Lesson 1Air intake path: air filter, intake manifold, and causes of restrictionDis section examine di diesel air intake path from filter to port dem, includin filter media, housin dem, ductin, manifold dem, an swirl device dem, plus common restriction cause dem, measurement method dem, an maintenance strategy dem.
Air filter media types an efficiency ratingsFilter housings, pre‑cleaners an snorkelsIntake duct routin, resonators an leaksManifold design, runners, swirl an tumbleSources of restriction, dust an ice buildupMeasurin restriction an service intervalsLesson 2High-pressure injection: common rail vs. pump‑line‑nozzle and mechanical injection pump fundamentalsDis section explain diesel high‑pressure fuel generation an control, comparin common rail an pump‑line‑nozzle, an detailin mechanical inline an rotary pump dem, timin, pressure control, an typical wear or failure mode dem.
Common rail layout, pressure control an sensorsPump‑line‑nozzle architecture an timin effectsInline mechanical pump elements an cam profileRotary/distributor pump operation an advancePressure waves, line length an injection shapinTypical high‑pressure leakage an test methodsLesson 3Intercooler function, pressure loss, fouling and cleaning considerationsDis section explain intercooler purpose an operation, comparin air‑to‑air an air‑to‑liquid design dem, addressin pressure loss, foulin, leak dem, cleanin method dem, an how charge‑air temperature affect power an emissions.
Charge‑air coolin benefits an heat transferAir‑to‑air versus air‑to‑liquid intercoolersPressure drop, flow balance an sizinOil foulin, soot deposits an leak pathsCleanin methods, flushin an dryin stepsTestin for leaks an performance lossLesson 4Ancillary components: EGR overview, PCV/ventilation basics, sensors relevant to diesel (MAP/MAF, coolant temp, oil pressure)Dis section review key ancillary diesel component dem, includin EGR an crankcase ventilation, plus critical sensor dem such as MAP, MAF, coolant temperature an oil pressure, an how dem interact wid di engine control unit.
EGR purpose, flow control an cooler issuesPCV an crankcase ventilation arrangementsMAP sensor role, mountin an failure modesMAF sensor types, contamination an testinCoolant temperature an oil pressure sensinSensor data use in diesel ECU strategiesLesson 5Cooling system: radiator, water pump, thermostat, coolant types and causes of overheatingDis section cover diesel coolin system layout an operation, includin radiator, pump, thermostat, coolant chemistry, flow path dem, an common overheatin cause dem, plus inspection, testin, an preventive maintenance practice dem.
Coolant flow path an heat transfer basicsRadiator, fan, shroud an airflow managementWater pump design, drive types an failuresThermostat operation, testin an replacementCoolant types, mixin rules an corrosion controlDiagnosin overheatin an hot‑spot conditionsLesson 6Injectors: nozzle types, spray patterns, wear symptoms, and leakage effectsDis section focus on diesel injector construction an function, coverin nozzle types, spray pattern dem, openin pressure, wear an cokin symptoms, leakage effects on emissions an power, an basic test an service practice dem.
Pintle, hole‑type an multi‑hole nozzlesSpray pattern, atomization an penetrationInjector openin pressure an pop testinNozzle cokin, erosion an seat wearInternal leakage, dribble an misfire effectsBasic cleanin, replacement an codinLesson 7Turbocharger components and operation: turbine, compressor, wastegate/variable geometry basicsDis section explain turbocharger construction an operation, coverin turbine an compressor aerodynamics, bearin system dem, wastegate an variable geometry control, boost limits, an failure symptoms link to lubrication or overspeed.
Turbine housin, wheel design an energy useCompressor maps, surge an choke regionsJournal an ball bearings, seals an coolinWastegate actuators, control lines an tuninVariable geometry vanes, actuators an sootTurbo failure modes, inspection an protectionLesson 8Fuel delivery system: fuel tank, lift pump, primary and secondary filters, and water separatorsDis section describe di low‑pressure fuel delivery path, from tank an pickup to lift pump, filter dem an water separator dem, emphasizin contamination control, air ingress, restriction diagnosis, an routine service procedure dem.
Fuel tank design, pickups an return routinLift pump types, primin an failure signsPrimary an secondary filter functionsWater separator design an drainin practiceAir leaks, suction restriction an cavitationService intervals an contamination controlLesson 9Lubrication system: oil types, oil pump, galleries, bearings and oil filter functionDis section detail diesel lubrication system design, oil grade dem an additives, pump types, galleries, bearings, an filtration, explainin how oil pressure generate, monitor, an maintain to prevent wear an overheatin.
Engine oil grades, base stocks an additivesOil pump types, drives an pressure regulationMain galleries, branch feeds an priority circuitsBearin lubrication, clearances an coolinOil filter types, bypass valves an serviceLow oil pressure diagnosis an common causes
