Unit 3: Tools, Technical References, Measurement, and Fasteners

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4.     Identify common fasteners and describe their use.

a.     Identify the different types of bolts, nuts, and washers; and describe their appropriate uses.

b.    Identify bolts by grade, diameter, length, and thread pitch.

c.     Identify different glues and sealants used in automotive service, and describe their appropriate use.

d.             Restore internal and external threads.

Modern Auto Tech.

Chapter 6 PP 70-84

PowerPoint –Automotive Measurement & math

Heavy Duty Truck Systems

Chapter 3 PP 37-78

PowerPoint – Tools & Fasteners

Unit 4: Brakes/Basic Hydraulics

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1.     Explore air brake diagnosis and repair.

a.     Identify and interpret air brake system concerns; determine necessary action.

b.    Research applicable service information; locate and interpret identification numbers, certification, and calibration decals.

Modern Auto Tech.

Chapter 71 & 72 PP 1369 - 1421

PowerPoint – Chapter 71 & 72

Heavy Duty Truck Systems

Chapter 31 PP 995 - 1050

PowerPoint – Air Brake Systems

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2.     Explore air supply and service systems.

a.     Evaluate customer concerns of poor stopping, air leaks, premature wear, pulling, grabbing, or dragging problems caused by supply, and service system malfunctions; determine needed action.

b.    Check air system build-up time and determine needed action.

c.     Drain air reservoir tanks; check for oil, water, and foreign material; determine needed action.

d.    Inspect, adjust, and align compressor drive belts, pulleys, and tensioners; replace as needed.

Modern Auto Tech.

Chapter 71 & 72 PP 1369 - 1421

PowerPoint – Chapter 71 & 72

Heavy Duty Truck Systems

Chapter 31 PP 995 - 1050

PowerPoint – Air Brake Systems

Unit 4: Brakes/Basic Hydraulics

11-30

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2.     Explore air supply and service systems.

e.     Inspect and test system pressure controls: governor, unloader assembly valves, intake screens, filters, lines, hoses, and fittings; replace as needed.

f.     Inspect air compressor, air cleaner/supply; inspect oil supply and coolant lines, fittings, and mounting brackets; repair or replace as needed.

g.    Inspect air system lines, hoses, fittings, and couplings; repair or replace as needed.

h.    Inspect and test air tank relief (safety) valves, one-way (single) check valves, two-way (double) check valves, and manual and automatic drain valves; replace as needed.

i.      Inspect and clean air dryer systems, filters, valves, heaters, wiring, and connectors; repair or replace as needed.

Modern Auto Tech.

Chapter 71 & 72 PP 1369 - 1421

PowerPoint – Chapter 71 & 72

Heavy Duty Truck Systems

Chapter 31 PP 995 - 1050

PowerPoint – Air Brake Systems

Unit 4

Unit 4: Diesel Systems and Theory   

11-9

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2.     Explore cylinder head and valve train diagnosis and repair.

a.     Remove, clean, inspect for visible damage, and replace cylinder head(s) assembly.

b.    Clean and inspect threaded holes, studs, and bolts for serviceability; determine needed action.

c.     Inspect cylinder head for cracks/damage; check mating surfaces for warpage; check condition of passages; inspect core/expansion and gallery plugs; determine needed action.

d.    Disassemble head and inspect valves, guides, seats, springs, retainers, rotators, locks, and seals; determine needed action.

e.     Measure valve head height relative to deck and valve face-to-seat contact; determine needed action.

f.     Inspect injector sleeves and seals; measure injector tip or nozzle protrusion; perform needed action.

g.    Reassemble cylinder head.

h.    Inspect, measure, and replace/reinstall overhead camshaft; measure/adjust end play and backlash.

i.      Inspect pushrods, rocker arms, rocker arm shafts, electronic wiring harness, and brackets for wear, bending, cracks, looseness, and blocked oil passages; perform needed action.

j.      Inspect cam followers; perform needed action.

k.             Adjust valve clearance.

Unit 4

Unit 4: Diesel Systems and Theory    

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3.    Explore engine block diagnosis and repair.

a.     Remove, inspect, service, and install pans, covers, vents, gaskets, seals, and wear rings.

b.    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.

c.     Inspect cylinder sleeve counterbore and lower bore; check bore distortion; determine needed action.

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

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

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

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

h.    Clean and inspect crankshaft for surface cracks and journal damage; check condition of oil passages; check passage plugs; measure journal diameter; determine needed action.

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

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

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

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

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

n.    Install and align flywheel housing; inspect flywheel housing(s) to transmission housing/engine mating surface(s) and measure flywheel housing face and bore runout; determine needed action.

o.             Inspect flywheel/flexplate (including ring gear) and mounting surfaces for cracks and wear; measure runout; determine needed action.