light vehicle diesel engineslight vehicle diesel engines james d. halderman curt ward 330 hudson...

LIGHT VEHICLE DIESEL ENGINES

James D. Halderman Curt Ward

330 Hudson Street, NY, NY 10013

A01_HALD8726_01_SE_FM.indd 1 12/1/17 1:50 PM

Vice President, Portfolio Management: Andrew Gilfillan

Editorial Assistant: Lara DimmickSenior Vice President, Marketing:

David GesellMarketing Coordinator: Elizabeth

MacKenzie-LambDirector, Digital Studio and Content

Production: Brian HylandManaging Producer: Jennifer SargunarContent Producer (Team Lead):

Faraz Sharique Ali

Copyright © 2019. Pearson Education, Inc. All Rights Reserved. Manufactured in the United States of America. This publication is protected by copyright, and permission should be obtained from the publisher prior to any prohibited reproduction, storage in a retrieval system, or transmis-sion in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise. For information regarding permissions, request forms, and the appropriate contacts within the Pearson Education Global Rights and Permissions department, please visit www.pearsoned.com/permissions/.

Acknowledgments of third-party content appear on the appropriate page within the text.

Unless otherwise indicated herein, any third-party trademarks, logos, or icons that may appear in this work are the property of their respective owners, and any references to third-party trade-marks, logos, icons, or other trade dress are for demonstrative or descriptive purposes only. Such references are not intended to imply any sponsorship, endorsement, authorization, or promotion of Pearson’s products by the owners of such marks, or any relationship between the owner and Pearson Education, Inc., authors, licensees, or distributors.

Library of Congress Cataloging-in-Publication Data

Names: Halderman, James D.Title: Light vehicle diesel engines / James D. Halderman.Description: First edition. | Hoboken : Pearson, [2019]Identifiers: LCCN 2017040414 | ISBN 9780134678726 (alk. paper) | ISBN 0134678729 (alk. paper)Subjects: LCSH: Diesel motor—Design—Textbooks.Classification: LCC TJ795 .H325 2019 | DDC 629.25/06—dc23 LC record available at

https://lccn.loc.gov/2017040414

Manager, Rights Management: Johanna Burke

Operations Specialist: Deidra SmithCover Design: Cenveo Publisher ServicesFull-Service Project Management and

Composition: Abinaya Rajendran, Integra Software Services Pvt. Ltd.

Printer/Binder: LSC Communications, Inc. Cover Printer: Phoenix Color/HagerstownText Font: Helvetica Neue LT W1G

ISBN 10: 0-13-467872-9ISBN 13: 978-0-13-467872-6

1 17


iii

This new title is designed to meet the needs of a semester course in light vehicle diesel engines. This title is designed to be the “keystone” course for an automotive program because it includes all of the advanced technology in on-board diagnosis and up-to-date diesel technology all in one title.

DEPTH OF CONTENT AND FORMAT Scope: The scope of this title is intended to meet the needs of a textbook that covers light vehicle diesel engines to supple-ment and enhance an automotive two-year curriculum. The first 9 chapters are designed to introduce diesel engine construction and engine mechanical systems. Chapters 10 through 21 cover the emission control and service procedures that every techni-cian needs to know when servicing a light vehicle diesel engine. Chapters 22 through 25 cover each of the most commonly used diesel engines in detail.

Organization: The content includes the basics needed by all service technicians and also covers the following organization for most systems:

■■ Purpose and function of the system■■ Parts involved and operational description■■ Diagnosis and service

ASE A9 CORRELATED This text material meets all of the tasks specified by ASE for the Light Diesel (A9) test content area. The correlation to both the text pages and the task sheet are found in appendix 2.

A COMPLETE INSTRUCTOR AND STUDENT SUPPLE-MENTS PACKAGE All Professional Technician textbooks are accompanied by a full set of instructor and student supple-ments. Please see page vi for a detailed list of supplements.

A FOCUS ON DIAGNOSIS AND PROBLEM SOLVING The Professional Technician Series has been developed to satisfy the need for a greater emphasis on problem diagno-sis. Automotive instructors and service managers agree that students and beginning technicians need more training in diagnostic procedures and skill development. To meet this need and demonstrate how real-world problems are solved, Case Studies features are included throughout and highlight how real-life problems are diagnosed and repaired.

The following pages highlight the unique core features that set the Professional Technician Series book apart from other automotive textbooks.

PREFACE


iv IN-TEXT FEATURES

IN-TEXT FEATURES

OBJECTIVES AND KEY TERMS The learning objectives are stated at the beginning of each chapter to help the reader and the instructors see what the objectives of the content being presented are designed to achieve. The key terms are listed at the beginning of each chapter along with the page number where the key term is first used and defined. The key terms are also set in bold type to make them easier to find in the text. The key terms are also listed and defined in the glossary.

TECH TIPS This feature is included in most chapters and helps the reader better understand how to perform a service or diagnostic procedure using real-world examples.

CASE STUDIES Used in many chapters, these are real-world examples of a fault and the procedure that was followed to find and correct a customer concern. The case studies include the “Three Cs” (Complaint, Cause and Correction).

26 CHAPTER 3

FOUR-VALVE CYLINDER HEADS In the past, diesel engines were designed with a two-valve configuration, having one intake valve and one exhaust valve in four-stroke engines. Most current designs are of a four-valve type, using two intake valves and two exhaust valves. Adding more than two valves per cylinder permits more air to flow into and out of the engine. ● SEE FIGURE 3–2.

◼ Valve duration is the number of degrees by which the crankshaft rotates when the valve is off the valve seat.

◼ The maximum amount of air moving through the opening area of a valve depends on the distance around the valve and the distance it lifts open. Using the normal opening lift of about 25% of the valve head diameter as an example, if

LEARNING OBJECTIVES: After studying this chapter, the reader should be able to: • Prepare for the Light Vehicle Diesel Engine (A9) ASE certification test content area “B” (Cylinder Head and Valve Train Diagnosis and Repair). • Explain the design and construction of cylinder heads. • Discuss camshaft design and valve train component operation. • Discuss the purpose and function of rocker arms and bridges. • Discuss the purpose, function, and operation of hydraulic valve lifters. • Describe how to disassemble a cylinder head. • Discuss valve-stem-to-guide clearance.

KEY TERMS: • Bridges 33 • Drainback holes 30 • Stellite® 28 • Valve duration 26 • Valve guides 26 • Valve lash 34• Valve train clearance 34

DIESEL CYLINDER HEADS AND VALVE TRAINS3

chapter

CONSTRUCTION Cylinder heads are constructed from either cast iron or aluminum alloy. ● SEE FIGURE 3–1.

Cylinder heads support the valves and valve train, and contain passages for the flow of intake air, exhaust gases, cool-ant, and sometimes engine oil. In an overhead camshaft design engine, the cylinder head also supports all of the valve train components, including the camshaft, rocker arms, or followers, as well as the intake and exhaust valves and valve guides.

FIGURE 3–1(A) An aluminum GM Duramax V-8 diesel engine cylinder head.

FIGURE 3–1(B) A cast iron Cummins 6.7 liter inline six-cylinder diesel engine cylinder head.

The Case of Erratic Electrical Symptoms

The owner of a 2010 Dodge Truck with a 6.7-liter Cummins engine complained of a noticeable change in the level of the interior or exterior lighting, as well as the speed of the blower motor.

The owner stated that this situation occurred just after starting the truck. The service technician was able to verify the customer concern and monitored the battery voltage using a scan tool to confirm what the technician thought was happening. The intake heaters on the Cummins 6.7 draw so much current that the battery voltage is reduced, causing the dim-ing of the interior lights and the blower motor to turn slower than normal. The intake manifold heaters may continue to run for several minutes after the vehicle has started. No repairs were made and the customer was informed as to why this situation was occurring.

Summary:Complaint – Customer complained that the interior lights were dimmer than normal shortly after starting the engine.Cause – The battery voltage was reduced by the high amperage draw of the intake heaters.Correction – No repairs were needed and the cus-tomer was informed that this was a normal condition on this diesel pickup.

Case Study

Why Check DTCs before Checking TSBs?

DTCs must be known before searching for service bulletins because bulletins often include information on solving problems that involve a stored diagnostic trouble code (DTC).

FREQUENTLY ASKED QUESTION?Think of a Two-Liter Bottle

A two-liter bottle contains two liters of liquid. This is the volume of all four cylinders combined in a two-liter four-cylinder engine. A six-liter engine would therefore have the piston displacement of three two-liter bottles.

TECH TIP

FREQUENTLY ASKED QUESTIONS Both authors have taught for many years and used this experience to address many of the questions heard from students as they are learning the subject material.


IN-TEXT FEATURES v

NOTE: Push on the rubber (elastomer sleeve) of the vibra-tion damper with your fingers or a pencil. If the rubber does not spring back, replace the damper.

NOTES Notes are included to point out a fact or situation that will help the reader better understand a specific task or procedure.

THE SUMMARY, REVIEW QUESTIONS, AND CHAPTER QUIZ at the end of each chapter help students review the material presented in the chapter and test themselves to see how much they’ve learned.

CAUTION: Some bearings may have oil holes in the top shell only. If these are installed incorrectly, no oil will flow to the connecting or main rods, resulting in instant engine failure. To help the oil spread across the entire bearing, some bearings use an oil groove.

DIESEL ENGINE COOLING SYSTEM 67

5. Water pumps are usually engine driven and circulate cool-ant through the engine and the radiator when the thermo-stat opens.

6. Coolant flows through the radiator hoses to and from the engine and through heater hoses to send heated coolant to the heater core in the passenger compartment.

7. All coolants are ethylene glycol-based. Some aftermarket coolants use propylene glycol.

8. The freezing temperature of the coolant can be tested using a hydrometer or refractometer.

1. The purpose and function of the cooling system is to maintain proper engine operating temperature.

2. The thermostat controls engine coolant temperature by opening at its rated opening temperature to allow coolant to flow through the radiator.

3. Coolant fans are designed to draw air through the radiator to aid in the heat transfer process, drawing the heat from the coolant and transferring it to the outside air through the radiator.

4. The cooling system should be tested for leaks using a hand-operated pressure pump.

SUMMARY

5. Why is a 50/50 mixture of antifreeze and water commonly used as a coolant?

6. What are the di�erences among IAT, OAT, and HOATcoolants?

7. What is the di�erence between galvanic activity and electrolysis?

1. What is normal operating coolant temperature?

2. How does the flow of coolant move through the engine and radiator?

3. Why is a cooling system pressurized?

4. What is the purpose of the coolant system bypass?

REVIEW QUESTIONS

7. As the percentage of antifreeze in the coolant increases, __________.a. The freezing point decreases (up to a point)b. The boiling point decreasesc. The heat transfer increasesd. All of the above

8. Adding a chemical to make ethylene glycol coolant bitter to the taste is called __________.a. Passivationb. Embittered

c. Refractometerd. Electrolysis

9. DEX-COOL is __________.a. Propylene glycolb. Ethylene glycolc. Is silicate and phosphate freed. Both b and c

10. A voltmeter was used to check the coolant and a reading of 0.1 volt with the engine o� was measured. A reading of 0.8 volt was measured with the engine running and all electrical accessories turned on. Technician A says that the coolant should be flushed to solve the galvanic ac-tivity. Technician B says that the ground wires and con-nections should be inspected and repaired to solve the electrolysis problem. Which technician is correct?a. Technician A onlyb. Technician B onlyc. Both Technicians A and Bd. Neither Technician A nor B

1. Coolant can be checked using a __________.a. Test stripb. Hydrometer

c. Refractometerd. Any of the above

2. What type of pump is a water pump?a. Positive displacementb. Centrifugal pumpc. Vane-type pumpd. Gear-type pump

3. What diagnostic trouble code (DTC) could be set if the thermostat is defective?a. P0300b. P0171

c. P0440d. P0128

4. Which statement is true about thermostats?a. The temperature marked on the thermostat is the tem-

perature at which the thermostat should be fully open.b. Thermostats control the flow of coolant to the heater.c. The temperature marked on the thermostat is the tem-

perature at which the thermostat should start to open.d. Both a and b

5. The normal operating temperature (coolant tempera-ture) of an engine equipped with a 195°F thermostat is __________.a. 175°F to 195°Fb. 185°F to 205°F

c. 195°F to 215°Fd. 175°F to 215°F

6. Coolant is water and __________.a. Methanolb. Glycerin

c. Kerosened. Ethylene glycol

CHAPTER QUIZ

WARNING

The cast-iron Cummins inline six-cylinder head is very heavy, requiring an engine hoist to remove it from the block. Attempting to lift the head with-out help or a hoist could result in personal injury.

CAUTIONS Cautions are stated whenever there is a possi-bility that the service being performed could result in damage to the vehicle or property if not done according to the procedure published in the service information.

WARNINGS Warnings are stated when there is a possibility that personal injury could result if the service work is not done according to the procedure published in the service information.

STEP BY STEP These photo sequences show the breakdown of the Duramax diesel engine (Chapter 23), the Cummins 6.7. liter six cylinder engine (Chapter 24), and the 3.0 liter Fiat Chrysler V-6 diesel engine (Chapter 25).


vi SUPPLEMENTS

SUPPLEMENTS

RESOURCES IN PRINT AND ONLINELight Vehicle Diesel Engines

Name of Supplement Print Online Audience Description

InstructorResource Manual0-13-467984-9

✔ Instructors NEW! The Ultimate teaching aid: Chapter summaries, key terms, chapter learning objectives, lecture resources, discuss/ demonstrate classroom activities, and answers to the in text review and quiz questions.

TestGen0-13-467987-3

✔ Instructors Test generation software and test bank for the text.

PowerPointPresentation0-13-467985-7

✔ Instructors Slides include chapter learning objectives, lecture outline of the text, and graphics from the book.

ASE CorrelatedTask Sheets – For Instructors0-13-470224-7

✔ Instructors Downloadable ASE task sheets for easy customization and development of unique task sheets.

ASE TaskSheets – For Students0-13-468039-1

✔ Students Study activity manual that correlates ASE Automobile Standards to chapters and page numbers in the text. Available to students at a discounted price when packaged with the text.

VitalSource eBook0-13-468038-3

✔ Students An alternative to purchasing the print text-book, students can subscribe to the same content online and save up to 50% off the suggested list price of the print text. Visit www.vitalsource.com

All online resources can be downloaded from the Instructor’s Resource Center: www.pearsonighered.com/irc


A C K N O W L E D G M E N T S vii

ACKNOWLEDGMENTS

A large number of people and organizations have cooperated in providing the reference material and technical information used in this text. The authors wish to express sincere thanks to the following persons for their special contributions:

Tom BirchYuba College

Carl BorsaniGraphic Home

Richard KriegerMichigan Institute of Technology

Jeff RehkopfFlorida State College

Chuck TaylorSinclair Community College

TECHNICAL AND CONTENT REVIEWERS The following people reviewed the manuscript before production and checked it for technical accuracy and clarity of presentation. Their sug-gestions and recommendations were included in the final draft of the manuscript. Their input helped make this textbook clear and technically accurate while maintaining the easy-to-read style that has made other books from the same author so popular.

A.C. DurdinMoraine Park Technical College

Al EngledahlCollege of DuPage

Tom FreelsSinclair Community College

Christopher FryHarry S Truman College

Marty KamimotoFresno City College

Richard KriegerMichigan Institute of Technology

Carlton H. Mabe, Sr.Virginia Western Community College

Kenneth RedickHudson Valley Community College

Jeff RehkopfFlorida State College

Matt RodaMott Community College

Chuck TaylorSinclair Community College

Dan WarningJoliet Junior College

SPECIAL THANKS The authors wish to thank Chuck Taylor of Sinclair Community College in Dayton, Ohio, plus Mario Dinovo and Brian Quinn of Joliet Junior College who helped with many of the photos. A special thanks to Dick Krieger, Jeff Rehkopf, and Tom Birch for their detailed and thor-ough reviews of the manuscript before publication. Most of all, we wish to thank Michelle Halderman for her assistance in all phases of manuscript preparation.

—Jim Halderman—Curt Ward


viii ABOUT THE AUTHORS

ABOUT THE AUTHORS

JIM HALDERMAN brings a world of experience, knowl-edge, 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.

He has a Bachelor of Science Degree from Ohio Northern University and a Masters 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 cer-tified Master Automotive Technician and Advanced Engine Performance (L1) ASE certified.

Jim is the author of many Automotive textbooks, all pub-lished 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 a member of the advi-sory board for Technological Studies department at Ohio Northern University.

Jim and his wife, Michelle, live in Dayton, Ohio. They have two children. You can reach Jim at:

[email protected]

CURT WARD Curt Ward brings a wealth of talent, experi-ence, and knowledge to his work. Curt is an automotive professor at Joliet Junior College and serves as a visiting auto-motive 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 has 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 is an ASE Master Automotive Technician.

Curt has presented technical seminars at numerous con-ferences 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.

Curt and his wife Tammy have five children and five grand-children. Together they enjoy traveling and exploring historical sites. In his spare time, Curt enjoys modeling 3-rail O-gauge railroads. You can reach Curt at:

[email protected]


ix

BRIEF CONTENTSchapter 1 Diesel Engine Operation 1

chapter 2 Diesel Engine Blocks and Rotating Assemblies 11

chapter 3 Diesel Cylinder Heads and Valve Trains 26

chapter 4 Diesel Engine Lubrication Systems 39

chapter 5 Diesel Engine Cooling System 51

chapter 6 Diesel Engine Condition Diagnosis 68

chapter 7 Diesel Engine Disassembly, Cleaning, and Crack Detection 82

chapter 8 Diesel Engine Assembly 93

chapter 9 Turbocharger Systems 107

chapter 10 Air Induction and EGR Systems 117

chapter 11 Diesel and Biodiesel Fuels 129

chapter 12 Fuel Supply and Low-Pressure Fuel Systems 135

chapter 13 High-Pressure Common Rail Diesel Fuel Systems 142

chapter 14 Hydraulically Actuated Electronic Unit Injector (HEUI) Systems 157

chapter 15 Exhaust and Aftertreatment Systems 165

chapter 16 Diesel Service Procedures 176

chapter 17 Drivetrain Electricity and Electronics 183

chapter 18 CAN and Network Communications 205

chapter 19 Diesel OBD II 222

chapter 20 OBD-II Diesel Monitors 230

chapter 21 OBD-II Diesel Diagnosis 239

chapter 22 Ford Power Stroke Diesel Engines 250

chapter 23 Duramax Diesel Engines 268

chapter 24 Cummins Diesel Engines 290

chapter 25 Fiat Chrysler Diesel Engines 309

appendix 1 A9 Sample ASE-Type Certification Test 323

appendix 2 ASE A9 Task Correlation Chart 326

Glossary 331

Index 338


xi

CONTENTSchapter 1

DIESEL ENGINE OPERATION 1■■ Learning Objectives 1■■ Key Terms 1■■ Engines 1■■ Four-Stroke Cycle Operation 1■■ Engine Construction Overview 3■■ Diesel Engines 4■■ Engine Size 6■■ Compression Ratio 7■■ Torque 8■■ Power 8

Summary 9review QueStionS 9Chapter Quiz 10

chapter 2

DIESEL ENGINE BLOCKS AND ROTATING ASSEMBLIES 11

■■ Learning Objectives 11■■ Key Terms 11■■ Diesel Engine Blocks 11■■ Crankshafts 14■■ Crankshaft Construction 16■■ Crankshaft Features 17■■ Crankshaft Service 18■■ Engine Bearings 19■■ Bearing Clearance 22■■ Camshaft Bearings 23


chapter 3

DIESEL CYLINDER HEADS AND VALVE TRAINS 26

■■ Learning Objectives 26■■ Key Terms 26■■ Cylinder Heads 26■■ Intake and Exhaust Valves 27

■■ Valve Seats 28■■ Valve Springs 29■■ Cylinder Head Passages 30■■ Camshaft 31■■ Rocker Arms and Bridges 33■■ Pushrods 33■■ Lifter or Tappets 34■■ Camshaft Removal 35■■ Cylinder Head Disassembly 35


chapter 4

DIESEL ENGINE LUBRICATION SYSTEMS 39

■■ Learning Objectives 39■■ Key Terms 39■■ Lubrication Principles 39■■ Oil Pumps 40■■ Oil Passages 43■■ Oil Pans 45■■ Engine Oil 46■■ API Rating 46■■ European Rating System 47■■ Oil Filters 47


chapter 5

DIESEL ENGINE COOLING SYSTEM 51

■■ Learning Objectives 51■■ Key Terms 51■■ Cooling Systems 51■■ Cooling System Operation 52■■ Thermostats 52■■ Radiators 54■■ Pressure Caps 55■■ Coolant Recovery Systems 56


■■ Water Pumps 57■■ Cooling Fans 58■■ Cooling System Testing 59■■ Coolant Temperature Warning Light 60■■ Coolant 61■■ Types of Coolant 62■■ Coolant Testing 64■■ Coolant Replacement Issues 66


chapter 6

DIESEL ENGINE CONDITION DIAGNOSIS 68

■■ Learning Objectives 68■■ Key Terms 68■■ Typical Engine-Related Complaints 68■■ Diagnostic Trouble Codes and Technical Service

Bulletins 68■■ Visual Inspection 69■■ Engine Noise/Vibration Diagnosis 71■■ Crankcase Pressure Test 72■■ Oil Pressure Testing 73■■ Misfire Diagnosis 74■■ Engine-Related Misfire Diagnosis 75■■ Compression Test 75■■ Engine Starting and Charging Diagnosis 77


chapter 7

DIESEL ENGINE DISASSEMBLY, CLEANING, AND CRACK DETECTION 82

■■ Learning Objectives 82■■ Key Terms 82■■ Preparing the Engine for Removal 82■■ Rotating Assemblies Removal 84■■ Cylinder Head Disassembly 85

■■ Mechanical Cleaning 86■■ Chemical Cleaners 87■■ Spray and Steam Cleaning 87■■ Thermal Cleaning 88■■ Tank and Vapor Cleaning 88■■ Ultrasonic and Vibratory Cleaning 89■■ Crack Detection 90


chapter 8

DIESEL ENGINE ASSEMBLY 93■■ Learning Objectives 93■■ Key Terms 93■■ Details 93■■ Short Block Preparation 93■■ Cylinder Head Preparation 94■■ Short Block Assembly 94■■ Piston/Rod Installation 98■■ Cylinder Head Installation 100■■ Torque-to-Yield Head Bolts 101■■ Valve Train Assembly 103■■ Final Assembly 104


chapter 9

TURBOCHARGER SYSTEMS 107■■ Learning Objectives 107■■ Key Terms 107■■ Introduction 107■■ Turbocharger Purpose and Function 107■■ Turbochargers 108■■ Boost Control 111■■ Variable Geometry Turbocharger 111■■ Air Charge Cooler 114■■ Turbocharger Diagnosis 114


xii CONTENTS


CONTENTS xiii

chapter 13

HIGH-PRESSURE COMMON RAIL DIESEL FUEL SYSTEMS 142

■■ Learning Objectives 142■■ Key Terms 142■■ Functions of High-Pressure Injection Systems 142■■ High-Pressure Common Rail Injection 144■■ High-Pressure Pump 146■■ Common Rail Injector 148■■ Powertrain Control Module 150■■ High-Pressure Common Rail (HPCR) Fuel System Service

Procedures 151


chapter 14

HYDRAULICALLY ACTUATED ELECTRONIC UNIT INJECTOR (HEUI) SYSTEMS 157

■■ Learning Objectives 157■■ Key Terms 157■■ HEUI Systems 157■■ Control Pressure 158■■ Injector Types 159■■ HEUI Service and Daignostics 161


chapter 15

EXHAUST AND AFTERTREATMENT SYSTEMS 165

■■ Learning Objectives 165■■ Key Terms 165■■ Exhaust Chemistry 165■■ Exhaust System Components 167■■ Diesel Oxidation Catalyst (DOC) 168

chapter 10

AIR INDUCTION AND EGR SYSTEMS 117

■■ Learning Objectives 117■■ Key Terms 117■■ Air Induction System 117■■ Air Induction System Diagnosis 120■■ Intake Manifold Heater 121■■ Glow Plugs 122■■ EGR System 124■■ EGR System Diagnosis 126


chapter 11

DIESEL AND BIODIESEL FUELS 129

■■ Learning Objectives 129■■ Key Terms 129■■ Diesel Fuel 129■■ Biodiesel 132■■ E-Diesel Fuel 133


chapter 12

FUEL SUPPLY AND LOW-PRESSURE FUEL SYSTEMS 135

■■ Learning Objectives 135■■ Key Terms 135■■ Low-Pressure Fuel System Components 135■■ Low-Pressure Fuel System Service 139



xiv CONTENTS

■■ Terminals and Connectors 196■■ Wire Repair 197■■ Relays 199■■ Switches 200■■ Speed Sensors 202■■ Throttle Position (TP) Sensor 202


chapter 18

CAN AND NETWORK COMMUNICATIONS 205

■■ Learning Objectives 205■■ Key Terms 205■■ Module Communications and Networks 205■■ Network Fundamentals 205■■ Module Communications Configuration 207■■ Network Communications Classifications 207■■ General Motors Communications Protocols 208■■ Ford Network Communications Protocols 211■■ Chrysler Communications Protocols 212■■ Controller Area Network 213■■ Honda/Toyota Communications 215■■ European Bus Communications 215■■ Network Communications Diagnosis 216■■ OBD-II Data Link Connector 219


chapter 19

DIESEL OBD II 222■■ Learning Objectives 222■■ Key Terms 222■■ OBD II 222■■ California OBD II 223■■ Monitors 224■■ Diagnostic Trouble Codes 224■■ OBD-II Freeze Frame 225■■ PCM Tests 226■■ Global OBD II 226


■■ NOx Adsorber Catalyst 168■■ Selective Catalyst Reduction (SCR) 169■■ Diesel Exhaust Fluid 169■■ Reductant Dosing Module 170■■ Diesel Particulate Filter (DPF) 170■■ Differential Presure Sensor 171■■ Temperature Sensors 172■■ NOx Sensors 173■■ Oxygen Sensors 173


chapter 16

DIESEL SERVICE PROCEDURES 176

■■ Learning Objectives 176■■ Key Terms 176■■ Overview 176■■ Intake Air System Maintenance 177■■ Engine Oil Service 178■■ Cooling System Service 178■■ Fuel System Service 180■■ Diesel Exhaust Fluid Service 180


chapter 17

DRIVETRAIN ELECTRICITY AND ELECTRONICS 183

■■ Learning Objectives 183■■ Key Terms 183■■ Introduction 183■■ Electricity 183■■ How Electrons Move Through A Conductor 185■■ Units of Electricity 186■■ Electrical Circuits 187■■ Electrical Schematics 188■■ Types of Circuit Faults 188■■ Fused Jumper Wire 191■■ Test Light 191■■ Digital Meters 192■■ Inductive Ammeters 195


CONTENTS xv

■■ High-Pressure Fuel System 259■■ High-Pressure Common Rail Fuel Injectors 260■■ Control System Inputs 262■■ Engine Outputs 263■■ Diesel Aftertreatment System 264■■ Five- and Six-Cylinder Power Stroke Diesel Engines 265


chapter 23

DURAMAX DIESEL ENGINES 268■■ Learning Objectives 268■■ Key Terms 268■■ Background 268■■ 2.8 Inline 4-Cylinder Duramax 272■■ Engine Mechanical 272■■ Cooling System 275■■ Cylinder Heads 277■■ Service Information 277■■ Low-Pressure Side Fuel System 278■■ Fuel Aeration 279■■ High-Pressure Fuel System 280■■ Glow Plugs and EGR 281■■ Duramax Diesel Aftertreatment System 282


chapter 24

CUMMINS DIESEL ENGINES 290■■ Learning Objectives 290■■ Key Terms 290■■ Background Cummins 5.9/6.7-Liter Engine 290■■ ISB 6.7 Engine Details 292■■ ISB 6.7 Engine Low-Pressure Fuel System 295■■ ISB 6.7 Engine High-Pressure Fuel System 296■■ Control System Inputs 298■■ Engine Outputs 298■■ Cummins 6.7-Liter Diesel Aftertreatment System 299■■ Cummins 5.0-Liter V-8 Engine 300■■ 5.0 V-8 Engine Mechanical 301■■ 5.0 V-8 Engine Low-Pressure Fuel System 301■■ 5.0 V-8 Engine High-Pressure Fuel System 302■■ Air Induction System 303

chapter 20

OBD-II DIESEL MONITORS 230■■ Learning Objectives 230■■ Key Terms 230■■ Major System Monitors 230■■ Comprehensive Component Monitor 230■■ Enabling Criteria 231■■ Misfire Monitor 232■■ Fuel System Monitor 233■■ Non-Continuous Monitors 233


chapter 21

OBD-II DIESEL DIAGNOSIS 239■■ Learning Objectives 239■■ Key Terms 239■■ The Diesel Engine Diagnostic Process 239■■ Verify the Customer Concern 240■■ Visual Inspection 240■■ Check for Any Stored DTCs 242■■ Check TSBs 243■■ Scan Tool Data 243■■ Pinpoint Tests 246■■ Determine the Root Cause 246■■ Flash Programming 246


chapter 22

FORD POWER STROKE DIESEL ENGINES 250

■■ Learning Objectives 250■■ Key Terms 250■■ Background 250■■ 6.7-Liter Power Stroke 252■■ 6.7 Cooling System 253■■ 6.7 Lubrication System 254■■ Engine Mechanical 254■■ Low-Pressure Fuel System 255■■ Diesel Fuel Conditioner Module (DFCM) 256


xvi CONTENTS

■■ Low-Pressure Fuel System 312■■ High-Pressure Fuel System 314■■ Control System Inputs 316■■ Engine Outputs 318■■ VM 3.0-Liter V-6 Diesel Aftertreatment System 318


appendix 1 A9 SAMPLE ASE-TYPE CERTIFICATION TEST 323

appendix 2 ASE A9 TASK CORRELATION CHART 326

GLOSSARY 331

INDEX 338

■■ Glow Plug System 304■■ EGR System 304■■ Exhaust Aftertreatment System 304


chapter 25

FIAT CHRYSLER DIESEL ENGINES 309

■■ Learning Objectives 309■■ Key Terms 309■■ Overview 309■■ Engine Identification 309■■ Service Information 310■■ Engine Mechanical 311


light vehicle diesel engineslight vehicle diesel engines james d. halderman curt ward 330 hudson...

Documents