Engine Compartment Inspection Fuel Systems

Transcription

1 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, caps, and vents and inspect throttle linkages and return springs NATEF Reference Number 7-2A1-1 and 7-2A1-2 P-1 Drain water from fuel system. 7-2A2 P-1 Water separator/fuel heater; replace fuel filter(s); prime and bleed fuel system. 7-2A3 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 Fuel 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 fuel tanks. a. Any signs of structural damage? b. Is there fuel leaking from any of the structural damaged areas? If yes: Detail what repairs need to be carried out: 2. Check fuel tanks mounts. a. Any signs of structural damage? b. Are fuel tank mounting bolts correctly torqued to the manufacturer s specifications? Is there leaking from any of the structural damaged areas? Manufacturer s recommended torque setting: ft/lbs Have the mounting bolts been torqued to specifications? Yes: and to ft/lbs No: If no: Detail why these mounts have not been torqued to specifications. 3. Check fuel lines. a. Any signs of damage/deterioration? If yes: List the damaged/deteriorated fuel line location: Engine Compartment Inspection Fuel Systems 2

3 4. Check fuel tank cap and vents. a. Any signs of damage/blockage? If yes: List steps to rectify: 5. Discuss the finding(s) with the instructor NATEF Reference Number: 7-2A1-1 and 7-2A1-2 TASK Continued Verify operator s concern, review past maintenance documents, and record condition on appropriate document. 6. Inspect throttle linkages and return springs (mechanical linkage models). Refer to manufacturer s workshop manual for layout and specifications for throttle linkage and return spring. a. Inspect the linkage for security, freedom in movement, and any potential damage. Any signs of potential damage? b. Is the linkage free to move without binding or jamming and the return springs in workable condition? If no: Detail what repairs need to be carried out: 7. Inspect throttle linkages, wiring harness, and return springs (drive-by-wire [electronic linkage] models). Refer to manufacturer s workshop manual for layout and specifications for throttle linkage, wiring harness, and return spring. a. Inspect the linkage for security, freedom in movement, and any potential damage: Any signs of potential damage? b. Is the linkage free to move without binding or jamming and are the return springs in workable condition? If no: Detail what repairs need to be carried out: Engine Compartment Inspection Fuel Systems 3

4 c. Referencing the appropriate workshop manual, carry out the following checks on the accelerator pedal potentiometer: Record the voltage reading at: Idle position: Volts Full throttle: Volts Are they within the manufacturer s specifications? If no: Provide your recommendation(s): d. Referencing the appropriate workshop manual, carry out the following checks on the fuel pump potentiometer: Record the voltage reading at: Idle position: Volts Full throttle: Volts Are they within the manufacturer s specifications? If no: Provide your recommendation(s): 8. Discuss the finding(s) with the instructor NATEF Reference Number: 7-2A1-1 and 7-2A1-2 TASK Continued Verify operator s concern, review past maintenance documents, and record condition on appropriate document. 9. Drain water from fuel system. a. Inspect the fuel tank for any signs of water contamination: Any signs of water contamination? If yes: Place a suitable drain capturing device under the fuel tank drain plug and drain off any water sediment contained within the fuel tank. 10. Inspect water separator/fuel heater; replace fuel filter(s); prime and bleed fuel system. a. Locate the fuel filter water trap, if fitted: Is there water visible in the water trap fuel bowl? If yes: Place a drain container under the sediment bowl of the filter and remove. Clean and dry the sediment bowl. Engine Compartment Inspection Fuel Systems 4

5 b. If a fuel heater is installed, inspect the wiring harness for any signs of damage or loose connections: Any signs of damage or loose connections? c. Referencing the manufacturer s specifications, locate the specification for the fuel heater: Manufacturer s recommended voltage: Volts Manufacturer s recommended wattage: Watts d. Measure and record fuel heater voltage with ignition off and ignition on: Ignition OFF voltage: Volts Ignition ON voltage: Volts If not within specifications: What are your recommendation(s)? e. As directed by your instructor, replace fuel filter(s). f. Replace water separation bowl on appropriate fuel filter: g. Ensure the sealing gasket is in good condition. h. Ensure the bowl is tightened to the manufacturer s recommendation. i. Prime the replacement filters and check for any signs of leaking. j. Bleed the fuel system to expel any air from the system. k. If directed by your instructor, start the engine and check for any signs of fuel leakage. l. Shut the engine down and undertake a final inspection of the fuel system. 11. Discuss the finding(s) with the instructor NATEF Reference Number: 7-2A2 7-2A3 Engine Compartment Inspection Fuel Systems 5