ASE Correlated Task Sheets for Light Vehicle Diesel Engines

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 U.S. community college for more than 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 U.S. 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 fifteen 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 thirteen 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’s 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 TechnicianAutomobile Advanced Engine performance “L1”Alternate Fuels Technician “F1”Light Vehicle Diesel Engines “A9”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.

• Table of Contents CHAPTER 1: DIESEL ENGINE OPERATION Learning ObjectivesKey TermsEnginesFour-Stroke Cycle OperationEngine Construction OverviewDiesel EnginesEngine SizeCompression RatioTorquePowerSummaryReview QuestionsChapter QuizCHAPTER 2: DIESEL ENGINE BLOCKS AND ROTATING ASSEMBLIES Learning ObjectivesKey TermsDiesel Engine BlocksCrankshaftsCrankshaft ConstructionCrankshaft FeaturesCrankshaft ServiceEngine BearingsBearing ClearanceCamshaft BearingsSummaryReview QuestionsChapter QuizCHAPTER 3: DIESEL CYLINDER HEADS AND VALVE TRAINS Learning ObjectivesKey TermsCylinder HeadsIntake and Exhaust ValvesValve SeatsValve SpringsCylinder Head PassagesCamshaftsRocker Arms and BridgesPushrodsLifters or TappetsCamshaft RemovalCylinder Head DisassemblySummaryReview QuestionsChapter QuizCHAPTER 4: DIESEL ENGINE LUBRICATION SYSTEMS Learning ObjectivesKey TermsLubrication PrinciplesOil PumpsOil PassagesOil PansEngine OilAPI RatingEuropean Rating SystemOil FiltersSummaryReview QuestionsCHAPTER 5: DIESEL ENGINE COOLING SYSTEM Learning ObjectivesKey TermsCooling SystemsCooling System OperationThermostatsRadiatorsPressure CapsCoolant Recovery SystemsWater PumpsCooling FansCooling System TestingCoolant Temperature Warning LightCoolantTypes of CoolantCoolant TestingCoolant Replacement IssuesSummaryReview QuestionsChapter QuizCHAPTER 6: DIESEL ENGINE CONDITION DIAGNOSIS Learning ObjectivesKey TermsTypical Engine-Related ComplaintsDiagnostic Trouble Codes and Technical Service BulletinsVisual InspectionEngine Noise/Vibration DiagnosisCrankcase Pressure TestOil Pressure TestingMisfire DiagnosisEngine-Related Misfire DiagnosisCompression TestEngine Starting and Charging DiagnosisSummaryReview QuestionsChapter QuizCHAPTER 7: DIESEL ENGINE DISASSEMBLY, CLEANING, AND CRACK DETECTION Learning ObjectivesKey TermsPreparing the Engine for RemovalRotating Assemblies RemovalCylinder Head DisassemblyMechanical CleaningChemical CleanersSpray and Steam WashingThermal CleaningTank and Vapor CleaningUltrasonic and Vibratory CleaningCrack DetectionSummaryReview QuestionsChapter QuizCHAPTER 8: DIESEL ENGINE ASSEMBLY Learning ObjectivesKey TermsDetailsShort Block PreparationCylinder Head PreparationShort Block AssemblyPiston/Rod InstallationCylinder Head InstallationTorque-to-Yield Head BoltsValve Train AssemblyFinal AssemblySummaryReview QuestionsChapter QuizCHAPTER 9: TURBOCHARGER SYSTEMS Learning ObjectivesKey TermsIntroductionTurbocharger Purpose and FunctionTurbochargersBoost ControlVariable Geometry TurbochargerAir Charge CoolerTurbocharger DiagnosisSummaryReview QuestionsChapter QuizCHAPTER 10: AIR INDUCTION AND EGR SYSTEMS Learning ObjectivesKey TermsAir Induction SystemAir Induction System DiagnosisIntake Manifold HeaterGlow PlugsEGR SystemEGR System DiagnosisSummaryReview QuestionsChapter QuizCHAPTER 11: DIESEL AND BIODIESEL FUEL Learning ObjectivesKey TermsDiesel FuelBiodieselE-Diesel FuelSummaryReview QuestionsChapter QuizCHAPTER 12: FUEL SUPPLY AND LOW-PRESSURE FUEL SYSTEMS Learning ObjectivesKey TermsLow-Pressure Fuel System ComponentsLow-Pressure Fuel System ServiceSummaryReview QuestionsChapter QuizCHAPTER 13: HIGH-PRESSURE COMMON RAIL DIESEL FUEL SYSTEMS Learning ObjectivesKey TermsFunctions of High-Pressure Injection SystemsHigh-Pressure Common Rail InjectionHigh-Pressure PumpCommon Rail InjectorPowertrain Control ModuleHigh-Pressure Common Rail (HPCR) Fuel System Service ProceduresSummaryReview QuestionsChapter QuizCHAPTER 14: HYDRAULICALLY ACTUATED ELECTRONIC UNIT INJECTOR (HEUI) SYSTEMS Learning ObjectivesKey TermsHEUI SystemsControl PressureInjector TypesHEUI Service and DiagnosticsSummaryReview QuestionsChapter QuizCHAPTER 15: EXHAUST AND AFTERTREATMENT SYSTEMS Learning ObjectivesKey TermsExhaust ChemistryExhaust System ComponentsDiesel Oxidation Catalyst (DOC)NOx Adsorber CatalystSelective Catalyst Reduction (SCR)Diesel Exhaust FluidReductant Dosing ModuleDiesel Particulate Filter (DPF)Differential Pressure SensorTemperature SensorsNOx SensorsOxygen SensorsSummaryReview QuestionsChapter QuizCHAPTER 16: DIESEL SERVICE PROCEDURES Learning ObjectivesKey TermsOverviewIntake Air System MaintenanceEngine Oil ServiceCooling System ServiceFuel System ServiceDiesel Exhaust Fluid ServiceSummaryReview QuestionsChapter QuizCHAPTER 17: DIESEL ENGINE ELECTRONICS Learning ObjectivesKey TermsIntroductionElectricityHow Electrons Move Through a ConductorUnits of ElectricityElectrical CircuitsElectrical SchematicsTypes of Circuit FaultsFused Jumper WireTest LightDigital MetersInductive AmmetersTerminals and ConnectorsWire RepairRelaysSwitchesSpeed SensorsThrottle Position (TP) SensorNetworksNetwork ClassificationsController Area NetworkSummaryReview QuestionsChapter QuizCHAPTER 18: CAN AND NETWORK COMMUNICATIONS Learning ObjectivesKey TermsModule Communications and NetworksNetwork FundamentalsModule Communications ConfigurationNetwork Communications ClassificationsGeneral Motors Communications ProtocolsFord Network Communications ProtocolsChrysler Communications ProtocolsController Area NetworkHonda/Toyota CommunicationsEuropean Bus CommunicationsNetwork Communications DiagnosisOBD-II Data Link ConnectorSummaryReview QuestionsChapter QuizCHAPTER 19: DIESEL OBD II Learning ObjectivesKey TermsOBD IICalifornia OBD IIMonitorsDiagnostic Trouble CodesOBD-II Freeze FramePCM TestsGlobal OBD IISummaryReview QuestionsChapter QuizCHAPTER 20: OBD-II DIESEL MONITORS Learning ObjectivesKey TermsMajor System MonitorsComprehensive Component MonitorEnabling CriteriaMisfire MonitorFuel System MonitorNon-Continuous MonitorsSummaryReview QuestionsChapter QuizCHAPTER 21: OBD-II DIESEL DIAGNOSIS Learning ObjectivesKey TermsThe Diesel Engine Diagnostic ProcessVerify the Customer ConcernVisual InspectionCheck for Any Stored DTCsCheck TSBsScan Tool DataPinpoint TestsDetermine the Root CauseFlash ProgrammingSummaryReview QuestionsChapter QuizCHAPTER 22: FORD POWER STROKE DIESEL ENGINES Learning ObjectivesKey TermsBackground6.7 Liter Power Stroke6.7 Cooling System6.7 Lubrication SystemEngine MechanicalLow-Pressure Fuel SystemDiesel Fuel Conditioner Module (DFCM)High-Pressure Fuel SystemHigh-Pressure Common Rail Fuel InjectorsControl System InputsEngine OutputsDiesel Aftertreatment SystemFive- and Six-Cylinder Power Stroke Diesel EnginesSummaryReview QuestionsChapter QuizCHAPTER 23: DURAMAX DIESEL ENGINES Learning ObjectivesKey TermsBackground2.8 Inline 4-Cylinder DuramaxEngine MechanicalCooling SystemCylinder HeadsService InformationLow-Pressure Side Fuel SystemFuel AerationHigh-Pressure Fuel SystemGlow Plugs and EGRDuramax Diesel Aftertreatment SystemPhoto Sequence – Duramax DisassemblySummaryReview QuestionsChapter QuizCHAPTER 24: CUMMINS DIESEL ENGINES Learning ObjectivesKey TermsBackground Cummins 5.9/6.7 Liter EngineISB 6.7 Engine DetailsISB 6.7 Engine Low-Pressure Fuel SystemISB 6.7 Engine High-Pressure Fuel SystemControl System InputsEngine OutputsCummins 6.7 Liter Diesel Aftertreatment SystemCummins 5.0 Liter Engine5.0 V-8 Engine Mechanical5.0 V-8 Engine Low-Pressure Fuel System5.0 V-8 Engine High-Pressure Fuel SystemAir Induction SystemGlow Plug SystemEGR SystemExhaust Aftertreatment SystemPhoto Sequence – 6.7 Liter Cummins EngineSummaryReview QuestionsChapter QuizCHAPTER 25: FIAT/JEEP DIESEL ENGINES Learning ObjectivesKey TermsOverviewEngine IdentificationService InformationEngine MechanicalLow-Pressure Fuel SystemHigh-Pressure Fuel SystemControl System InputsEngine OutputsVM 3.0 Liter V-6 Diesel Aftertreatment SystemSummaryReview Questions