• 1 DIESEL ENGINES GENERAL ENGINE DIAGNOSIS GRADING SCALE: 0 ...

1
DIESEL ENGINES
GENERAL ENGINE DIAGNOSIS
GRADING SCALE: 0-100 PTS.
=========================================================================
page - SCORING COMPLETION
TASKLIST pages ATTEMPT DATE
in book 1 2
========================================================================
Listen to and verify operators
complaint; reveiw past maintenance
records; determine needed repairs _______ _____ _____ ____________
Inspect fuel, oil and coolant levels _______ _____ _____ ____________
Inspect engine assembly and
compartment for fuel, oil, coolant
air and other leaks; determine
needed repairs _______ _____ _____ ____________
Listen to engine noises; determine
needed repairs _______ _____ _____ ____________
Check engine exhaust smoke color
and quantity; determine needed
repairs _______ _____ _____ ____________
Perform air intake system pressure
and/or restriction test(s);
determine needed repairs _______ _____ _____ ____________
Perform manifold and/or air box
pressure tests; determine needed
repairs _______ _____ _____ ____________
Perform exhaust back pressure tests
determine needed repairs _______ _____ _____ ____________
Perform crankcase pressure test;
determine needed repairs _______ _____ _____ ____________
Diagnose no cranking, cranks but
fails to start, hard starting and
starts but does not continue to run
problems; determine needed repairs _______ _____ _____ ____________
Diagnose surging, rough operation,
misfiring, low power, slow accel,
slow decel and shutdown problems;
determine needed repairs _______ _____ _____ ____________
 2
DIESEL ENGINES
GENERAL ENGINE DIAGNOSIS
GRADING SCALE: 0-100 PTS.
=========================================================================
page - SCORING COMPLETION
TASKLIST pages ATTEMPT DATE
in book 1 2
========================================================================
Diagnose engine vibration problems;
determine needed repairs _______ _____ _____ ____________
Locate a misfiring cylinder;
determine needed repairs
_______ _____ _____ ____________
Check cooling system for operation;
determine needed repairs _______ _____ _____ ____________
Check lubrication system operation
determine needed repairs _______ _____ _____ ____________
 3
DIESEL ENGINES
CYLINDER HEAD AND VALVE TRAIN DIAGNOSIS AND REPAIR
GRADING SCALE: 0-100 PTS.
=======================================================================
page - SCORING COMPLETION
TASKLIST pages ATTEMPT DATE
in book 1 2
======================================================================
Remove, clean, inspect and replace
cylinder head(s) assembly _______ _____ _____ ____________
Inspect threaded holes, studs and
bolts for serviceability; service-
replace as needed _______ _____ _____ ____________
Inspect cylinder head mating
surface areas for warpage; inspect
for visible cracks/damage; check
condition of passages; inspect core
and galley plugs; determine needed
repairs _______ _____ _____ ____________
Inspect and test valve springs for
squareness, pressure and free height
comparison; replace as needed _______ _____ _____ ____________
Inspect valve spring retainers
and/or rotators and locks; replace
as needed _______ _____ _____ ____________
Measure valve guides for wear, check
valve guide-to-stem clearance and
measure valve guide height; repair/
replace as needed _______ _____ _____ ____________
Replace/recondition valve guides _______ _____ _____ ____________
Inspect, recondition or replace
valves _______ _____ _____ ____________
Inspect and recondition/replace
valve seats _______ _____ _____ ____________
Measure valve head height relative
to deck, valve face-to-seat contact
and valve seat concentricity;
service seats and valves as needed _______ _____ _____ ____________
 4
DIESEL ENGINES
CYLINDER HEAD AND VALVE TRAIN DIAGNOSIS AND REPAIR
GRADING SCALE: 0-100 PTS.
=======================================================================
page - SCORING COMPLETION
TASKLIST pages ATTEMPT DATE
in book 1 2
========================================================================
Measure injector tip or
nozzle protrusion where specified by
manufacturer _______ _____ _____ ____________
Inspect, clean and/or replace pre-
combustion chambers _______ _____ _____ ____________
Inspect and/or replace valve bridges
(crossheads, yokes) and guides;
adjust to specification _______ _____ _____ ____________
Reassemble cylinder head and vacum
test valve sealing _______ _____ _____ ____________
Inspect push rods, rocker arms,
rocker arm shafts and brackets for
wear, bending, cracks, looseness and
blocked oil passages; repair/replace
as needed _______ _____ _____ ____________
Inspect, adjust/replace cam follower _______ _____ _____ ____________
Adjust valve clearance _______ _____ _____ ____________
 5
DIESEL ENGINES
ENGINE BLOCK DIAGNOSIS AND REPAIR
GRADING SCALE: 0-100 PTS.
=======================================================================
page - SCORING COMPLETION
TASKLIST pages ATTEMPT DATE
in book 1 2
========================================================================
Inspect, service and install pans,
covers, vents, gaskets, seals and
wear rings _______ _____ _____ ____________
Clean and inspect engine block for
cracks, mating surfaces areas for
warpage; check condition of passages
core and gallery plugs; inspect
threaded holes, studs, dowel pins
and bolts for serviceability;service
replace as needed _______ _____ _____ ____________
Inspect cylinder sleeve counterbore
and lower bore; check bore distort-
ion; determine needed repairs _______ _____ _____ ____________
Clean, inspect and measure cylinder
walls or liners for wear and damage;
determine needed service _______ _____ _____ ____________
Replace cylinder liners and seals;
check and adjust liner height _______ _____ _____ ____________
Inspect camshaft bearings for wear
and damage; determine needed repairs _______ _____ _____ ____________
Inspect, measure and replace/install
camshaft; measure/adjust end play _______ _____ _____ ____________
Clean and inspect crankshaft for
surface cracks and journal damage;
check condition of oil passage(s);
check passage plugs; measure journal
diameter and fillet radius;determine
needed service _______ _____ _____ ____________
Check main bearing bore cap fit;
determine needed service _______ _____ _____ ____________
Inspect and replace main bearings;
check bearing clearances; check and
 6
adjust crankshaft end play _______ _____ _____ ____________
DIESEL ENGINES
ENGINE BLOCK DIAGNOSIS AND REPAIR
GRADING SCALE: 0-100 PTS.
=======================================================================
page - SCORING COMPLETION
TASKLIST pages ATTEMPT DATE
in book 1 2
========================================================================
Inspect, replace and time drive gear
train. (includes checking gear wear
and backlash of crankshaft, camshaft
auxiliary drive and idler gears plus
servicing shafts, bushings and
bearings.) _______ _____ _____ ____________
Clean, inspect, measure or replace
pistons, pins and retainers _______ _____ _____ ____________
Measure piston-to-cylinder wall
clearance _______ _____ _____ ____________
Check ring-to-groove clearance and
end gap; install rings on pistons _______ _____ _____ ____________
Identify piston and bearing wear
patterns; check bearing bore and
bushing condition; determine needed
repairs _______ _____ _____ ____________
Assemble pistons and connecting rods
and install in block; replace rod
bearings and check clearances; check
piston cooling jets (nozzles) for
condition, position and clearance _______ _____ _____ ____________
Inspect, measure, service/replace
crankshaft vibration damper and
flywheel _______ _____ _____ ____________
Inspect, install and align flywheel
housing _______ _____ _____ ____________
 7
DIESEL ENGINES
LUBRICATION SYSTEMS DIAGNOSIS AND REPAIR
GRADING SCALE: 0-100 PTS.
=======================================================================
page - SCORING COMPLETION
TASKLIST pages ATTEMPT DATE
in book 1 2
========================================================================
Check engine oil, pressure, guage
and sending unit _______ _____ _____ ____________
Check engine oil level, contaminants
and consumption; determine needed
repairs _______ _____ _____ ____________
Inspect, measure, repair/replace oil
pump drives, inlet pipes and screens _______ _____ _____ ____________
Inspect, repair/replace oil pressure
regulator valve(s), by-pass and
pressure relief popet valve(s) _______ _____ _____ ____________
Inspect, clean, test, reinstall or
replace, and align oil cooler; test
reinstall/replace differential valve
and thermostat; inspect and repair/
replace lines and hoses _______ _____ _____ ____________
Inspect turbocharger lubrication
system; determine needed repairs _______ _____ _____ ____________
 8
DIESEL ENGINES
COOLING SYSTEM DIAGNOSIS AND REPAIR
GRADING SCALE: 0-100 PTS.
=======================================================================
page - SCORING COMPLETION
TASKLIST pages ATTEMPT DATE
in book 1 2
========================================================================
Check engine coolant level,
contamination and consumption;
determine needed repairs _______ _____ _____ ____________
Check coolant temperature, guage
and sending unit _______ _____ _____ ____________
Inspect, reinstall/replace and
adjust drive belts _______ _____ _____ ____________
Inspect and replace thermostat(s)
by-passes, housing(s) and seals _______ _____ _____ ____________
Check conditioner and coolant
concentration levels; determine
needed repairs _______ _____ _____ ____________
Flush and refill cooling system;
bleed air from system _______ _____ _____ ____________
Inspect, repair/replace water pump,
hoses and idler pulley _______ _____ _____ ____________
Inspect, pressure test, and clean
radiator, pressure cap, and tank(s);
determine needed service(s) _______ _____ _____ ____________
Inspect, repair/replace fan hub, fan
fan clutch, controls, thermostats
and fan shroud _______ _____ _____ ____________
 9
DIESEL ENGINES
AIR INDUCTION AND EXHAUST SYSTEMS DIAGNOSIS AND REPAIR
GRADING SCALE: 0-100 PTS.
=======================================================================
page - SCORING COMPLETION
TASKLIST pages ATTEMPT DATE
in book 1 2
========================================================================
Inspect, service/replace air intake
piping, air cleaner and element _______ _____ _____ ____________
Inspect turbocharger and/or engine
driven blowers and piping system;
determine needed repairs _______ _____ _____ ____________
Remove and replace turbocharger and
engine driven blowers _______ _____ _____ ____________
Inspect, repair/replace intake
manifold, gaskets and connections _______ _____ _____ ____________
Inspect, clean, test and repair/
replace aftercooler(intercooler) _______ _____ _____ ____________
Inspect, repair/replace exhaust
manifold, piping, mufflers and mount
hardware _______ _____ _____ ____________
 10
DIESEL ENGINES
ENGINE BRAKES
GRADING SCALE: 0-100 PTS.
=======================================================================
page - SCORING COMPLETION
TASKLIST pages ATTEMPT DATE
in book 1 2
========================================================================
Inspect and adjust engine brakes;
determine needed repairs _______ _____ _____ ____________
Inspect, test, adjust, repair/repl
engine brake control circuits
switches and solenoids _______ _____ _____ ____________
Inspect, repair/replace engine brake
housing, valves, seals, screens
lines and fittings _______ _____ _____ ____________