Copyright Goodheart-Willcox Co., Inc. 8 Chapter 1 Introduction to Diesel Engines . . . . . 15 Diesel versus Gasoline Engines 16 Diesel Engine Stroke Cycle / Supplying Air and Fuel / Compression Ratios / Durability / Diesel Drawbacks Diesel Engine History 19 Early Theories and Successes / The Silent Otto Engine / The Development of the Diesel Engine / Continued Development of the Diesel Engine / Modern Diesel Applications / Continued Advances in Diesel Engine Efficiency Chapter 2 Shop Safety . . . . . . . . . . . . . . . . . . . . 27 Safety Notices 28 Personal Safety 28 Personal Protective Equipment Shop Safety Rules 29 Shop Cleanliness / Vehicle Safety Rules / Diesel Fuel Safety Precautions / Cleaning Equipment Fire Prevention 31 General Fire Safety Rules / Using a Fire Extinguisher Right-to-Know Laws 33 Hazardous Materials / Handling Hazardous Waste Chapter 3 Tools, Precision Tools, and Fasteners . . . 37 Hand Tools 38 Wrenches / Sockets and Socket Handles / Torque Wrench / Allen Wrenches / Torx Drivers and Sockets / Screwdrivers / Pliers and Cutters / Hammers / Saws and Knives / Files / Chisels and Punches / Vise and C-Clamps / Other Hand Tools Power Tools 45 Stationary Power Tools Engine Measuring Tools 48 Micrometers / Reading a Micrometer / Depth Gauge / Vernier Calipers / Telescoping and Small Hole Gauges / Feeler Gauges / Dial Indicator / Cylinder Bore Dial Gauge / Digital Tachometer / Infrared Thermometer / Cylinder Compression Gauge / Manometer Table of Contents Specialized Diesel Tools and Equipment 53 Injection System Tools Electrical Test Equipment 55 Multimeters / Test Lights Computer System Diagnostic Tools 56 Fasteners 56 Bolt and Screw Terminology / U.S. and Metric Nuts Thread Repairs 58 Applying Torque to a Fastener 58 Chapter 4 Principles of Engine Operation . . . . . 61 Major Engine Components 62 Cylinder Block and Cylinder Liners / Pistons / Crankshaft / Connecting Rods / Oil Pan / Flywheel / Vibration Dampers / Camshaft / Valve Train Components / Cylinder Head / Valves / Intake and Exhaust Manifolds / Superchargers / Turbochargers / Charge Air Coolers Diesel Engine Classifications 63 Engine Cycle Design / Four-Stroke Cycle Engines / Two-Stroke Cycle Engines Cylinder Number and Configuration 76 Inline Engines / V-type Engines / W-type and Delta Engine Configurations / Radial Engines / Double-acting Piston Combustion Chamber Designs 78 Direct Injection Chamber / Indirect Injection Chamber Diesel Fuel Injection Systems 80 Injection System Functions / Types of Fuel Injection Systems Engine Performance Terms and Formulas 82 Bore and Stroke / Displacement / Compression Ratio / Pressure / Volumetric Efficiency / Specific Gravity / Mean Effective Pressure Horsepower and Torque 84 Horsepower / Torque Chapter 5 Engine Blocks . . . . . . . . . . . . . . . . . . . 87 Cylinder Blocks 88