Identify engine fuel, oil, coolant, air, and other leaks; determine needed action.

Lesson Planfor

DIT 110-111Introduction to Diesel Engines

Course HS Title: / INTRO TO DIESEL ENGINE / Program:
KCTCS Courses included in HS Title: (Lesson is prepared for course highlighted.)
KCTCS Course No. / KCTCS Course Title
DIT 110 / Introduction To Diesel Engines
Introduction/Context / This lesson will instruct students on how to identify engine fuel, oil, coolant, air, and other leaks, and determine needed action. Knowledge of these techniques, and the skills required to correct problems associated with this task are necessary for a student to learn if they wish to compete for high paying, high skilled jobs in a Diesel/Medium-Heavy Truck repair facility. Students need to be able to perform this task to 100% accuracy. Incorrectly performing this task can lead to engine concerns, safety problems, or create customer satisfaction issues.
Prepared By / School / Date:
Grade Level / No. Students / No.IEP's: / Lesson Length:
Task
Identify causes of engine fuel, oil, coolant, air, and other leaks; determine needed action.
No. / Objective
Given the proper tools and instructions, students will be able to identify engine fuel, oil, coolant, air, and other leaks, determine needed action, and pass a written exam on the task with 100% by the end of the course.

Connections:

Skills Standards:
OH 001
OH 002
OH 003
OD 002
OD 003
OD 005
Common Core Technical Standards:
TD-SYS-2
New Common Core Standards:
RST 11-12.2
RST 11-12 3
N-Q-1

INSTRUCTIONAL MATERIALS/TECHNOLOGY

Teacher Designed Materials and Other Handouts

Instructor can use the content section of this plan to create a handout for the students.

Textbooks and Workbooks

Author / Title/ISBN No. / Edition / Publisher / Pages
Kershaw/Bennett / Today's Technician-Medium/Heavy Duty Truck Diesel Engines / 2001 / Delmar / 177, 203
Norman, Sorinchock, Scharff / Diesel Technology / Seventh / Goodheart/Wilcox / 597

Equipment

Quantity / Item / Source
As Needed / Coolant Pressure Gauge / Various
As Needed / Pressure Gauge/Air / Various

Content/Presentation/Demonstration Outline

Explain to students how to identify leaks in the engine, fuel, oil, coolant, air systems.
Instruct students that the most common cause of engine failure is dirt. Let them know that leaks in the air induction system will draw dirt into the engine. An AIR INDUCTION LEAK on the suction side, no matter how small, can cause an eventual engine failure.
Teach students to test for leakage in the air induction system using a manually regulated compressed air supply and a pressure gauge capable of reading 0-95 psi (0-1 03.4 kPa). Instruct students to block off the air inlet pipe or mask off the outer diameter of the air cleaner inlet with duct tape, then disconnect the air cleaner restriction indicator or tubing at the air cleaner. Next, tell them to install a fitting and connect the indicator or tubing and the pressure test gauge. Instruct them to remove the pipe plug from the intake manifold, connect the manually regulated air supply, and adjust to 5 psi (34.47 kPa). Have students coat the ductwork and tubing connections with a soap solution and watch for bubbles at the joints, and tell them to repair any leakage found.
Instruct students that to find external oil leaks, steam or pressure wash the engine, then load it on a chassis dynamometer or road test it to determine source. Let them know that oil leaks can be caused by external leaks (valve covers, oil pan, seal failure). Also, let students know that high oil consumption (which can be confused with a leak) can be caused by continuous high speed driving, crankcase ventilation problems, valve guide/seal wear, glazed cylinder liners or sleeves, aeration, high oil temperatures, piston ring failure or a piston fault.
Instruct students that Fuel leaks will cause a fuel odor and poor fuel economy Tell students if they suspect a Fuel leak, to check at the tank, the filter, or the fuel lines
Inform students that cooling system leakage is common, and the system should be inspected by the operator daily. Let them know that cold leaks may be caused by contraction of mated components at joints, especially hose clamps. Cold leaks often cease to leak at operating temperatures. Explain that many fleet operators replace all the coolant after a prescribed in-service period regardless of its appearance to avoid the costs incurred in a breakdown.
Instruct students that pressure testing a cooling system will locate most external cooling system leaks. Let them know that a typical cooling system pressure testing kit consists of a hand-actuated pump and gauge assembly calibrated to ±25 psi (170 kPa) plus various adapters for the different types of fill necks and radiator caps. Some are capable of vacuum testing.
Explain that internal leaks can be more difficult to locate. Tell students that when coolant is present in the engine oil, it appears as a milky sludge before settling to the bottom of the oil pan. Let them know that it is the first fluid to exit the oil pan when the drain plug is removed.
When the leak is caused by failure of the wet liner seal, tell students to remove the oil pan, allow the oil to drip for a period, and then pressurize the cooling system using standard hand pump apparatus and place a sheet of cardboard under the engine. Explain that wet liner 0-ring seals may leak either cold or hot and even this method is not certain.
Instruct students that to determine if combustion gases are leaking into the cooling system, remove the piping to the upper radiator tank and thermostat. Next, fill the engine with coolant (water will do), disconnect water pump drive (if possible), and run the engine. Let them know that the appearance of bubbles indicates that combustion gases are leaking into the coolant.
Inform students that the use of cooling system agents that claim to stop leaks should generally be avoided EVEN in a situation that might be described as an emergency. Explain that they may work temporarily, but they have been known to plug thermostats, radiator or heater cores, and oil cooler bundles. Generally, they cause more trouble than they cure.

Applications/Practice

1 / Refer to Content.

Evaluation and feedback Prior to Testing or Lab Work

1 / Objective 1/ Formative assessment / Instructor will observe students as they practice the procedure to assure correct procedure and safety practices are being followed. A checklist should be utilized to chart student progress on the task. Questioning techniques will be utilized as necessary to demonstrate student comprehension / depth of knowledge. 4/ Adaptations and/or accommodations for special needs students will be added if required.

STUDENT ASSESSMENT:(Assess student progress with performance criteria.)

1 / Objective 1/ Summative assessment / written test questions on stated objective / depth of knowledge 4/ adaptation and / or accommodations for special needs students will be added if required.
IMPACT--Reflection/Analysis of Teaching and Learning: (How did students progress in relation to the state objectives? Was the instruction successful? Analyze samples of student work, particularly that which is unsatisfactory, for the purpose of planning further instruction.)
REFINEMENT--Lesson Extension and Follow-up: (To be filled in as the lesson is modified during initial planning and/or during the teaching learning process.)