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 OPERATION
Learning 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 ASSEMBLIES
Learning 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 TRAINS
Learning 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 SYSTEMS
Learning 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 SYSTEM
Learning 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 DIAGNOSIS
Learning 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 DETECTION
Learning 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 ASSEMBLY
Learning 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 SYSTEMS
Learning 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 SYSTEMS
Learning 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 FUEL
Learning Objectives
Key Terms
Diesel Fuel
Biodiesel
E-Diesel Fuel
Summary
Review Questions
Quiz

12. FUEL SUPPLY AND LOW-PRESSURE FUEL SYSTEMS
Learning Objectives
Key Terms
Low-Pressure Fuel System Components
Low-Pressure Fuel System Service
Summary
Review Questions
Quiz

13. HIGH-PRESSURE COMMON RAIL DIESEL FUEL SYSTEMS
Learning 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) SYSTEMS
Learning Objectives
Key Terms
HEUI Systems
Control Pressure
Injector Types
HEUI Service and Diagnostics
Summary
Review Questions
Quiz

15. EXHAUST AND AFTERTREATMENT SYSTEMS
Learning 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 PROCEDURES
Learning 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 ELECTRONICS
Learning 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 COMMUNICATIONS
Learning 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 II
Learning 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 MONITORS
Learning 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 DIAGNOSIS
Learning 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 ENGINES
Learning 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 ENGINES
Learning 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 ENGINES
Learning 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 ENGINES
Learning 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