- Compression ignition
- How a diesel ignites fuel: air is compressed enough to self-heat to about 540°C (1000°F), then injected fuel ignites from that heat — no spark plug.
- Diesel four-stroke cycle
- Intake (air only), compression, power (compression ignition), exhaust — two crankshaft revolutions per cylinder.
- Glow plug
- A cold-start aid that heats the chamber or intake air to help a cold diesel start and cut white smoke. Not an igniter — combustion is still by compression.
- Black diesel smoke
- Incomplete combustion from too much fuel or too little air — restricted air filter, low boost, or over-fueling injectors.
- Blue diesel smoke
- Oil burning in the cylinder — worn rings or liners, worn valve guides/seals, or a leaking turbo seal.
- White diesel smoke
- Unburned fuel from low cylinder temperature (cold engine, weak glow plugs, low compression) or coolant entering the chamber.
- Cylinder cutout (balance) test
- Disable each injector one at a time and watch RPM/sound. Little or no change = that cylinder is weak (injector, compression, or electrical).
- First step after a dead cylinder on cutout
- Check that cylinder's injector wiring harness before tearing down — rule out an electrical fault first.
- Compression test (diesel)
- Measures mechanical sealing of rings, valves, and liners; separates a fuel/injector problem from a mechanical one on a weak cylinder.
- Diesel knock from incorrect timing
- Confirm by inspecting crankshaft and camshaft timing marks — the most direct check of injection timing.
- Harmonic balancer (damper)
- Damps crankshaft torsional vibration. A damaged balancer can cause noise and vibration only at high RPM.
- Scan tool in diagnosis
- The first instrument on a modern diesel — pull fault codes and freeze-frame data, and command components to confirm operation.
- Freeze-frame data
- A snapshot of sensor values captured when a fault code set, used to recreate the conditions of the concern.
- Restricted air filter symptom
- Increased fuel consumption and decreased power — not enough air for proper combustion, often with black smoke.
- Delayed acceleration, clean filter & intake
- Check the fuel injectors next — they directly affect the engine's ability to make power.
- Vapor lock after a hot soak
- Fuel vaporizes from residual heat before reaching the engine, causing hard starting and erratic idle after sitting hot.
- Diagnostic sequence
- Verify → gather codes/data → test to isolate → interpret → repair → confirm. Diagnose the cause, not just the symptom.
- Verify the concern
- Confirm and reproduce the customer complaint before testing — never start replacing parts off an assumption.
- Engine knock under load
- A deep, rhythmic knock that worsens under load points to the bottom end — rod or main bearings.
- Valve-train tick
- A lighter tick that rises with RPM is usually excessive valve lash or a worn lifter/follower.
- Low cylinder temperature white smoke
- Incomplete combustion because cylinder temperatures are too low to fully burn the fuel.
- Blue smoke + rapid oil loss
- Oil burning in the engine — typically worn piston rings or cylinder liners.
- Engine starts then stalls (fuel)
- Most likely air trapped in the fuel system — it can't hold the pressure/flow needed to keep running.
- Symptom vs. cause
- The symptom is a clue, not the diagnosis. T2 questions reward picking the correct next diagnostic step.
- Glow plugs and engine power
- Glow plugs are for cold starts; they do not cause black smoke or low power during normal running.
- Cylinder head
- Seals the top of the cylinders and houses the valves, seats, guides, and (on OHC engines) the camshaft.
- Warped cylinder head
- Causes head-gasket failure, coolant/oil leaks, overheating, and compression loss. Must be machined flat.
- Check head flatness
- Use a straightedge and feeler gauge across the deck; high spots or warp call for resurfacing.
- Wrong head-gasket thickness after resurfacing
- Alters combustion-chamber volume and valve-to-piston clearance, causing low compression on all cylinders.
- Pitted or worn valve seats
- Often repaired by installing valve-seat inserts rather than replacing the entire cylinder head.
- Cracked cylinder head
- Can cause intermittent misfiring and loss of compression as the crack intermittently breaks the chamber seal.
- Excessive valve stem-to-guide clearance
- Lets oil into the combustion chamber, increasing oil consumption and causing blue smoke.
- Valve lash
- Clearance in the valve train for thermal expansion. Too little burns valves; too much ticks and wears.
- Insufficient valve clearance result
- A valve may not fully close, risking valve-to-piston interference and burned valves with lost compression.
- Faulty hydraulic lifters
- Cause a loud ticking that increases with RPM because they can't maintain proper clearance.
- Bent pushrod cause
- Valve float at high RPM — the valve doesn't follow the cam profile, stressing the pushrod.
- Worn camshaft lobes
- Usually caused by poor or contaminated oil; the lobes rely on a clean oil film against the lifters/followers.
- Camshaft bearing seizure
- From inadequate lubrication or debris; the friction can stress and even snap the camshaft.
- Camshaft timing fault
- Incorrect cam timing can cause hot-start difficulty (clearances tighten cold, expand hot) and compression issues.
- Metal shavings after a rebuild
- Often camshaft-lobe deterioration if the cam wasn't replaced or was improperly installed/lubricated.
- Burned exhaust valve
- Caused by poor sealing or too-little lash; produces low compression and a misfire in one cylinder.
- Valve seat insert
- A hardened ring pressed into the head to restore a worn or damaged valve seat without replacing the head.
- Engine block
- Holds the cylinders (often replaceable liners), crankshaft, pistons, and bearings.
- Cylinder liner (sleeve)
- A replaceable cylinder wear surface (wet or dry) so the bore can be renewed without scrapping the block.
- Wet liner
- A liner in direct contact with coolant, sealed by O-rings at the bottom. A failed seal lets coolant into the crankcase.
- Liner protrusion
- How far a liner stands above the deck; out of spec causes head-gasket sealing problems and premature gasket failure.
- Liner protruding too much
- Prevents the head gasket from sealing properly, leading to premature head-gasket failure.
- Bore taper
- Difference in cylinder diameter top vs. bottom of ring travel due to wear; excessive taper calls for reboring/re-sleeving.
- Out-of-round bore
- A bore worn unevenly so it's no longer a true circle; often from uneven thermal expansion or overheating.
- Oversize pistons
- Require reboring the cylinders to the oversize spec for correct piston-to-cylinder clearance.
- Resurfacing the block deck
- Removes high spots so the deck is flat and seals the head gasket; checked with a straightedge and feeler gauge.
- Cracked engine block
- Can let coolant into the oil passages even with a good head gasket; high-pressure blocks are repaired by welding with pre/post-heat.
- Plastigage
- A plastic strip crushed between a bearing and journal to measure oil clearance by comparing the flattened width to a chart.
- Excessive main bearing clearance
- Causes a deep bottom-end knock under load and low oil pressure (worst warm at idle).
- Main-bore misalignment
- Uneven load on the bearings causes excessive or repeated main-bearing wear even with a good crankshaft.
- Crankshaft thrust bearing
- Controls crankshaft axial (end-to-end) movement; incorrect installation can cause premature main-bearing failure.
- Rear main seal repeated failure
- If the seal and crank surface are good, suspect a misaligned bell housing placing uneven pressure on the seal.
- Piston rings
- Seal combustion and control oil. Worn rings/liners cause blue smoke and low compression.
- High oil use after a ring job
- Next step: measure cylinder-wall clearances to verify the bores are in spec and the rings are seating.
- Ridge reaming
- Removing the unworn lip at the top of the bore before pushing pistons out, so rings and pistons aren't damaged.
- Crack detection methods
- Magnetic-particle (Magnaflux) or dye-penetrant inspection find cracks in the block, head, or crankshaft.
- Oil pump
- Circulates pressurized oil through the bearings and galleries. A worn pump or failing gears can lower pressure or shed metal flakes.
- Low oil pressure, warm at idle
- Most likely excessive main bearing clearance after a rebuild — oil escapes the bearings faster at low pump speed.
- Erratic oil pressure at all speeds
- Points to aerated oil (air bubbles) or air on the pump's suction side; the pump can't maintain steady pressure.
- Aerated engine oil
- Oil mixed with air bubbles, which the pump can't pressurize consistently — causing erratic oil-pressure readings.
- Frothy or milky oil
- Coolant contamination — think head gasket, cracked oil cooler, cracked block/head, or a failed liner seal.
- Oil cooler
- A heat exchanger that uses coolant to cool engine oil. A cracked oil cooler mixes coolant and oil.
- Cracked oil cooler
- Allows coolant to enter the oil (or oil into coolant), causing contamination and bearing wear — a commonly missed cause.
- Oil-pressure relief valve test
- Increase engine speed and observe the pressure at which the valve opens to confirm it limits pressure correctly.
- Oil-pressure light after a filter change
- First check that the new oil filter is installed correctly — improper installation can restrict oil flow.
- Metal flakes besides bearing wear
- Failing oil-pump gears can shed metal flakes found in the oil at a change.
- Thermostat
- A temperature-controlled valve that blocks coolant flow to the radiator until the engine warms, then opens to regulate temperature.
- Thermostat stuck closed
- Causes overheating — no coolant flow reaches the radiator.
- Thermostat stuck open
- Keeps the engine running too cool, hurting economy and heater output and slowing warm-up.
- Runs hot, good coolant & thermostat
- Suspect airflow — radiator fins blocked by debris reduce cooling efficiency.
- Fan clutch stuck engaged
- Makes the cooling fan run at full speed all the time regardless of engine temperature.
- Water pump
- Belt- or gear-driven pump that circulates coolant through the engine and radiator. A weep-hole leak signals a failing seal.
- Noise after a water-pump replacement
- Verify pulley-system alignment next — misalignment causes noise and wear on belts and pulleys.
- Discolored coolant with sediment
- Indicates contamination (rust/scale) and the need to flush the cooling system.
- High-pH coolant
- Can corrode aluminum cooling-system parts; coolant must be maintained at the correct chemistry.
- Cylinder cutout temp drop on one cylinder
- A clogged coolant passage near that cylinder can show up as an unexpected temperature drop during the test.
- Radiator pressure cap
- Seals the system and raises the coolant boiling point; also lets coolant return from the overflow as the engine cools.
- Turbocharger
- Exhaust-driven; its turbine spins a compressor to force more air into the cylinders (boost) for more power.
- Boost
- Above-atmospheric intake pressure made by the turbo. Low boost causes low power and black smoke.
- Charge air cooler (CAC / intercooler)
- Cools the hot, compressed air from the turbo so it's denser, improving combustion and lowering emissions.
- Oil in the charge air cooler
- Usually a failed turbocharger oil seal letting engine oil into the induction system.
- CAC or intercooler hose leak
- Loses turbocharger boost pressure, reducing engine power.
- Wastegate
- A valve that limits maximum boost by bypassing exhaust around the turbine; a faulty actuator causes under- or over-boost.
- Low boost, all else good
- A faulty turbocharger wastegate actuator can prevent correct boost, lowering power.
- Exhaust back pressure
- Pressure built up in the exhaust; excessive (plugged DPF, restriction) reduces power and raises temperatures.
- Larger-diameter exhaust pipe
- Can decrease back pressure and lose low-end torque if not properly tuned.
- New exhaust whistle (not turbo)
- Often a crack in the exhaust manifold or pipe letting exhaust gases escape.
- EGR (exhaust gas recirculation)
- Routes inert exhaust into the intake to lower combustion temperature and reduce NOx.
- Clogged EGR cooler
- Reduces EGR flow, which raises NOx emissions.
- Best EGR test
- Use a scan tool to command the EGR valve while monitoring engine RPM/data — the most accurate functional check.
- DOC (diesel oxidation catalyst)
- First aftertreatment device; oxidizes carbon monoxide and hydrocarbons and helps raise temperature for DPF regen.
- DPF (diesel particulate filter)
- Traps soot from the exhaust; the soot is burned off during regeneration. A plugged DPF restricts exhaust and cuts power.
- Regeneration
- Burning off soot collected in the DPF, passively while driving or actively by raising exhaust temperature.
- SCR (selective catalytic reduction)
- Sprays DEF into the exhaust to convert NOx into harmless nitrogen and water over a catalyst.
- DEF (diesel exhaust fluid)
- A urea-and-water solution used by SCR to reduce NOx. Running out can force a reduced-power (derate) mode.
- Aftertreatment order
- DOC → DPF → SCR (DEF): oxidize, then trap soot, then kill NOx.
- Excessive soot in exhaust
- Often an air-induction issue (restriction or leak) causing incomplete combustion from insufficient air.
- Restricted air filter result
- Low power and poor acceleration with black smoke from inadequate air supply.
- Air-induction pressure (MAP/boost) sensor fault
- Can over-estimate air density and cause over-fueling, hurting performance and emissions.
- Charge air
- The pressurized intake air supplied by the turbo and cooled by the CAC before it enters the cylinders.
- Intake throttle (air control) valve
- On some diesels controls intake airflow (for EGR/regen/shutdown); an intermittent power loss can trace to it.
- Unit injector
- An injector with its own high-pressure pump per cylinder, cam-driven and (on electronic units) solenoid-fired.
- Faulty unit injector
- Misfires only its own cylinder, since each injector serves one cylinder.
- HEUI
- Hydraulically actuated, electronically controlled unit injection — uses high-pressure engine oil to actuate the injectors.
- HEUI hard starting
- Low or aerated engine oil can cause hard starting and rough running because oil actuates the injectors.
- Common rail (HPCR)
- One high-pressure pump charges a shared rail; the ECM commands solenoid/piezo injectors to fire.
- Rail pressure
- Fuel pressure in the common rail, controlled by the ECM. A drop under demand points to a failing high-pressure pump.
- Rail pressure drops under demand
- Most likely a failing high-pressure fuel pump that can't keep up with increased demand.
- Air in the fuel system
- A compressible bubble that absorbs injection pressure — causing hard starting, starting-then-stalling, and rough running.
- Starts then stalls after a filter change
- Air trapped in the fuel system; prime and bleed the air out before running.
- Priming / bleeding
- Removing trapped air (often with a manual primer pump) after fuel-side work so a solid fuel column reaches the injectors.
- Bleed the HPCR rail
- After a high-pressure common-rail repair, bleed air from the rail with the manual primer before cranking to prevent air lock.
- Excessive injector return (back-leakage)
- Lowers high-side fuel pressure and reduces a cylinder's output; can indicate an internal injector leak.
- Dripping injector nozzle
- Causes a rich condition, incomplete combustion, blue smoke, and a misfire on that one cylinder.
- Chuffing injector at idle
- Typically a sticking nozzle needle interrupting proper fuel flow.
- Diesel fuel in the engine oil
- A defective fuel injector seal can let fuel into the chamber and past the rings into the crankcase, contaminating the oil.
- Empty fuel-filter housing overnight
- Fuel drained back toward the tank — a bad check valve failed to hold prime.
- Single injector not delivering fuel
- Suspect an open injector coil, seized plunger, or blown fuse — not a clogged filter (which would affect all injectors).
- Temperature-dependent misfire (warming)
- Monitor live data for injector performance variance to pinpoint the failing injector.
- Higher-than-normal fuel temperature
- Often an inoperative fuel cooler that should reduce fuel temperature as it circulates.
- Hard-start fuel checks
- Check for air in the system, incorrect fuel timing, and clogged filters — high fuel pressure is not a hard-start cause.
- Cylinder balance: no change when cut
- Check the injector wiring harness for that cylinder first before invasive teardown.
- Lower injection rate on one unit injector
- Often excessive fuel return from an internal injector leak.
- Common-rail noise and vibration
- Air in the fuel system can cause combustion-timing issues that produce excessive noise and vibration.
- Fuel filter purpose
- Removes water and contaminants; primary and secondary filters protect injection components. Clogged filters cause hard starting and low power.
- Water in diesel fuel
- Corrodes and damages injection components; a fuel/water separator drains collected water.
- Transfer (supply / lift) pump
- Low-pressure pump that moves fuel from the tank through the filters to the high-pressure pump or injectors.
- High-pressure fuel pump
- Generates the very high pressure needed for diesel injection; failure shows as low rail pressure and poor power.
- Injector opening pressure
- The pressure at which a mechanical injector nozzle opens to spray; incorrect pressure affects atomization and combustion.
- Atomization
- Breaking fuel into a fine mist for complete combustion; poor atomization (worn nozzle) causes smoke and lost power.
- Injection timing
- When fuel is injected relative to piston position; too advanced/retarded causes knock, smoke, and power loss.
- ECM (engine control module)
- The computer that controls injection quantity and timing, rail pressure, EGR, and aftertreatment from sensor inputs.
- Fuel return line restriction
- Can raise system pressure or fuel temperature and disturb injector operation.
- Cetane number
- A measure of diesel fuel's ignition quality; low cetane can cause hard starting, noise, and white smoke.
- Piezo vs. solenoid injectors
- Common-rail injectors use fast solenoid or piezo actuators commanded by the ECM for multiple injection events per cycle.
- Multiple injection events
- A common-rail injector can fire pilot, main, and post injections per cycle to cut noise, emissions, and aid regen.
- Fuel pressure regulator
- Controls supply or rail pressure; a fault can cause low power, hard starting, or pressure that won't hold.
- Cracking pressure (nozzle)
- The set pressure at which a mechanical injector nozzle opens; tested on a pop tester for spray pattern and pressure.
- Smoke limiter / fuel-air ratio control
- Limits fueling until boost rises so the engine doesn't pour black smoke on acceleration.
- Starter motor
- Cranks the high-compression diesel to start. Slow cranking with a good battery points to circuit resistance.
- Slow cranking, battery good
- High resistance in the starter circuit — corroded/loose cables or poor grounds cause a voltage drop.
- Voltage-drop test
- Measures lost voltage across a cable/connection under load to find high resistance the meter alone won't show.
- High voltage drop on the ground side
- Indicates poor ground connections adding resistance to the starting circuit.
- Solenoid clicks, motor won't turn
- Often a defective starter solenoid that can't pass current to the motor.
- Starter won't disengage
- A sticking pinion gear stays meshed with the flywheel after the engine starts.
- Excessive cranking before start (Tech A/B)
- Both a weak battery (low cranking speed) and high circuit resistance can be the cause.
- Alternator
- Belt-driven generator that recharges the batteries and powers the electrical system while the engine runs.
- No charge at idle, charges as RPM rises
- Most likely loose drive-belt tension — the alternator can't spin fast enough at idle to make voltage.
- Battery light stays on after alternator swap
- Verify the wiring connections at the alternator and the warning-light circuit before re-replacing parts.
- Voltage regulator
- Controls alternator output voltage; a fault causes under- or over-charging.
- Open alternator diodes
- Reduce output and add AC ripple; cause low charging voltage and possible electrical noise.
- Confirm charging
- Measure charging voltage with the engine running and load applied to verify the system is keeping up.
- Overrunning (one-way) clutch
- In the starter, lets the pinion freewheel once the engine starts so the starter isn't back-driven.
- Parasitic draw
- A current draw with everything off that can drain batteries overnight; found with a current test on the circuits.
- Battery state-of-charge vs. capacity
- A battery can be fully charged yet still fail a load test if its capacity is gone — test both before condemning.
- Engine brake (compression-release)
- A 'Jake brake' that opens the exhaust valves near TDC with fuel cut, releasing compression energy so the engine absorbs power.
- Engine brake purpose
- Reduces the load on the service (wheel) brakes on long downgrades, preventing brake fade.
- How the engine brake slows the truck
- It turns the engine into an air compressor that throws away its compressed-air energy, so the engine resists turning.
- Engine brake electrical diagnosis
- Check for supply voltage at the engine brake switch and solenoids first when the brake fails to activate.
- Uneven braking across cylinders
- Points to a worn/sticking mechanism, a defective solenoid on one cylinder, or wrong slave-piston (control-valve) clearance.
- Weak braking only at high RPM
- Check the engine brake control-valve (slave-piston) clearance first.
- Loud snap then loss of engine braking
- Can indicate a broken engine-brake actuator spring.
- Engine brake solenoid
- Controls oil flow to the slave piston that opens the exhaust valve; a defective solenoid disables that cylinder's braking.
- Engine-brake enabling conditions
- Typically requires the throttle closed, the clutch engaged, and a minimum RPM; fuel is cut when it activates.
- Slave piston
- The hydraulic piston in the engine brake that pushes the exhaust valve open near TDC to release compression.
- Engine brake vs. service brake
- The engine brake slows the truck by absorbing engine power; it supplements, not replaces, the service (wheel) brakes.
- Engine brake and exhaust noise
- The loud 'bark' is the released compressed air escaping the exhaust; excessive noise can indicate a fault or missing muffling.
- Diesel compression ratio
- Typically about 16:1 to 22:1 — far higher than gasoline — to self-heat the air enough for compression ignition.
- Pop tester
- A bench tool that pressurizes a mechanical injector to check its opening (crack) pressure and spray pattern.
- Coolant in the oil sources
- Head gasket, cracked oil cooler, cracked block/head, or a failed wet-liner seal.
- Glow plug system fault
- Weak or dead glow plugs cause hard cold starts and white smoke until the engine warms.
- Turbo bearing wear check
- Inspect compressor/turbine shaft for excessive play and the wheels for damage or oil leakage.
- Crankcase ventilation (CCV)
- Vents blow-by gases from the crankcase; a blocked or failed system can build pressure and push out oil.
- Blow-by
- Combustion gases slipping past the rings into the crankcase; excessive blow-by indicates worn rings or liners.
- Cylinder leak-down test
- Applies compressed air to a cylinder at TDC and reads where it escapes (valves, rings, or head gasket).
- Injection timing too advanced
- Can cause a diesel knock, higher cylinder pressure, and possible engine damage.
- Fuel cooler
- Lowers fuel temperature in the return circuit; an inoperative cooler raises fuel temperature and can hurt performance.
- Head bolts (stretch / TTY)
- Many diesels use torque-then-angle (torque-to-yield) head bolts tightened in sequence; replace once removed if specified.
- Valve float
- When valves can't follow the cam profile at high RPM; can bend pushrods and cause valve-to-piston contact.
- Cylinder glazing
- A smooth, shiny bore surface that prevents new rings from seating, causing oil use and blow-by.
- Honing
- Cross-hatching the cylinder/liner surface so new rings seat and retain oil; done after boring or before a re-ring.
- Coolant filter / SCA
- Heavy-diesel coolant uses supplemental coolant additives to protect wet liners from cavitation pitting.
- Liner cavitation (pitting)
- Vibration-formed bubbles erode wet liners; controlled by correct coolant additives and a filled system.
- DPF differential pressure sensor
- Reads the pressure drop across the DPF to estimate soot load and trigger regeneration.
- NOx sensor
- Measures NOx before/after SCR so the ECM can meter DEF and verify aftertreatment efficiency.
- Forced (manual) regeneration
- A technician-commanded DPF regen used when soot load is high and passive/active regen hasn't cleaned the filter.
- DEF dosing (metering) unit
- Injects the correct amount of DEF into the SCR system based on NOx and temperature; clogging or freezing causes faults.
- Engine derate
- A reduced-power protection mode triggered by faults such as low DEF, high DPF soot, or aftertreatment problems.
- Battery isolator / parallel batteries
- Heavy trucks use multiple batteries in parallel for cranking; a weak cell drags down the whole bank.
- Two-speed / gear-reduction starter
- Uses gear reduction for high cranking torque on big diesels; high resistance still causes slow cranking.
- Boost (turbo) lag
- The delay before the turbo builds boost; excessive lag can come from leaks, a worn turbo, or a sticking VGT.
- Variable-geometry turbo (VGT)
- A turbo with movable vanes the ECM adjusts for boost across the RPM range; sticking vanes cause low power or codes.
- Exhaust manifold crack
- Causes a whistle/tick and a boost or back-pressure leak; can lower turbo performance.
- Compression test interpretation
- Uniformly low = worn rings/liners or timing; one low cylinder = a leaking valve, head gasket, or that hole's rings.
- Technician A / Technician B format
- Judge each technician's statement separately as true or false, then pick A only, B only, both, or neither.