware; repair or replace as needed. Inspect exhaust after treatment devices; determine necessary action Inspect and test preheater/inlet air heater, or glow plug system and controls; perform needed action. Inspect and test exhaust gas recirculation (EGR) system including EGR valve, cooler, piping, filter, electronic sensors, controls, and wiring; determine needed action NATEF Reference Number 2007 NATEF Priority Level F1-8 P-3 F1-29 P-2 F1-10 P-2 F1-11 P-3 F1-12 P-2 F1-13 P-3 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. 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. Medium Heavy Vehicle Diesel Engine 1

2 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 Inspect intake manifold, gaskets, and connections; replace as needed. F Reference the manufacturer s workshop and inspect the intake manifold, gaskets, and connections. b. If no, list your recommendations for any rectifications: 2. Discuss the findings with your instructor NATEF Reference Number: F1-8 TASk Inspect, clean, and test charge air cooler assemblies; inspect aftercooler assemblies; replace as needed. F Reference the manufacturer s workshop and inspect, clean, and test charge the air cooler assemblies. 2. Clean the air cooler assemblies. 3. Inspect the air cooler assemblies. 4. Test charge the air cooler assemblies. Medium Heavy Vehicle Diesel Engine 2

3 b. If no, list your recommendations for any rectifications: 5. If directed by your instructor, replace the components as necessary. 6. Discuss the findings with your instructor NATEF Reference Number: F1-9 TASk Inspect exhaust manifold, piping, mufflers, and mounting hardware; repair or replace as needed. F Reference the manufacturer s workshop and inspect the exhaust manifold, piping, mufflers, and mounting hardware. a. Inspect the exhaust manifold. b. Inspect the exhaust piping. c. Inspect the muffler. d. Inspect the exhaust pipe mounting hardware. 2. Overall assessment b. If no, list your recommendations for any rectifications: 3. If directed by your instructor, follow workshop manual instructions and repair or replace the components as needed. Medium Heavy Vehicle Diesel Engine 3

4 4. Discuss the findings with your instructor NATEF Reference Number: F Discuss the findings with your instructor. TASk Inspect exhaust after treatment devices; determine necessary action. F Identify the type of treatment device fitted to your vehicle: 2. Reference the manufacturer s workshop and inspect the exhaust after treatment devices. a. Carry out a visual inspection of the treatment device. b. If the treatment device is a diesel particulate filter, attach the diagnostic coder reader to the vehicle. c. Are there any codes present or stored in the reader? i. If yes, list the codes: d. Carry out a forced re-generation of the particulate filter. 3. If your vehicle is fitted with another type of exhaust treatment device, name the device: 4. Briefly describe the testing procedure for this unit as outlined in the appropriate workshop manual: 5. As outlined above, carry out a visual inspection of the treatment device. a. Require replacement: Yes: No: b. If yes, list your recommendations for any rectifications: Medium Heavy Vehicle Diesel Engine 4

5 6. Discuss the findings with your instructor NATEF Reference Number: F1-11 TASk Inspect and test preheater/inlet air heater, or glow plug system and controls; perform needed action. F Identify the type of air induction system heating device fitted to your vehicle: 2. Reference the manufacturer s workshop and inspect and test the preheater/inlet air heater. a. Carry out a visual inspection of the heating device. b. Carry out a visual inspection of the glow plug system. ii. If yes, list your recommendations for any rectifications: 3. Discuss the findings with your instructor NATEF Reference Number: F1-12 TASk Inspect and test exhaust gas recirculation (EGR) system including EGR valve, cooler, piping, filter, electronic sensors, controls, and wiring; determine needed action. F Reference the manufacturer s workshop and inspect and test the exhaust gas recirculation (EGR) system including the EGR valve, cooler, piping, filter, electronic sensors, controls, and wiring. a. Inspect and test the exhaust gas recirculation (EGR) system including the EGR valve. b. Inspect and test the cooler and piping. c. Inspect and test the filter. Medium Heavy Vehicle Diesel Engine 5

6 d. Inspect and test the electronic sensors. e. Inspect and test the controls and wiring. 2. Overall assessment b. If no, list your recommendations for any rectifications: 3. Discuss the findings with your instructor NATEF Reference Number: F1-13 Medium Heavy Vehicle Diesel Engine 6

Medium Heavy Vehicle Diesel Engine 1

Medium Heavy Vehicle Diesel Engine Student/intern information: Name Class Vehicle used for this activity: Year Make Model Odometer VIN Learning Objective / Task (Lubrication Systems) Test engine oil pressure