ASE Correlated Task Sheets for Light Vehicle Diesel Engines

<h2>Table of Contents</h2> <p> </p> <ul> <li><strong>CHAPTER 1: DIESEL ENGINE OPERATION</strong> <ul> <li>Learning Objectives</li> <li>Key Terms</li> <li>Engines</li> <li>Four-Stroke Cycle Operation</li> <li>Engine Construction Overview</li> <li>Diesel Engines</li> <li>Engine Size</li> <li>Compression Ratio</li> <li>Torque</li> <li>Power</li> <li>Summary</li> <li>Review Questions</li> <li>Chapter Quiz</li> </ul></li> <li><strong>CHAPTER 2: DIESEL ENGINE BLOCKS AND ROTATING ASSEMBLIES</strong> <ul> <li>Learning Objectives</li> <li>Key Terms</li> <li>Diesel Engine Blocks</li> <li>Crankshafts</li> <li>Crankshaft Construction</li> <li>Crankshaft Features</li> <li>Crankshaft Service</li> <li>Engine Bearings</li> <li>Bearing Clearance</li> <li>Camshaft Bearings</li> <li>Summary</li> <li>Review Questions</li> <li>Chapter Quiz</li> </ul></li> <li><strong>CHAPTER 3: DIESEL CYLINDER HEADS AND VALVE TRAINS</strong> <ul> <li>Learning Objectives</li> <li>Key Terms</li> <li>Cylinder Heads</li> <li>Intake and Exhaust Valves</li> <li>Valve Seats</li> <li>Valve Springs</li> <li>Cylinder Head Passages</li> <li>Camshafts</li> <li>Rocker Arms and Bridges</li> <li>Pushrods</li> <li>Lifters or Tappets</li> <li>Camshaft Removal</li> <li>Cylinder Head Disassembly</li> <li>Summary</li> <li>Review Questions</li> <li>Chapter Quiz</li> </ul></li> <li><strong>CHAPTER 4: DIESEL ENGINE LUBRICATION SYSTEMS</strong> <ul> <li>Learning Objectives</li> <li>Key Terms</li> <li>Lubrication Principles</li> <li>Oil Pumps</li> <li>Oil Passages</li> <li>Oil Pans</li> <li>Engine Oil</li> <li>API Rating</li> <li>European Rating System</li> <li>Oil Filters</li> <li>Summary</li> <li>Review Questions</li> </ul></li> <li><strong>CHAPTER 5: DIESEL ENGINE COOLING SYSTEM</strong> <ul> <li>Learning Objectives</li> <li>Key Terms</li> <li>Cooling Systems</li> <li>Cooling System Operation</li> <li>Thermostats</li> <li>Radiators</li> <li>Pressure Caps</li> <li>Coolant Recovery Systems</li> <li>Water Pumps</li> <li>Cooling Fans</li> <li>Cooling System Testing</li> <li>Coolant Temperature Warning Light</li> <li>Coolant</li> <li>Types of Coolant</li> <li>Coolant Testing</li> <li>Coolant Replacement Issues</li> <li>Summary</li> <li>Review Questions</li> <li>Chapter Quiz</li> </ul></li> <li><strong>CHAPTER 6: DIESEL ENGINE CONDITION DIAGNOSIS</strong> <ul> <li>Learning Objectives</li> <li>Key Terms</li> <li>Typical Engine-Related Complaints</li> <li>Diagnostic Trouble Codes and Technical Service Bulletins</li> <li>Visual Inspection</li> <li>Engine Noise/Vibration Diagnosis</li> <li>Crankcase Pressure Test</li> <li>Oil Pressure Testing</li> <li>Misfire Diagnosis</li> <li>Engine-Related Misfire Diagnosis</li> <li>Compression Test</li> <li>Engine Starting and Charging Diagnosis</li> <li>Summary</li> <li>Review Questions</li> <li>Chapter Quiz</li> </ul></li> <li><strong>CHAPTER 7: DIESEL ENGINE DISASSEMBLY, CLEANING, AND CRACK DETECTION</strong> <ul> <li>Learning Objectives</li> <li>Key Terms</li> <li>Preparing the Engine for Removal</li> <li>Rotating Assemblies Removal</li> <li>Cylinder Head Disassembly</li> <li>Mechanical Cleaning</li> <li>Chemical Cleaners</li> <li>Spray and Steam Washing</li> <li>Thermal Cleaning</li> <li>Tank and Vapor Cleaning</li> <li>Ultrasonic and Vibratory Cleaning</li> <li>Crack Detection</li> <li>Summary</li> <li>Review Questions</li> <li>Chapter Quiz</li> </ul></li> <li><strong>CHAPTER 8: DIESEL ENGINE ASSEMBLY</strong> <ul> <li>Learning Objectives</li> <li>Key Terms</li> <li>Details</li> <li>Short Block Preparation</li> <li>Cylinder Head Preparation</li> <li>Short Block Assembly</li> <li>Piston/Rod Installation</li> <li>Cylinder Head Installation</li> <li>Torque-to-Yield Head Bolts</li> <li>Valve Train Assembly</li> <li>Final Assembly</li> <li>Summary</li> <li>Review Questions</li> <li>Chapter Quiz</li> </ul></li> <li><strong>CHAPTER 9: TURBOCHARGER SYSTEMS</strong> <ul> <li>Learning Objectives</li> <li>Key Terms</li> <li>Introduction</li> <li>Turbocharger Purpose and Function</li> <li>Turbochargers</li> <li>Boost Control</li> <li>Variable Geometry Turbocharger</li> <li>Air Charge Cooler</li> <li>Turbocharger Diagnosis</li> <li>Summary</li> <li>Review Questions</li> <li>Chapter Quiz</li> </ul></li> <li><strong>CHAPTER 10: AIR INDUCTION AND EGR SYSTEMS</strong> <ul> <li>Learning Objectives</li> <li>Key Terms</li> <li>Air Induction System</li> <li>Air Induction System Diagnosis</li> <li>Intake Manifold Heater</li> <li>Glow Plugs</li> <li>EGR System</li> <li>EGR System Diagnosis</li> <li>Summary</li> <li>Review Questions</li> <li>Chapter Quiz</li> </ul></li> <li><strong>CHAPTER 11: DIESEL AND BIODIESEL FUEL</strong> <ul> <li>Learning Objectives</li> <li>Key Terms</li> <li>Diesel Fuel</li> <li>Biodiesel</li> <li>E-Diesel Fuel</li> <li>Summary</li> <li>Review Questions</li> <li>Chapter Quiz</li> </ul></li> <li><strong>CHAPTER 12: FUEL SUPPLY AND LOW-PRESSURE FUEL SYSTEMS</strong> <ul> <li>Learning Objectives</li> <li>Key Terms</li> <li>Low-Pressure Fuel System Components</li> <li>Low-Pressure Fuel System Service</li> <li>Summary</li> <li>Review Questions</li> <li>Chapter Quiz</li> </ul></li> <li><strong>CHAPTER 13: HIGH-PRESSURE COMMON RAIL DIESEL FUEL SYSTEMS</strong> <ul> <li>Learning Objectives</li> <li>Key Terms</li> <li>Functions of High-Pressure Injection Systems</li> <li>High-Pressure Common Rail Injection</li> <li>High-Pressure Pump</li> <li>Common Rail Injector</li> <li>Powertrain Control Module</li> <li>High-Pressure Common Rail (HPCR) Fuel System Service Procedures</li> <li>Summary</li> <li>Review Questions</li> <li>Chapter Quiz</li> </ul></li> <li><strong>CHAPTER 14: HYDRAULICALLY ACTUATED ELECTRONIC UNIT INJECTOR (HEUI) SYSTEMS</strong> <ul> <li>Learning Objectives</li> <li>Key Terms</li> <li>HEUI Systems</li> <li>Control Pressure</li> <li>Injector Types</li> <li>HEUI Service and Diagnostics</li> <li>Summary</li> <li>Review Questions</li> <li>Chapter Quiz</li> </ul></li> <li><strong>CHAPTER 15: EXHAUST AND AFTERTREATMENT SYSTEMS</strong> <ul> <li>Learning Objectives</li> <li>Key Terms</li> <li>Exhaust Chemistry</li> <li>Exhaust System Components</li> <li>Diesel Oxidation Catalyst (DOC)</li> <li>NOx Adsorber Catalyst</li> <li>Selective Catalyst Reduction (SCR)</li> <li>Diesel Exhaust Fluid</li> <li>Reductant Dosing Module</li> <li>Diesel Particulate Filter (DPF)</li> <li>Differential Pressure Sensor</li> <li>Temperature Sensors</li> <li>NOx Sensors</li> <li>Oxygen Sensors</li> <li>Summary</li> <li>Review Questions</li> <li>Chapter Quiz</li> </ul></li> <li><strong>CHAPTER 16: DIESEL SERVICE PROCEDURES</strong> <ul> <li>Learning Objectives</li> <li>Key Terms</li> <li>Overview</li> <li>Intake Air System Maintenance</li> <li>Engine Oil Service</li> <li>Cooling System Service</li> <li>Fuel System Service</li> <li>Diesel Exhaust Fluid Service</li> <li>Summary</li> <li>Review Questions</li> <li>Chapter Quiz</li> </ul></li> <li><strong>CHAPTER 17: DIESEL ENGINE ELECTRONICS</strong> <ul> <li>Learning Objectives</li> <li>Key Terms</li> <li>Introduction</li> <li>Electricity</li> <li>How Electrons Move Through a Conductor</li> <li>Units of Electricity</li> <li>Electrical Circuits</li> <li>Electrical Schematics</li> <li>Types of Circuit Faults</li> <li>Fused Jumper Wire</li> <li>Test Light</li> <li>Digital Meters</li> <li>Inductive Ammeters</li> <li>Terminals and Connectors</li> <li>Wire Repair</li> <li>Relays</li> <li>Switches</li> <li>Speed Sensors</li> <li>Throttle Position (TP) Sensor</li> <li>Networks</li> <li>Network Classifications</li> <li>Controller Area Network</li> <li>Summary</li> <li>Review Questions</li> <li>Chapter Quiz</li> </ul></li> <li><strong>CHAPTER 18: CAN AND NETWORK COMMUNICATIONS</strong> <ul> <li>Learning Objectives</li> <li>Key Terms</li> <li>Module Communications and Networks</li> <li>Network Fundamentals</li> <li>Module Communications Configuration</li> <li>Network Communications Classifications</li> <li>General Motors Communications Protocols</li> <li>Ford Network Communications Protocols</li> <li>Chrysler Communications Protocols</li> <li>Controller Area Network</li> <li>Honda/Toyota Communications</li> <li>European Bus Communications</li> <li>Network Communications Diagnosis</li> <li>OBD-II Data Link Connector</li> <li>Summary</li> <li>Review Questions</li> <li>Chapter Quiz</li> </ul></li> <li><strong>CHAPTER 19: DIESEL OBD II</strong> <ul> <li>Learning Objectives</li> <li>Key Terms</li> <li>OBD II</li> <li>California OBD II</li> <li>Monitors</li> <li>Diagnostic Trouble Codes</li> <li>OBD-II Freeze Frame</li> <li>PCM Tests</li> <li>Global OBD II</li> <li>Summary</li> <li>Review Questions</li> <li>Chapter Quiz</li> </ul></li> <li><strong>CHAPTER 20: OBD-II DIESEL MONITORS</strong> <ul> <li>Learning Objectives</li> <li>Key Terms</li> <li>Major System Monitors</li> <li>Comprehensive Component Monitor</li> <li>Enabling Criteria</li> <li>Misfire Monitor</li> <li>Fuel System Monitor</li> <li>Non-Continuous Monitors</li> <li>Summary</li> <li>Review Questions</li> <li>Chapter Quiz</li> </ul></li> <li><strong>CHAPTER 21: OBD-II DIESEL DIAGNOSIS</strong> <ul> <li>Learning Objectives</li> <li>Key Terms</li> <li>The Diesel Engine Diagnostic Process</li> <li>Verify the Customer Concern</li> <li>Visual Inspection</li> <li>Check for Any Stored DTCs</li> <li>Check TSBs</li> <li>Scan Tool Data</li> <li>Pinpoint Tests</li> <li>Determine the Root Cause</li> <li>Flash Programming</li> <li>Summary</li> <li>Review Questions</li> <li>Chapter Quiz</li> </ul></li> <li><strong>CHAPTER 22: FORD POWER STROKE DIESEL ENGINES</strong> <ul> <li>Learning Objectives</li> <li>Key Terms</li> <li>Background</li> <li>6.7 Liter Power Stroke</li> <li>6.7 Cooling System</li> <li>6.7 Lubrication System</li> <li>Engine Mechanical</li> <li>Low-Pressure Fuel System</li> <li>Diesel Fuel Conditioner Module (DFCM)</li> <li>High-Pressure Fuel System</li> <li>High-Pressure Common Rail Fuel Injectors</li> <li>Control System Inputs</li> <li>Engine Outputs</li> <li>Diesel Aftertreatment System</li> <li>Five- and Six-Cylinder Power Stroke Diesel Engines</li> <li>Summary</li> <li>Review Questions</li> <li>Chapter Quiz</li> </ul></li> <li><strong>CHAPTER 23: DURAMAX DIESEL ENGINES</strong> <ul> <li>Learning Objectives</li> <li>Key Terms</li> <li>Background</li> <li>2.8 Inline 4-Cylinder Duramax</li> <li>Engine Mechanical</li> <li>Cooling System</li> <li>Cylinder Heads</li> <li>Service Information</li> <li>Low-Pressure Side Fuel System</li> <li>Fuel Aeration</li> <li>High-Pressure Fuel System</li> <li>Glow Plugs and EGR</li> <li>Duramax Diesel Aftertreatment System</li> <li>Photo Sequence – Duramax Disassembly</li> <li>Summary</li> <li>Review Questions</li> <li>Chapter Quiz</li> </ul></li> <li><strong>CHAPTER 24: CUMMINS DIESEL ENGINES</strong> <ul> <li>Learning Objectives</li> <li>Key Terms</li> <li>Background Cummins 5.9/6.7 Liter Engine</li> <li>ISB 6.7 Engine Details</li> <li>ISB 6.7 Engine Low-Pressure Fuel System</li> <li>ISB 6.7 Engine High-Pressure Fuel System</li> <li>Control System Inputs</li> <li>Engine Outputs</li> <li>Cummins 6.7 Liter Diesel Aftertreatment System</li> <li>Cummins 5.0 Liter Engine</li> <li>5.0 V-8 Engine Mechanical</li> <li>5.0 V-8 Engine Low-Pressure Fuel System</li> <li>5.0 V-8 Engine High-Pressure Fuel System</li> <li>Air Induction System</li> <li>Glow Plug System</li> <li>EGR System</li> <li>Exhaust Aftertreatment System</li> <li>Photo Sequence – 6.7 Liter Cummins Engine</li> <li>Summary</li> <li>Review Questions</li> <li>Chapter Quiz</li> </ul></li> <li><strong>CHAPTER 25: FIAT/JEEP DIESEL ENGINES</strong> <ul> <li>Learning Objectives</li> <li>Key Terms</li> <li>Overview</li> <li>Engine Identification</li> <li>Service Information</li> <li>Engine Mechanical</li> <li>Low-Pressure Fuel System</li> <li>High-Pressure Fuel System</li> <li>Control System Inputs</li> <li>Engine Outputs</li> <li>VM 3.0 Liter V-6 Diesel Aftertreatment System</li> <li>Summary</li> <li>Review Questions</li> </ul></li> </ul> <p></p>