Inspect, Clean, and Test Charge Air Cooler Assemblies; Replace As Needed
Inspect, clean, and test charge air cooler assemblies; replace as needed.
Lesson Plan for
DIT 112 Diesel Engines
Course HS Title: / Diesel Engines / Program:KCTCS Courses included in HS Title: (Lesson is prepared for course highlighted.)
KCTCS Course No. / KCTCS Course Title
DIT 112 / Diesel Engines
Introduction/Context / This lesson will instruct the student on how to inspect, clean, and test charge air cooler assemblies, and replace as needed. Knowledge of these techniques and the skills required to correct problems associated with this task are necessary for a student to acquire if they wish to compete for high paying, high skilled jobs in a Diesel Repair Facility. Entry level technicians need to be able to perform this task to 100% accuracy. Incorrectly performing this task can lead to an automobile accident or create customer satisfaction issues.
Prepared By / School / Date:
Grade Level / No. Students / No.IEP's: / Lesson Length:
Task
Inspect, clean, and test charge air cooler assemblies; replace as needed.
Objective
Given the proper tools and instruction, the student will be able to inspect, clean, and test charge air cooler assemblies, replace as needed, and pass a written test covering the task with 100% accuracy.
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
Textbooks and Workbooks
Various / Diesel Engines ASE Test Prep / 2007 / Delmar / 47-48
Equipment
Content/Presentation/Demonstration Outline
Instruct students that aftercoolers usually require less removal time and can be inspected visually while still in the vehicle. Tell students to wash fins with low-pressure water and straighten as necessary. Have them inspect for missing or loose fins, dented or cinched tubes, corrosion, or holes in tubes. Let them know that leaks can be detected by running the engine, spraying the aftercooler tubes with soap and water, and watching for bubbles.
Teach students that an intercooler cools the pressurized air using liquid coolant in the opposite way the radiator works. Explain that heated air is passed through small tubes inside a chamber, usually aluminum, through which coolant is circulated. Heat from the air is transferred to the tubes and on to the coolant, which is cooled by the radiator.
Inform students that intercoolers are more difficult to inspect, but typically, the indicator is engine performance. Tell them that If the engine has been shut down for a while, there may be traces of water in the oil or the engine may produce a white smoke when running. The turbocharger may have signs of liquid leakage from its compressor outlet or corrosion on the fins. Explain that this would also result in unexplained loss of coolant in the radiator while the engine is still cold.
Tell them that often internal leaking of the intercooler can be misdiagnosed as a cracked head or blown head gasket. Let them know that one common problem with intercoolers is airlocks. Explain that when maintenance is performed on the engine resulting in refilling, the coolant air must be bled from the intercooler coolant chamber. Inform students that failure to do so could reduce the effectiveness of the cooler and cause overheating due to steam pressure build-up.
Applications/Practice
Evaluation and feedback Prior to Testing or Lab Work
STUDENT ASSESSMENT:(Assess student progress with performance criteria.)
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.)