COURSE COMPETENCIES:

 

 

 1. Demonstrate knowledge of the history of Navistar’s partnership with Ford Motor Company to revolutionize the

    medium duty diesel engine truck market.

 2. Distinguish between the 6.9L IDI, 7.3L IDI, 7.3L DI Turbo, 7.3L, 6.0L, 6.4L, and the 6.7L Powerstroke, and be able to

    research the service and repair procedures required to work on the Ford Powerstroke Engine.

 3. Perform 7.3L through 6.7L scheduled service adjustment procedures and engine evaluations.

 4. Conduct engine diagnostics to determine problems and adjustments or repairs.

 5. Recognize the differences between the mechanical Bosch Standyane injection pumps, high pressure lift pumps supplying the

    Caterpillar designed and built HUEI injection to the latest 29,000 psi high-pressure Bosch common-rail fuel injection system.

 6. Perform injection pump inspection, testing.

 7. Identify the differences among HEUI injection nozzles and understand their principle operations.

 8. Perform injector performance testing evaluation, repair and/or replacement.

 9. Identify, inspect, test, evaluate and repair glow plug pre-heaters.

 10. Identify, inspect test, evaluate and repair charge air intercoolers as used on turbocharged engines.

 11. Identify, inspect, test, evaluate and repair common turbochargers including the Holset turbocharger, the

     Two-Stage Variable Turbocharger, and the latest single-sequential Honeywell Turbocharger.

 12. Identify various models of manual and automatic transmissions used from first to last production dates.

 TOPICAL OUTLINE:

 

 

 I. Powerstroke History and Development

      a. Designs

      b. Applications

      c. Partnership History

      d. Marketing Strategy

 II. B Series Engine Identification

      a. Model series identification.

      b. Production year and series

      c. Production year, series and rated horse power

      d. Series and  use applications

 III. Scheduled Engine Service and Adjustments

      a. Overhead valve adjustment procedures on Powerstroke

      b. Inspection and adjustment of injection pump timing

 IV. Engine Performance and Diagnostic Procedures

      a. Cylinder balance test

      b. Wet, dry and leak-down compression test

      c. Injector cut-out test

      d. Diagnostic fault codes

 V. Fuel Injection Pumps

      a. Model Identification

      b. Pressure specifications and calibration adjustments

      c. Timing specifications and adjustment procedures

      d. Injection pump removal replacement installation procedures

 VI. Fuel Injection Nozzles

      a. Model Identifications as related to production years and engine series

      b. Dynamic testing by injector cut-out test and cylinder balance test

      c. Static testing by bench testing poppet pressures and leak test

 VII. Glow Plug Pre-Heaters

      a. Principle usage and purpose

      b. Condition inspection, circuit testing, voltage and amp draw; evaluation, repair and replacement

 VIII. Intercoolers

      a. Principles and purpose

      b. Inspection, testing for leakage or restrictions

 IX. Turbochargers

      a. Models and sizes as related to production years and rated horse power

      b. Principles and theories of exhaust heat turbine compressors

 X. Manual and Automatic Transmissions

      a. Identification of manual transmissions used in progression of production years and related to rated horse power

      b. Identification of  automatic transmissions used in progression of production years and related to rated horse power