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DIESEL ENGINE OPERATION AND DIAGNOSIS 19
Objectives ,[object Object],[object Object],[object Object],[object Object]
Objectives ,[object Object],[object Object],[object Object],[object Object]
DIESEL ENGINES
Diesel Engines ,[object Object],[object Object],[object Object]
Diesel Engines ,[object Object],[object Object],[object Object]
Diesel Engines ,[object Object],[object Object],[object Object]
Diesel Engines ,[object Object],[object Object],[object Object]
Diesel Engines ,[object Object],[object Object]
Diesel Engines ,[object Object],[object Object]
Figure 19-1   Diesel combustion occurs when fuel is injected into the hot, highly compressed air in the cylinder.
Figure 19-2   A typical injector pump type of automotive diesel fuel–injection system.
Diesel Engines ,[object Object],[object Object],[object Object],[object Object],[object Object]
Diesel Engines ,[object Object],[object Object],[object Object],[object Object],[object Object]
Diesel Engines ,[object Object],[object Object],[object Object],[object Object]
Diesel Engines ,[object Object],[object Object],[object Object],[object Object]
Diesel Engines ,[object Object],[object Object]
Diesel Engines ,[object Object],[object Object]
Chart 19-1   Comparison between a typical gasoline and a diesel engine.
Figure 19-3   A Cummins diesel engine as found in a Dodge pickup truck. A high-pressure pump (up to 30,000 PSI) is used to supply diesel fuel to this common rail, which has tubes running to each injector. Note the thick cylinder walls and heavy-duty construction.
Figure 19-4   A rod/piston assembly from a 5.9 liter Cummins diesel engine used in a Dodge pickup truck.
Diesel Engines ,[object Object],[object Object]
Diesel Engines ,[object Object],[object Object]
Diesel Engines ,[object Object],[object Object]
Diesel Engines ,[object Object]
Diesel Engines ,[object Object],[object Object],[object Object]
Diesel Engines ,[object Object],[object Object],[object Object]
Diesel Engines ,[object Object],[object Object],[object Object]
Diesel Engines ,[object Object],[object Object],[object Object]
Diesel Engines ,[object Object],[object Object],[object Object]
Diesel Engines ,[object Object],[object Object],[object Object]
Diesel Engines ,[object Object],[object Object],[object Object]
Figure 19-5   An indirect injection diesel engine uses a prechamber and a glow plug.
Figure 19-6   A direct injection diesel engine injects the fuel directly into the combustion chamber. Many designs do not use a glow plug.
Diesel Engines ,[object Object],[object Object]
Diesel Engines ,[object Object],[object Object]
Diesel Engines ,[object Object],[object Object]
THREE PHASES OF COMBUSTION
Three Phases of Combustion ,[object Object],[object Object],[object Object]
FUEL TANK AND LIFT PUMP
Fuel Tank and Lift Pump ,[object Object],[object Object],[object Object]
Fuel Tank and Lift Pump ,[object Object],[object Object],[object Object]
Fuel Tank and Lift Pump ,[object Object],[object Object],[object Object]
Fuel Tank and Lift Pump ,[object Object],[object Object],[object Object]
Fuel Tank and Lift Pump ,[object Object],[object Object],[object Object]
Fuel Tank and Lift Pump ,[object Object],[object Object],[object Object]
Fuel Tank and Lift Pump ,[object Object],[object Object]
Fuel Tank and Lift Pump ,[object Object],[object Object],[object Object]
Fuel Tank and Lift Pump ,[object Object]
Figure 19-7   A fuel temperature sensor is being tested using an ice bath.
INJECTION PUMP
Injection Pump ,[object Object],[object Object],[object Object]
Injection Pump ,[object Object],[object Object],[object Object]
Injection Pump ,[object Object],[object Object],[object Object]
Injection Pump ,[object Object]
Figure 19-8   A typical distributor-type diesel injection pump showing the pump, lines, and fuel filter.
Injection Pump ,[object Object],[object Object]
Injection Pump ,[object Object],[object Object]
Injection Pump ,[object Object],[object Object],[object Object]
Injection Pump ,[object Object]
Figure 19-9   A schematic of Standadyne diesel fuel–injection pump assembly showing all of the related components.
Injection Pump ,[object Object],[object Object]
Injection Pump ,[object Object],[object Object],[object Object]
Figure 19-10   Overview of a computer-controlled high-pressure common rail V-8 diesel engine.
HEUI SYSTEM
Heui System ,[object Object],[object Object]
Heui System ,[object Object],[object Object],[object Object]
Heui System ,[object Object],[object Object],[object Object]
Heui System ,[object Object],[object Object],[object Object]
Heui System  ,[object Object],[object Object],[object Object]
Heui System  ,[object Object],[object Object],[object Object]
Figure 19-11   A HEUI injector from a Ford PowerStroke diesel engine. The O-ring grooves indicate the location of the O-rings that seal the fuel section of the injector from coolant and from the engine oil.
Heui System  ,[object Object],[object Object],[object Object]
Heui System  ,[object Object],[object Object]
Heui System  ,[object Object],[object Object],[object Object],[object Object]
Heui System  ,[object Object],[object Object],[object Object],[object Object]
Heui System  ,[object Object],[object Object],[object Object],[object Object]
DIESEL INJECTOR NOZZLES
Diesel Injector Nozzles ,[object Object],[object Object],[object Object],[object Object]
Diesel Injector Nozzles ,[object Object],[object Object],[object Object],[object Object]
Diesel Injector Nozzles ,[object Object],[object Object]
Diesel Injector Nozzles ,[object Object],[object Object]
Diesel Injector Nozzles ,[object Object],[object Object]
Diesel Injector Nozzles ,[object Object],[object Object],[object Object]
Figure 19-12   Typical computer-controlled diesel engine fuel injectors.
Figure 19-13   A Duramax injector showing all the internal parts.
GLOW PLUGS
Glow Plugs ,[object Object],[object Object]
Figure 19-14   A glow plug assortment showing the various types and sizes of glow plugs used. Always use the specified glow plugs.
Glow Plugs ,[object Object],[object Object],[object Object]
Glow Plugs ,[object Object],[object Object]
Glow Plugs ,[object Object],[object Object]
Figure 19-15   A schematic of a typical glow plug circuit. Notice that the glow plug relay and intake air heater relay are both computer controlled.
Glow Plugs ,[object Object],[object Object],?
Figure 19-16   A wire-wound electric heater is used to warm the intake air on some diesel engines.
ENGINE-DRIVEN VACUUM PUMP
Engine-Driven Vacuum Pump ,[object Object],[object Object]
Engine-Driven Vacuum Pump ,[object Object],[object Object],[object Object]
DIESEL FUEL HEATERS
Diesel Fuel Heaters ,[object Object],[object Object]
ACCELERATOR PEDAL POSITION SENSOR
Accelerator Pedal Position Sensor  ,[object Object],[object Object]
Accelerator Pedal Position Sensor  ,[object Object],[object Object]
Figure 19-17   A typical accelerator pedal position (APP) sensor uses three different sensors in one package with each creating a different voltage as the accelerator is moved.
DIESEL ENGINE TURBOCHARGERS
Diesel Engine Turbochargers ,[object Object],[object Object],[object Object]
Diesel Engine Turbochargers ,[object Object],[object Object]
Figure 19-18   A Cummins diesel turbocharger is used to increase the power and torque of the engine.
Diesel Engine Turbochargers ,[object Object],[object Object],[object Object]
Figure 19-19   An air charge cooler is used to cool the compressed air.
Diesel Engine Turbochargers ,[object Object],[object Object],[object Object]
Diesel Engine Turbochargers ,[object Object],[object Object],[object Object]
Diesel Engine Turbochargers ,[object Object],[object Object]
Diesel Engine Turbochargers ,[object Object],[object Object],[object Object]
Diesel Engine Turbochargers ,[object Object],[object Object],[object Object]
Diesel Engine Turbochargers ,[object Object],[object Object],[object Object]
Figure 19-20   A variable vane turbocharger allows the boost to be controlled without the need of a wastegate.
EXHAUST GAS RECIRCULATION
Exhaust Gas Recirculation ,[object Object],[object Object]
Exhaust Gas Recirculation ,[object Object],[object Object]
Exhaust Gas Recirculation ,[object Object],[object Object],[object Object]
Exhaust Gas Recirculation ,[object Object],[object Object]
Exhaust Gas Recirculation ,[object Object]
Figure 19-21   A cutaway showing the exhaust cooler. The cooler the exhaust is, the more effective it is in controlling NOx emissions.
DIESEL PARTICULATE MATTER
Diesel Particulate Matter  ,[object Object],[object Object],[object Object]
Diesel Particulate Matter  ,[object Object],[object Object],[object Object],[object Object],?
Figure 19-22   Relative size of particulate matter to a human hair.
Diesel Particulate Matter  ,[object Object],[object Object],[object Object]
DIESEL OXIDATION CATALYST
Diesel Oxidation Catalyst ,[object Object],[object Object],[object Object]
Diesel Oxidation Catalyst ,[object Object],[object Object],[object Object],[object Object]
Diesel Oxidation Catalyst ,[object Object],[object Object],[object Object]
Figure 19-23   Chemical reaction within the DOC.
DIESEL EXHAUST PARTICULATE FILTER
Diesel Exhaust Particulate Filter ,[object Object],[object Object]
Figure 19-24   Aftertreatment of diesel exhaust is handled by the DOC and DPF.
Diesel Exhaust Particulate Filter ,[object Object],[object Object],[object Object]
Figure 19-25   The soot is trapped in the passages of the DPF. The exhaust has to flow through the sides of the trap and exit.
Diesel Exhaust Particulate Filter ,[object Object],[object Object],[object Object]
Figure 19-26   EGT 1 and EGT 2 are used by the PCM to help control after treatment.
Diesel Exhaust Particulate Filter ,[object Object],[object Object],[object Object]
Diesel Exhaust Particulate Filter ,[object Object],[object Object],[object Object]
Diesel Exhaust Particulate Filter ,[object Object],[object Object]
Diesel Exhaust Particulate Filter ,[object Object],[object Object],[object Object]
Diesel Exhaust Particulate Filter ,[object Object],[object Object],[object Object]
Diesel Exhaust Particulate Filter ,[object Object],[object Object],[object Object]
Diesel Exhaust Particulate Filter ,[object Object],[object Object],[object Object]
Diesel Exhaust Particulate Filter  ,[object Object],[object Object]
Diesel Exhaust Particulate Filter  ,[object Object],[object Object],?
Diesel Exhaust Particulate Filter  ,[object Object],[object Object]
Diesel Exhaust Particulate Filter  ,[object Object],[object Object]
Figure 19-27   Regeneration burns the soot and renews the DPF.
Diesel Exhaust Particulate Filter  ,[object Object],[object Object],[object Object],?
Diesel Exhaust Particulate Filter ,[object Object],[object Object],[object Object]
Diesel Exhaust Particulate Filter ,[object Object],[object Object],[object Object]
SELECTIVE CATALYTIC REDUCTION
Selective Catalytic Reduction ,[object Object],[object Object],[object Object]
Selective Catalytic Reduction ,[object Object],[object Object]
Figure 19-30   Diesel exhaust fluid costs $3 to $4 a gallon and is housed in a separate container that holds from 5 to 10 gallons, or enough to last until the next scheduled oil change in most diesel vehicles that use SCR.
Selective Catalytic Reduction ,[object Object],[object Object]
Selective Catalytic Reduction ,[object Object],[object Object]
Figure 19-31   Urea (diesel exhaust fluid) injection is used to reduce NOx exhaust emissions. It is injected after the diesel oxidation catalyst (DOC) and before the diesel particulate filter (DPF) on this 6.7 liter Ford diesel engine.
Selective Catalytic Reduction ,[object Object],[object Object],[object Object]
Selective Catalytic Reduction ,[object Object],[object Object],[object Object]
Selective Catalytic Reduction ,[object Object],[object Object],[object Object]
Selective Catalytic Reduction ,[object Object],[object Object]
DIESEL EXHAUST SMOKE DIAGNOSIS
Diesel Exhaust Smoke Diagnosis ,[object Object],[object Object],[object Object],[object Object]
Diesel Exhaust Smoke Diagnosis ,[object Object],[object Object],[object Object]
Diesel Exhaust Smoke Diagnosis ,[object Object],[object Object],[object Object]
Diesel Exhaust Smoke Diagnosis ,[object Object],[object Object],[object Object]
Diesel Exhaust Smoke Diagnosis ,[object Object],[object Object],[object Object],[object Object]
Diesel Exhaust Smoke Diagnosis ,[object Object],[object Object],[object Object],[object Object]
Diesel Exhaust Smoke Diagnosis ,[object Object],[object Object],[object Object]
Diesel Exhaust Smoke Diagnosis ,[object Object],[object Object],[object Object]
Diesel Exhaust Smoke Diagnosis ,[object Object],[object Object],[object Object]
Diesel Exhaust Smoke Diagnosis ,[object Object],[object Object]
Diesel Exhaust Smoke Diagnosis ,[object Object],[object Object]
DIESEL PERFORMANCE DIAGNOSIS
Diesel Performance Diagnosis ,[object Object],[object Object],[object Object]
Diesel Performance Diagnosis ,[object Object],[object Object],[object Object],[object Object]
Diesel Performance Diagnosis ,[object Object]
Chart 19-2   The values can be obtained by using a scan tool and basic test equipment. Always follow the vehicle manufacturer’s recommended procedures.
Chart 19-2 (continued)   The values can be obtained by using a scan tool and basic test equipment. Always follow the vehicle manufacturer’s recommended procedures.
Figure 19-32   A pressure gauge checking the fuel pressure from the lift pump on a Cummins 6.7 liter diesel.
COMPRESSION TESTING
Compression Testing ,[object Object],[object Object],[object Object]
Compression Testing ,[object Object],[object Object],[object Object]
Compression Testing ,[object Object]
Figure 19-33   A compression gauge that is designed for the higher compression rate of a diesel engine should be used when checking the compression.
GLOW PLUG RESISTANCE BALANCE TEST
Glow Plug Resistance Balance Test ,[object Object],[object Object]
Glow Plug Resistance Balance Test ,[object Object],[object Object]
Glow Plug Resistance Balance Test ,[object Object],[object Object]
Glow Plug Resistance Balance Test ,[object Object],[object Object]
Glow Plug Resistance Balance Test ,[object Object],[object Object]
INJECTOR POP TESTING
Injector Pop Testing ,[object Object],[object Object]
Injector Pop Testing ,[object Object],[object Object]
Injector Pop Testing ,[object Object],[object Object]
Injector Pop Testing ,[object Object],[object Object]
Figure 19-34   A typical pop tester used to check the spray pattern of a diesel engine injector.
Figure 19-35   The letters on the side of this injector on a Cummins 6.7 liter diesel indicate the calibration number for the injector.
DIESEL EMISSION TESTING
Diesel Emissions Testing ,[object Object],[object Object],[object Object]
Diesel Emissions Testing ,[object Object],[object Object],[object Object]
Diesel Emissions Testing ,[object Object],[object Object],[object Object]
Diesel Emissions Testing ,[object Object],[object Object],[object Object]
Chart 19-3  An opacity test is sometimes used during a state emission test on diesel engines.
Diesel Emissions Testing ,[object Object],[object Object],[object Object]
Diesel Emissions Testing ,[object Object],[object Object],[object Object]
Diesel Emissions Testing ,[object Object],[object Object],[object Object]
Diesel Emissions Testing ,[object Object],[object Object],[object Object]
Diesel Emissions Testing ,[object Object],[object Object],[object Object]
Diesel Emissions Testing ,[object Object],[object Object],[object Object]
TECH TIP ,[object Object],[object Object],BACK TO  PRESENTATION ,[object Object]
TECH TIP ,[object Object],[object Object],BACK TO  PRESENTATION ,[object Object],NOTE: Some diesel engines, such as the General Motors Duramax V-8, are equipped with a priming pump located under the hood on top of the fuel filter. Pushing down and releasing the priming pump with a vent valve open will purge any trapped air from the system. Always follow the vehicle manufacturer’s instructions.
FREQUENTLY ASKED QUESTION ,[object Object],[object Object],? BACK TO  PRESENTATION This high temperature can harm injectors and glow plugs, as well as pistons, head gaskets, and other major diesel engine components. If contaminated fuel is suspected, first smell the fuel at the filler neck. If the fuel smells like gasoline, then the tank should be drained and refilled with diesel fuel. If the smell test does not indicate a gasoline or any rancid smell, then test a sample for proper specific gravity. NOTE: Diesel fuel designed for on-road use should be green. Red diesel fuel (high sulfur) should only be found in off-road or farm equipment.
FREQUENTLY ASKED QUESTION ,[object Object],[object Object],? BACK TO  PRESENTATION However, it was discovered that the small soot particulates when breathed in are not expelled from the lungs like larger particles but instead get trapped in the deep areas of the lungs where they accumulate.
WARNING ,[object Object],BACK TO  PRESENTATION
FREQUENTLY ASKED QUESTION ,[object Object],[object Object],? BACK TO  PRESENTATION ,[object Object]
TECH TIP ,[object Object],[object Object],BACK TO  PRESENTATION Then use a piece of cardboard to locate the high-pressure leak.  When a Duramax diesel is running, the pressure in the common rail and injector tubes can reach over 20,000 PSI. At these pressures, the diesel fuel is atomized and cannot be seen but can penetrate the skin and cause personal injury. A leak will be shown as a dark area on the cardboard. When a leak is found, shut off the engine and find the exact location of the leak without the engine running. CAUTION: Sometimes a leak can actually cut through the cardboard, so use extreme care.
TECH TIP ,[object Object],[object Object],BACK TO  PRESENTATION ,[object Object]

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  • 1. DIESEL ENGINE OPERATION AND DIAGNOSIS 19
  • 2.
  • 3.
  • 5.
  • 6.
  • 7.
  • 8.
  • 9.
  • 10.
  • 11. Figure 19-1 Diesel combustion occurs when fuel is injected into the hot, highly compressed air in the cylinder.
  • 12. Figure 19-2 A typical injector pump type of automotive diesel fuel–injection system.
  • 13.
  • 14.
  • 15.
  • 16.
  • 17.
  • 18.
  • 19. Chart 19-1 Comparison between a typical gasoline and a diesel engine.
  • 20. Figure 19-3 A Cummins diesel engine as found in a Dodge pickup truck. A high-pressure pump (up to 30,000 PSI) is used to supply diesel fuel to this common rail, which has tubes running to each injector. Note the thick cylinder walls and heavy-duty construction.
  • 21. Figure 19-4 A rod/piston assembly from a 5.9 liter Cummins diesel engine used in a Dodge pickup truck.
  • 22.
  • 23.
  • 24.
  • 25.
  • 26.
  • 27.
  • 28.
  • 29.
  • 30.
  • 31.
  • 32.
  • 33. Figure 19-5 An indirect injection diesel engine uses a prechamber and a glow plug.
  • 34. Figure 19-6 A direct injection diesel engine injects the fuel directly into the combustion chamber. Many designs do not use a glow plug.
  • 35.
  • 36.
  • 37.
  • 38. THREE PHASES OF COMBUSTION
  • 39.
  • 40. FUEL TANK AND LIFT PUMP
  • 41.
  • 42.
  • 43.
  • 44.
  • 45.
  • 46.
  • 47.
  • 48.
  • 49.
  • 50. Figure 19-7 A fuel temperature sensor is being tested using an ice bath.
  • 52.
  • 53.
  • 54.
  • 55.
  • 56. Figure 19-8 A typical distributor-type diesel injection pump showing the pump, lines, and fuel filter.
  • 57.
  • 58.
  • 59.
  • 60.
  • 61. Figure 19-9 A schematic of Standadyne diesel fuel–injection pump assembly showing all of the related components.
  • 62.
  • 63.
  • 64. Figure 19-10 Overview of a computer-controlled high-pressure common rail V-8 diesel engine.
  • 66.
  • 67.
  • 68.
  • 69.
  • 70.
  • 71.
  • 72. Figure 19-11 A HEUI injector from a Ford PowerStroke diesel engine. The O-ring grooves indicate the location of the O-rings that seal the fuel section of the injector from coolant and from the engine oil.
  • 73.
  • 74.
  • 75.
  • 76.
  • 77.
  • 79.
  • 80.
  • 81.
  • 82.
  • 83.
  • 84.
  • 85. Figure 19-12 Typical computer-controlled diesel engine fuel injectors.
  • 86. Figure 19-13 A Duramax injector showing all the internal parts.
  • 88.
  • 89. Figure 19-14 A glow plug assortment showing the various types and sizes of glow plugs used. Always use the specified glow plugs.
  • 90.
  • 91.
  • 92.
  • 93. Figure 19-15 A schematic of a typical glow plug circuit. Notice that the glow plug relay and intake air heater relay are both computer controlled.
  • 94.
  • 95. Figure 19-16 A wire-wound electric heater is used to warm the intake air on some diesel engines.
  • 97.
  • 98.
  • 100.
  • 102.
  • 103.
  • 104. Figure 19-17 A typical accelerator pedal position (APP) sensor uses three different sensors in one package with each creating a different voltage as the accelerator is moved.
  • 106.
  • 107.
  • 108. Figure 19-18 A Cummins diesel turbocharger is used to increase the power and torque of the engine.
  • 109.
  • 110. Figure 19-19 An air charge cooler is used to cool the compressed air.
  • 111.
  • 112.
  • 113.
  • 114.
  • 115.
  • 116.
  • 117. Figure 19-20 A variable vane turbocharger allows the boost to be controlled without the need of a wastegate.
  • 119.
  • 120.
  • 121.
  • 122.
  • 123.
  • 124. Figure 19-21 A cutaway showing the exhaust cooler. The cooler the exhaust is, the more effective it is in controlling NOx emissions.
  • 126.
  • 127.
  • 128. Figure 19-22 Relative size of particulate matter to a human hair.
  • 129.
  • 131.
  • 132.
  • 133.
  • 134. Figure 19-23 Chemical reaction within the DOC.
  • 136.
  • 137. Figure 19-24 Aftertreatment of diesel exhaust is handled by the DOC and DPF.
  • 138.
  • 139. Figure 19-25 The soot is trapped in the passages of the DPF. The exhaust has to flow through the sides of the trap and exit.
  • 140.
  • 141. Figure 19-26 EGT 1 and EGT 2 are used by the PCM to help control after treatment.
  • 142.
  • 143.
  • 144.
  • 145.
  • 146.
  • 147.
  • 148.
  • 149.
  • 150.
  • 151.
  • 152.
  • 153. Figure 19-27 Regeneration burns the soot and renews the DPF.
  • 154.
  • 155.
  • 156.
  • 158.
  • 159.
  • 160. Figure 19-30 Diesel exhaust fluid costs $3 to $4 a gallon and is housed in a separate container that holds from 5 to 10 gallons, or enough to last until the next scheduled oil change in most diesel vehicles that use SCR.
  • 161.
  • 162.
  • 163. Figure 19-31 Urea (diesel exhaust fluid) injection is used to reduce NOx exhaust emissions. It is injected after the diesel oxidation catalyst (DOC) and before the diesel particulate filter (DPF) on this 6.7 liter Ford diesel engine.
  • 164.
  • 165.
  • 166.
  • 167.
  • 168. DIESEL EXHAUST SMOKE DIAGNOSIS
  • 169.
  • 170.
  • 171.
  • 172.
  • 173.
  • 174.
  • 175.
  • 176.
  • 177.
  • 178.
  • 179.
  • 181.
  • 182.
  • 183.
  • 184. Chart 19-2 The values can be obtained by using a scan tool and basic test equipment. Always follow the vehicle manufacturer’s recommended procedures.
  • 185. Chart 19-2 (continued) The values can be obtained by using a scan tool and basic test equipment. Always follow the vehicle manufacturer’s recommended procedures.
  • 186. Figure 19-32 A pressure gauge checking the fuel pressure from the lift pump on a Cummins 6.7 liter diesel.
  • 188.
  • 189.
  • 190.
  • 191. Figure 19-33 A compression gauge that is designed for the higher compression rate of a diesel engine should be used when checking the compression.
  • 192. GLOW PLUG RESISTANCE BALANCE TEST
  • 193.
  • 194.
  • 195.
  • 196.
  • 197.
  • 199.
  • 200.
  • 201.
  • 202.
  • 203. Figure 19-34 A typical pop tester used to check the spray pattern of a diesel engine injector.
  • 204. Figure 19-35 The letters on the side of this injector on a Cummins 6.7 liter diesel indicate the calibration number for the injector.
  • 206.
  • 207.
  • 208.
  • 209.
  • 210. Chart 19-3 An opacity test is sometimes used during a state emission test on diesel engines.
  • 211.
  • 212.
  • 213.
  • 214.
  • 215.
  • 216.
  • 217.
  • 218.
  • 219.
  • 220.
  • 221.
  • 222.
  • 223.
  • 224.

Notas do Editor

  1. Figure 19-1 Diesel combustion occurs when fuel is injected into the hot, highly compressed air in the cylinder.
  2. Figure 19-2 A typical injector pump type of automotive diesel fuel–injection system.
  3. Chart 19-1 Comparison between a typical gasoline and a diesel engine.
  4. Figure 19-3 A Cummins diesel engine as found in a Dodge pickup truck. A high-pressure pump (up to 30,000 PSI) is used to supply diesel fuel to this common rail, which has tubes running to each injector. Note the thick cylinder walls and heavy-duty construction.
  5. Figure 19-4 A rod/piston assembly from a 5.9 liter Cummins diesel engine used in a Dodge pickup truck.
  6. Figure 19-5 An indirect injection diesel engine uses a prechamber and a glow plug.
  7. Figure 19-6 A direct injection diesel engine injects the fuel directly into the combustion chamber. Many designs do not use a glow plug.
  8. Figure 19-7 A fuel temperature sensor is being tested using an ice bath.
  9. Figure 19-8 A typical distributor-type diesel injection pump showing the pump, lines, and fuel filter.
  10. Figure 19-9 A schematic of Standadyne diesel fuel–injection pump assembly showing all of the related components.
  11. Figure 19-10 Overview of a computer-controlled high-pressure common rail V-8 diesel engine.
  12. Figure 19-11 A HEUI injector from a Ford PowerStroke diesel engine. The O-ring grooves indicate the location of the O-rings that seal the fuel section of the injector from coolant and from the engine oil.
  13. Figure 19-12 Typical computer-controlled diesel engine fuel injectors.
  14. Figure 19-13 A Duramax injector showing all the internal parts.
  15. Figure 19-14 A glow plug assortment showing the various types and sizes of glow plugs used. Always use the specified glow plugs.
  16. Figure 19-15 A schematic of a typical glow plug circuit. Notice that the glow plug relay and intake air heater relay are both computer controlled.
  17. Figure 19-16 A wire-wound electric heater is used to warm the intake air on some diesel engines.
  18. Figure 19-17 A typical accelerator pedal position (APP) sensor uses three different sensors in one package with each creating a different voltage as the accelerator is moved.
  19. Figure 19-18 A Cummins diesel turbocharger is used to increase the power and torque of the engine.
  20. Figure 19-19 An air charge cooler is used to cool the compressed air.
  21. Figure 19-20 A variable vane turbocharger allows the boost to be controlled without the need of a wastegate.
  22. Figure 19-21 A cutaway showing the exhaust cooler. The cooler the exhaust is, the more effective it is in controlling NOx emissions.
  23. Figure 19-22 Relative size of particulate matter to a human hair.
  24. Figure 19-23 Chemical reaction within the DOC.
  25. Figure 19-24 Aftertreatment of diesel exhaust is handled by the DOC and DPF.
  26. Figure 19-25 The soot is trapped in the passages of the DPF. The exhaust has to flow through the sides of the trap and exit.
  27. Figure 19-26 EGT 1 and EGT 2 are used by the PCM to help control after treatment.
  28. Figure 19-27 Regeneration burns the soot and renews the DPF.
  29. Figure 19-30 Diesel exhaust fluid costs $3 to $4 a gallon and is housed in a separate container that holds from 5 to 10 gallons, or enough to last until the next scheduled oil change in most diesel vehicles that use SCR.
  30. Figure 19-31 Urea (diesel exhaust fluid) injection is used to reduce NOx exhaust emissions. It is injected after the diesel oxidation catalyst (DOC) and before the diesel particulate filter (DPF) on this 6.7 liter Ford diesel engine.
  31. Chart 19-2 The values can be obtained by using a scan tool and basic test equipment. Always follow the vehicle manufacturer’s recommended procedures.
  32. Chart 19-2 (continued) The values can be obtained by using a scan tool and basic test equipment. Always follow the vehicle manufacturer’s recommended procedures.
  33. Figure 19-32 A pressure gauge checking the fuel pressure from the lift pump on a Cummins 6.7 liter diesel.
  34. Figure 19-33 A compression gauge that is designed for the higher compression rate of a diesel engine should be used when checking the compression.
  35. Figure 19-34 A typical pop tester used to check the spray pattern of a diesel engine injector.
  36. Figure 19-35 The letters on the side of this injector on a Cummins 6.7 liter diesel indicate the calibration number for the injector.
  37. Chart 19-3 An opacity test is sometimes used during a state emission test on diesel engines.