Standard

 

DET 133 - Diesel Engine Overhaul and Servicing II

Course Description

A continuation of DET 132, introducing diesel engines used in medium & heavy duty trucks & heavy equipment, with emphasis on engine systems and components.    Topics include:  lubricating systems, cooling systems, cylinder blocks & liners, crankshafts & bearings, pistons & connecting rods, camshafts, gear trains, & timing, cylinder head assemblies, air induction & exhaust systems, and engine brakes & retarders.  Using and intrepreting test and measuring instruments is highly emphasized.

 

Competency Areas

Hours

 

Lubricating Systems     

Class

1

Cooling Systems

D. Lab

0

Cylinder Blocks & Liners

P. Lab/O.B.I.

9

Crankshafts & Bearings

Credit

4

Pistons & Connecting Rods

 

 

Camshafts, Gear Trains, & Timing

 

 

Cylinder Head Assemblies

 

 

Air Induction & Exhaust Systems

 

 

Engine Brakes & Retarders

 

 

 

Prerequisite:

DET 132

Corequisite:

     

 

Course Guide

 

Competency

After completing this section, the student will:

Hours

Class

D.Lab

P.Lab/

O.B.I.

LUBRICATION SYSTEMS

0

0

10

 

Understand terms and definitions

 

 

 

 

Understand the basic components of a lubrication system

 

 

 

 

Identify lubrication system components and describe their functions

 

 

 

 

Identify basic types of oil filters and describe their operation

 

 

 

 

Understand basic oil pump designs and their operation

 

 

 

 

Understand basic oil cooler designs

 

 

 

 

Identify types of oil coolers according to descriptions of their operation

 

 

 

 

Determine sources of oil contamination

 

 

 

 

Understand how to monitor lubrication system

 

 

 

 

Understand API use codes

 

 

 

 

Understand factors to consider when choosing an engine oil

 

 

 

 

Service and install oil pump and oil pump drive components

 

 

 

 

Service and inspect lubrication system screens and pipes

 

 

 

 

Service and inspect oil pressure regulator valve and bypass valves

 

 

 

 

Service and inspect oil cooler and lines

 

 

 

COOLING SYSTEMS

0

0

10

 

Understand terms and definitions

 

 

 

 

Understand common types of cooling systems

 

 

 

 

Locate cooling system components for an air-cooled engine and describe their functions

 

 

 

 

Locate cooling system components for a liquid-cooled engine and describe their functions

 

 

 

 

Define the operation of air-cooled and liquid-cooled engines

 

 

 

 

Understand effects of incorrect temperature regulation

 

 

 

 

Define common types of radiators

 

 

 

 

Define types of drives for water pumps

 

 

 

 

Identify parts of a water pump

 

 

 

 

Understand types of drive belts

 

 

 

 

Identify coolant items and their functions

 

 

 

 

Describe the types of antifreeze

 

 

 

 

Be familiar with the characteristics of a suitable antifreeze

 

 

 

 

Understand the purposes of a radiator cap

 

 

 

 

Define typical radiator cap operation

 

 

 

 

Flush, refill, and bleed coolant system

 

 

 

 

Inspect water pump, belts, and hoses

 

 

 

 

Check operation of fan assembly and controls

 

 

 

 

Test operation of thermostat installed in engine

 

 

 

 

Test operation of thermostat on the bench

 

 

 

 

Check operation and accuracy of temperature indicating system

 

 

 

CYLINDER BLOCKS & LINERS

0

0

10

 

Understand terms and definitions

 

 

 

 

Understand types of cylinder block cooling methods

 

 

 

 

Understand types of cylinder liners

 

 

 

 

Understand characteristics of cylinder liners

 

 

 

 

Understand causes of abnormal sleeve wear

 

 

 

 

Pressure test a cylinder block

 

 

 

 

Disassemble and clean a cylinder block

 

 

 

 

Inspect a cylinder block

 

 

 

 

Install new camshaft bushings

 

 

 

 

Clean and inspect cylinder bores

 

 

 

 

Install cylinder liners and set liner protrusion

 

 

 

CRANKSHAFTS & BEARINGS

1

0

10

 

Understand terms and definitions

 

 

 

 

Identify parts of a crankshaft

 

 

 

 

Understand engine design according to crankshaft

 

 

 

 

Understand crankshaft throw characteristics

 

 

 

 

Understand crankshaft balancing methods

 

 

 

 

Describe crankshaft lubrication

 

 

 

 

Understand characteristics of a good bearing

 

 

 

 

Be familiar with bearing materials and their characteristics

 

 

 

 

Identify parts of main and connecting rod bearings

 

 

 

 

Understand special design features of main bearings

 

 

 

 

Identify types of thrust bearings

 

 

 

 

Understand symptoms of bearing failure

 

 

 

 

Understand types of vibration dampers

 

 

 

 

Describe functions of a flywheel

 

 

 

 

Remove, clean, and inspect a crankshaft

 

 

 

 

Install main bearings and crankshaft

 

 

 

 

Perform an in-frame bearing roll-in

 

 

 

 

Inspect viscous vibration damper/harmonic balancer

 

 

 

 

Inspect bonded vibration damper/harmonic balancer

 

 

 

 

Inspect flywheel

 

 

 

PISTONS & CONNECTING RODS

0

0

10

 

Understand terms and definitions

 

 

 

 

Describe primary components of a piston and connecting rod assembly

 

 

 

 

Describe piston and connecting rod components and their functions

 

 

 

 

Describe parts of a piston and their function

 

 

 

 

Describe common piston designs

 

 

 

 

Understand types of piston crown designs

 

 

 

 

Describe types of piston rings

 

 

 

 

Understand common types of piston ring end gaps

 

 

 

 

Understand piston ring designs

 

 

 

 

Describe characteristics of piston ring designs

 

 

 

 

Understand parts of a connecting rod and their description

 

 

 

 

Understand common causes of abnormal piston wear

 

 

 

 

Understand possible causes of high oil consumption and blow-by

 

 

 

 

Remove, disassemble, and inspect a piston and connecting rod assembly

 

 

 

 

Measure piston-to-cylinder wall clearance and ring end gap

 

 

 

 

Assemble and install piston and connecting rod assembly

 

 

 

CAMSHAFTS, TRAINS, & TIMING

0

0

10

 

Understand terms and definitions

 

 

 

 

Understand primary parts of a camshaft

 

 

 

 

Describe types of camshafts

 

 

 

 

Understand operation of camshaft

 

 

 

 

Understand parts of a cam lob and their definitions

 

 

 

 

Identify parts of a valve train

 

 

 

 

Understand valve actuation

 

 

 

 

Understand two-stroke and four-stroke valve timing

 

 

 

 

Understand types of camshaft bushings

 

 

 

 

Describe types of cam followers and lifters

 

 

 

 

Understand methods of driving the camshaft

 

 

 

 

Understand gear timing

 

 

 

 

Remove, clean, and inspect a camshaft

 

 

 

 

Remove, inspect, and install cam bushings

 

 

 

 

Install a camshaft and set cam timing

 

 

 

CYLINDER HEAD ASSEMBLIES

0

0

10

 

Understand terms and definitions

 

 

 

 

Understand functions of the cylinder head

 

 

 

 

Understand basic cylinder head designs

 

 

 

 

Describe parts of a typical valve

 

 

 

 

Understand parts of a valve and their functions

 

 

 

 

Understand basic valve assembly components

 

 

 

 

Understand valve assembly components and their functions

 

 

 

 

Describe steps in the operation of a valve rotator

 

 

 

 

Understand common cylinder head problems

 

 

 

 

Understand common valve/seat problems

 

 

 

 

Locate and label intake and exhaust valves

 

 

 

 

Clean and inspect a cylinder head

 

 

 

 

Recondition a cylinder head

 

 

 

 

Install a cylinder head assembly and adjust valves

 

 

 

AIR INDUCTION & EXHAUST SYSTEMS

0

0

10

 

Understand terms and definitions

 

 

 

 

Describe basic air induction components

 

 

 

 

Understand air induction components and their functions

 

 

 

 

Understand types of air induction systems

 

 

 

 

Identify main parts of a turbocharger

 

 

 

 

Understand starting aid devices

 

 

 

 

Describe basic exhaust system components

 

 

 

 

Describe exhaust system components and their functions

 

 

 

 

Understand sequence of operation for an air induction and exhaust system

 

 

 

 

Understand scavenging process for two-stroke and four-stroke diesel engines

 

 

 

 

Understand agricultural/industrial and motor vehicle exhaust systems

 

 

 

 

Describe parts of a typical catalytic converter

 

 

 

 

Understand operation of a catalytic converter

 

 

 

 

Inspect and test air induction system

 

 

 

 

Inspect and service turbo/supercharger and related components

 

 

 

 

Clean and test jacket water intercooler

 

 

 

 

Clean and test air-to-air intercooler

 

 

 

 

Inspect and test exhaust system

 

 

 

 

Inspect starting preheater controls

 

 

 

 

Test starting fluid system and controls

 

 

 

ENGINE BRAKES & RETARDERS

0

0

10

 

Understand terms and definitions

 

 

 

 

Describe common types of engine brakes and retarders

 

 

 

 

Describe advantages of engine brake and retarder systems

 

 

 

 

Understand typical engine compression brake components

 

 

 

 

Understand engine compression brake components and their functions

 

 

 

 

Understand engine operation with the engine compression brake energized

 

 

 

 

Describe exhaust brake components and their functions

 

 

 

 

Understand engine operation with the engine exhaust brake energized

 

 

 

 

Describe hydraulic engine retarder components

 

 

 

 

Describe hydraulic engine retarder components and their functions

 

 

 

 

Understand engine operation with the hydraulic engine retarder

 

 

 

 

Understand electric driveline retarder components and their functions

 

 

 

 

Understand engine operation with an electric driveline retarder energized

 

 

 

 

Remove, inspect, install, and adjust a Jacobs engine brake

 

 

 

 

Check operation of a BrakeSaver

 

 

 

 

Check operation of an exhaust brake

 

 

 

 

Remove, clean, and install an exhaust brake

 

 

 

 

Check operation of a driveline retarder

 

 

 

 

Suggested Resources

 

Mitchell Information Systems.  (2002).  “Mitchell on Demand”.  San Diego, California.

Multistate Academic and Vocational Curriculum Consortium.  (2002).  “Diesel Technology Series”.   Stillwater, Oklahoma.

Norman, Andrew & others.   (2001).  Diesel Technology.  Tinley Park, Illinois:  Goodheart-Willcox.

Norman, Andrew & others.   (2001).  Heavy Duty Truck Systems.  Albany, New York:  Delmar Publishing.

Norris, David & Tony Elkins.  (2002).  Automotive Information Specialists.  Gulf Breeze, Florida:  Motor/Alldata.