Lesson 1Fuel system inspection: filters, supply pump, injectors, fuel pressure testingYou will master step-by-step fuel system checks, from filters and supply pumps to injectors and rail pressure testing, to spot blockages, leaks, and wear causing hard starting, low power, or too much smoke in diesel engines.
Primary and secondary fuel filtersLift pump flow and pressure checksHigh-pressure pump performance testsInjector balance and return flow testsRail pressure sensor and valve checksAir ingress and fuel leak detectionLesson 2Repair and overhaul decisions: when to clean vs replace injectors/turbo, gasket and head work, fuel system rebuildsHere you will learn guidelines for repair and overhaul choices, knowing when to clean, adjust, or replace injectors, turbos, gaskets, and fuel parts, balancing cost, downtime, and long-term reliability for farm equipment.
Evaluating service history and hoursClean, repair, or replace injectorsTurbocharger cleaning versus rebuildHead gasket and cylinder head workFuel system partial versus full rebuildEstimating cost, downtime, and riskLesson 3Cooling and thermal management: coolant flow, thermostat, radiator, fan operationThis section covers cooling system parts and heat control, teaching how to test coolant flow, thermostat and radiator function, and fan operation to avoid overheating and keep stable diesel engine temperatures under load.
Coolant type, mixture, and contaminationWater pump flow and cavitation checksThermostat opening test proceduresRadiator blockage and airflow testsFan clutch and electric fan diagnosisPressure cap and system leak testsLesson 4Symptoms analysis: interpreting black smoke, power loss, overheating patternsThis section trains you to read common diesel symptoms like black smoke, power loss, and overheating, linking each to probable root causes and guiding systematic checks instead of guesswork part changes.
Black, blue, and white smoke patternsPower loss under load versus at idleOverheating trends and load influenceHard starting and misfire indicatorsNoise, vibration, and harshness cluesCreating a symptom-based test planLesson 5Air intake and filtration checks: restrictions, mass airflow, intercooler inspectionThis section explains checking air intake and filters, including restriction tests, mass airflow checks, and intercooler inspection, to stop dust entry, low boost, and power drop in farm diesel engines.
Air filter types and service limitsMeasuring intake restriction and vacuumChecking ducts for collapse or leaksMass airflow and volumetric efficiencyIntercooler blockage and leak testsDust ingress and engine wear risksLesson 6Turbocharger and exhaust systems: boost pressure tests, shaft play, leaksHere we cover turbocharger and exhaust workings, including boost pressure tests, shaft play checks, and leak finding, to tell normal wear from failures causing power loss, smoke, or overboost in farm diesels.
Turbocharger components and functionsBoost pressure test setup and limitsChecking shaft play and bearing wearExhaust leaks and backpressure issuesInterpreting turbo noise and vibrationWastegate and VGT control checksLesson 7Diesel combustion fundamentals: air-fuel ratio, turbocharging, EGR basicsYou will go over diesel combustion basics, including air-fuel mix, turbo effects, and simple EGR workings, to link theory with real issues like smoke, rough running, and poor fuel economy in tractors.
Diesel four-stroke cycle reviewAir-fuel ratio and excess air factorTurbocharging impact on combustionEGR purpose and basic operationInjection timing and combustion noiseCombustion defects and visible smokeLesson 8Tools and measurements for engines: pressure gauges, multimeter, compression tester, smoke/soot inspection toolsHere you will learn right choice and use of diagnostic tools for diesel engines, like pressure gauges, multimeters, compression testers, and smoke tools, for accurate, consistent readings in the field workshop.
Safety and calibration of test toolsUsing fuel and oil pressure gaugesMultimeter tests on engine circuitsCompression and leak-down testersExhaust opacity and smoke metersRecording and reporting test resultsLesson 9Compression and mechanical checks: leak-down, cylinder compression tester proceduresThis section covers compression and mechanical checks, including leak-down testing, to spot top-end, bottom-end, and valve train issues affecting diesel performance and starting.
Preparing engine for compression testsInterpreting compression readingsLeak-down test setup and safetyLocating leakage paths by soundValve train and cam timing checksPiston, ring, and liner wear signsLesson 10Electronic controls and sensors: temperature, MAP/boost, fuel rail pressure sensors, ECU fault codesThis section explains how key diesel sensors and ECU work together, reading and understanding fault codes, and testing temperature, MAP/boost, and fuel rail pressure to confirm or rule out electronic faults.
Coolant and intake air temperature sensorsMAP and boost pressure sensor operationFuel rail pressure sensor testingECU fault code reading and clearingUsing live data and freeze-frameSensor wiring and connector checks
