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Module 5 study guide 1. Tools used in baring the engine over Breaker bar 2.

Valve overlap procedure One cylinder at a time 3. Valve adjustment procedure/ sequence/ grip feel/ magnetic feel Intake(0.05mm magnetic feel) and exhaust(0.08mm grip feel) valves first then the retarder adjust screw(0.06mm grip feel). 4. Oil filter module housing drain location? The very bottom port of the filter module 5. Does oil drain when the filter is removed and where? Yes, when the oil filter housing drain valve is opened. 6. Where is the oil pressure regulator located? In the oil filter module, below the oil cooler 7. Coolant flow and mixer valves controls flow to what components? To the low temperature radiator and the charge air coolers 8. Coolant control valve testing procedures-operating test temperature Measure the LTR inlet and outlet temps. Their temp. difference should be 5*f lower than the CAC difference which is measure by comparing the ECT2 and IAT2 temps. 9. What EST tools are used to perform testing? Servicemaxx 10. True or false: All of the coolant passes through both the conventional and low temperature radiators before entering the charge air coolers. False, the systems are separated by the coolant control valves 11. True or false: Coolant for the charge air coolers never passes through the conventional radiator. False, the coolants do mix but the coolant from the radiator doesnt pass through the CACs normally. 12. What sensor is combined with IAT2 and where is it located?

MAP Sensor, on the ITV elbow 13. Temperature is measured before or after gases are mixed from the EGR Before 14. Duty cycle operation for the Fuel Pressure Control Valve (High rail and low rail pressure) 100% for zero pressure delivery and 0% for maximum pressure delivery 15. True or false: Fuel pressure control valve measures the pressure of the non-filtered fuel in the fuel filter module. False, clean filtered fuel 16. True or false: Pressure limiting valve on the fuel rail opens at 1850 bar. False, it opens at 1790 bar which is the equivalent of 26,000psi 17. True or false: When the valve is open it will maintain a maximum pressure of 800 bars until the engine has been shut down True, which is the equivalent of 11,600 psi 18. Glow Plug operation: Function and purpose Its part of the cold start assist. It heats the intake air by vaporizing and igniting fuel in the air inlet duct. 19. Cold start relay: Function and purpose It controls the output current to the glow plug via command signal from the ECM 20. Turbocharger operation (Low pressure, high pressure) Exhaust enters the HP turbo then goes to the LP turbo. And air enters the LP turbo, flows through the LPCAC and then goes to the HP turbo. 21. Turbocharger diverter valve location and operation In the turbine housing of the high pressure turbo and sends past exhaust gas the turbine to prevent over boosting or over speeding the turbo impeller shaft 22. Intake throttle valve operation: Mounted in the inlet tract, sometimes creates a restriction by the ECM to increase EGR flow or to raise the EGT for regeneration 23. Exhaust gas differential pressure sensor (location, function and purpose)

Mounted on the Diesel Particulate Filter, measure the differences in pressure of the DPF from the inlet and the outlet. Tells the Aftertreatment Control Module the soot load of the filter to help it determine when to induce regeneration. 24. Aftertreatment Control Module location in pre and post 2010 engines In pre-2010 engines the ACM is mounted on the inner frame rail and on post 2010 engines its integrated into the ECM 25. True or false: When fuel is being injected onto the glow plug, the MAT sensor value will increase when cranking. True 26. True or false: If the IAT2(boost temp) sensor value does not increase with KOEO the next step is to check the glow plug current draw True 27. What is the high crankcase pressure test: Use the crankcase pressure tool and measure at low & high idle. If ok, replace the crankcase depression regulator and measure at dipstick tube. If high, measure at dipstick tube. If high, replace service breather filter element and test at dipstick tube. If high, check for plugged pathway inside service breather housing or a plugged cyclone. Replace cyclone and retest. 28. If air compressor test: If the crankcase pressure is still high after the other tests, measure the crankcase pressure after disconnecting the compressor supply. If the pressure is normal, replace the air compressor. 29. Turbo test: Disconnect oil return pipe and block off the oil drain port in the crankcase and oil drain on the turbo. Retest quickly or severe turbo damage will occur. If the pressure is normal, replace the turbp 30. True or false: The previous 3 tests were servicemaxx tests. True 31. True or False: The relative compression test identifies a weak cylinder and the injector disable test identifies a problem with the same cylinder, the engine probably has a mechanical problem in that cylinder. True