Engine Compartment Inspection Air Induction and Exhaust Systems

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James Hilary Lawson
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1 Engine Compartment Inspection Air Induction and Exhaust Systems Student/intern information: Name Class Vehicle used for this activity: Year Make Model Odometer VIN Learning Objective/Task Check exhaust system mountings for looseness and damage. Check engine exhaust system for leaks, proper routing, and damaged or missing components. Check air induction system: piping, charge air cooler, hoses, clamps, and mountings; check for air restrictions and leaks. Inspect turbocharger for leaks; check mountings and connections NATEF Reference Number 7-3A1 P-1 7-3A2 P-1 7-3A3 P-1 7-3A4 P-1 Check operation of engine/exhaust brake. 7-3A5 P-1 Service or replace air filter as needed; check and reset air filter restriction indicator. 7-3A6 P 1 Inspect and service crankcase ventilation system. 7-3A7 P NATEF Priority Level Recommended Resource Materials CDX Diesel: Preventive Maintenance and Inspection 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 fuel concern Vehicle manufacturer s workshop manual Manufacturer-specific tools, depending on the concern Vehicle lifting equipment, if applicable 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), wear and use all OSHA-approved 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. Engine Compartment Inspection Air Induction and Exhaust Systems 1

2 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 Verify operator s concern, review past maintenance documents, and record condition on appropriate document. 1. Check the exhaust system mountings for looseness and damage. a. Any signs of looseness or structural damage? 2. Check engine exhaust system for leaks, proper routing, and damaged or missing components. a. Any sign of leaks? If yes: Detail what repairs need to be carried out: b. Check engine exhaust system. Look for faulty routing, damage, or missing components: Does the system meet the manufacturer s specifications? If no: What repairs are necessary to rectify the system? 3. Check the air induction system: piping, charge air cooler, hoses, clamps, and mountings; check for air restrictions and leaks. a. Any signs of structural damage? b. Piping: c. Charged air cooler: d. Air induction hoses: Engine Compartment Inspection Air Induction and Exhaust Systems 2

3 e. Hose clamps and mountings: Manufacturer s torque setting hose clamps: in/lbs Hose clamps tightened to: in/lbs Any clamps extremely loose? If yes: Remove that pipe and check for any signs of dust entry. Any evidence of dust leakage at joint? If yes; what are the recommendation(s)? f. Are the mounting bolts correctly torqued to manufacturer s specifications? Manufacturer s recommended torque setting: ft/lbs Have the mounting bolts been torqued to specifications? Yes: and to ft/lbs No: If no: Why have these mounts not been torqued to specifications? g. Remove air cleaner and check serviceability for element: Clean and reuse: Requires replacing: h. Does air cleaner element housing show signs of dust entry? 4. Discuss the finding(s) with the instructor NATEF Reference Number: 7-3A1 7-3A3 5. Inspect turbocharger for leaks; check mountings and connections. a. Any signs of damage/leakage? b. Are mounting bolts correctly torqued to manufacturer s specifications? Manufacturer s recommended torque setting: ft/lbs Have the mounting bolts been torqued to specifications? Yes: and to ft/lbs No: If no: Why have these mounts not been torqued to specifications? Engine Compartment Inspection Air Induction and Exhaust Systems 3

4 c. Turbocharger connections: Good: Need replacing: Manufacturer s torque setting hose clamps: ft/lbs Hose clamps tightened to: ft/lbs 6. Discuss the finding(s) with the instructor NATEF Reference Number: 7-3A4 7. Service or replace air filter as needed; check and reset air filter restriction indication. Service air cleaner in accordance with manufacturer s recommendations, or replace the air cleaner element in accordance with manufacturer s recommendations: a. Record actions: Serviced: Replaced: b. With reference to appropriate workshop manual, reset air filter restriction indicator. 8. Discuss the finding(s) with the instructor NATEF Reference Number: 7-3A6 9. Check operation of engine/exhaust brake. a. 12-volt system: Power supply should be between 12 14V: Actual voltage: Volts b. 24-volt system: Power supply should be between 24 28V: Actual voltage: Volts c. With reference to appropriate workshop manual, engine braking (example Jacob s engine brake), check volt drop across the following closed switches: Dash switch: VD Clutch switch: VD Throttle switch: VD Engine Compartment Inspection Air Induction and Exhaust Systems 4

5 d. Are these results within the manufacturer s specification? If no: What are your recommendations? e. Check all wiring harnesses for soundness, correct routing, and condition: To final check the operation of the engine compression brake, you may be required to test drive the vehicle on the school grounds or on a hoist, both of which carry severe risks. Before attempting this task, you must seek and have full permission from your supervisor/ instructor and follow all the college/instructor guidelines exactly. Results of test drive (if approved and undertaken): Pass: Fail: If failed: What are your recommendation(s)? 10. Discuss the finding(s) with the instructor NATEF Reference Number: 7-3A5 11. Inspect and service crankcase ventilation system. a. Service the crankcase ventilation system in accordance with manufacturer s recommendations. b. Record actions: Serviced: Replaced: 12. Discuss the finding(s) with the instructor NATEF Reference Number: 7-3A7 Engine Compartment Inspection Air Induction and Exhaust Systems 5

Engine Compartment Inspection Fuel Systems

Engine Compartment Inspection Fuel Systems Student/intern information: Name Class Vehicle used for this activity: Year Make Model Odometer VIN Learning Objective/Task Check fuel tanks, mountings, lines,