,Solution manual for Modern Diesel Technology
Light Duty Diesels, 2nd Edition Sean Bennett
Notes
1- The file is chapter after chapter.
2- We have shown you 10 or five pages.
3- The file contains all Appendix and Excel
sheet if it exists.
4- We have all what you need, we make
update at every time. There are many
new editions waiting you.
5- If you think you purchased the wrong file
You can contact us at every time, we can
replace it with true one.
Our email:
,CHAPTER 1
REVIEW QUESTIONS
1. When is a worker more likely to be injured?
A. First day on the job
B. During the first year of employment
C. During the second to fourth years of employment
D. During the year before retirement
2. When lifting a heavy object, which of the following should be true?
A. Keep your back straight while lifting.
B. Keep the weight you are lifting close to your body.
C. Bend your legs and lift using the leg muscles.
D. All of the above.
3. Which of the following best describes the purposes of LOTO?
A. A workplace lottery
B. Vehicle and equipment securement during servicing
C. Certification standards for PPE
D. CVSA safety standards
4. Which of the following is usually a requirement of a safety shoe or boot?
A. UL certification
B. Steel sole shank
C. Steel toe
D. All of the above
5. What type of gloves should never be worn when working with refrigerant?
A. Synthetic rubber
B. Vinyl disposable
C. Leather welding gloves
D. Latex rubber gloves
6. Which of the following is under the most pressure?
A. Oxygen cylinders
B. Acetylene cylinders
C. Diesel fuel tanks
D. Gasoline fuel tanks
7. Which type of fire can usually be safely extinguished with water?
A. Class A
B. Class B
C. Class C
D. Class D
8. When attempting to suppress a Class C fire in a chassis, which of the following is good practice?
A. Disconnect the batteries.
B. Use a carbon dioxide fire extinguisher.
C. Avoid inhaling the fumes produced by burning conduit.
D. All of the above.
9. What color is used to indicate the fuel hose in an oxyacetylene station?
A. Green
B. Red
C. Yellow
D. Blue
,10. In which direction do you tighten an oxygen cylinder fitting?
A. CW
B. CCW
C. Depends on the manufacturer
,CHAPTER 2
REVIEW QUESTIONS
1. An 8-cylinder diesel engine has a bore of 80 mm and a stroke of 100 mm. Which of the following
correctly describes the engine?
A. 80 inch displacement
B. 10 liter displacement
C. Oversquare
D. Undersquare
2. Which of the following best describes the term engine displacement?
A. Total piston swept volume
B. Mean effective pressure
C. Peak horsepower
D. Peak torque
3. Convert the displacement of a Cummins 6.7 liter engine into cubic inches.
A. 350 cubic inches
B. 409 cubic inches
C. 440 cubic inches
D. 500 cubic inches
4. Which of the following engine subsystems plays the larger role in managing engine output?
A. Air induction system
B. Throttle body circuit
C. Fuel system
D. Lubrication circuit
5. What percentage of the potential heat energy of the fuel does the modern diesel engine convert to
useful mechanical energy when it is operating at its best efficiency?
A. 20 percent
B. 40 percent
C. 60 percent
D. 80 percent
6. Where does scavenging take place on a four-stroke cycle, diesel engine?
A. BDC after the power stroke
B. TDC after the compression stroke
C. Valve overlap
D. 10 to 20 degrees ATDC on the power stroke
7. Ideally, where should peak cylinder pressure occur during the power stroke?
A. TDC
B. 10 to 20 degrees ATDC
C. 90 degrees ATDC
D. At gas blowdown
8. Technician A says that all current light-duty highway diesel engines are hydromechanically man-
aged. Technician B says that the popularity of private automobile diesel engines has been increas-
ing since 2017. Who is correct?
A. Technician A only
B. Technician B only
C. Both A and B
D. Neither A nor B
, 9. Which of the following best describes MEP during engine operation?
A. Combustion pressure acting on a piston
B. Compression pressure produced by a piston
C. Combustion pressure minus compression pressure acting on a piston.
D. Intake pressure minus exhaust pressure in a cylinder
10. What term is used to specify the ignition temperature of a diesel fuel?
A. Cetane number (CN)
B. Flash point
C. 700 degrees Celsius
D. Vaporization temperature
,CHAPTER 3
REVIEW QUESTIONS
1. Where would a Ni-Resist insert be found?
A. Upper ring belt, aluminum trunk piston
B. Lower ring belt, articulating piston
C. Upper ring belt, crosshead piston
D. Trunk piston, pin boss
2. Under which of the following conditions would a piston ring seal most effectively?
A. Low engine temps
B. High engine temps
C. Low cylinder pressures
D. High cylinder pressures
3. Where would you most likely find a slinger?
A. Crankshaft main seals
B. Piston leading edge
C. Oil spray jet
D. Big end journal
4. What should be used to measure rod and main journal bearing clearances?
A. Tram gauges
B. Dial indicators
C. Plastigage
D. Snap gauges
5. Technician A says that an advantage of forged steel trunk pistons is that their weight is equiv-
alent to that of aluminum and they are much tougher. Technician B says that steel trunk pistons
are popular in recent engines because they have reduced headland volume. Who is correct?
A. Technician A only
B. Technician B only
C. Both A and B
D. Neither A nor B
6. Technician A says that keystone rings are common in high-performance diesel engines. Technician
B says that keystone con rods have a wedge-shaped small end. Who is correct?
A. Technician A only
B. Technician B only
C. Both A and B
D. Neither A nor B
7. Which of the following would be most likely to occur if an engine was run under load with a failed
vibration damper?
A. Increased fuel consumption
B. Increased cylinder blowby
C. Camshaft failure
D. Crankshaft failure
8. What is the upper face of a piston assembly known as?
A. Crown
B. Skirt
C. Boss
D. Trunk
, 9. Which term is used to describe the cylinder volume between the piston upper compression ring and
its leading edge?
A. Dead volume
B. Headland volume
C. Toroidal recess
D. Clearance volume
10. Which of the following tools should be used to check a cylinder block deck for warpage?
A. Master bar
B. Dial indicator
C. Laser
D. Straightedge and feeler gauges
INTERNET EXERCISES
1. Search out the Mahle and Federal Mogul websites: Identify some of their products.
2. Log on to some manufacturers of light duty diesel engines such as Ford, GM, Detroit Diesel, Cum-
mins (Dodge), Caterpillar, John Deere, and Perkins. Compare the specified engine torque and
power outputs of engines of similar displacements.
3. Select one light duty diesel engine you are familiar with: go online and check the pricing for a new
OEM crankshaft. Compare this with a rebuilt-exchange crankshaft for the same engine.
4. Select one of the following pickup trucks powered by a diesel engine: GM 6600, Ford 6.7, or Cum-
mins (Dodge) 6.7. Suppose that you are to enter a 500-mile race (on a banked corner, oval track)
competing against truck(s), you did not select with the intention of winning the race: outline the
reasons in bullet form that you would win the race.
5. Compare pricing of OEM and aftermarket diesel engine piston rings: consult iATN discussion
threads to determine if there is a downside to using aftermarket rings.
6. Use a search engine to research machine shops that will recondition diesel engine crankshafts:
identify what process they use and check out the warranty offered with each type of repair.
,CHAPTER 4
REVIEW QUESTIONS
1. Technician A says that most current diesel engines use a one-piece cylinder head gasket that con-
tains integral fire rings. Technician B says that most current diesel engines use a one-piece cylinder
head gasket that have integral rubber grommets to seal oil and coolant passages. Who is correct?
A. Technician A only
B. Technician B only
C. Both A and B
D. Neither A nor B
2. When observing a typical cylinder head fastener torque sequence, where would the first pair of
bolts to be torqued be located?
A. At the front of the cylinder head
B. At the center of the cylinder head
C. At the rear of the cylinder head
D. One at the front, one at the rear
3. When timing a diesel engine gearset, which of the following would be a common way of identi-
fying a timing index on a gear?
A. o
B. G
C. YYY
D. P
4. The location on a cam profile that is exactly opposite the toe is referred to as the:
A. Sole
B. Nose
C. Ramp
D. Heel
5. In which direction must a camshaft be rotated on a diesel engine with a crankshaft that is rotated
clockwise?
A. Clockwise (CW) only
B. Counterclockwise (CCW) only
C. Either CW or CCW is OK depending on the engine
6. Which tool would be required to measure the cam lift of a cylinder blockñmounted camshaft in
position?
A. Dial indicator
B. Outside micrometer
C. Depth micrometer
D. Thickness gauges
7. A camshaft gear is usually precisely positioned on the camshaft using a(n):
A. Dial indicator
B. Interference fit
C. Key and keyway
D. Captured thrust washer
8. When grinding a valve face to remove pitting, the critical specification to monitor during machin-
ing would be the:
A. Shank diameter
B. Stem
C. Poppet diameter
D. Margin
, 9. Which of the following engine running conditions would be more likely to cause a valve float con-
dition?
A. Engine lug down
B. Engine overspeed
C. Operating in the torque rise profile
D. Operating in the droop curve
10. You are about to set the valves over number 2 cylinder on a typical inline four-cylinder engine.
Which of the following would likely be true on most engines?
A. Valves over number 2 should be rocking.
B. Valves over number 3 should be rocking.
C. Valves over number 1 should show full lash.
D. Valves over number 4 should show full lash.
INTERNET EXERCISES
1. Use a search engine to check out the QuickWay and Sioux Tools websites. Check out each com-
panyís valve servicing equipment.
2. Use a search engine and key in <tempilstick> to see what you come up with.
3. Use the Web to identify valve lash specifications for the intake and exhaust valves of a diesel en-
gine of your choosing. Cross check this information with the manufacturer specs if they are avail-
able to you.
4. Use the Web to identify the forums for one of the Big Three diesels: Ford Power Stroke (3.0 and
6.7), GM Duramax (3.0 and 6.6/6600), or Dodge (Fiat 3.0 and Cummins ISB 6.7). Make a list of
the key differences in the cylinder head design and timing geartrains.
5. Use the Web to research the specification data on the Dodge Cummins ISB inline six-cylinder en-
gine versus the V8-configured GM Duramax and Ford Power Stroke engines. Make a note of the
differences you identify.
Light Duty Diesels, 2nd Edition Sean Bennett
Notes
1- The file is chapter after chapter.
2- We have shown you 10 or five pages.
3- The file contains all Appendix and Excel
sheet if it exists.
4- We have all what you need, we make
update at every time. There are many
new editions waiting you.
5- If you think you purchased the wrong file
You can contact us at every time, we can
replace it with true one.
Our email:
,CHAPTER 1
REVIEW QUESTIONS
1. When is a worker more likely to be injured?
A. First day on the job
B. During the first year of employment
C. During the second to fourth years of employment
D. During the year before retirement
2. When lifting a heavy object, which of the following should be true?
A. Keep your back straight while lifting.
B. Keep the weight you are lifting close to your body.
C. Bend your legs and lift using the leg muscles.
D. All of the above.
3. Which of the following best describes the purposes of LOTO?
A. A workplace lottery
B. Vehicle and equipment securement during servicing
C. Certification standards for PPE
D. CVSA safety standards
4. Which of the following is usually a requirement of a safety shoe or boot?
A. UL certification
B. Steel sole shank
C. Steel toe
D. All of the above
5. What type of gloves should never be worn when working with refrigerant?
A. Synthetic rubber
B. Vinyl disposable
C. Leather welding gloves
D. Latex rubber gloves
6. Which of the following is under the most pressure?
A. Oxygen cylinders
B. Acetylene cylinders
C. Diesel fuel tanks
D. Gasoline fuel tanks
7. Which type of fire can usually be safely extinguished with water?
A. Class A
B. Class B
C. Class C
D. Class D
8. When attempting to suppress a Class C fire in a chassis, which of the following is good practice?
A. Disconnect the batteries.
B. Use a carbon dioxide fire extinguisher.
C. Avoid inhaling the fumes produced by burning conduit.
D. All of the above.
9. What color is used to indicate the fuel hose in an oxyacetylene station?
A. Green
B. Red
C. Yellow
D. Blue
,10. In which direction do you tighten an oxygen cylinder fitting?
A. CW
B. CCW
C. Depends on the manufacturer
,CHAPTER 2
REVIEW QUESTIONS
1. An 8-cylinder diesel engine has a bore of 80 mm and a stroke of 100 mm. Which of the following
correctly describes the engine?
A. 80 inch displacement
B. 10 liter displacement
C. Oversquare
D. Undersquare
2. Which of the following best describes the term engine displacement?
A. Total piston swept volume
B. Mean effective pressure
C. Peak horsepower
D. Peak torque
3. Convert the displacement of a Cummins 6.7 liter engine into cubic inches.
A. 350 cubic inches
B. 409 cubic inches
C. 440 cubic inches
D. 500 cubic inches
4. Which of the following engine subsystems plays the larger role in managing engine output?
A. Air induction system
B. Throttle body circuit
C. Fuel system
D. Lubrication circuit
5. What percentage of the potential heat energy of the fuel does the modern diesel engine convert to
useful mechanical energy when it is operating at its best efficiency?
A. 20 percent
B. 40 percent
C. 60 percent
D. 80 percent
6. Where does scavenging take place on a four-stroke cycle, diesel engine?
A. BDC after the power stroke
B. TDC after the compression stroke
C. Valve overlap
D. 10 to 20 degrees ATDC on the power stroke
7. Ideally, where should peak cylinder pressure occur during the power stroke?
A. TDC
B. 10 to 20 degrees ATDC
C. 90 degrees ATDC
D. At gas blowdown
8. Technician A says that all current light-duty highway diesel engines are hydromechanically man-
aged. Technician B says that the popularity of private automobile diesel engines has been increas-
ing since 2017. Who is correct?
A. Technician A only
B. Technician B only
C. Both A and B
D. Neither A nor B
, 9. Which of the following best describes MEP during engine operation?
A. Combustion pressure acting on a piston
B. Compression pressure produced by a piston
C. Combustion pressure minus compression pressure acting on a piston.
D. Intake pressure minus exhaust pressure in a cylinder
10. What term is used to specify the ignition temperature of a diesel fuel?
A. Cetane number (CN)
B. Flash point
C. 700 degrees Celsius
D. Vaporization temperature
,CHAPTER 3
REVIEW QUESTIONS
1. Where would a Ni-Resist insert be found?
A. Upper ring belt, aluminum trunk piston
B. Lower ring belt, articulating piston
C. Upper ring belt, crosshead piston
D. Trunk piston, pin boss
2. Under which of the following conditions would a piston ring seal most effectively?
A. Low engine temps
B. High engine temps
C. Low cylinder pressures
D. High cylinder pressures
3. Where would you most likely find a slinger?
A. Crankshaft main seals
B. Piston leading edge
C. Oil spray jet
D. Big end journal
4. What should be used to measure rod and main journal bearing clearances?
A. Tram gauges
B. Dial indicators
C. Plastigage
D. Snap gauges
5. Technician A says that an advantage of forged steel trunk pistons is that their weight is equiv-
alent to that of aluminum and they are much tougher. Technician B says that steel trunk pistons
are popular in recent engines because they have reduced headland volume. Who is correct?
A. Technician A only
B. Technician B only
C. Both A and B
D. Neither A nor B
6. Technician A says that keystone rings are common in high-performance diesel engines. Technician
B says that keystone con rods have a wedge-shaped small end. Who is correct?
A. Technician A only
B. Technician B only
C. Both A and B
D. Neither A nor B
7. Which of the following would be most likely to occur if an engine was run under load with a failed
vibration damper?
A. Increased fuel consumption
B. Increased cylinder blowby
C. Camshaft failure
D. Crankshaft failure
8. What is the upper face of a piston assembly known as?
A. Crown
B. Skirt
C. Boss
D. Trunk
, 9. Which term is used to describe the cylinder volume between the piston upper compression ring and
its leading edge?
A. Dead volume
B. Headland volume
C. Toroidal recess
D. Clearance volume
10. Which of the following tools should be used to check a cylinder block deck for warpage?
A. Master bar
B. Dial indicator
C. Laser
D. Straightedge and feeler gauges
INTERNET EXERCISES
1. Search out the Mahle and Federal Mogul websites: Identify some of their products.
2. Log on to some manufacturers of light duty diesel engines such as Ford, GM, Detroit Diesel, Cum-
mins (Dodge), Caterpillar, John Deere, and Perkins. Compare the specified engine torque and
power outputs of engines of similar displacements.
3. Select one light duty diesel engine you are familiar with: go online and check the pricing for a new
OEM crankshaft. Compare this with a rebuilt-exchange crankshaft for the same engine.
4. Select one of the following pickup trucks powered by a diesel engine: GM 6600, Ford 6.7, or Cum-
mins (Dodge) 6.7. Suppose that you are to enter a 500-mile race (on a banked corner, oval track)
competing against truck(s), you did not select with the intention of winning the race: outline the
reasons in bullet form that you would win the race.
5. Compare pricing of OEM and aftermarket diesel engine piston rings: consult iATN discussion
threads to determine if there is a downside to using aftermarket rings.
6. Use a search engine to research machine shops that will recondition diesel engine crankshafts:
identify what process they use and check out the warranty offered with each type of repair.
,CHAPTER 4
REVIEW QUESTIONS
1. Technician A says that most current diesel engines use a one-piece cylinder head gasket that con-
tains integral fire rings. Technician B says that most current diesel engines use a one-piece cylinder
head gasket that have integral rubber grommets to seal oil and coolant passages. Who is correct?
A. Technician A only
B. Technician B only
C. Both A and B
D. Neither A nor B
2. When observing a typical cylinder head fastener torque sequence, where would the first pair of
bolts to be torqued be located?
A. At the front of the cylinder head
B. At the center of the cylinder head
C. At the rear of the cylinder head
D. One at the front, one at the rear
3. When timing a diesel engine gearset, which of the following would be a common way of identi-
fying a timing index on a gear?
A. o
B. G
C. YYY
D. P
4. The location on a cam profile that is exactly opposite the toe is referred to as the:
A. Sole
B. Nose
C. Ramp
D. Heel
5. In which direction must a camshaft be rotated on a diesel engine with a crankshaft that is rotated
clockwise?
A. Clockwise (CW) only
B. Counterclockwise (CCW) only
C. Either CW or CCW is OK depending on the engine
6. Which tool would be required to measure the cam lift of a cylinder blockñmounted camshaft in
position?
A. Dial indicator
B. Outside micrometer
C. Depth micrometer
D. Thickness gauges
7. A camshaft gear is usually precisely positioned on the camshaft using a(n):
A. Dial indicator
B. Interference fit
C. Key and keyway
D. Captured thrust washer
8. When grinding a valve face to remove pitting, the critical specification to monitor during machin-
ing would be the:
A. Shank diameter
B. Stem
C. Poppet diameter
D. Margin
, 9. Which of the following engine running conditions would be more likely to cause a valve float con-
dition?
A. Engine lug down
B. Engine overspeed
C. Operating in the torque rise profile
D. Operating in the droop curve
10. You are about to set the valves over number 2 cylinder on a typical inline four-cylinder engine.
Which of the following would likely be true on most engines?
A. Valves over number 2 should be rocking.
B. Valves over number 3 should be rocking.
C. Valves over number 1 should show full lash.
D. Valves over number 4 should show full lash.
INTERNET EXERCISES
1. Use a search engine to check out the QuickWay and Sioux Tools websites. Check out each com-
panyís valve servicing equipment.
2. Use a search engine and key in <tempilstick> to see what you come up with.
3. Use the Web to identify valve lash specifications for the intake and exhaust valves of a diesel en-
gine of your choosing. Cross check this information with the manufacturer specs if they are avail-
able to you.
4. Use the Web to identify the forums for one of the Big Three diesels: Ford Power Stroke (3.0 and
6.7), GM Duramax (3.0 and 6.6/6600), or Dodge (Fiat 3.0 and Cummins ISB 6.7). Make a list of
the key differences in the cylinder head design and timing geartrains.
5. Use the Web to research the specification data on the Dodge Cummins ISB inline six-cylinder en-
gine versus the V8-configured GM Duramax and Ford Power Stroke engines. Make a note of the
differences you identify.
