Lesson 1Air intake path: air filter, intake manifold, and causes of restrictionThis part looks at diesel air intake from filter to holes, including filter stuff, boxes, pipes, manifolds, and swirl tools, plus common block causes, measure ways, and upkeep plans for local dust.
Air filter media types and efficiency ratingsFilter housings, pre‑cleaners and snorkelsIntake duct routing, resonators and leaksManifold design, runners, swirl and tumbleSources of restriction, dust and ice buildupMeasuring restriction and service intervalsLesson 2High-pressure injection: common rail vs. pump‑line‑nozzle and mechanical injection pump fundamentalsThis part explains diesel high-pressure fuel making and control, comparing common rail and pump-line-nozzle, and detailing mechanical straight and turning pumps, timing, pressure hold, and usual wear or breaks.
Common rail layout, pressure control and sensorsPump‑line‑nozzle architecture and timing effectsInline mechanical pump elements and cam profileRotary/distributor pump operation and advancePressure waves, line length and injection shapingTypical high‑pressure leakage and test methodsLesson 3Intercooler function, pressure loss, fouling and cleaning considerationsThis part explains intercooler job and work, comparing air-to-air and air-to-liquid types, tackling pressure drop, dirt, leaks, clean ways, and how hot charge-air cuts power and raises smoke.
Charge‑air cooling benefits and heat transferAir‑to‑air versus air‑to‑liquid intercoolersPressure drop, flow balance and sizingOil fouling, soot deposits and leak pathsCleaning methods, flushing and drying stepsTesting for leaks and performance lossLesson 4Ancillary components: EGR overview, PCV/ventilation basics, sensors relevant to diesel (MAP/MAF, coolant temp, oil pressure)This part reviews key extra diesel parts, including EGR and crankcase airing, plus main sensors like MAP, MAF, coolant heat and oil push, and how they link with engine control box.
EGR purpose, flow control and cooler issuesPCV and crankcase ventilation arrangementsMAP sensor role, mounting and failure modesMAF sensor types, contamination and testingCoolant temperature and oil pressure sensingSensor data use in diesel ECU strategiesLesson 5Cooling system: radiator, water pump, thermostat, coolant types and causes of overheatingThis part covers diesel cooling setup and work, including radiator, pump, thermostat, coolant mix, flow ways, and common hot causes, plus check, test, and stop-hot upkeep ways.
Coolant flow path and heat transfer basicsRadiator, fan, shroud and airflow managementWater pump design, drive types and failuresThermostat operation, testing and replacementCoolant types, mixing rules and corrosion controlDiagnosing overheating and hot‑spot conditionsLesson 6Injectors: nozzle types, spray patterns, wear symptoms, and leakage effectsThis part focuses on diesel sprayer build and job, covering nozzle kinds, spray shapes, open pressure, wear and dirt signs, leak effects on smoke and power, and basic test and fix ways.
Pintle, hole‑type and multi‑hole nozzlesSpray pattern, atomization and penetrationInjector opening pressure and pop testingNozzle coking, erosion and seat wearInternal leakage, dribble and misfire effectsBasic cleaning, replacement and codingLesson 7Turbocharger components and operation: turbine, compressor, wastegate/variable geometry basicsThis part explains turbo build and work, covering turbine and compressor air flow, bearing setups, wastegate and changing shape control, boost limits, and break signs from oil lack or too fast spin.
Turbine housing, wheel design and energy useCompressor maps, surge and choke regionsJournal and ball bearings, seals and coolingWastegate actuators, control lines and tuningVariable geometry vanes, actuators and sootTurbo failure modes, inspection and protectionLesson 8Fuel delivery system: fuel tank, lift pump, primary and secondary filters, and water separatorsThis part describes low-pressure fuel path, from tank and pickup to lift pump, filters and water removers, stressing dirt control, air entry, block fixing, and regular service steps.
Fuel tank design, pickups and return routingLift pump types, priming and failure signsPrimary and secondary filter functionsWater separator design and draining practiceAir leaks, suction restriction and cavitationService intervals and contamination controlLesson 9Lubrication system: oil types, oil pump, galleries, bearings and oil filter functionThis part details diesel oiling setup, oil kinds and adds, pump types, galleries, bearings, and filtering, explaining how oil push is made, watched, and kept to stop wear and hot spots.
Engine oil grades, base stocks and additivesOil pump types, drives and pressure regulationMain galleries, branch feeds and priority circuitsBearing lubrication, clearances and coolingOil filter types, bypass valves and serviceLow oil pressure diagnosis and common causes
