| Preface |
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ix | |
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Chapter 1 Shop and Personal Safety |
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1 | (18) |
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1 | (1) |
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2 | (1) |
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2 | (1) |
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2 | (1) |
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2 | (1) |
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2 | (1) |
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Personal Protective Equipment |
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2 | (3) |
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2 | (1) |
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3 | (1) |
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3 | (1) |
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4 | (1) |
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4 | (1) |
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5 | (1) |
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5 | (1) |
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5 | (1) |
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5 | (2) |
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6 | (1) |
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6 | (1) |
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7 | (1) |
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7 | (1) |
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7 | (3) |
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7 | (3) |
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10 | (2) |
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10 | (1) |
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10 | (1) |
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11 | (1) |
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11 | (1) |
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11 | (1) |
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Chassis and Shop Electrical Safety |
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12 | (1) |
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12 | (1) |
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Chassis Wiring and Connectors |
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12 | (1) |
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Mains Electrical Equipment |
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13 | (1) |
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13 | (4) |
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14 | (1) |
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15 | (1) |
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16 | (1) |
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16 | (1) |
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17 | (1) |
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18 | (1) |
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Chapter 2 Introduction to Diesel Engines |
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19 | (12) |
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20 | (1) |
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Vocational Automotive Diesels |
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20 | (1) |
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Off-Highway Light Duty Diesels |
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20 | (1) |
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21 | (1) |
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21 | (1) |
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21 | (1) |
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22 | (2) |
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Direct Injection, Compression Ignition Engine |
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23 | (1) |
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Engine Systems and Circuits |
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24 | (1) |
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25 | (1) |
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25 | (2) |
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26 | (1) |
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27 | (1) |
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Mean Effective Pressure (MEP) |
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27 | (1) |
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Cylinder Pressure and Throw Leverage |
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28 | (1) |
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28 | (1) |
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29 | (1) |
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30 | (1) |
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Chapter 3 Cylinder Block Assemblies |
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31 | (34) |
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32 | (1) |
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Function of the Powertrain |
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32 | (1) |
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Cylinder Block and Crankcase |
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32 | (1) |
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32 | (13) |
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33 | (1) |
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Aluminum Trunk-Type Pistons |
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34 | (1) |
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Forged Steel Trunk-Type Pistons |
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35 | (2) |
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37 | (1) |
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Combustion Chamber Designs |
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37 | (1) |
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37 | (1) |
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38 | (1) |
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39 | (1) |
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40 | (1) |
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41 | (1) |
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42 | (1) |
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42 | (1) |
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Piston and Cylinder Wall Lubrication |
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43 | (1) |
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44 | (1) |
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Piston Thrust and Antithrust Side Identification |
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44 | (1) |
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45 | (2) |
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45 | (1) |
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Connecting Rod Construction |
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45 | (1) |
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46 | (1) |
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47 | (1) |
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47 | (8) |
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48 | (1) |
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48 | (1) |
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48 | (1) |
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Removal of a Crankshaft from Cylinder Block |
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49 | (1) |
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50 | (1) |
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51 | (1) |
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Reconditioning Crankshafts |
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51 | (1) |
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Front and Rear Main Seals |
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51 | (1) |
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51 | (2) |
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53 | (2) |
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55 | (1) |
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Vibration Damper Construction |
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55 | (1) |
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Solid Rubber Vibration Dampers |
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56 | (1) |
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56 | (2) |
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56 | (1) |
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57 | (1) |
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57 | (1) |
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Reconditioning and Inspecting Flywheels |
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58 | (1) |
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58 | (3) |
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58 | (1) |
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Cylinder Block Construction |
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58 | (1) |
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58 | (1) |
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59 | (1) |
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Final Inspection and Assembly |
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60 | (1) |
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60 | (1) |
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61 | (1) |
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61 | (1) |
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62 | (1) |
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63 | (1) |
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64 | (1) |
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Chapter 4 Cylinder Heads and Timing Train |
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65 | (24) |
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66 | (1) |
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66 | (3) |
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Cylinder Head Disassembly, Inspection, and Reconditioning |
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66 | (1) |
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Cylinder Head Installation |
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67 | (2) |
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69 | (1) |
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69 | (2) |
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69 | (1) |
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70 | (1) |
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71 | (4) |
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71 | (2) |
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Removing and Installing the Camshaft |
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73 | (2) |
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75 | (11) |
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76 | (1) |
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76 | (3) |
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79 | (1) |
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79 | (1) |
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79 | (1) |
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Inspecting Valve Springs and Retainers |
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80 | (1) |
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81 | (1) |
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82 | (4) |
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Creating a Valve Polar Diagram |
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86 | (1) |
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86 | (1) |
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87 | (1) |
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88 | (1) |
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Chapter 5 Intake and Exhaust Systems |
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89 | (23) |
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90 | (1) |
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Diesel Engine Breathing Circuit |
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90 | (2) |
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Gas Flow in Breathing Circuit |
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90 | (2) |
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92 | (3) |
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92 | (2) |
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94 | (1) |
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95 | (7) |
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95 | (1) |
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96 | (4) |
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100 | (1) |
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101 | (1) |
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101 | (1) |
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101 | (1) |
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101 | (1) |
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102 | (1) |
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Types of Charge Air Coolers |
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102 | (1) |
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Boost Circuit Troubleshooting |
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103 | (1) |
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Testing Air-to-Air Coolers |
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103 | (1) |
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Exhaust Gas Recirculation |
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103 | (2) |
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104 | (1) |
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104 | (1) |
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104 | (1) |
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Valve Design and Breathing |
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105 | (1) |
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105 | (1) |
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Parallel Port Valve Configurations |
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105 | (1) |
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105 | (1) |
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105 | (1) |
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Exhaust System Components |
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106 | (3) |
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106 | (1) |
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107 | (1) |
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Engine Exhaust Aftertreatment |
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107 | (1) |
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108 | (1) |
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109 | (1) |
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Troubleshooting Exhaust Aftertreatment Systems |
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109 | (1) |
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Breathing Circuit Sensors |
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109 | (1) |
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109 | (1) |
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110 | (1) |
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111 | (1) |
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Chapter 6 Cooling and Lubrication Circuits |
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112 | (37) |
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113 | (1) |
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113 | (19) |
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113 | (1) |
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114 | (5) |
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Cooling System Components |
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119 | (6) |
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Coolant Circuit Management |
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125 | (1) |
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126 | (1) |
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127 | (2) |
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129 | (1) |
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129 | (3) |
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Engine Lubricating Circuit |
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132 | (13) |
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133 | (1) |
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Engine Oil Classification and Terminology |
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134 | (1) |
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135 | (1) |
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136 | (1) |
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Lubrication System Components |
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137 | (3) |
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Filter Types and Efficiencies |
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140 | (5) |
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Lubricating Circuit Problems |
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145 | (1) |
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145 | (2) |
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147 | (1) |
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148 | (1) |
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Chapter 7 Chassis Electrical Circuits |
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149 | (35) |
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150 | (1) |
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150 | (6) |
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150 | (1) |
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150 | (2) |
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152 | (3) |
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155 | (1) |
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156 | (8) |
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Ground and Insulated Circuits |
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156 | (1) |
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Starter Circuit Components |
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157 | (1) |
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157 | (3) |
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160 | (1) |
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161 | (3) |
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164 | (1) |
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Glow Plug Circuit Management |
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165 | (1) |
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165 | (1) |
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Electrical Troubleshooting |
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165 | (13) |
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Charging System Failures and Testing |
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165 | (5) |
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Cranking Circuit Diagnostics |
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170 | (2) |
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Troubleshooting the Cranking Circuit |
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172 | (6) |
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178 | (4) |
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Reading an Oscilloscope Graph |
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178 | (1) |
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179 | (1) |
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180 | (2) |
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182 | (1) |
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182 | (2) |
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Chapter 8 Fuel Subsystems |
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184 | (20) |
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184 | (1) |
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Chapter 8 Fuel Subsystem Layout |
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185 | (1) |
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186 | (2) |
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186 | (1) |
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187 | (1) |
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188 | (8) |
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189 | (1) |
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189 | (2) |
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191 | (2) |
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193 | (3) |
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Integrated Fuel Management Modules |
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196 | (1) |
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Fuel Charging/Transfer Pumps |
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196 | (3) |
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196 | (1) |
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197 | (1) |
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197 | (1) |
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198 | (1) |
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Monitoring the Fuel Subsystem |
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199 | (3) |
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199 | (1) |
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Charging to Injection Circuit |
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200 | (2) |
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202 | (1) |
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203 | (1) |
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Chapter 9 Injector Nozzles |
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204 | (17) |
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204 | (2) |
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205 | (1) |
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Multiple-Orifice Injectors |
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205 | (1) |
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206 | (1) |
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206 | (3) |
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207 | (2) |
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209 | (1) |
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209 | (1) |
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210 | (4) |
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211 | (3) |
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214 | (1) |
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214 | (5) |
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Removal of Injectors from the Cylinder Head |
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214 | (2) |
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216 | (3) |
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219 | (1) |
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219 | (1) |
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220 | (1) |
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220 | (1) |
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Chapter 10 Pump-Line-Nozzle Injection Systems |
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221 | (35) |
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222 | (1) |
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Port-Helix Metering Pumps |
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222 | (11) |
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223 | (1) |
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223 | (3) |
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Injection Pump Components |
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226 | (1) |
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Governor or Rack Actuator Housing |
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227 | (3) |
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Timing Injection Pumps to an Engine |
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230 | (2) |
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Delivery, Injection, and Combustion |
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232 | (1) |
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Opposed-Plunger, Inlet-Metering Injection Pumps |
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233 | (9) |
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Inlet-Metering Injection Pumps |
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234 | (3) |
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Inlet-Metering Distributor Pump Circuits |
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237 | (3) |
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240 | (1) |
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Governor Operation Summary |
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240 | (1) |
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241 | (1) |
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Opposed-Plunger, Inlet-Metering Pump Summary |
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242 | (1) |
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Sleeve-Metering, Single Plunger Distributor Pumps |
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242 | (11) |
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242 | (1) |
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Construction and Operation |
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243 | (5) |
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248 | (4) |
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Timing a VE pump to an Engine |
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252 | (1) |
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253 | (1) |
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253 | (2) |
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255 | (1) |
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Chapter 11 Engine Electronics |
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256 | (21) |
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257 | (1) |
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257 | (1) |
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257 | (1) |
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258 | (9) |
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258 | (1) |
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259 | (1) |
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260 | (1) |
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260 | (2) |
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262 | (2) |
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264 | (1) |
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265 | (2) |
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267 | (1) |
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267 | (3) |
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267 | (1) |
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268 | (1) |
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269 | (1) |
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270 | (5) |
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271 | (4) |
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275 | (1) |
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275 | (1) |
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276 | (1) |
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276 | (1) |
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Chapter 12 Electronic Diesel Fuel Injection Systems |
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277 | (28) |
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278 | (1) |
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278 | (4) |
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278 | (1) |
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278 | (4) |
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282 | (1) |
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282 | (8) |
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283 | (1) |
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283 | (1) |
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283 | (1) |
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283 | (1) |
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Injection Actuation Circuit |
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283 | (1) |
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284 | (3) |
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287 | (1) |
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287 | (1) |
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288 | (1) |
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288 | (2) |
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290 | (10) |
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290 | (1) |
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291 | (1) |
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CR Subsystems and Components |
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292 | (2) |
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294 | (1) |
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Rail Pressure Management Control |
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295 | (1) |
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295 | (3) |
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Rail Pressure Control Valves |
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298 | (1) |
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298 | (1) |
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299 | (1) |
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299 | (1) |
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CR Electrohydraulic Injectors |
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300 | (2) |
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Injector Operating Phases |
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300 | (1) |
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Reprogramming and Diagnostics |
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301 | (1) |
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302 | (1) |
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303 | (1) |
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304 | (1) |
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Chapter 13 Emission Controls |
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305 | (20) |
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306 | (1) |
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306 | (1) |
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306 | (2) |
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307 | (1) |
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307 | (1) |
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307 | (1) |
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Diesel Engine Emission Controls |
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308 | (1) |
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Factors Influencing Emissions |
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308 | (1) |
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External Emission Controls |
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309 | (1) |
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309 | (1) |
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309 | (1) |
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310 | (2) |
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311 | (1) |
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311 | (1) |
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Diesel Particulate Filters (DPFs) |
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312 | (3) |
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313 | (1) |
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313 | (1) |
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313 | (1) |
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DPF Temperature Monitoring |
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313 | (1) |
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314 | (1) |
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Selective Catalytic Reduction (SCR) |
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315 | (6) |
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315 | (1) |
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316 | (4) |
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320 | (1) |
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Miscellaneous Factors That Limit Noxious Emissions |
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321 | (2) |
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Positive Crankcase Ventilation |
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321 | (1) |
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321 | (1) |
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Variable-Geometry Turbochargers |
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321 | (2) |
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323 | (1) |
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323 | (1) |
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323 | (1) |
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324 | (1) |
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324 | (1) |
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Chapter 14 Servicing and Maintenance |
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325 | (27) |
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325 | (1) |
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Service Literature and Diagnostic Software |
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326 | (1) |
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327 | (1) |
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Startup and Engine Break-In |
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327 | (5) |
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327 | (3) |
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330 | (2) |
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Air Intake System Maintenance |
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332 | (2) |
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Air Filter Restriction Gauge |
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332 | (1) |
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333 | (1) |
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334 | (3) |
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334 | (2) |
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Changing the Engine Oil and Oil Filter |
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336 | (1) |
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337 | (3) |
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338 | (1) |
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339 | (1) |
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340 | (7) |
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Ultra-Low-Sulfur Diesel Fuel |
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340 | (1) |
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341 | (1) |
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341 | (2) |
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343 | (1) |
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344 | (1) |
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345 | (1) |
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Combination Filter/Separators Modules |
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346 | (1) |
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Emissions Aftertreatment Service |
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347 | (3) |
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Selective Catalytic Reduction |
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347 | (3) |
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Diesel Particulate Filter Service |
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350 | (1) |
|
|
|
350 | (1) |
|
|
|
351 | (1) |
|
|
|
351 | (1) |
|
Chapter 15 Diagnostics and Testing |
|
|
352 | (39) |
|
|
|
353 | (1) |
|
|
|
353 | (1) |
|
|
|
354 | (10) |
|
Onboard Diagnostic Lights |
|
|
354 | (1) |
|
|
|
354 | (1) |
|
Connecting to the Chassis Data Bus |
|
|
354 | (1) |
|
|
|
355 | (1) |
|
|
|
355 | (1) |
|
|
|
356 | (2) |
|
|
|
358 | (6) |
|
Mechanical Troubleshooting |
|
|
364 | (12) |
|
|
|
364 | (4) |
|
|
|
368 | (1) |
|
Cylinder Balance Problems |
|
|
369 | (2) |
|
High Exhaust Temperature Readings |
|
|
371 | (1) |
|
|
|
371 | (1) |
|
|
|
371 | (1) |
|
|
|
372 | (1) |
|
|
|
373 | (1) |
|
|
|
374 | (1) |
|
|
|
374 | (1) |
|
|
|
374 | (1) |
|
|
|
375 | (1) |
|
|
|
375 | (1) |
|
Fuel Pump/Injector Scuffing |
|
|
376 | (1) |
|
Quick Reference Diagnostic Charts |
|
|
376 | (1) |
|
|
|
376 | (13) |
|
Using a Scopemeter to Verify CAN Activity |
|
|
385 | (1) |
|
Troubleshooting Two-Wire Bus Malfunctions |
|
|
386 | (1) |
|
|
|
387 | (1) |
|
|
|
388 | (1) |
|
|
|
388 | (1) |
|
|
|
389 | (1) |
|
|
|
389 | (1) |
|
|
|
390 | (1) |
| Glossary |
|
391 | (42) |
| Acronyms |
|
433 | (5) |
| Index |
|
438 | |
