Light Vehicle Diesel Engines

<strong>1. DIESEL ENGINE OPERATION<br></strong>Learning Objectives <br>Key Terms <br>Engines <br>Four-Stroke Cycle Operation <br>Engine Construction Overview <br>Diesel Engines <br>Engine Size <br>Compression Ratio <br>Torque <br>Power <br>Summary <br>Review Questions <br>Quiz <br> <strong><br>2. DIESEL ENGINE BLOCKS AND ROTATING ASSEMBLIES<br></strong>Learning Objectives <br>Key Terms <br>Diesel Engine Blocks <br>Crankshafts <br>Crankshaft Construction <br>Crankshaft Features <br>Crankshaft Service <br>Engine Bearings <br>Bearing Clearance <br>Camshaft Bearings <br>Summary <br>Review Questions <br>Quiz <br> <strong><br>3. DIESEL CYLINDER HEADS AND VALVE TRAINS<br></strong>Learning Objectives <br>Key Terms <br>Cylinder Heads <br>Intake and Exhaust Valves <br>Valve Seats <br>Valve Springs <br>Cylinder Head Passages <br>Camshafts <br>Rocker Arms and Bridges <br>Pushrods <br>Lifters or Tappets <br>Camshaft Removal <br>Cylinder Head Disassembly <br>Summary <br>Review Questions <br>Quiz <br> <br> <strong>4. DIESEL ENGINE LUBRICATION SYSTEMS<br></strong>Learning Objectives <br>Key Terms <br>Lubrication Principles <br>Oil Pumps <br>Oil Passages <br>Oil Pans <br>Engine Oil <br>API Rating <br>European Rating System <br>Oil Filters <br>Summary <br>Review Questions <br> <br> <strong>5. DIESEL ENGINE COOLING SYSTEM<br></strong>Learning Objectives <br>Key Terms <br>Cooling Systems <br>Cooling System Operation <br>Thermostats <br>Radiators <br>Pressure Caps <br>Coolant Recovery Systems <br>Water Pumps <br>Cooling Fans <br>Cooling System Testing <br>Coolant Temperature Warning Light <br>Coolant <br>Types of Coolant <br>Coolant Testing <br>Coolant Replacement Issues <br>Summary <br>Review Questions <br>Quiz <br> <br> <strong>6. DIESEL ENGINE CONDITION DIAGNOSIS<br></strong>Learning Objectives <br>Key Terms <br>Typical Engine-Related Complaints <br>Diagnostic Trouble Codes and Technical Service Bulletins <br>Visual Inspection <br>Engine Noise/Vibration Diagnosis <br>Crankcase Pressure Test <br>Oil Pressure Testing <br>Misfire Diagnosis <br>Engine-Related Misfire Diagnosis <br>Compression Test <br>Engine Starting and Charging Diagnosis <br>Summary <br>Review Questions <br>Quiz <br> <br> <strong>7. DIESEL ENGINE DISASSEMBLY, CLEANING, AND CRACK DETECTION<br></strong>Learning Objectives <br>Key Terms <br>Preparing the Engine for Removal <br>Rotating Assemblies Removal <br>Cylinder Head Disassembly <br>Mechanical Cleaning <br>Chemical Cleaners <br>Spray and Steam Washing <br>Thermal Cleaning <br>Tank and Vapor Cleaning <br>Ultrasonic and Vibratory Cleaning <br>Crack Detection <br>Summary <br>Review Questions <br>Quiz <br> <br> <strong>8. DIESEL ENGINE ASSEMBLY<br></strong>Learning Objectives <br>Key Terms <br>Details <br>Short Block Preparation <br>Cylinder Head Preparation <br>Short Block Assembly <br>Piston/Rod Installation <br>Cylinder Head Installation <br>Torque-to-Yield Head Bolts <br>Valve Train Assembly <br>Final Assembly <br>Summary <br>Review Questions <br>Quiz <br> <br> <strong>9. TURBOCHARGER SYSTEMS<br></strong>Learning Objectives <br>Key Terms <br>Introduction <br>Turbocharger Purpose and Function <br>Turbochargers <br>Boost Control <br>Variable Geometry Turbocharger <br>Air Charge Cooler <br>Turbocharger Diagnosis <br>Summary <br>Review Questions <br>Quiz <br> <br> <strong>10. AIR INDUCTION AND EGR SYSTEMS<br></strong>Learning Objectives <br>Key Terms <br>Air Induction System <br>Air Induction System Diagnosis <br>Intake Manifold Heater <br>Glow Plugs <br>EGR System <br>EGR System Diagnosis <br>Summary <br>Review Questions <br>Quiz <br> <br> <strong>11. DIESEL AND BIODIESEL FUEL<br></strong>Learning Objectives <br>Key Terms <br>Diesel Fuel <br>Biodiesel <br>E-Diesel Fuel <br>Summary <br>Review Questions <br>Quiz <br> <br> <strong>12. FUEL SUPPLY AND LOW-PRESSURE FUEL SYSTEMS<br></strong>Learning Objectives <br>Key Terms <br>Low-Pressure Fuel System Components <br>Low-Pressure Fuel System Service <br>Summary <br>Review Questions <br>Quiz <br> <br> <strong>13. HIGH-PRESSURE COMMON RAIL DIESEL FUEL SYSTEMS<br></strong>Learning Objectives <br>Key Terms <br>Functions of High-Pressure Injection Systems <br>High-Pressure Common Rail Injection <br>High-Pressure Pump <br>Common Rail Injector <br>Powertrain Control Module <br>High-Pressure Common Rail (HPCR) Fuel System Service Procedures <br>Summary <br>Review Questions <br>Quiz <br> <br> <strong>14. HYDRAULICALLY ACTUATED ELECTRONIC UNIT INJECTOR (HEUI) SYSTEMS<br></strong>Learning Objectives <br>Key Terms <br>HEUI Systems <br>Control Pressure <br>Injector Types <br>HEUI Service and Diagnostics <br>Summary <br>Review Questions <br>Quiz <br> <br> <strong>15. EXHAUST AND AFTERTREATMENT SYSTEMS<br></strong>Learning Objectives <br>Key Terms <br>Exhaust Chemistry <br>Exhaust System Components <br>Diesel Oxidation Catalyst (DOC) <br>NOx Adsorber Catalyst <br>Selective Catalyst Reduction (SCR) <br>Diesel Exhaust Fluid <br>Reductant Dosing Module <br>Diesel Particulate Filter (DPF) <br>Differential Pressure Sensor <br>Temperature Sensors <br>NOx Sensors <br>Oxygen Sensors <br>Summary <br>Review Questions <br>Quiz <br> <br> <strong>16. DIESEL SERVICE PROCEDURES<br></strong>Learning Objectives <br>Key Terms <br>Overview <br>Intake Air System Maintenance <br>Engine Oil Service <br>Cooling System Service <br>Fuel System Service <br>Diesel Exhaust Fluid Service <br>Summary <br>Review Questions <br>Quiz <br> <br> <strong>17. DIESEL ENGINE ELECTRONICS<br></strong>Learning Objectives <br>Key Terms <br>Introduction <br>Electricity <br>How Electrons Move Through a Conductor <br>Units of Electricity <br>Electrical Circuits <br>Electrical Schematics <br>Types of Circuit Faults <br>Fused Jumper Wire <br>Test Light <br>Digital Meters <br>Inductive Ammeters <br>Terminals and Connectors <br>Wire Repair <br>Relays <br>Switches <br>Speed Sensors <br>Throttle Position (TP) Sensor <br>Networks <br>Network Classifications <br>Controller Area Network <br>Summary <br>Review Questions <br>Quiz <br> <br> <strong>18. CAN AND NETWORK COMMUNICATIONS<br></strong>Learning Objectives <br>Key Terms <br>Module Communications and Networks <br>Network Fundamentals <br>Module Communications Configuration <br>Network Communications Classifications <br>General Motors Communications Protocols <br>Ford Network Communications Protocols <br>Chrysler Communications Protocols <br>Controller Area Network <br>Honda/Toyota Communications <br>European Bus Communications <br>Network Communications Diagnosis <br>OBD-II Data Link Connector <br>Summary <br>Review Questions <br>Quiz <br> <br> <strong>19. DIESEL OBD II<br></strong>Learning Objectives <br>Key Terms <br>OBD II <br>California OBD II <br>Monitors <br>Diagnostic Trouble Codes <br>OBD-II Freeze Frame <br>PCM Tests <br>Global OBD II <br>Summary <br>Review Questions <br>Quiz <br> <br> <strong>20. OBD-II DIESEL MONITORS<br></strong>Learning Objectives <br>Key Terms <br>Major System Monitors <br>Comprehensive Component Monitor <br>Enabling Criteria <br>Misfire Monitor <br>Fuel System Monitor <br>Non-Continuous Monitors <br>Summary <br>Review Questions <br>Quiz <br> <br> <strong>21. OBD-II DIESEL DIAGNOSIS<br></strong>Learning Objectives <br>Key Terms <br>The Diesel Engine Diagnostic Process <br>Verify the Customer Concern <br>Visual Inspection <br>Check for Any Stored DTCs <br>Check TSBs <br>Scan Tool Data <br>Pinpoint Tests <br>Determine the Root Cause <br>Flash Programming <br>Summary <br>Review Questions <br>Quiz <br> <br> <strong>22. FORD POWER STROKE DIESEL ENGINES<br></strong>Learning Objectives <br>Key Terms <br>Background <br>6.7 Liter Power Stroke <br>6.7 Cooling System <br>6.7 Lubrication System <br>Engine Mechanical <br>Low-Pressure Fuel System <br>Diesel Fuel Conditioner Module (DFCM) <br>High-Pressure Fuel System <br>High-Pressure Common Rail Fuel Injectors <br>Control System Inputs <br>Engine Outputs <br>Diesel Aftertreatment System <br>Five- and Six-Cylinder Power Stroke Diesel Engines <br>Summary <br>Review Questions <br>Quiz <br> <br> <strong>23. DURAMAX DIESEL ENGINES<br></strong>Learning Objectives <br>Key Terms <br>Background <br>2.8 Inline 4-Cylinder Duramax <br>Engine Mechanical <br>Cooling System <br>Cylinder Heads <br>Service Information <br>Low-Pressure Side Fuel System <br>Fuel Aeration <br>High-Pressure Fuel System <br>Glow Plugs and EGR <br>Duramax Diesel Aftertreatment System <br>Photo Sequence - Duramax Disassembly <br>Summary <br>Review Questions <br>Quiz <br> <br> <strong>24. CUMMINS DIESEL ENGINES<br></strong>Learning Objectives <br>Key Terms <br>Background Cummins 5.9/6.7 Liter Engine <br>ISB 6.7 Engine Details <br>ISB 6.7 Engine Low-Pressure Fuel System <br>ISB 6.7 Engine High-Pressure Fuel System <br>Control System Inputs <br>Engine Outputs <br>Cummins 6.7 Liter Diesel Aftertreatment System <br>Cummins 5.0 Liter Engine <br>5.0 V-8 Engine Mechanical <br>5.0 V-8 Engine Low-Pressure Fuel System <br>5.0 V-8 Engine High-Pressure Fuel System <br>Air Induction System <br>Glow Plug System <br>EGR System <br>Exhaust Aftertreatment System <br>Photo Sequence - 6.7 Liter Cummins Engine <br>Summary <br>Review Questions <br>Quiz <br> <br> <strong>25. FIAT/JEEP DIESEL ENGINES<br></strong>Learning Objectives <br>Key Terms <br>Overview <br>Engine Identification <br>Service Information <br>Engine Mechanical <br>Low-Pressure Fuel System <br>High-Pressure Fuel System <br>Control System Inputs <br>Engine Outputs <br>VM 3.0 Liter V-6 Diesel Aftertreatment System <br>Summary <br>Review Questions <br>