Light Vehicle Diesel Engines

About our authors Jim Halderman brings a world of experience, knowledge and talent to his work. His automotive service experience includes working as a flat-rate technician, a business owner and a professor of automotive technology at a leading US community college for over 20 years.He has a Bachelor of Science degree from Ohio Northern University and a master's degree in Education from Miami University in Oxford, Ohio. Jim also holds a US Patent for an electronic transmission control device. He is an ASE-certified Master Automotive Technician and Advanced Engine Performance (L1) ASE certified. Jim is the author of many automotive textbooks all published by Pearson.Jim has presented numerous technical seminars to national audiences, including the California Automotive Teachers (CAT) and the Illinois College Automotive Instructor Association (ICAIA). He is also a member and presenter at the North American Council of Automotive Teachers (NACAT). Jim was also named Regional Teacher of the Year by General Motors Corporation and is a member of the advisory board for the Technological Studies department at Ohio Northern University.Curt Ward brings a wealth of talent, experience and knowledge to his work. Curt is an automotive professor at Joliet Junior College and serves as a visiting automotive instructor at Southern Illinois University. Previously he was an adjunct professor at other area community colleges. Before his work at the college, Curt worked as a technical training instructor for the Chrysler Corporation for 15 years. Prior to his years at Chrysler, he worked as a technician, shop foreman and service manager in the retail sector of the automotive industry for 13 years. During this time Curt became a Chrysler Master Technician.Curt has an Associates of Applied Science in Automotive Service Technology from Southern Illinois University. He has a Bachelor of Fine Arts in Organizational Communications from North Central College. He earned his master's degree in Adult Education at the University of Phoenix. Curt holds the following ASE certifications: ASE Master Automotive Technician, Automobile Advanced Engine performance “L1”, Alternate Fuels Technician “F1”, Light Vehicle Diesel Engines “A9”, and Automotive Maintenance and Light Repair “G1”.Curt has presented technical seminars at numerous conferences around the country. He has presented for the Illinois College Automotive Instructor Association (ICAIA), the California Automotive Teachers (CAT), and the North American Council of Automotive Teachers (NACAT).Curt is an active member in the Illinois Automotive Instructor Association (ICAIA) and the North American Council of Automotive Teachers (NACAT). He has served as the Secretary and the President of the NACAT organization and was the Conference Host for the 2015 NACAT Conference. In 2015 Curt was named the NACAT MVP award winner for his outstanding contribution to the NACAT organization.

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