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 Copyright © 2019. Pearson Education, Inc. All Rights Reserved. Manufactured in the United States of America. 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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 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 supple- ments. 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 vibra- tion 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.