DPE 2010 - Diesel Engine Mechanical

Safety

• Identify and practice general shop safety rules and procedures.
• Utilizing safe procedures for handling of tools and equipment.
• Identifying and using proper placement of floor jacks and jack stands.
• Identifying and using proper procedures for safe lift operation.
• Utilizing proper ventilation procedures for working within the lab/shop area.
• Identifying marked safety areas.
• Identifying the location and the types of fire extinguishers and other fire safety equipment.
• Demonstrating knowledge of the procedures for using fire extinguishers and other fire safety equipment.
• Identifying the location and use of eye wash stations.
• Identifying the location of the posted evacuation routes.
• Complying with the required use of safety glasses, ear protection, gloves, and shoes during lab/shop activities.
• Identifying and wearing appropriate clothing for lab/shop activities.
• Securing hair and removing jewelry for lab/shop activities.
• Demonstrating awareness of the safety aspects of supplemental restraint systems (SRS), electronic brake control systems, and hybrid vehicle high voltage circuits.
• Demonstrating awareness of the safety aspects of high voltage circuits (such as high intensity discharge (HID) lamps, ignition systems, injection systems, etc.).
• Locating and demonstrating knowledge of material safety data sheets (MSDS).

Tools and Equipment

• Identify tools and their usage in automotive applications.
• Identifying standard and metric designation.
• Demonstrating safe handling and use of appropriate tools.
• Demonstrating proper cleaning, storage, and maintenance of tools and equipment.
• Demonstrating proper use of precision measuring tools
• Examples: micrometer, dial-indicator, dial-caliper

Diesel Engines

• Inspect fuel, oil, Diesel Exhaust Fluid (DEF) and coolant levels, and condition; determine needed action.
• Identify engine fuel, oil, coolant, air, and other leaks; determine needed action.
• Listen for engine noises; determine needed action.
• Observe engine exhaust smoke color and quantity; determine needed action.
• Check engine no cranking, cranks but fails to start, hard starting, and starts but does not continue to run problems; determine needed action.
• Identify engine surging, rough operation, misfiring, low power, slow deceleration, slow acceleration, and shutdown problems; determine needed action.
• Identify engine vibration problems.
• Check and record electronic diagnostic codes.

Cylinder Head and Valve Train

• Inspect cylinder head for cracks/damage; check mating surfaces for warpage; check condition of passages; inspect core/expansion and gallery plugs; determine needed action.
• Disassemble head and inspect valves, guides, seats, springs, retainers, rotators, locks, and seals; determine needed action.
• Measure valve head height relative to deck and valve face-to-seat contact; determine needed action.
• Inspect injector sleeves and seals; measure injector tip or nozzle protrusion; determine needed action.
• Inspect valve train components; determine needed action.
• Reassemble cylinder head.
• Inspect, measure, and replace/reinstall overhead camshaft; measure/adjust end play and backlash.
• Inspect electronic wiring harness and brackets for wear, bending, cracks, and looseness; determine needed action.
• Adjust valve bridges (crossheads); adjust valve clearances and injector settings.

Engine Block

• Perform crankcase pressure test; determine needed action.
• Remove, inspect, service, and install pans, covers, gaskets, seals, wear rings, and crankcase ventilation components.
• Disassemble, clean, and inspect engine block for cracks/damage; measure mating surfaces for warpage; check condition of passages, core/expansion and gallery plugs; inspect threaded holes, studs, dowel pins, and bolts for serviceability; determine needed action.
• Inspect cylinder sleeve counter bore and lower bore; check bore distortion; determine needed action.
• Clean, inspect, and measure cylinder walls or liners for wear and damage; determine needed action.
• Replace/reinstall cylinder liners and seals; check and adjust liner height (protrusion).
• Inspect in-block camshaft bearings for wear and damage; determine needed action.
• Inspect, measure, and replace/reinstall in-block camshaft; measure/adjust end play.
• Clean and inspect crankshaft for surface cracks and journal damage; check condition of oil passages; check passage plugs; measure journal diameter; determine needed action.
• Inspect main bearings for wear patterns and damage; replace as needed; check bearing clearances; check and correct crankshaft end play.
• Inspect, install, and time gear train; measure gear backlash; determine needed action.
• Inspect connecting rod and bearings for wear patterns; measure pistons, pins, retainers, and bushings; perform needed action.
• Determine piston-to-cylinder wall clearance; check ring-to-groove fit and end gap; install rings on pistons.
• Assemble pistons and connecting rods; install in block; install rod bearings and check clearances.
• Check condition of piston cooling jets (nozzles); determine needed action.
• Inspect crankshaft vibration damper; determine needed action.
• Install and align flywheel housing; inspect flywheel housing(s) to transmission housing/engine mating surface(s) and measure flywheel housing face and bore runout; determine needed action.
• Inspect flywheel/flexplate (including ring gear) and mounting surfaces for cracks and wear; measure runout; determine needed action.

Lubrication Systems

• Test engine oil pressure and check operation of pressure sensor, gauge, and/or sending unit; test engine oil temperature and check operation of temperature sensor; determine needed action.
• Check engine oil level, condition, and consumption; determine needed action.
• Inspect and measure oil pump, drives, inlet pipes, and pick-up screens; check drive gear clearances; determine needed action.
• Inspect oil pressure regulator valve(s), by-pass and pressure relief valve(s), oil thermostat, and filters; determine needed action.
• Inspect, clean, and test oil cooler and components; determine needed action.
• Inspect turbocharger lubrication systems; determine needed action.
• Determine proper lubricant and perform oil and filter change.

Cooling System

• Check engine coolant type, level, condition, and consumption; test coolant for freeze protection and additive package concentration; determine needed action.
• Test coolant temperature and check operation of temperature and level sensors, gauge, and/or sending unit; determine needed action.
• Inspect and reinstall/replace pulleys, tensioners and drive belts; adjust drive belts and check alignment.
• Inspect thermostat(s), by-passes, housing(s), and seals; replace as needed.
• Recover coolant, flush, and refill with recommended coolant/additive package; bleed cooling
• system.
• Inspect coolant conditioner/filter assembly for leaks; inspect valves, lines, and fittings; replace as needed.
• Inspect water pump and hoses; replace as needed.
• Inspect, clean, and pressure test radiator. Pressure test cap, tank(s), and recovery systems; determine needed action.
• Inspect thermostatic cooling fan system (hydraulic, pneumatic, and electronic) and fan shroud; replace as needed.
• Inspect turbo charger cooling systems; determine needed action.

Air Induction and Exhaust Systems

• Perform air intake system restriction and leakage tests; determine needed action.
• Perform intake manifold pressure (boost) test; determine needed action.
• Check exhaust back pressure; determine needed action.
• Inspect turbocharger(s), wastegate, and piping systems; determine needed action.
• Inspect turbocharger(s) (variable ratio/geometry VGT), pneumatic, hydraulic, electronic controls, and actuators.
• Check air induction system: piping, hoses, clamps, and mounting; service or replace air filter as needed.
• Remove and reinstall turbocharger/wastegate assembly.
• Inspect intake manifold, gaskets, and connections; replace as needed.
• Inspect, clean, and test charge air cooler assemblies; replace as needed.
• Inspect exhaust manifold, piping, mufflers, and mounting hardware; repair or replace as needed.
• Inspect exhaust after treatment devices; determine necessary action.
• Inspect and test preheater/inlet air heater, or glow plug system and controls; perform needed action.
• Inspect exhaust gas recirculation (EGR) system including EGR valve, cooler, piping, filter, electronic sensors, controls, and wiring; determine needed action.

Fuel Supply System

• Check fuel level, and condition; determine needed action.
• Perform fuel supply and return system tests; determine needed action.
• Inspect fuel tanks, vents, caps, mounts, valves, screens, crossover system, supply and return lines and fittings; determine needed action.
• Inspect, clean, and test fuel transfer (lift) pump, pump drives, screens, fuel/water separators/indicators, filters, heaters, coolers, ECM cooling plates, and mounting hardware; determine needed action.
• Inspect and test pressure regulator systems (check valves, pressure regulator valves, and restrictive fittings); determine needed action.
• Check fuel system for air; determine needed action; prime and bleed fuel system; check primer pump.

Electronic Fuel Management System

• Inspect and test power and ground circuits and connections; measure and interpret voltage, voltage drop, amperage, and resistance readings using a digital multimeter (DMM); determine needed action.
• Interface with vehicle’s on-board computer; perform diagnostic procedures using electronic service tool(s) (to include PC based software and/or data scan tools); determine needed action.
• Check and record electronic diagnostic codes and trip/operational data; monitor electronic data; clear codes; determine further diagnosis.
• Locate and use relevant service information (to include diagnostic procedures, flow charts, and wiring diagrams).
• Inspect and replace electrical connector terminals, seals, and locks.
• Inspect and test switches, sensors, controls, actuator components, and circuits; adjust or replace as needed.
• Using electronic service tool(s) access and interpret customer programmable parameters.
• Perform on-engine inspections, tests and adjustments on electronic unit injectors (EUI); determine needed action.
• Remove and install electronic unit injectors (EUI) and related components; recalibrate ECM (if applicable).
• Perform cylinder contribution test utilizing electronic service tool(s).
• Perform on-engine inspections and tests on hydraulic electronic unit injectors (HEUI) and system electronic controls; determine needed action.
• Perform on-engine inspections and tests on hydraulic electronic unit injector (HEUI) high pressure oil supply and control systems; determine needed action.
• Perform on-engine inspections and tests on high pressure common rail (HPCR) type injection systems; determine needed action.
• Inspect high pressure injection lines, hold downs, fittings and seals; determine needed action.

Engine Brakes

• Inspect and adjust engine compression/exhaust brakes; determine needed action.
• Inspect, test, and adjust engine compression/exhaust brake control circuits, switches, and solenoids; determine needed action.
• Inspect engine compression/exhaust brake housing, valves, seals, lines, and fittings; determine needed action.