DIET 1030 Syllabus

Cylinder Head and Valve Train
Order            Description
   1                 Perform removal, cleaning, inspection for visible damage, and replacement of cylinder head(s)
                      assembly
   2                 Perform cleaning and inspection of threaded holes, studs, and bolts for serviceability and
                      determine needed action
   3                 Inspect cylinder head for cracks or other damage
   4                 Check mating surfaces for warpage
   5                 Check condition of cylinder head passages
   6                 Inspect core/expansion and gallery plugs and determine needed action
   7                 Perform disassembly of cylinder head and inspect valves, guides, seats, springs, retainers,
                      rotators, locks, and seals; and determine needed action
   8                 Measure valve head height relative to deck and valve face-to-seat contact and determine 
                      needed action
   9                 Inspect injector sleeves and seals
  10                Measure injector tip or nozzle protrusion and determine needed action
  11                Inspect valve train components and determine needed action
  12                Perform reassembly of cylinder head
  13                Inspect, measure, and replace/reinstall overhead camshaft
  14                Perform measurement and/or adjustment of camshaft end play and backlash
  15                Inspect cam followers and determine needed action
  16                Perform adjustment of valve bridges (crossheads), valve clearances, and injector settings

 

Engine Block
Order         Description
   1              Perform crankcase pressure test and determine needed action
   2              Perform removal, inspection, service, and installation of engine pans, covers, gaskets, seals,
                   wear rings, and crankcase ventilation components
   3              Perform disassembly, cleaning, and inspection of engine block for cracks or other damage
   4              Perform measurement of mating surfaces for warpage
   5              Check condition of passages and core/expansion and gallery plugs in the block
   6              Perform inspection of threaded holes, studs, dowel pins, and bolts for serviceability and
                   determine needed action
   7              Inspect cylinder sleeve counter bore and lower bore
   8              Check bore distortion and determine needed action
   9              Perform cleaning, inspection, and measuring of cylinder walls or liners for wear and damage and
                   determine needed action
  10             Perform replacement/reinstallation of cylinder liners and seals and adjust liner height
                   (protrusion)
  11             Inspect in-block camshaft bearings for wear and damage and determine needed action
  12             Perform inspection, measuring and replacement/reinstallation of in-block camshafts and measure
                   and adjust end play
  13             Clean and inspect crankshaft for surface cracks and journal damage
  14             Check condition of oil passages and oil passage plugs
  15             Measure crank shaft journal diameters and determine needed action
  16             Inspect main bearings for wear patterns and damage and replace as needed
  17             Check bearing clearances
  18             Check and correct crankshaft end play
  19             Perform inspection, installation, and timing of engine gear train
  20             Measure gear backlash and determine needed action
  21             Inspect connecting rod and bearings for wear patterns
  22             Measure pistons, pins, retainers, and bushings and perform needed actions
  23             Determine piston to cylinder wall clearance
  24             Check ring-to-groove fit and end gap
  25             Perform installation of rings on pistons
  26             Perform assembly of pistons and connecting rods
  27             Perform installation of pistons into cylinder bores
  28             Perform installation of rod bearings and check clearances

 

Engine Lubrication System
Order         Description
   1              Test engine oil pressure and check operation of pressure sensor, gauge, and/or sending unit;
                   determine needed action
   2              Test engine oil temperature and check operation of temperature sensor; determine needed
                   action
   3              Check engine oil level, condition, and consumption; determine needed action
   4              Inspect and measure oil pump, drives, inlet pipes, and pick up screens, as well as drive gear
                   clearances; determine needed action
   5              Inspect oil pressure regulator valves, by-pass and pressure relief valves, oil thermostat, and
                   filters; determine needed action
   6              Inspect, clean and test oil cooler and components; determine needed action
   7              Inspect turbocharger lubrication and cooling systems; determine needed action
   8              Determine proper lubricant and perform oil and filter change

 

Hydraulic Pumps
Order         Description
   1              Identify system fluid type
   2              Identify causes of pump failure, unusual pump noises, temperature, flow, and leakage
                   problems; determine needed action
   3              Determine pump type, rotation, and drive system
   4              Perform removal and installation of pump and then prime and/or bleed system
   5              Inspect pump inlet for restrictions and leaks; determine needed action
   6              Inspect pump outlet for restrictions and leaks; determine needed action

 

Engine Cooling System
Order         Description
   1              Check engine coolant type, level, condition, and consumption
   2              Test coolant for freeze protection and additive package concentration; determine needed action
   3              Test coolant temperature and check operation of temperature level sensors, gauge, and/or
                   sending unit; determine needed action
   4              Inspect and reinstall/replace pulleys, tensioners, and drive belts
   5              Perform adjustment of drive belts and check alignment
   6              Inspect thermostats, by-passes, housings, and seals; replace as needed
   7              Perform recovery, flushing, and refilling of cooling system with recommended coolant/additive
                   package
   8              Perform bleeding procedure of cooling system
   9              Inspect coolant conditioner/filter assembly for leaks
  10             Inspect cooling system valves, lines, and fittings; replace as needed
  11             Inspect water pump and hoses; replace as needed
  12             Perform inspection, cleaning, and pressure testing of radiator, pressure cap, tanks, and recovery
                   systems; determine needed action
  13             Inspect thermostatic cooling fan system (hydraulic, pneumatic, and electronic) and fan shroud;
                   replace as need

Air Induction and Exhaust System
Order         Description
   1              Perform air intake system restriction and leakage tests; determine needed action
   2              Perform intake manifold pressure (boost) test; determine needed action
   3              Perform exhaust back pressure test; determine needed action
   4              Inspect turbocharger(s), waste gate, and piping systems; determine needed action
   5              Inspect and test turbocharger(s) (variable ratio/geometry VGT), pneumatic, hydraulic, and
                   electronic controls and actuators
   6              Check air induction system piping, hoses, clamps, and mounting
   7              Perform service or replacement of air filter as needed
   8              Perform removal and reinstallation of turbocharger/waste gate assembly
   9              Inspect intake manifold gaskets and connections; replace as needed
  10             Inspect, clean, and test charge air cooler assemblies
  11             Inspect after cooler assemblies and replace as needed
  12             Inspect exhaust manifold, piping, mufflers, and mounting hardware; repair or replace as needed
  13             Inspect exhaust after treatment devices; determine necessary action
  14             Inspect and test preheater/inlet air heater, or glow plug system and controls; perform needed
                   action
  15             Inspect and test exhaust gas recirculation (EGR) system including EGR valve, cooler, piping,
                   filter, electronic sensors, controls, and wiring; determine needed action

 

Fuel Supply System
Order         Description
   1              Check fuel level and condition; determine needed action
   2              Perform fuel supply and return system tests; determine needed action
   3              Inspect fuel tanks, vents, caps, mounts, valves, screens, crossover system, supply and return
                   lines, and fittings; determine needed action
   4              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
   5              Inspect and test low pressure regulator systems (check valves, pressure regulator valves, and
                   restrictive fittings); determine needed action
   6              Check fuel system for air; determine needed action
   7              Perform priming and bleeding procedures of fuel system and check primer pump

 

Electronic Fuel Management System
Order         Description
   1              Inspect and test power and ground circuits and connections by measuring and interpreting
                   voltage, voltage drop, amperage, and resistance readings using a digital multimeter (DMM);
                   determine needed action
   2              Interface with vehicle's on-board computer and perform diagnostic procedures using
                   recommended electronic diagnostic equipment and tools (to include PC based software and/or
                   data scan tools); determine needed action
   3              Check and record electronic diagnostic codes and trip/operational data
   4              Monitor electronic data and clear codes; determine further diagnosis
   5              Locate and use relevant service information (to include diagnostic procedures, flow charts, and
                   wiring diagrams)
   6              Perform inspection and replacement of electrical connector terminals, seals, and locks
   7              Inspect and test switches, sensors, controls, actuator components, and circuits
   8              Perform adjustment or replacement of these components as needed
   9              Access and interpret customer programmable parameters using recommended electronic
                   diagnostic tools (to include PC based software and/or data scan tools)
  10             Inspect, test, and adjust electronic unit injectors (EUI); determine needed action
  11             Perform removal and installation of electronic unit injectors (EUI) and related components and
                   recalibrate ECM (if applicable)
  12             Perform cylinder contribution test utilizing recommended electronic diagnostic tool
  13             Perform on-engine inspections and tests on hydraulic electronic unit injectors and system