STANDARD COMPETENCIES:

 

 1. Remove, inspect, service, and install pans, covers, gaskets, seals, wear rings, and crankcase ventilation components.

 2. Disassemble, clean, and inspect engine block for cracks/damage; measure mating surfaces for warpage; check condition of passages,

    core/expansion and gallery plugs; inspect threaded holes, studs, dowel pins, and bolts for serviceability; determine needed action.

 3. Inspect cylinder sleeve counter bore and lower bore; check bore distortion; determine needed action.

 4. Clean, inspect, and measure cylinder walls or liners for wear and damage; determine needed action.

 5. Replace/reinstall cylinder liners and seals; check and adjust liner height (protrusion).

 6. Inspect in-block camshaft bearings for wear and damage; determine needed action.

 7. Inspect, measure, and replace/reinstall in-block camshaft; measure/adjust end play.

 8. Clean and inspect crankshaft for surface cracks and journal damage; check condition of oil passages; check passage plugs;

    measure journal diameter; determine needed action.

 9. Inspect main bearings for wear patterns and damage; replace as needed; check bearing clearances; check and correct crankshaft end play.

 10. Inspect, install, and time gear train; measure gear backlash; determine needed action.

 11. Inspect connecting rod and bearings for wear patterns; measure pistons, pins, retainers, and bushings; perform needed action.

 12. Determine piston-to-cylinder wall clearance; check ring-to-groove fit and end gap; install rings on pistons.

 13. Assemble pistons and connecting rods; install in block; install rod bearings and check clearances.

 14. Check condition of piston cooling jets (nozzles); determine needed action.

 15. Inspect crankshaft vibration damper; determine needed action.

 16. Install and align flywheel housing; inspect flywheel housing(s) to transmission housing/engine mating surface(s)

     and measure flywheel housing face and bore run out; determine needed action.

 17. Test engine oil pressure and check operation of pressure sensor, gauge, and/or sending unit; test engine oil temperature

     and check operation of temperature sensor; determine needed action.

 18. Check engine oil level, condition, and consumption, perform crankcase pressure test, determine needed action.

 19. Inspect and measure oil pump, drives, inlet pipes, and pick-up screens; check drive gear clearances; determine needed action.

 20. Inspect oil pressure regulator valve(s), by-pass and pressure relief valve(s), oil thermostat, and filters; determine needed action.

 21. Inspect, clean, and test oil cooler and components; determine needed action.

 22. Inspect turbocharger lubrication and cooling systems; determine needed action.

 23. Inspect and adjust engine compression/exhaust brakes; determine needed action.

 24. Inspect, test, and adjust engine compression/exhaust brake control circuits, switches, and solenoids; repair or replace as needed.

 25. Inspect engine compression/exhaust brake housing, valves, seals, lines, and fittings; repair or replace as needed.

 TOPICAL OUTLINE:

 

 I.      Diesel Engine Block Diagnosis and Repair

         A.      Cylinder Block Construction

         B.      Disassembly inspection and cleaning

         C.      Final inspection, testing, reconditioning and re-assembly

 II.     Lubrication Systems Diagnosis and Repair

         A.      Lubrication Systems

         B.      System Components

         C.      System Testing

         D.      Trouble Shooting

 III.    Engine Brakes

         A.      Operation

         B.      Control Circuits