MODERN DIESEL TECHNOLOGY DIESEL ENGINES - CENGAGE LEARNING

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Acronyms

AC alternating current C carbon
A/C air conditioning CA communications adapter (serial link)
ACC adaptive cruise control CAC charge air cooling
ACERT Advanced Combustion Emissions CAN Controller Area Network
Reduction Technology CARB California Air Resources Board
ADC analog to digital converter cc cubic centimeter
ADEM advanced diesel engine management (system) CCV closed crankcase ventilation
ADS Association of Diesel Specialists CCW counterclockwise or left-hand rotation
AFC air/fuel control C-EGR cooled exhaust gas recirculation
AFR air/fuel ratio CEL check engine light
ANSI American National Standards Institute cfm cubic feet (per) minute
API American Petroleum Institute CFR ceramic fiber reinforced
APT American pipe thread CFV critical flow venturi
APT axial power turbine CG constant geometry
ASE (National Institute for) Automotive Service CGI clean gas induction (Caterpillar EGR)
Excellence CGI compacted graphite iron
ASME American Society of Mechanical Engineers CI compression ignition
ASTM American Society for Testing Materials cid cubic inch displacement
At ampere turns CLM coolant level module
ATA American Trucking Association CMAC chassis mounted charge air cooling
ATAAC air-to-air after-cooling CMP camshaft position
ATDC after top dead center CN cetane number
atm unit of pressure equivalent to one unit CNG compressed natural gas
of atmospheric pressure CO carbon monoxide
BDC bottom dead center CO2 carbon dioxide
BHP brake horsepower COE cab-over-engine (truck chassis)
BIOS basic input/output system CPC common powertrain controller (DDC and MB)
BOE beginning of energizing CPL control parts list (Cummins part numbers)
BOI beginning of injection CPS camshaft position sensor
BP brake power CPS characters per second
BPS bits per second CPU central processing unit
BTDC before top dead center CR common rail
BTM brushless torque motor CRS Caterpillar regeneration system (DPF)
Btu British thermal unit
333

334 Acronyms

CTS coolant temperature sensor EMS engine management system
CTV continuously open throttle valve EOE ending of energizing
CW clockwise EOF end of frame (multiplexing packet)
DC direct current EOI end of injection
DCA diesel coolant additives EOL end of line (programming)
DDC Detroit Diesel Corporation EPA Environmental Protection Agency
DDDL Detroit Diesel diagnostic link EPS engine position sensor
DDEC Detroit Diesel electronic controls ESS engine speed sensor
DDL diagnostic data link EST electronic service tool
DDR digital diagnostic reader ET Electronic Technician (Caterpillar diagnostic
DDT digital diagnostic tool software)
DI direct injection ETR energized to run
DID driver information display EUI electronic unit injector
DIP dual inline package (chip) EUP electronic unit pump
DMM digital multimeter FACR fuel-amplified common rail system
DOC diesel oxidation catalyst FET field effect transistor
DOC direct-operated check (valve) FM frequency modulation
DOD displacement on demand FMI failure mode indicator (SAE)
DOHC double overhead cam FMVSS Federal Motor Vehicle Safety Standard
DOS disk operating system FST field service tips
DMF diesel multistage filter GHGs greenhouse gases
DPF diesel particulate filter gnd ground
DTC diagnostic trouble code gph gallons per hour
DVOM digital volt ohmmeter GPS global positioning satellite
ECI electronically controlled injection GUI graphical user interface
ECM electronic/engine control module H hydrogen
ECS evaporative (emission) control system HC hydrocarbon
ECT engine coolant temperature HDEO heavy-duty engine oil
ECU electronic/engine control unit HE hydroerosive (machining technology)
EDU electronic distributor unit (DDEC) HEUI hydraulically actuated electronic unit injector
EEC electronic engine control HEV hybrid electric vehicle
EECU electronic engine control unit Hg mercury
EEPROM electronically erasable, programmable IBC inner base circle
read-only memory I/C integrated circuit
EFPA electronic foot pedal assembly ICU instrument control unit
EG ethylene glycol id inside diameter
EGR exhaust gas recirculation ID identify
EHI electrohydraulic injector IDI indirect injection
ELC extended life coolant IDM injector driver module (Navistar)
EMA Engine Manufacturer’s Association I-EGR internal exhaust gas recirculation
EMF electromotive force IHP indicated horsepower
EMI electromagnetic interference INSITE Cummins PC software
EMI electromagnetic injector IRT injector response time

Acronyms 335

ISIS international (trucks) (online) service NTC negative temperature coefficient
information system NV-RAM nonvolatile random-access memory
ISO International Standards Organization O oxygen
IVS idle verification switch OBC outer base circle
KAM keep-alive memory OBD on-board diagnostics
KAMPWR electrical circuit that powers KAM OCR optical character recognition
(Navistar) OCV open circuit voltage
km kilometers od outside diameter
KPa kiloPascals OEM original equipment manufacturer
LAN local area network OOS out-of-service
LCD liquid crystal display OS operating system
LED light-emitting diode OSHA Occupational Safety and Health
LNC lean NOx catalyst Administration
LNG liquefied natural gas Pa Pascal
LPG liquid petroleum gas PC personal computer
LS limiting speed PCM powertrain control module
LS low sulfur PCU powertrain control unit
LSG limiting speed governor PCV positive crankcase ventilation
MAF mass airflow sensors PDI predelivery inspection
MAP manifold actual pressure PDM power distribution module
MCP motor control module PG propylene glycol
MD Master Diagnostics (Navistar troubleshooting pH power hydrogen (measure of acidity/alkalinity)
software) PHC partially-burned hydrocarbons
MEP mean effective pressure PID parameter identifier (SAE)
MEUI mechanically-actuated, electronically- PLC power line carrier (multiplexing)
controlled, electronic unit injector. PLC programmable logic controller (smart relay)
MHz megahertz PLD German acronym meaning ECM (MB engines)
MID message identifier (SAE) PLN pump-line nozzle (diesel fuel injection)
MIL malfunction indicator lamp PM particulate matter
mm millimeter PM preventative maintenance
MPa megapascals PN positive–negative ( junction semiconductor)
MPC multiprotocol cartridge/card (ProLink) PNP positive–negative–positive (semiconductor)
MSDS material safety data sheets POST power-on self-test
N nitrogen ppb parts per billion
NAC NOx adsorber catalyst ppm parts per million
NAFTA North American Free Trade Agreement PROM programmable read-only memory
(Mexico, USA, and Canada) psi pounds per square inch
NDR nozzle differential ratio PTC positive temperature coefficient
Nm Newton-meter PTO power take-off
NOP nozzle opening pressure PW pulse width
NO2 nitrogen dioxide PWM pulse width modulation
NOX oxides of nitrogen QSOL QuickServe OnLine (Cummins)
NPN negative–positive–negative (semiconductor) R resistance

336 Acronyms

RAM random-access memory TPS throttle position sensor
RCRA Resource Conservation and TRS timing reference sensor (DDEC)
Recovery Act TSB technical service bulletin
rms root mean square ULEV ultralow emissions vehicle
ROM read-only memory ULS ultralow sulfur (fuel)
RP recommended practice (ATA-TMC) ULSD ultralow sulfur diesel
RPCV rail pressure control valve UNC unified (thread) coarse
RS regeneration system (DPF operation) UNF unified (thread) fine
RSG road speed governing UPC universal product code
RSL road speed limit USB universal serial bus
S sulfur UV ultraviolet
SAE Society of Automotive Engineers V volt
SAE J1587 data bus software protocols V-Bat battery system voltage
SAE J1667 emission testing standards VCO valve closes orifice (nozzle)
SAE J1708 data bus hardware protocols VCP valve closing pressure
SAE J1939 data bus hardware/software protocols VCU vehicle control unit
(CAN 2.0 HD) VECTRO Volvo electronic controls
SCA supplemental cooling additive (system) VG variable geometry
VG variable geometry VGA video graphics array
SCR selective catalytic reduction VI viscosity index
SEL stop engine light VIN vehicle identification number
SEO stop engine override VIP vehicle interface program
s.i. Syste`me International (metric system) V-MAC vehicle management and control
SI spark ignited VN variable nozzle
SID subsystem identifier (SAE) VOC volatile organic compound
SIS service information systems (generic VPM vehicle personality module (Caterpillar/
and Caterpillar specific) Navistar)
SO2 sulfur dioxide VR voltage regulator
SOHC single overhead cam V-Ref reference voltage (almost always ±5 VDC)
SOI start of injection VS variable speed
SRS synchronous reference sensor (DDEC) VSC variable speed control
STEO stop engine override VSG variable speed governor
STOP stop engine light VSL vehicle speed limit
SVS spill valve solenoid (Cat MEUI) VSS vehicle speed sensor
TBN total base number (lubes) VVA variable valve actuator
TBS turbo-boost sensor VVT variable valve timing
TDC top dead center W watt
TDS total dissolved solids WHMIS Workplace Hazardous Materials
TEL top engine limit (Cat: high idle) Information System
TEM timing event marker WIF water in fuel (sensor)
TIR total indicated runout WiFi wireless fidelity
TMC Technical and Maintenance Council WOT wide open throttle
TP throttle position

Index

Note: Page numbers referencing figures are italicized and followed by an ‘‘f.’’ Page numbers referencing tables are italicized and
followed by a ‘‘t.’’

Absorbent filtration, 127 BDC. See Bottom dead center BTDC. See Before top dead center
A/C. See Air conditioning Bearing(s) Bubble collapse, 105
Accumulator, 281 Bundle-type oil cooler, 129–130, 130f
Acetylene cylinders, 12 bedplate main, 74 Bushings, 33, 87, 87f, 209
Active regeneration, 297 camshaft, 87, 87f Butane lighters, 5–6
Actively pressurized cooling system (APCS), clearance of, 72–73, 72f, 73t Buttress screws, 208
construction and design of, 72, 72f Bypass filters and valves, 128–129
158–159 crankshaft end play and, 73
Actuators, 255 etched main, 71 CA. See Communications adapter
friction, 72 Cab-over-engine (COE), 198
in dual actuator EUIs, 270–274, 271f–272f removal and installation of, 73–74 CACs. See Charge air coolers
piezoelectric, 238, 239, 249 retention, 73, 74f California Air Resources Board (CARB),
in single actuator EUIs, 269–270, 269f rollover, 74
VVA, 177 spun, 71 290, 290f
AdBlue, 298 thrust, 73 Calipers, 22, 23f, 29
Adsorbent filtration, 127 Bearing shells, 67–68, 73, 74f Cam geometry, 84
Aerated oil, 122 Bedplate main bearings, 74 Cam ground, 56
A-frame hoists, 31 Before top dead center (BTDC), 47 Cam profile, 84, 85f
After top dead center (ATDC), 47, 49–50 Bending forces, 68 Camshaft(s)
Aftercoolers, 174 Big end, 66
Air, 40 Blotter test, 133 bushings/bearings, 87, 87f
Air brakes, 184 Boots, 2–3, 3f cam profile in, 84, 85f
Air cleaners, 166–167 Bore construction and design of, 84–85, 86f
Air conditioning (A/C), 199 counter, 204–205 end play, 87, 87f
Air filters, 166–167 dial bore gauges and, 25–27, 25f–26f, 28f inspection of, 86–87, 86f, 208–209
Air tools, 32, 33f parent bore engines and, 102–105 removal and installation of, 85–86
Air-to-air heat exchangers, 173–174 stroke and, 47, 47f role of, 83–84
Aluminum trunk type pistons, 55–56, 56f Bottom dead center (BDC), 41–45, 47 timing overhead, 83, 83f
American Petroleum Institute (API), Boundary lubrication, 119 Canister type fuel filters, 222
Bourdon gauge, 131 CARB. See California Air Resources Board
122–123, 123f Brake fade, 184 Carbon dioxide (CO2), 291
Anaerobic sealants, 204 Brakes Carbon monoxide (CO), 292
Antifreeze, 141, 143–144, 144t, 147 air, 184 Cartridge fuel filters, 222
Antithrust side, 65 BrakeSaver, 193–194, 193f Catalytic converters, 178, 295–296, 297f
APCS. See Actively pressurized cooling system engine compression, 183, 185–192, 187f, Caterpillar BrakeSaver, 193–194, 193f
API. See American Petroleum Institute Caterpillar compression brakes, 190, 191f
Aqueous urea, 298 189f, 190f, 191f, 190t Cavitation, 105, 145, 145f
Arc welding abuse, 10. See also Electric modern, 184 CCV. See Closed crankcase ventilation
operation principles of, 185–187 C-EGR. See Cooled EGR
arc welding supplementary systems of, 184 Central processing unit (CPU), 252–254, 254f
Articulating pistons, 58–59, 58f Breaker/flex bars, 19 Centrifugal filters, 128–129
Ash, 121, 123 Breather filter, 223, 223f Cetane number (CN), 46
ATDC. See After top dead center Breathing circuit CFV. See Critical flow venturi
atms. See Units of atmosphere charge air coolers in, 173–174, 174f CG turbochargers. See Constant geometry
Atomization, 234 components of, 164–166
Automatic bleeding valve, 266 exhaust gas recirculation in, 175–176, 175f turbochargers
Auxiliary heat exchangers, 150 exhaust system components in, 177–178 CGI. See Clean gas induction
gas flow in, 164, 165f CGI blocks. See Compacted graphite iron blocks
Back care, 4–5, 5f intake system in, 164, 166–167, 166f Chain hoists, 8
Back leakage, 242 sensors, 179 Chains, 32
Backfire, 14 turbochargers in, 167–173, 168f–171f, 173f Channel section rings, 63
Bar pressure measurement, 36 valve design and, 176–177, 176f Charge air coolers (CACs), 173–174, 174f, 299
Barrel faced rings, 62f, 63 Charging circuit, 218
Base circle (BC), 84–85
337

338 Index

Charging pressure, 224, 224f role of, 65–66, 66f Cylinder head valves
Charging pump, 222, 227–230, 227f–230f tensional loading and, 67 design and materials of, 90–91, 90f–91f
Chassis Constant geometry (CG) turbochargers, 168–169 inspection of, 91, 91f
Constant throttle valves (CTVs), 191–192, 192f operation of, 91
data bus, 256–258, 257f–258f Coolant, 121–122 servicing of, 92, 210
engine reinstalled to, 215 blending of, 146–147 valve lash adjustment and, 93–97,
engine removed from, 199–200 in cooling system, 143–147, 144t, 94f–97f
safety, 10–15, 12f–15f valve polar diagram and, 98
Chatter, 242 145f–146f, 152–153 valve seat inserts and, 92–93, 92f
Cherry pickers, 8, 8f, 31, 32f ELC, 143, 147 VVT and, 90, 97
Chopper wheel. See Pulse wheel filters, 152, 152f
CI. See Compression ignition heaters, 159–160, 159f Cylinder heads
CJ-4 oil, 122–123, 123f, 134 monitoring circuit, 152–153 disassembly, inspection, and reconditioning
Clamping force, 35 pumps, 151–152, 151f–152f of, 108–110
Classes, of fires, 6, 7f SCAs and, 143, 144–147, 145f–146f installation of, 110–111, 110f–111f
Clean gas induction (CGI), 175, 294–295, 295f types of, 143–144, 144t reassembly of, 209–210
Clearance volume, 47 Cooled EGR (C-EGR), 175–176, 175f, 294, 295f rocker housing covers and, 111–112
Clevis, 88 Cooling system role of, 108, 109f
Closed crankcase ventilation (CCV), antiboil properties of, 141, 142f
APCS, 158–159 Cylinder pressure, 49–50, 54
299–300, 299f components of, 147–152, 148f–149f, 150t, Cylinder volume, 47
Clothing, 5, 5f Cylinder wall lubrication, 64–65
CN. See Cetane number 151f–152f Cylinder wear ridge, 106, 106f
CO. See Carbon monoxide coolant in, 143–147, 144t, 145f–146f,
CO2. See Carbon dioxide Dampers, 74–76, 75f
COE. See Cab-over-engine 152–153 Data bus, 256–258, 257f–258f
Coefficient of friction, 184 cooling fans in, 155–157, 156f–157f DCA. See Diesel coolant additive
Cold sludge, 122 in DD15 engine, 140, 141f Depth gauges, 27
Combination compression and scraper functions of, 140 Detergents, 121
heat transfer and, 140 DI. See Direct injection
rings, 62, 62f management of, 158–159 Dial bore gauges, 25–27, 25f–26f, 28f
Combination square, 27 problems with, 157–158 Dial indicators, 24, 24f–25f
Combination wet/dry liners, 106 thermostats in, 153–155, 154f Diamond dowels, 212
Combustion chamber designs, 59–60 Counter bore, 204–205 Dies, 21–22
Combustion pressure, 48 Counterflow radiators, 149 Diesel coolant additive (DCA), 144
Come-alongs, 8 CPU. See Central processing unit Diesel CR fuel systems, 274–275, 274f, 275t
Command sensors, 246 CR fuel systems. See Common rail fuel systems Diesel cycle
Common manifold turbocharging, 172 Cracked rods, 66, 66f
Common rail (CR) fuel systems, 235, 242 Crankcase, 103, 299–300, 299f four-stroke, 41–44, 42f–44f, 164
Crankshafts two-stroke, 45, 45f–46f
diesel, 274–275, 274f, 275t configurations of, 68, 68f Diesel emissions, 290, 294–300, 295f,
EHIs in, 283–285, 284f construction of, 69–70, 69f
FACR, 285–286, 286f dynamic balance and, 68–69 297f–299f
fuel subsystem of, 278, 278f end play of, 73 Diesel filters, 222–227, 223f–224f,
history of, 264 failure of, 70–71
management electronics of, 276–277 hydrodynamic suspension and, 68 226f–227f, 296–297, 297f–298f
rail in, 274 inspection of, 71 Diesel fired coolant heater, 159f, 160
routing circuit of, 277–286, 277f–286f reconditioning of, 71 Diesel fuel, 46, 219
subsystems and components of, 275–276 removed from cylinder block, 70, 70f Diesel particulate filters (DPFs), 296–297,
Communications adapter (CA), 198, 256 Creep, 111, 111f
Compacted graphite iron (CGI) blocks, Critical flow venturi (CFV), 251, 251f 297f–298f
Crossflow radiators, 148–149, 149f Diffusers, 178
102f, 103 Crossflow valve configurations, 176, 176f Digital multimeter (DMM), 11, 247
Companion cylinders, 93 Crosshatch, 107–108, 107f Dipsticks, 125
Composite steel trunk pistons, 58, 58f Crosshead pistons, 58 Direct injection (DI), 48, 59, 234
Compressed fluids, 9 Crossover pipe, 220–221, 220f Disassembly, engine, 200–203, 201f, 203f
Compression. See also Engine compression Crown, piston, 55, 55f, 59–60 Dished piston crown, 60
CTVs. See Constant throttle valves Dispersants, 121
brakes Customer data programming, 257, 259 Dividers, 29
pressure, 48 Cutting fluids, 22, 22t DMM. See Digital multimeter
ratio, 48 Cutting torches, 14, 14f Double pass radiators, 149, 149f
rings, 61, 62, 62f Cylinder block(s) Downflow radiators, 148, 148f–149f
stroke, 42, 42f–43f, 44 categories of, 103–106 Download, 260
Compression ignition (CI), 48 checking of, 106–107, 107f DPFs. See Diesel particulate filters
Compressional loads, 67 crankshafts removed from, 70, 70f Drill bits, 22
Compressor housing, 168 design and construction of, 102–103, 102f–104f Droplet sizing, 235–236, 236f
Concept gears, 83 flywheel housings and, 108 Dry element filters, 167
Connecting rods forces, 102 Dry liners, 105–106, 106f
compressional loading and, 67 functions of, 102–103, 102f Dual actuator EUIs, 270–274, 271f–272f
construction of, 66, 67f liner reconditioning and, 107–108, 107f
cracked, 66, 66f reassembly of, 204–205 ECM. See Engine/electronic control module
inspection of, 67–68 EDCs. See Electronic digital calipers
keystone, 66 EEPROM. See Electronically erasable PROM
reassembly of, 205–206, 205f, 207f EG. See Ethylene glycol

Index 339

EGR system. See Exhaust gas recirculation English/metric conversion, 35–36 Fuel-amplified common rail (FACR)
system Environmental Protection Agency (EPA), system, 285–286, 286f

EHIs. See Electrohydraulic injectors 290, 293t Full articulating pistons, 58, 58f
ELC. See Extended life coolant EPG. See Exhaust pressure governor Fuel charging pumps, 227–230, 227f–230f
Electric arc welding, 10, 15, 15f Equipment safety, 6–8 Fuel filters, 219, 219f, 222–227, 223f–224f,
Electric primer pumps, 230 EST. See Electronic service tool
Electric sensors, 153 Etched main bearings, 71 226f–227f, 278
Electrical safety, 10–15, 12f–15f Ethylene glycol (EG), 143, 144, 144t Fuel heaters, 219, 219f, 226–227, 227f
Electric-over-hydraulic compression brakes, 188 EUI. See Electronic unit injector system Fuel sending units, 221
Electrohydraulic injectors (EHIs), Exhaust Fuel subsystem

238–240, 238f, 242, 272, 275, brakes, 185–187, 187f complete circuit of, 229f, 230
283–285, 284f extraction, 8–9, 9f components of, 218, 218f–219f, 266
Electrohydraulic nozzles, 238–240, 238f, 242 manifolds, 112–113, 172, 177 of CR systems, 278, 278f
Electronic control module. See Engine/ stroke, 43–44, 43f EUI and, 265–266, 265f
electronic control module system components, in breathing circuit, fuel charging/transfer pumps in,
Electronic diesel fuel injection systems.
See Common rail fuel systems; Electronic 177–178 227–230, 227f–230f
unit injector system valves, 90 fuel filters in, 219, 219f, 222–227,
Electronic digital calipers (EDCs), 22, 23f Exhaust gas recirculation (EGR) system, 164,
Electronic service tool (EST), 11, 258, 258f 223f–224f, 226f–227f
Electronic unit injector (EUI) system 166, 175–176, 175f, 200, 294, 295f objectives of, 218–219, 218f–219f
fuel subsystem and, 265–266, 265f Exhaust pressure governor (EPG), 187 tank in, 219–222, 219f, 222f–223f
history of, 264 Expansion-sensing gauges, 153 Fuel tanks, 219–222, 219f, 222f–223f
injectors in, 98, 201–202, 235, 269–274, 269f, Extended life coolant (ELC), 143, 147 Full flow filters, 128, 128f
External engine compression brakes,
271f–272f Gas blowby, 61–62
input circuit and, 266–267, 267f–268f 185–187, 187f Gasket yield point, 111
management electronics of, 267–268, 268f External gear pumps, 125–126, 126f Gauges, 22, 25–29, 25f–26f, 28f, 131, 166f, 167
output circuit and, 268 Eye protection, 3, 3f, 14, 29 Gear pumps, 125–127, 126f, 227–229, 227f, 229f
overview of, 264–265 Gerotor pumps, 126–127
Electronically erasable PROM FACR system. See Fuel-amplified Glass bead blasters, 33–34
common rail system Glasses, 3, 3f, 29
(EEPROM), 254–255 Glaze busting, 107
Emissions Fans, 155–157, 156f–157f Gloves, 4
Fanstat, 156 Ground strap, 11
CARB and, 290, 290f Fastener grades and torques, 34–35, 34f
diesel, 290, 294–300, 295f, 297f–299f Feedback assembly, 82, 97–98 Hacksaws, 22
field testing of smoke density and, Feeler gauges, 29 Hall-effect sensors, 250
Ferrotherm articulating pistons, 58 Hammers, 20, 21f, 31
300–302, 300f–301f Film strength, 121 Hand primer pumps, 228f, 229–230
smog and, 291–294, 293t Filter bypass valves, 128–129 Hand tools, 18f, 19–22, 20f–21f
smoke analysis and, 302 Filters Hard value NOPs, 234
EMS. See Engine management system HC. See Hydrocarbons
End play, 73, 87, 87f air, 166–167 Head gasket, 111
Engine(s) coolant, 152, 152f Headers, 148
barring of, 96–97, 97f diesel, 222–227, 223f–224f, 226f–227f, Headland volume, 56–57, 59
cleaning and inspection of, 203–204 Hearing protection, 3–4, 4f
disassembly of, 200–203, 201f, 203f 296–297, 297f–298f Heat energy, 40
displacement, 43, 47 fuel, 219, 219f, 222–227, 223f–224f, Heat exchanger, 143, 150, 166, 173–174
key principles of, 49–50 Heat transfer, 140
reassembly of, 204–215, 205f–209f, 212f–215f 226f–227f, 278 Helical gears, 82
removal of, 198–200 oil, 127–129, 128f Hg manometer. See Mercury manometer
systems and circuits, 46 primary and secondary, 219, 222, 223f High-pressure lines, 282–283, 283f
terminology of, 40–41, 46–47, 48f servicing of, 223–224, 224f High-pressure pumps, 278–283, 279f–283f, 285
types of, 47, 102–105, 140, 141f Fire point, 48, 120 Honing, 68, 107–108
Engine compression brakes, 183, 185–188, 187f Fire rings, 210 Hydraulic engine brakes, 186–188
external, 185–187, 187f Fire safety, 6, 7f Hydraulic injectors, 234, 234f
internal, 185, 187–192, 189f–192f, 190t Flanged injectors, 241 Hydraulic system safety, 9–10
Engine/electronic control module (ECM), Flash point, 120 Hydrocarbons (HC), 291
Flashback, 14 Hydrodynamic suspension, 68, 119, 120f
140, 188, 276 Flex bars, 19 Hydrometer, 144
CPU in, 252–254, 254f Fluid friction, 119
diesel emissions and, 294 Flywheel housing concentricity, 212 IBC. See Inner base circle
in EUI management electronics, Flywheel housings, 108, 212–215, IDI. See Indirect injection
I-EGR. See Internal exhaust gas recirculation
267–268, 268f 212f–215f Ignition temperature. See Fire point
functions of, 246, 247f, 252, 253f, 268, 269f Flywheels, 76–77, 77f Impeller, 168
input circuit and, 246–252, 247f–252f Follower, 88, 89f Indirect injection (IDI), 48
memory of, 254–255 Forged steel trunk type pistons, 57, 57f Induction hardened parent bore, 105
multiplexing and, 255–258, 255f, 257f–258f Forward leakage, 242 Induction pulse generator, 249–250, 250f
outputs of, 255 Four-stroke diesel cycle, 41–44, 42f–44f, 164 Inertia, 48
programming of, 257–260 Friction, 48, 118–119, 184
Engine management system (EMS), 276 Friction bearings, 72
Engine retarders. See Brakes Fuel

types of, 40, 46, 121, 219
water in, 223, 227, 227f, 251, 266

340 Index

Inhibitors, 120–121 oil filter in, 127–129, 128f Oil
Injector drivers, 255 oil pan in, 125, 125f analysis of, 133–134
Injector nozzles oil pressure measurement in, 130–133, API classifications of, 122–123, 123f, 134
BrakeSaver using, 194
installation of, 210–211, 242 131f–132f choice of, 124–125
multiple-orifice, 234–238, 234f–238f oil pump in, 125–127, 126f classification and terminology,
testing of, 240–242 pressure-regulating valves in, 127, 280 120–121, 121f
Injector train. See Valve and injector trains problems with, 134 contamination and degradation of,
Injectors scavenge pumps in, 113, 127 121–122
EHI, 238–240, 238f, 242, 272, 275, turbocharger, 172 extended changes of, 134
Lubricity, 120 filters, 127–129, 128f
283–285, 284f Lugging, 69 hydrodynamic suspension and, 68, 119, 120f
in EUI system, 98, 201–202, 235, multigrade, 120, 123–124, 123f
MAF sensors. See Mass airflow sensors pressure measurement of, 130–133, 131f–132f
269–274, 269f, 271f–272f Magnetic flux test, 203–204 role of, 119, 120f
flanged, 241 Mains electrical equipment, 11–12, 12f SAE viscosity grades of, 123–124, 123f
hydraulic, 234, 234f Major thrust side, 65 synthetic, 124
mechanical, 98, 234 Manifold-boost. See Turbo-boost
seized, 241 Mann type (M-type) piston crown, 60 Oil control rings, 62–64, 64f
Inlet restriction, 221 Manual electromechanical switches, 252 Oil coolers, 129–130, 130f–131f
Inlet restriction gauges, 166f, 167 Mass airflow (MAF) sensors, 250–251, Oil pans
Inline piston pumps, 279, 280f
Inner base circle (IBC), 84–85 251f functions of, 113, 114f
Input circuit, 276 Master bar, 204 inspection of, 115
ECM and, 246–252, 247f–252f Mean effective pressure (MEP), 49 in lubrication systems, 125, 125f
EUI system and, 266–267, 267f–268f Mechanical injectors, 98, 234 removal of, 113–114
Inside bevel rings, 62f, 63 Mechanical straining, 127 Oil pump, 125–127, 126f
Intake circuit, 164, 166–167, 166f Mechanical unit injectors (MUIs), 98 Oil ring side clearance, 64, 64f
Intake manifolds, 112, 113f, 176 MEP. See Mean effective pressure Opacity meters, 300–301, 300f–301f
Intake stroke, 41–42, 42f–43f, 44 Mercury (Hg) manometer, 223 O-rings, 105, 204
Intake system, 164, 166–167, 166f Message Identifier (MID), 256, 267 Outer base circle (OBC), 84
Intake valves, 90 Metric system, 35–36 Output circuit, 268, 277
Intercoolers, 174 Mexican hat piston crown, 59–60 Overhead cam (OHC), 208
Interference angles, 91 Micrometers, 22, 23f–24f Oversquare engine, 47
Internal combustion engine, 40 Microprocessor, 246 Oxyacetylene equipment, 12–15, 12f–14f, 33
Internal engine compression brakes, 185, MID. See Message Identifier Ozone, 291, 292–293
Midstop liners. See Combination wet/dry liners
187–192, 189f–192f, 190t Minor thrust side, 65 Packets, 256
Internal exhaust gas recirculation (I-EGR), 175 Monitoring sensors, 246 Pallet links, 90
Monocomp, 58, 58f Parallel port valve configurations, 176
J standards, 256, 257f, 301–302 Monotherm piston, 57 Parent bore engines, 102–105
Jacks, 7–8, 31–32 M-type piston crown. See Mann type Partial blocking thermostat. See Side
Jacobs brakes, 188–189, 189f–190f
Journal surface hardening methods, 69–70 piston crown bypass thermostat
Muffler volume, 178 Particulate traps. See Diesel particulate filters
Keepers. See Split locks MUIs. See Mechanical unit injectors Passive regeneration, 296
Keystone rings, 62f, 63 Multigrade oils, 120, 123–124, 123f PCV. See Positive crankcase ventilation
Keystone rods, 66 Multiple-orifice injector nozzles, 234–238, Peak pressure, 236
Kinetic energy, 40 Personal safety, 2–6, 3f, 14, 29
234f–238f PG. See Propylene glycol
Lands, 61 Multiplexing, 246, 255–257, 255f, 257f pH level, 146
Lifters, 88 Multipulse injection, 285 Photochemical smog, 291
Lifting, 4–8, 5f, 8f Pickup tube, 220–221
Light extinction, 301 NA. See Naturally aspirated Piezoelectric actuators, 238, 239, 249
Liners, 102 NACs. See NOx adsorber catalysts Pin boss, 56
Nalcool, 144 Piston assemblies
combination wet/dry, 106 Naturally aspirated (NA), 40, 164
dry, 105–106, 106f NDR. See Nozzle differential ratio articulating, 58–59, 58f
protrusion of, 204–205, 205f Negative temperature coefficient (NTC) combustion chamber designs in, 59–60
reconditioning of, 107–108, 107f cylinder wall lubrication and, 64–65
removal of, 203, 203f thermistor, 153, 248 piston cooling in, 60, 60f
wet, 105–106, 105f–106f, 145f, 204 Ni-Resist insert, 55, 56f, 62f reassembly of, 205–208, 205f–208f
Load rotors, 32 Nitrogen compounds, 293, 296 reuse of, 65
Luber-finer filters, 128 NOP. See Nozzle opening pressure rings in, 61–64, 62f, 64f
Lubrication. See also Oil NOx adsorber catalysts (NACs), 296 role of, 54
boundary, 119 Nozzle differential ratio (NDR), 237 terminology of, 54–55, 55f
cylinder wall, 64–65 Nozzle opening pressure (NOP), 234, 273 thrust forces in, 59
thick film, 119 Nozzle seat, 237 trunk type, 55–58, 56f–58f
Lubrication systems NTC thermistor. See Negative temperature wrist pins in, 65
basic components of, 118, 118f Piston cooling jets, 130, 131f, 205
dipsticks in, 125 coefficient thermistor Piston crown, 55, 55f, 59–60
friction and, 118–119 Piston pumps, 278–279, 279f–280f
oil coolers in, 129–130, 130f–131f OBC. See Outer base circle
OHC. See Overhead cam

Index 341

Piston rings, 61–64, 62f, 64f Radial piston pump, 278–279, 279f Secondary filter, 219, 222
Plastigage, 28–29, 72–73, 72f, 73t, 205 Radiator cap, 150–151, 151t Seized injectors, 241
Plate-type oil cooler, 130, 130f Radiators, 148–150, 148f–149f Selective catalytic reduction (SCR), 298, 299f
Pliers, 20, 21f Rail pressure control valve, 275, 279–283, Self–regeneration, 296
Plunger-type pumps, 228, 228f Sensors
PM. See Preventative maintenance 280f–283f
Pneumatics safety, 9–10, 10f Rail pressure management control (RPMC), breathing circuit, 179
Popping pressure, 234 command, 246
Position sensors, 249–250, 250f 277 electric, 153
Positive crankcase ventilation (PCV), 299 Rail pressure sensor, 275 hall-effect, 250
Positive displacement, 224 RAM. See Random-access memory MAF, 250–251, 251f
Positive filtration, 127, 167 Ram air, 148, 173 monitoring, 246
Potentiometer, 249, 250f Random-access memory (RAM), 254 position, 249–250, 250f
Pour point, 120, 121f Ratchets, 19, 29f rail pressure, 275
Power stroke, 42–44, 42f–43f Ratio, 48 variable capacitance, 131, 131f,
Powertrain, 54 Read-only memory (ROM), 254–255
Precision measuring tools, 23f–26f, Reamers, 22 248–249, 249f
Rear cam bushings, 209 Serial bus, 255–256, 255f
24–29, 28f Reassembly, 211–215, 212f–215f Service information systems (SIS), 198
Precleaners, 166–167 Service literature, 198
Presses, 31, 31f of connecting rods, 205–206, 205f, 207f Shear, 100
Pressure of cylinder blocks, 204–205 Shear strength, 35
of cylinder heads, 209–210 Shop safety. See Safety
bar, 36 of piston assemblies, 205–208, Shop tools, 8, 8f, 12–15, 12f–14f, 30–34, 31f–33f
charging, 224, 224f Shrouds, 156–157
combustion, 48 205f–208f Shutters, 155
compression, 48 of timing geartrains, 208–209, 209f SI. See Spark ignited
conversions, 36 Rectangular rings, 62f, 63 Side bypass thermostat, 154
cylinder, 49–50, 54 Reference voltage (V-Ref), 246–252, Single actuator EUI, 269–270, 269f
exhaust, 187 Single-pass principle, 148
mean effective, 49 248f–251f SIS. See Service information systems
nozzle opening, 234, 273 Refueling, 230 Sledgehammers, 31
oil, 130–133, 131f–132f Regeneration cycle, 296 Sleeves. See Liners
peak, 236 Rejected heat, 48, 49f, 140, 164 Sliding ring volute turbos, 171–172, 171f
popping, 234 Reprogramming, 257 Slings, 32
rail, 275, 277, 279–283, 280f–283f Resonation, 178 Small end. See Rod eye
Pressure-regulating valves, 127, 275, Retarder, 184. See also Brakes Small-hole gauges, 28
Ring belt, 56 Smart switches, 252
279–283, 280f–283f Ring end gap, 206 Smog, 291–294, 293t
Preventative maintenance (PM), 133 Ring gear replacement, 76–77 Smoke analysis, 302
Primary filter, 219, 222, 223f Ring grooves, 61 Smoke density, field testing of, 300–302,
Processing circuit, 276 Ring stagger, 207, 207f
Programmable ROM (PROM), 254–255 Rings 300f–301f
Progressive step engine braking, Snap gauges. See Telescoping gauges
fire, 210 Snap test, 301
190–191, 190t O-rings, 105, 204 SO2. See Sulfur dioxide
PROM. See Programmable ROM piston, 61–64, 62f, 64f Soak tank, 203
Proprietary data programming, 257, Rocker housing covers, 111–112 Society of Automotive Engineers (SAE), 34,
Rocker level, 88
259–260 Rod caps, 67, 208, 208f 34f, 120
Propylene glycol (PG), 143, 144, 144t Rod eye, 66 J standards of, 256, 257f, 301–302
Pullers, 33, 201, 201f Rods. See Connecting rods oil viscosity grades of, 123–124, 123f
Pulse wheel, 249 Roller type cam follower, 88, 89f Soft value, 234
Pumping principle, 228 ROM. See Read-only memory Solid lifters, 88
Pumps RPMC. See Rail pressure management control Spark ignited (SI), 48
Spectrographic testing, 133
charging, 222, 227–230, 227f–230f SAE. See Society of Automotive Engineers Split locks, 90
coolant, 151–152, 151f–152f Safety Spray nozzle targeting, 60, 60f
electric primer, 230 Spreader bars, 32, 199
fuel charging, 227–230, 227f–230f chassis and electrical, 10–15, 12f–15f Spun bearings, 71
gear, 125–127, 126f, 227–229, fire, 6, 7f Spur gears, 82
general shop precautions, 8–10, 9f–10f Square engine, 47
227f, 229f lifting, 4–5, 5f Standard conversions, 35–36
hand primer, 228f, 229–230 personal, 2–6, 3f, 14, 29 Static discharge, 11
high-pressure, 278–283, 279f–283f, 285 rules, 1–2 Straight grades, 124
oil, 125–127, 126f shop equipment, 6–8 Stray voltage damage, 158
piston, 278–279, 279f–280f Safety relief valve, 266 Stud extractors, 21
plunger-type, 228, 228f Sandblasters, 33–34 Suction circuit, 218
scavenge, 113, 127 SCAs. See Supplemental cooling additives Sulfur dioxide (SO2), 291
supply, 266 Scavenge pumps, 113, 127 Sump, 113
timing, 285, 285f Scavenging, 43, 45, 45f Supplemental cooling additives (SCAs), 143,
transfer, 219, 219f, 227–230, 227f–230f SCR. See Selective catalytic reduction
water, 151–152, 151f–152f Scraper rings, 61, 62 144–147, 145f–146f
Pushrods and tubes, 88–89 Screw extractors, 21
Pyrometer, 177, 251, 252f Seal lines, 241

342 Index

Supply pump, 266 TPS. See Throttle position sensors Valve margin, 92
Switches, 251–252, 252f Train, 84. See also Timing geartrains; Valve and Valve polar diagram, 98
Synthetic oil, 124 Valve seat inserts, 92–93, 92f
injector trains Valve springs and retainers, 91, 91f
Tachometers, 34 Transfer pumps, 219, 219f, 227–230, Variable capacitance sensor, 131, 131f,
Taper faced rings, 62f, 63
Tappet. See Rocker level 227f–230f 248–249, 249f
Taps, 21 Trapezoidal rings. See Keystone rings Variable geometry (VG) turbocharger, 169–170,
TDC. See Top dead center Trunk type pistons, 55–58, 56f–58f
TDS. See Total dissolved solids Tuned manifolds, 112–113 299–300
Telescoping gauges, 27–28 Turbine, 168 Variable nozzle (VN) turbocharger,
Tempilstick, 83, 209 Turbo-boost, 40, 174
Template torque, 111, 112f Turbochargers 170–171, 170f–171f
Tensile strength, 35 Variable pitch blades, 155, 155f
Tensional loads, 67 in breathing circuit, 167–173, 168f–171f, 173f Variable valve actuator (VVA), 177
Thermal efficiency, 48 variable geometry, 169–170, 299–300 Variable valve timing (VVT), 90, 97, 177
Thermal expansion, 57 variable nozzle, 170–171, 170f–171f VCO nozzles. See Valve closes orifice nozzles
Thermistors, 153, 248, 248f Turbulence, 59 Venting, 221
Thermocouple principle, 251, 252f Two-stroke diesel cycle, 45, 45f–46f VG turbocharger. See Variable geometry
Thermostats, 153–155, 154f
Thick film lubrication, 119 UL. See Underwriter’s Laboratories turbocharger
Thin film lubrication. See Boundary lubrication Ultralow sulfur (ULS), 219 VI. See Viscosity index
Thread chasers, 21–22 Undersquare engine, 47 Vibration dampers, 74–76, 75f
Thread pitch gauges, 22 Underwriter’s Laboratories (UL), 2, 3f Viscosity, 100, 123–124, 123f
Throttle position sensors (TPS), 249–250, 250f Units of atmosphere (atms), 36 Viscosity index (VI), 120
Throw leverage, 49–50 Upload verification, 260 VN turbocharger. See Variable nozzle
Thrust bearing, 73 Urea, 298
Thrust face, 59 turbocharger
Timing geartrains, 82f–83f Valve(s). See also Cylinder head valves; Valve VOCs. See Volatile organic compounds
and injector trains Volatile organic compounds (VOCs), 292
reassembly of, 208–209, 209f Volumetric efficiency, 41
timing gears in, 82–83 automatic bleeding, 266 Volute controlled VG, 170–172, 170f–171f
Timing overhead camshafts, 83, 83f bypass, 128–129 V-Ref. See Reference voltage
Timing pumps, 285, 285f constant throttle, 191–192, 192f VVA. See Variable valve actuator
TIR. See Total indicated runout crossflow, 176, 176f VVT. See Variable valve timing
Tone wheel, 250 design of, 176–177, 176f
Tools exhaust, 90 Washers, 33, 203
air, 32, 33f intake, 90 Wastegate controlled VG, 169–170
EST, 11, 258, 258f parallel port configurations of, 176 Water drainage valve, 266
hand, 18f, 19–22, 20f–21f pressure-regulating, 127, 275, 279–283, Water manifold, 151, 157
kit of, 18, 18f, 29–30, 29f Water pumps, 151–152, 151f–152f
precision measuring, 23f–26f, 24–29, 28f 280f–283f Water separators, 219, 219f,
shop, 8, 8f, 12–15, 12f–14f, 30–34, safety relief, 266
in VVA, 177 225–226, 227f
31f–33f in VVT, 90, 97, 177 Water-in-fuel (WIF), 223, 227, 227f,
Top bypass thermostat, 154 water drainage, 266
Top dead center (TDC), 41–45, 47, 49, 93, Valve and injector trains 251, 266
followers in, 88, 89f Welding, 4, 10, 15, 15f
211–212 pushrods and tubes in, 88–89 Wet liners, 105–106, 105f–106f, 145f, 204
Torque twist control devices, 70 rocker arms in, 89–90 WIF. See Water-in-fuel
Torsional stresses, 69 role of, 84, 87 Williams exhaust brakes, 187, 187f
Total dissolved solids (TDS), 146, 146f typical, 87–88, 88f Winter fronts, 156
Total indicated runout (TIR), 24, 25f Valve closes orifice (VCO) nozzles, Wrenches, 18–20, 18f, 20f, 29, 29f
Wrist pins, 56
237–238, 238f, 299
Valve float, 91 Yield point, 111
Yield strength, 35