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DSL 203 Diesel Engine Repair

This course introduces various diesel engines and related components, their operations and service and repair procedures. Laboratory activities include hands-on exercises on trainer/dead engines relating to the operation, servicing, and repair of the engines as well as related engine systems: cooling, lubrication, exhaust, and related systems. Students also perform live engine evaluation and diagnosis.

Credits

4

Prerequisite

Prerequisites: AUT 102 and AUT 103 and AUT 104

See Course Syllabus

Course Number and Title:

DSL 203 Diesel Engine Repair

Campus Location

  • Georgetown

Prerequisites

Prerequisites: AUT 102 and AUT 103 and AUT 104

Course Credits and Hours

4 credit(s)

2 lecture hours/week

6 lab hours/week

Course Description

This course introduces various diesel engines and related components, their operations and service and repair procedures. Laboratory activities include hands-on exercises on trainer/dead engines relating to the operation, servicing, and repair of the engines as well as related engine systems: cooling, lubrication, exhaust, and related systems. Students also perform live engine evaluation and diagnosis.

Additional Materials

Safety glasses

Required Text(s)

Obtain current textbook information by viewing the campus bookstore - https://www.dtcc.edu/bookstores online or visit a campus bookstore. Check your course schedule for the course number and section.

Disclaimer

None

Core Course Performance Objectives (CCPOs)

  1. Explain various diesel engine designs, and explain its operation and service. (CCC 1, 2, 4, 5, 6; PGC 1, 2, 3, 4, 5)
  2. Analyze various diesel cylinder head and valve trains, and explain its operation and perform proper test procedures. (CCC 1, 2, 3, 4, 5, 6; PGC 1, 2, 3, 4, 5)
  3. Demonstrate proper operation, and service of various diesel engine blocks. (CCC 1, 2, 3, 4, 5, 6; PGC 1, 2, 3, 4, 5)
  4. Demonstrate proper operation, and service of basic diesel lubrication system. (CCC 1, 2, 3, 4, 5, 6; PGC 1, 2, 3, 4, 5)
  5. Analyze diesel cooling systems, and perform proper testing procedures. (CCC 1, 2, 3, 4, 5, 6; PGC 1, 2, 3, 4, 5)
  6. Describe air induction and exhaust systems, and explain its operation and service. (CCC 1, 2, 3, 4, 5, 6; PGC 1, 2, 3, 4, 5)
  7. Explain different diesel fuel system designs, and perform proper testing procedures. (CCC 1, 2, 3, 4, 5, 6; PGC 1, 2, 3, 4, 5)
  8. Explain various engine braking designs, and perform proper testing procedures. (CCC 1, 2, 3, 4, 5, 6; PGC 1, 2, 3, 4, 5)

See Core Curriculum Competencies and Program Graduate Competencies at the end of the syllabus. CCPOs are linked to every competency they develop.

Measurable Performance Objectives (MPOs)

Upon completion of this course, the student will:

  1. Explain various diesel engine designs, and explain its operation and service.
    1. Use vehicle service information, including fluid type, vehicle service history, service precautions, and technical service bulletins.
    2. Check the level and condition of fuel, oil, diesel exhaust fluid (DEF), and coolant.
    3. Inspect engine assembly for fuel, oil, coolant, air, and other leaks; and determine needed action.
    4. Check engine operation (starting and running) including: noise, vibration, smoke, etc.; and determine need action.
    5. Interpret appropriate electronic service tool(s) and procedures to diagnose problems; check, record, and clear diagnostic codes; check and record trip/operational data; reset maintenance monitor (if applicable); and interpret digital multimeter (DMM) readings.
    6. Identify system components, configurations, and types of the following: cylinder head(s), valve train, engine block, engine lubrication, engine cooling, air induction, exhaust, fuel, and engine braking.
    7. Check engine no-crank, cranks but fails to start, hard starting, and starts but does not continue to run problems; and determine needed action.
  2. Analyze various diesel cylinder head and valve trains, and explain its operation and perform proper test procedures.
    1. Check electronic wiring harness and brackets for wear, bending, cracks, and proper securement; and determine needed action.
    2. Inspect cylinder head for cracks/damage; check mating surfaces for warpage; check condition of passages; inspect core/expansion and gallery plugs; and determine needed action.
    3. Inspect injector sleeves and seals, valve train components; and determine needed action.
    4. Perform proper valve adjustment on bridges (crossheads), and adjust valve clearances and injector settings.
  3. Demonstrate proper operation, and service of various diesel engine blocks.
    1. Check crankshaft vibration damper; inspect engine mounts; and determine needed action.
    2. Inspect, service, and install pans, covers, gaskets, seals, wear rings, and crankcase ventilation components.
    3. Perform crankcase pressure test.
    4. Demonstrate proper removal and installation on flywheel housing; inspect flywheel housing(s) to transmission housing/engine mating surface(s); measure flywheel housing face and bore runout; and determine needed action.
    5. Check flywheel/flexplate (including ring gear) and mounting surfaces for cracks and wear; measure runout; and determine needed action.
  4. Demonstrate proper operation and service of basic diesel lubrication system.
    1. Perform engine oil pressure test(s); check operation of pressure sensor, gauge, and/or sending unit; test engine oil temperature and check operation of temperature sensor; and determine needed action.
    2. Check engine oil level, condition, and consumption; take engine oil sample; and determine needed action.
    3. Determine proper lubricant, and perform oil and filter service.
    4. Check, clean, and test oil cooler and component service as needed.
    5. Inspect turbocharger lubrication systems, and service as needed.
  5. Analyze diesel cooling systems, and perform proper testing procedures.
    1. Check engine coolant type, level, and condition; and test coolant for freeze protection and additive package concentration.
    2. Perform coolant temperature test(s); test operation of temperature and level sensors, gauge, and/or sending unit; and determine needed action.
    3. Check and reinstall/replace pulleys, tensioners and drive belts; and adjust drive belts and check alignment.
    4. Recover coolant; flush and refill with recommended coolant/additive package; bleed cooling system, inspect coolant conditioner/filter assembly for leaks; inspect valves, lines, and fittings; and replace as needed.
    5. Inspect and pressure test cooling system(s); pressure test cap, tank(s), and recovery systems; inspect radiator and mountings; and determine needed action.
    6. Inspect thermostatic cooling fan system (hydraulic, pneumatic, and electronic) and fan shroud; and determine needed action.
    7. Diagnose engine coolant consumption, and determine needed action.
    8. Inspect thermostat(s), by-passes, housing(s), and seals; and replace as needed.
  6. Describe air induction and exhaust systems, and explain its operation and service.
    1. Check  turbocharger(s), wastegate(s), piping systems, air induction system including: cooler assembly, piping, hoses, clamps, and mountings; replace air filter as needed; and reset restriction indicator (if applicable).
    2. Inspect intake manifold, gaskets, connections, engine exhaust system, exhaust gas recirculation (EGR) system, and exhaust aftertreatment system for leaks, mounting, proper routing, and damaged or missing components; and determine needed action.
    3. Check the crankcase ventilation system, and service as needed.
    4. Troubleshoot exhaust gas recirculation (EGR) system including: EGR valve, cooler, piping, filter, electronic sensors, controls, and wiring; and determine needed action.
    5. Inspect variable ratio geometry turbocharger (VGT), controls, and actuators (pneumatic, hydraulic, and electronic).
    6. Troubleshoot charge air cooler operation, exhaust aftertreatment systems, operation, and components.
  7. Explain different diesel fuel system designs, and perform proper testing procedures.
    1. Check fuel level and condition, fuel tanks, vents, caps, mounts, valves, screens, crossover system, hoses, lines, and fittings; and determine needed action.
    2. Inspect low pressure fuel system components (fuel pump, pump drives, screens, fuel/water separators/indicators, hoses, lines, filters, heaters, coolers, ECM cooling plates, check valves, pressure regulator valves, restrictive fittings, and mounting hardware); and determine needed action.
    3. Perform fuel filter replacement; and prime and bleed fuel system.
    4. Perform fuel supply and return system tests; and determine needed action.
    5. Perform cylinder contribution test using electronic service tool(s).
  8. Explain various engine braking designs, and perform proper testing procedures.
    1. Check engine compression and/or exhaust brake housing, valves, seals, lines, and fittings; and determine needed action.
    2. Check and adjust engine compression and/or exhaust brake systems; and determine needed action.
    3. Perform proper test procedures, and adjust engine compression and/or exhaust brake control circuits, switches, and solenoids; and determine needed action.

Evaluation Criteria/Policies

The grade will be determined using the Delaware Tech grading system:

90-100 = A
80-89 = B
70-79 = C
0-69 = F
Students should refer to the Catalog/Student Handbook for information on the Academic Standing Policy, the Academic Integrity Policy, Student Rights and Responsibilities, and other policies relevant to their academic progress.

Final Course Grade

Calculated using the following weighted average

Evaluation Measure

Percentage of final grade

Summative -(4-6) Tests (equally weighted)

20 %

Summative -(7-10) Quizzes (equally weighted)

20 %

Summative/Formative-Minimum 10 Repair Orders/Worksheets (equally weighted)

30%

Summative Assessments - Minimum 2 Practical Assessments (equally weighted) 

30%

TOTAL

100%

Program Graduate Competencies (PGCs are the competencies every graduate will develop specific to his or her major)

  1. Use appropriate diesel diagnostic and service equipment, hand tools, and precision measuring devices to determine and perform the proper repair as necessary.
  2. Interpret diesel electronic service information, service manuals, and diagnostic charts.
  3. Document service repair procedures that accurately reference the 3Cs:
    1. Customer complaint verification
    2. Correct the problem
    3. Complete the repair
  4. Employ proper diesel industry service facility safety practices.
  5. Practice professional conduct as required in the diesel industry.

Core Curriculum Competencies (CCCs are the competencies every graduate will develop)

  1. Apply clear and effective communication skills.
  2. Use critical thinking to solve problems.
  3. Collaborate to achieve a common goal.
  4. Demonstrate professional and ethical conduct.
  5. Use information literacy for effective vocational and/or academic research.
  6. Apply quantitative reasoning and/or scientific inquiry to solve practical problems.

Students in Need of Accommodations Due to a Disability

We value all individuals and provide an inclusive environment that fosters equity and student success. The College is committed to providing reasonable accommodations for students with disabilities. Students are encouraged to schedule an appointment with the campus Disabilities Support Counselor to request an accommodation needed due to a disability. The College's policy on accommodations for persons with disabilities can be found in the College's Guide to Requesting Academic Accommodations and/or Auxiliary Aids Students may also access the Guide and contact information for Disabilities Support Counselors through the Student Resources web page under Disabilities Support Services, or visit the campus Advising Center.

Minimum Technology Requirements

Minimum technology requirements for all distance education type courses.

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