STANDARD COMPETENCIES:

 

 1. Inspect fuel, oil, Diesel Exhaust Fluid (DEF), and coolant levels and condition; determine needed action.

 2. Identify causes of engine fuel, oil, coolant, air, and other leaks; determine needed action.

 3. Listen for engine noises; determine needed action.

 4. Observe engine exhaust smoke color and quantity; determine needed action.

 5. Identify engine no cranking, cranks but fails to start, hard starting, and starts but does not

    continue to run problems; determine needed action.

 6. Identify causes of engine surging, rough operation, misfiring, low power, slow deceleration,

    slow acceleration, vibration, and shutdown problems; determine needed action.

 7. Check and record electronic diagnostic codes.

 8. Inspect cylinder head for cracks/damage; check mating surfaces for warpage; check

    condition of passages; inspect core/expansion and gallery plugs; determine needed action.

 9. Disassemble head and inspect valves, guides, seats, springs, retainers, rotators, locks, and

    seals; determine needed action.

 10. Measure valve head height relative to deck and valve face-to-seat contact; determine

     needed action.

 11. Inspect injector sleeves and seals; measure injector tip or nozzle protrusion; determine

     needed action.

 12. Inspect valve train components; determine needed action.

 13. Reassemble cylinder head.

 14. Inspect, measure, and replace/reinstall overhead camshaft; measure/adjust end play and

     backlash.

 15. Adjust valve bridges (crossheads); adjust valve clearances and injector settings.

 16. Inspect electronic wiring harness and brackets for wear, bending, cracks, and looseness;

     determine needed action.

 17. Check engine coolant type, level, condition, and consumption; test coolant for freeze

     protection and additive package concentration; determine needed action.

 18. Test coolant temperature and check operation of temperature and level sensors, gauge,

     and/or sending unit; determine needed action.

 19. Inspect thermostat(s), by-passes, housing(s), and seals; replace as needed.

 20. Inspect coolant conditioner/filter assembly for leaks; inspect valves, lines, and fittings;

     replace as needed.

 TOPICAL OUTLINE:

 

 I.      General Engine Diagnosis

         A.      Visual Inspection of Fluids

         B.      How a Diesel Engine Works

         C.      Engine Performance Tests

 II.     Cylinder Head and Valve Train Diagnosis and Repair

         A.      Inspection of Cylinder Heads

         B.      Valves

         C.      Injector Sleeves

         D.      Overhead Cams

         E.      Valve Adjustments

 III.    Cooling System Diagnosis and Repair

         A.      Inspection of Cooling System

         B.      Coolant Tests (Identify Type) (Freeze Protection)

         C.      Coolant Flow and Purpose

         D.      Cooling Fans

         E.      Cooling System Tests