Light Vehicle Diesel Engines / James D

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: Manager, Rights Management: Andrew Gilfillan Johanna Burke Editorial Assistant: Lara Dimmick Operations Specialist: Deidra Smith Senior Vice President, Marketing: Cover Design: Cenveo Publisher Services David Gesell Full-Service Project Management and Marketing Coordinator: Elizabeth Composition: Abinaya Rajendran, MacKenzie-Lamb Integra Software Services Pvt. Ltd. Director, Digital Studio and Content Printer/Binder: LSC Communications, Inc. Production: Brian Hyland Cover Printer: Phoenix Color/Hagerstown Managing Producer: Jennifer Sargunar Text Font: Helvetica Neue LT W1G Content Producer (Team Lead): Faraz Sharique Ali

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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

1 17

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

A01_HALD8726_01_SE_FM.indd 2 12/1/17 1:50 PM PREFACE

This new title is designed to meet the needs of a semester ASE A9 CORRELATED This text material meets all of the course in light vehicle diesel engines. This title is designed to tasks specified by ASE for the Light Diesel (A9) test content be the “keystone” course for an automotive program because it area. The correlation to both the text pages and the task sheet includes all of the advanced technology in on-board diagnosis are found in appendix 2. and up-to-date diesel technology all in one title. A COMPLETE INSTRUCTOR AND STUDENT SUPPLE- DEPTH OF CONTENT AND FORMAT MENTS PACKAGE All Professional Technician textbooks Scope: The scope of this title is intended to meet the needs of are accompanied by a full set of instructor and student supple- a textbook that covers light vehicle diesel engines to supplements. Please see page vi for a detailed list of supplements. ment and enhance an automotive two-year curriculum. The first 9 chapters are designed to introduce diesel engine construction A FOCUS ON DIAGNOSIS AND PROBLEM SOLVING and engine mechanical systems. Chapters 10 through 21 cover The Professional Technician Series has been developed to the emission control and service procedures that every techni- satisfy the need for a greater emphasis on problem diagno- cian needs to know when servicing a light vehicle diesel engine. sis. Automotive instructors and service managers agree that Chapters 22 through 25 cover each of the most commonly used students and beginning technicians need more training in diesel engines in detail. diagnostic procedures and skill development. To meet this need and demonstrate how real-world problems are solved, Organization: The content includes the basics needed by all Case Studies features are included throughout and highlight service technicians and also covers the following organization how real-life problems are diagnosed and repaired. for most systems: The following pages highlight the unique core features that ■■ Purpose and function of the system set the Professional Technician Series book apart from other ■■ Parts involved and operational description automotive textbooks.

■■ Diagnosis and service

iii

A01_HALD8726_01_SE_FM.indd 3 12/1/17 1:50 PM IN-TEXT FEATURES

chapter DIESEL CYLINDER HEADS Case Study AND VALVE TRAINS 3 The Case of Erratic Electrical Symptoms The owner of a 2010 Dodge Truck with a 6.7-liter LEARNING OBJECTIVES: After studying this chapter, the reader should be able to: • Prepare for the Light Vehicle Diesel Cummins engine complained of a noticeable change 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 in the level of the interior or exterior lighting, as well 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 as the speed of the blower motor. •Valve train clearance 34 The owner stated that this situation occurred just

FOUR-VALVE CYLINDER HEADS In the past, diesel after starting the truck. The service technician was engines were designed with a two-valve configuration, having one intake valve and one exhaust valve in four-stroke engines. able to verify the customer concern and monitored Most current designs are of a four-valve type, using two intake CONSTRUCTION Cylinder heads are constructed from valves and two exhaust valves. Adding more than two valves either cast iron or aluminum alloy. ● SEE FIGURE 3–1. per cylinder permits more air to flow into and out of the engine. the battery voltage using a scan tool to conﬁrm what Cylinder heads support the valves and valve train, and ● SEE FIGURE 3–2. contain passages for the flowof intake air, exhaust gases, cool- ◼ Valve duration is the number of degrees by which the the technician thought was happening. The intake ant, and sometimes engine oil. In an overhead camshaft design crankshaft rotates when the valve is off the valve seat. engine, the cylinder head also supports all of the valve train ◼ The maximum amount of air moving through the opening heaters on the Cummins 6.7 draw so much current components, including the camshaft, rocker arms, or followers, area of a valve depends on the distance around the valve as well as the intake and exhaust valves and valve guides. and the distance it lifts open. Using the normal opening lift that the battery voltage is reduced, causing the dim- of about 25% of the valve head diameter as an example, if 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 FIGURE 3–1(A) An aluminum GM Duramax V-8 diesel engine FIGURE 3–1(B) A cast iron Cummins 6.7 liter inline six- cylinder head. cylinder diesel engine cylinder head. lights were dimmer than normal shortly after starting the engine. 26 CHAPTER 3 Cause – The battery voltage was reduced by the high amperage draw of the intake heaters. OBJECTIVES AND KEY TERMS The learning objectives Correction – No repairs were needed and the cus- are stated at the beginning of each chapter to help the reader tomer was informed that this was a normal condition and the instructors see what the objectives of the content being on this diesel pickup. 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 CASE STUDIES Used in many chapters, these are real-world also set in bold type to make them easier to find in the text. The examples of a fault and the procedure that was followed to find key terms are also listed and defined in the glossary. and correct a customer concern. The case studies include the “Three Cs” (Complaint, Cause and Correction).

TECH TIP ? FREQUENTLY ASKED QUESTION

Think of a Two-Liter Bottle Why Check DTCs before Checking TSBs? A two-liter bottle contains two liters of liquid. This is DTCs must be known before searching for service the volume of all four cylinders combined in a two-liter bulletins because bulletins often include information four-cylinder engine. A six-liter engine would therefore on solving problems that involve a stored diagnostic have the piston displacement of three two-liter bottles. trouble code (DTC).

FREQUENTLY ASKED QUESTIONS Both authors have TECH TIPS This feature is included in most chapters and taught for many years and used this experience to address helps the reader better understand how to perform a service or many of the questions heard from students as they are learning diagnostic procedure using real-world examples. the subject material.

iv IN-TEXT FEATURES

A01_HALD8726_01_SE_FM.indd 4 12/1/17 1:50 PM NOTE: Push on the rubber (elastomer sleeve) of the vibration damper with your fingers or a pencil. If the rubber SUMMARY

1. The purpose and function of the cooling system is to 5. Water pumps are usually engine driven and circulate cool- does not spring back, replace the damper. maintain proper engine operating temperature. ant through the engine and the radiator when the thermo- 2. The thermostat controls engine coolant temperature by stat opens. opening at its rated opening temperature to allow coolant 6. Coolant ﬂows through the radiator hoses to and from the to ﬂow through the radiator. engine and through heater hoses to send heated coolant Notes are included to point out a fact or situation 3. Coolant fans are designed to draw air through the radiator to the heater core in the passenger compartment. NOTES to aid in the heat transfer process, drawing the heat from 7. All coolants are ethylene glycol-based. Some aftermarket the coolant and transferring it to the outside air through coolants use propylene glycol. that will help the reader better understand a specific task or the radiator. 8. The freezing temperature of the coolant can be tested 4. The cooling system should be tested for leaks using a using a hydrometer or refractometer. procedure. hand-operated pressure pump.

REVIEW QUESTIONS

CAUTION: Some bearings may have oil holes in the top 1. What is normal operating coolant temperature? 5. Why is a 50/50 mixture of antifreeze and water commonly 2. How does the ﬂow of coolant move through the engine used as a coolant? shell only. If these are installed incorrectly, no oil will and radiator? 6. What are the dierences among IAT, OAT, and HOAT 3. Why is a cooling system pressurized? coolants? 4. What is the purpose of the coolant system bypass? 7. What is the dierence between galvanic activity and flow to the connecting or main rods, resulting in instant electrolysis? engine failure. To help the oil spread across the entire bearing, some bearings use an oil groove. CHAPTER QUIZ

1. Coolant can be checked using a ______. 7. As the percentage of antifreeze in the coolant increases, a. Test strip c. Refractometer ______. b. Hydrometer d. Any of the above a. The freezing point decreases (up to a point) CAUTIONS Cautions are stated whenever there is a possi- 2. What type of pump is a water pump? b. The boiling point decreases a. Positive displacement c. The heat transfer increases b. Centrifugal pump d. All of the above bility that the service being performed could result in damage to c. Vane-type pump 8. Adding a chemical to make ethylene glycol coolant bitter d. Gear-type pump to the taste is called ______. the vehicle or property if not done according to the procedure 3. What diagnostic trouble code (DTC) could be set if the a. Passivation c. Refractometer thermostat is defective? b. Embittered d. Electrolysis published in the service information. a. P0300 c. P0440 9. DEX-COOL is ______. b. P0171 d. P0128 a. Propylene glycol 4. Which statement is true about thermostats? b. Ethylene glycol a. The temperature marked on the thermostat is the tem- c. Is silicate and phosphate free perature at which the thermostat should be fully open. d. Both b and c b. Thermostats control the ﬂow of coolant to the heater. 10. A voltmeter was used to check the coolant and a reading c. The temperature marked on the thermostat is the tem- of 0.1 volt with the engine o was measured. A reading WARNING perature at which the thermostat should start to open. of 0.8 volt was measured with the engine running and all d. Both a and b electrical accessories turned on. Technician A says that 5. The normal operating temperature (coolant tempera- the coolant should be ﬂushed to solve the galvanic ac- ture) of an engine equipped with a 195°F thermostat is tivity. Technician B says that the ground wires and con- ______. nections should be inspected and repaired to solve the The cast-iron Cummins inline six-cylinder head is a. 175°F to 195°F c. 195°F to 215°F electrolysis problem. Which technician is correct? b. 185°F to 205°F d. 175°F to 215°F a. Technician A only b. Technician B only 6. Coolant is water and ______. very heavy, requiring an engine hoist to remove it c. Both Technicians A and B a. Methanol c. Kerosene d. Neither Technician A nor B from the block. Attempting to lift the head with- b. Glycerin d. Ethylene glycol out help or a hoist could result in personal injury. DIESEL ENGINE COOLING SYSTEM 67

THE SUMMARY, REVIEW QUESTIONS, AND CHAPTER WARNINGS Warnings are stated when there is a possibility QUIZ at the end of each chapter help students review the that personal injury could result if the service work is not done material presented in the chapter and test themselves to see according to the procedure published in the service information. how much they’ve learned.

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).

IN-TEXT FEATURES v

A01_HALD8726_01_SE_FM.indd 5 12/1/17 1:50 PM SUPPLEMENTS

RESOURCES IN PRINT AND ONLINE Light Vehicle Diesel Engines Name of Supplement Print Online Audience Description Instructor ✔ Instructors NEW! The Ultimate teaching aid: Chapter Resource Manual summaries, key terms, chapter learning 0-13-467984-9 objectives, lecture resources, discuss/ demonstrate classroom activities, and answers to the in text review and quiz questions. TestGen ✔ Instructors Test generation software and test bank for 0-13-467987-3 the text. PowerPoint ✔ Instructors Slides include chapter learning objectives, Presentation lecture outline of the text, and graphics from 0-13-467985-7 the book. ASE Correlated ✔ Instructors Downloadable ASE task sheets for easy Task Sheets – customization and development of unique For Instructors task sheets. 0-13-470224-7 ASE Task ✔ Students Study activity manual that correlates Sheets – ASE Automobile Standards to chapters For Students and page numbers in the text. Available 0-13-468039-1 to students at a discounted price when packaged with the text. VitalSource eBook ✔ Students An alternative to purchasing the print text- 0-13-468038-3 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

vi SUPPLEMENTS

A01_HALD8726_01_SE_FM.indd 6 12/1/17 1:50 PM ACKNOWLEDGMENTS

A large number of people and organizations have cooperated in Christopher Fry providing the reference material and technical information used Harry S Truman College in this text. The authors wish to express sincere thanks to the Marty Kamimoto following persons for their special contributions: Fresno City College Tom Birch Richard Krieger Yuba College Michigan Institute of Technology Carl Borsani Carlton H. Mabe, Sr. Graphic Home Virginia Western Community College Richard Krieger Kenneth Redick Michigan Institute of Technology Hudson Valley Community College Jeff Rehkopf Jeff Rehkopf Florida State College Florida State College Chuck Taylor Matt Roda Sinclair Community College Mott Community College Chuck Taylor Sinclair Community College TECHNICAL AND CONTENT REVIEWERS The following Dan Warning people reviewed the manuscript before production and checked Joliet Junior College it for technical accuracy and clarity of presentation. Their sug- gestions and recommendations were included in the final draft of SPECIAL THANKS The authors wish to thank Chuck the manuscript. Their input helped make this textbook clear and Taylor of Sinclair Community College in Dayton, Ohio, plus technically accurate while maintaining the easy-to-read style that Mario Dinovo and Brian Quinn of Joliet Junior College who has made other books from the same author so popular. helped with many of the photos. A special thanks to Dick A.C. Durdin Krieger, Jeff Rehkopf, and Tom Birch for their detailed and thor- Moraine Park Technical College ough reviews of the manuscript before publication. Most of all, Al Engledahl we wish to thank Michelle Halderman for her assistance in all College of DuPage phases of manuscript preparation. Tom Freels —Jim Halderman Sinclair Community College —Curt Ward

ACKNOWLEDGMENTS vii

A01_HALD8726_01_SE_FM.indd 7 12/1/17 1:50 PM ABOUT THE AUTHORS

JIM HALDERMAN brings a world of experience, knowl- CURT WARD Curt Ward brings a wealth of talent, experi- edge, and talent to his work. His automotive service experience ence, and knowledge to his work. Curt is an automotive includes working as a flat-rate technician, a business owner, professor at Joliet Junior College and serves as a visiting auto- and a professor of Automotive Technology at a leading U.S. motive instructor at Southern Illinois University. Previously he community college. was an adjunct professor at other area community colleges. He has a Bachelor of Science Degree from Ohio Northern Before his work at the college, Curt worked as a technical University and a Masters Degree in Education from Miami training instructor for the Chrysler Corporation for fifteen years. University in Oxford, Ohio. Jim also holds a U.S. Patent for Prior to his years at Chrysler, he has worked as a technician, an electronic transmission control device. He is an ASE cer- shop foreman and service manager in the retail sector of the tified Master Automotive Technician and Advanced Engine automotive industry for thirteen years. During this time Curt Performance (L1) ASE certified. became a Chrysler Master Technician. Curt has an Associates Jim is the author of many Automotive textbooks, all pub- of Applied Science in Automotive Service Technology from lished by Pearson. Southern Illinois University. He has a Bachelor’s of Fine Arts in Jim has presented numerous technical seminars to Organizational Communications from North Central College. He national audiences including the California Automotive earned his Master’s degree in Adult Education at the University Teachers (CAT) and the Illinois College Automotive Instructor of Phoenix. Curt is an ASE Master Automotive Technician. Association (ICAIA). He is also a member and presenter Curt has presented technical seminars at numerous con- at the North American Council of Automotive Teachers ferences around the country. He has presented for the Illinois (NACAT). Jim was also named Regional Teacher of the Year College Automotive Instructor Association (ICAIA), the California by General Motors Corporation and a member of the advi- Automotive Teachers (CAT), and the North American Council of sory board for Technological Studies department at Ohio Automotive Teachers (NACAT). Northern University. Curt is an active member in the Illinois Automotive Jim and his wife, Michelle, live in Dayton, Ohio. They have Instructor Association (ICAIA) and the North American Council two children. You can reach Jim at: 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 [email protected] 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]

viii ABOUT THE AUTHORS

A01_HALD8726_01_SE_FM.indd 8 12/1/17 1:50 PM BRIEF CONTENTS

chapter 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

A01_HALD8726_01_SE_FM.indd 9 12/1/17 1:50 PM A01_HALD8726_01_SE_FM.indd 10 12/1/17 1:50 PM CONTENTS

chapter 1 ■■ Valve Seats 28 ■■ Valve Springs 29 DIESEL ENGINE OPERATION 1 ■■ Cylinder Head Passages 30 ■■ Learning Objectives 1 ■■ Camshaft 31 ■■ Key Terms 1 ■■ Rocker Arms and Bridges 33 ■■ Engines 1 ■■ Pushrods 33 ■■ Four-Stroke Cycle Operation 1 ■■ Lifter or Tappets 34 ■■ Engine Construction Overview 3 ■■ Camshaft Removal 35 ■■ Diesel Engines 4 ■■ Cylinder Head Disassembly 35

■■ Engine Size 6 Summary 37 ■■ Compression Ratio 7 Review Questions 38 ■■ Torque 8 Chapter Quiz 38 ■■ Power 8

Summary 9 Review Questions 9 chapter 4 Chapter Quiz 10 DIESEL ENGINE LUBRICATION SYSTEMS 39 chapter 2 ■■ Learning Objectives 39 DIESEL ENGINE BLOCKS AND ■■ Key Terms 39 ■■ Lubrication Principles 39 ROTATING ASSEMBLIES 11 ■■ Oil Pumps 40 ■■ Learning Objectives 11 ■■ Oil Passages 43 ■■ Key Terms 11 ■■ Oil Pans 45 ■■ Diesel Engine Blocks 11 ■■ Engine Oil 46 ■■ Crankshafts 14 ■■ API Rating 46 ■■ Crankshaft Construction 16 ■■ European Rating System 47 ■■ Crankshaft Features 17 ■■ Oil Filters 47

■■ Crankshaft Service 18 Summary 50 ■■ Engine Bearings 19 Review Questions 50 ■■ Bearing Clearance 22 Chapter Quiz 50 ■■ Camshaft Bearings 23

Summary 24 Review Questions 25 chapter 5 Chapter Quiz 25 DIESEL ENGINE COOLING SYSTEM 51 chapter 3 ■■ Learning Objectives 51 DIESEL CYLINDER HEADS AND ■■ Key Terms 51 ■■ Cooling Systems 51 VALVE TRAINS 26 ■■ Cooling System Operation 52 ■■ Learning Objectives 26 ■■ Thermostats 52 ■■ Key Terms 26 ■■ Radiators 54 ■■ Cylinder Heads 26 ■■ Pressure Caps 55 ■■ Intake and Exhaust Valves 27 ■■ Coolant Recovery Systems 56

A01_HALD8726_01_SE_FM.indd 11 12/1/17 1:50 PM ■■ Water Pumps 57 ■■ Mechanical Cleaning 86 ■■ Cooling Fans 58 ■■ Chemical Cleaners 87 ■■ Cooling System Testing 59 ■■ Spray and Steam Cleaning 87 ■■ Coolant Temperature Warning Light 60 ■■ Thermal Cleaning 88 ■■ Coolant 61 ■■ Tank and Vapor Cleaning 88 ■■ Types of Coolant 62 ■■ Ultrasonic and Vibratory Cleaning 89 ■■ Coolant Testing 64 ■■ Crack Detection 90 ■■ Coolant Replacement Issues 66 Summary 91 Summary 67 Review Questions 91 Review Questions 67 Chapter Quiz 91 Chapter Quiz 67

chapter 8 chapter 6 DIESEL ENGINE ASSEMBLY 93 DIESEL ENGINE CONDITION ■■ Learning Objectives 93 DIAGNOSIS 68 ■■ Key Terms 93 ■■ Details 93 ■■ Learning Objectives 68 ■■ Short Block Preparation 93 ■■ Key Terms 68 ■■ Cylinder Head Preparation 94 ■■ Typical Engine-Related Complaints 68 ■■ Short Block Assembly 94 ■■ Diagnostic Trouble Codes and Technical Service Bulletins 68 ■■ Piston/Rod Installation 98 ■■ ■■ Visual Inspection 69 Cylinder Head Installation 100 ■■ ■■ Engine Noise/Vibration Diagnosis 71 Torque-to-Yield Head Bolts 101 ■■ ■■ Crankcase Pressure Test 72 Valve Train Assembly 103 ■■ ■■ Oil Pressure Testing 73 Final Assembly 104

■■ Misfire Diagnosis 74 Summary 105 ■■ Engine-Related Misfire Diagnosis 75 Review Questions 106 ■■ Compression Test 75 Chapter Quiz 106 ■■ Engine Starting and Charging Diagnosis 77

Summary 80 Review Questions 81 chapter 9 Chapter Quiz 81 TURBOCHARGER SYSTEMS 107 ■■ Learning Objectives 107 chapter 7 ■■ Key Terms 107 ■■ Introduction 107 DIESEL ENGINE DISASSEMBLY, ■■ Turbocharger Purpose and Function 107 CLEANING, AND CRACK ■■ Turbochargers 108 ■■ Boost Control 111 DETECTION 82 ■■ Variable Geometry Turbocharger 111 ■■ Learning Objectives 82 ■■ Air Charge Cooler 114 ■■ Key Terms 82 ■■ Turbocharger Diagnosis 114 ■■ Preparing the Engine for Removal 82 Summary 116 ■■ Rotating Assemblies Removal 84 Review Questions 116 ■■ Cylinder Head Disassembly 85 Chapter Quiz 116

xii CONTENTS

A01_HALD8726_01_SE_FM.indd 12 12/1/17 1:50 PM chapter 10 chapter 13 AIR INDUCTION AND EGR HIGH-PRESSURE COMMON RAIL SYSTEMS 117 DIESEL FUEL SYSTEMS 142 ■■ Learning Objectives 117 ■■ Learning Objectives 142 ■■ Key Terms 117 ■■ Key Terms 142 ■■ Air Induction System 117 ■■ Functions of High-Pressure Injection Systems 142 ■■ Air Induction System Diagnosis 120 ■■ High-Pressure Common Rail Injection 144 ■■ Intake Manifold Heater 121 ■■ High-Pressure Pump 146 ■■ Glow Plugs 122 ■■ Common Rail Injector 148 ■■ EGR System 124 ■■ Powertrain Control Module 150 ■■ EGR System Diagnosis 126 ■■ High-Pressure Common Rail (HPCR) Fuel System Service Procedures 151 Summary 127 Review Questions 128 Summary 155 Chapter Quiz 128 Review Questions 155 Chapter Quiz 156

chapter 11 chapter 14 DIESEL AND BIODIESEL FUELS 129 HYDRAULICALLY ACTUATED ■■ Learning Objectives 129 ELECTRONIC UNIT INJECTOR ■■ Key Terms 129 (HEUI) SYSTEMS 157 ■■ Diesel Fuel 129 ■■ Learning Objectives 157 ■■ Biodiesel 132 ■■ Key Terms 157 ■■ E-Diesel Fuel 133 ■■ HEUI Systems 157

Summary 134 ■■ Control Pressure 158 Review Questions 134 ■■ Injector Types 159 Chapter Quiz 134 ■■ HEUI Service and Daignostics 161

Summary 164 Review Questions 164 chapter 12 Chapter Quiz 164 FUEL SUPPLY AND LOW-PRESSURE FUEL chapter 15 SYSTEMS 135 EXHAUST AND AFTERTREATMENT ■■ Learning Objectives 135 ■■ Key Terms 135 SYSTEMS 165 ■■ Low-Pressure Fuel System Components 135 ■■ Learning Objectives 165 ■■ Low-Pressure Fuel System Service 139 ■■ Key Terms 165 ■■ Exhaust Chemistry 165 Summary 140 ■■ Exhaust System Components 167 Review Questions 141 ■■ Diesel Oxidation Catalyst (DOC) 168 Chapter Quiz 141

CONTENTS xiii

A01_HALD8726_01_SE_FM.indd 13 12/1/17 1:50 PM ■■ NO Adsorber Catalyst 168 x ■■ Terminals and Connectors 196 ■■ Selective Catalyst Reduction (SCR) 169 ■■ Wire Repair 197 ■■ Diesel Exhaust Fluid 169 ■■ Relays 199 ■■ Reductant Dosing Module 170 ■■ Switches 200 ■■ Diesel Particulate Filter (DPF) 170 ■■ Speed Sensors 202 ■■ Differential Presure Sensor 171 ■■ Throttle Position (TP) Sensor 202 ■■ Temperature Sensors 172 Summary 203 ■■ NOx Sensors 173 Review Questions 203 ■■ Oxygen Sensors 173 Chapter Quiz 204 Summary 174 Review Questions 174 Chapter Quiz 174 chapter 18 CAN AND NETWORK chapter 16 COMMUNICATIONS 205 ■■ Learning Objectives 205 DIESEL SERVICE ■■ Key Terms 205 PROCEDURES 176 ■■ Module Communications and Networks 205 ■■ Network Fundamentals 205 ■■ Learning Objectives 176 ■■ Module Communications Configuration 207 ■■ Key Terms 176 ■■ Network Communications Classifications 207 ■■ Overview 176 ■■ General Motors Communications Protocols 208 ■■ Intake Air System Maintenance 177 ■■ Ford Network Communications Protocols 211 ■■ Engine Oil Service 178 ■■ Chrysler Communications Protocols 212 ■■ Cooling System Service 178 ■■ Controller Area Network 213 ■■ Fuel System Service 180 ■■ Honda/Toyota Communications 215 ■■ Diesel Exhaust Fluid Service 180 ■■ European Bus Communications 215 Summary 181 ■■ Network Communications Diagnosis 216 Review Questions 181 ■■ OBD-II Data Link Connector 219 Chapter Quiz 182 Summary 220 Review Questions 221 Chapter Quiz 221 chapter 17 DRIVETRAIN ELECTRICITY AND chapter 19 ELECTRONICS 183 DIESEL OBD II 222 ■■ Learning Objectives 183 ■■ ■■ Key Terms 183 Learning Objectives 222 ■■ ■■ Introduction 183 Key Terms 222 ■■ ■■ Electricity 183 OBD II 222 ■■ ■■ How Electrons Move Through A Conductor 185 California OBD II 223 ■■ ■■ Units of Electricity 186 Monitors 224 ■■ ■■ Electrical Circuits 187 Diagnostic Trouble Codes 224 ■■ ■■ Electrical Schematics 188 OBD-II Freeze Frame 225 ■■ ■■ Types of Circuit Faults 188 PCM Tests 226 ■■ ■■ Fused Jumper Wire 191 Global OBD II 226

■■ Test Light 191 Summary 228 ■■ Digital Meters 192 Review Questions 228 ■■ Inductive Ammeters 195 Chapter Quiz 228

xiv CONTENTS

A01_HALD8726_01_SE_FM.indd 14 12/1/17 1:50 PM chapter 20 ■■ High-Pressure Fuel System 259 ■■ High-Pressure Common Rail Fuel Injectors 260 OBD-II DIESEL MONITORS 230 ■■ Control System Inputs 262 ■■ Learning Objectives 230 ■■ Engine Outputs 263 ■■ Key Terms 230 ■■ Diesel Aftertreatment System 264 ■■ Major System Monitors 230 ■■ Five- and Six-Cylinder Power Stroke Diesel Engines 265

■■ Comprehensive Component Monitor 230 Summary 266 ■■ Enabling Criteria 231 Review Questions 266 ■■ Misfire Monitor 232 Chapter Quiz 266 ■■ Fuel System Monitor 233 ■■ Non-Continuous Monitors 233 Summary 237 chapter 23 Review Questions 237 Chapter Quiz 237 DURAMAX DIESEL ENGINES 268 ■■ Learning Objectives 268 ■■ Key Terms 268 chapter 21 ■■ Background 268 ■■ 2.8 Inline 4-Cylinder Duramax 272 OBD-II DIESEL DIAGNOSIS 239 ■■ Engine Mechanical 272 ■■ Learning Objectives 239 ■■ Cooling System 275 ■■ Key Terms 239 ■■ Cylinder Heads 277 ■■ The Diesel Engine Diagnostic Process 239 ■■ Service Information 277 ■■ Verify the Customer Concern 240 ■■ Low-Pressure Side Fuel System 278 ■■ Visual Inspection 240 ■■ Fuel Aeration 279 ■■ Check for Any Stored DTCs 242 ■■ High-Pressure Fuel System 280 ■■ Check TSBs 243 ■■ Glow Plugs and EGR 281 ■■ Scan Tool Data 243 ■■ Duramax Diesel Aftertreatment System 282

■■ Pinpoint Tests 246 Summary 288 ■■ Determine the Root Cause 246 Review Questions 288 ■■ Flash Programming 246 Chapter Quiz 288

Summary 249 Review Questions 249 Chapter Quiz 249 chapter 24 CUMMINS DIESEL ENGINES 290 ■■ Learning Objectives 290 chapter 22 ■■ Key Terms 290 FORD POWER STROKE DIESEL ■■ Background Cummins 5.9/6.7-Liter Engine 290 ■■ ISB 6.7 Engine Details 292 ENGINES 250 ■■ ISB 6.7 Engine Low-Pressure Fuel System 295 ■■ Learning Objectives 250 ■■ ISB 6.7 Engine High-Pressure Fuel System 296 ■■ Key Terms 250 ■■ Control System Inputs 298 ■■ Background 250 ■■ Engine Outputs 298 ■■ 6.7-Liter Power Stroke 252 ■■ Cummins 6.7-Liter Diesel Aftertreatment System 299 ■■ 6.7 Cooling System 253 ■■ Cummins 5.0-Liter V-8 Engine 300 ■■ 6.7 Lubrication System 254 ■■ 5.0 V-8 Engine Mechanical 301 ■■ Engine Mechanical 254 ■■ 5.0 V-8 Engine Low-Pressure Fuel System 301 ■■ Low-Pressure Fuel System 255 ■■ 5.0 V-8 Engine High-Pressure Fuel System 302 ■■ Diesel Fuel Conditioner Module (DFCM) 256 ■■ Air Induction System 303

CONTENTS xv

A01_HALD8726_01_SE_FM.indd 15 12/1/17 1:50 PM ■■ Glow Plug System 304 ■■ Low-Pressure Fuel System 312 ■■ EGR System 304 ■■ High-Pressure Fuel System 314 ■■ Exhaust Aftertreatment System 304 ■■ Control System Inputs 316 ■■ Engine Outputs 318 Summary 307 ■■ VM 3.0-Liter V-6 Diesel Aftertreatment System 318 Review Questions 307 Chapter Quiz 307 Summary 322 Review Questions 322 Chapter Quiz 322 chapter 25

FIAT CHRYSLER DIESEL appendix 1 ENGINES 309 A9 SAMPLE ASE-TYPE CERTIFICATION TEST 323 ■■ Learning Objectives 309 ■■ Key Terms 309 appendix 2 ■■ Overview 309 ASE A9 TASK CORRELATION CHART 326 ■■ Engine Identification 309 GLOSSARY 331 ■■ Service Information 310 ■■ Engine Mechanical 311 INDEX 338

xvi CONTENTS

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