Tim Reggio Certification Committee Chair Gerhardt's, Inc., Jefferson, La

Introduction
Specialists within the Fuel Injection and Turbocharger industry who, like you, have
participated within the TechCert Program, helped accumulate the training sources listed in
this guide.
The publications are designed to help sharpen your technical skills of the diesel fuel
injection and turbochargers in use today. Many of the situations posed on the TechCert tests
are addressed in the recommended publications for study – the more your learn, the better
your chances of passing the tests.
It should be noted several manufacturers will not release internal publications to

those who are not “authorized service centers” for their products. Some of the information
listed in this publication is considered proprietary information. If a TechCert candidate needs
to reference such publications, he/she may be required to obtain such information from an
Authorized Service Dealer or Central Distributor for the manufacturer. Depending upon the
TechCert testing applicants’ relationship with-in the diesel fuel injection or turbocharger
community, the material may not be available.
Several of the books referenced in this guide may be found at your local library or
bookstore.
One should realize studying books and publications alone typically would
not be enough to pass the tests. Practical experience with the equipment is generally required
in order to become familiar with the engines, pumps, injectors and turbochargers.
Please write or call the organizations listed in this publication for further information,
availability and prices.
Good luck in your preparation for the TechCert exams!
TIM REGGIO
Certification Committee Chair
Gerhardt’s, Inc., Jefferson, La.
DAVID A. FEHLING
A.D.S.
Executive Director
Association Headquarters, Overland Park, KS.
1
NEWS RELEASE
Contact: David Fehling FOR IMMEDIATE RELEASE:

816-444-3500 January 16, 2001
A.D.S. TO OFFER NEW DIESEL ENGINE DIAGNOSTICS TEST

The Association of Diesel Specialists (A.D.S) announced that its newest TechCert test, the Diesel Engine
Diagnostics Test (TC7), will be offered for the first time during the Spring 2001 test session in May.
The test is designed to measure knowledge of the skills required to diagnose sophisticated diesel engine electronic
fuel control systems on medium and heavy-duty trucks. "The TC7 test has been developed in response to the needs
expressed by our fellow members and was written by a cross-section of industry experts familiar with all aspects of
electronic diesel engine diagnostics," said Tim Reggio A.D.S. Certification Committee Chair. Reggio goes on to say
“the TC7 certification test will fill the need for Certified drive-in technicians as so many A.D.S. members have
diversified into the drive-in and drive-out business in the last two to three years.”
Technicians interested in taking the new test must be currently A.D.S. TechCert certified in the basic Diesel Engine
Theory & Operation (TC1) test category. A.D.S. also recommends at least two years of drive-in experience.
Certification will be good for five years. Technicians must recertify at that point in order to keep their credential
current.
The test consists of questions that will determine a technicians' diagnostic knowledge of diesel mechanical and
computer-controlled fuel systems. Questions cover both generic diesel engine systems, as well as several specific
types of electronic diesel fuel control systems.
Due to the TC7 test's depth and scope, A.D.S. recommends that technicians not register for other tests offered on
the same evening test session. The 50-question test addresses five content areas:
♦ General Diesel Engine Diagnosis,

♦ Starting and Charging System Diagnosis
♦ Air Induction and Exhaust Systems Diagnosis
♦ Cooling and Lubricating Systems Diagnosis
♦ Fuel Systems Diagnosis
Specifications for the Diesel Engine Diagnostic Test (TC7) and the Task List are available on the A.D.S. website at
www.diesel.org under TechCert or by contacting A.D.S. Headquarters at Tel. 816-444-3500 Fax. 816-444-0330
E-mail: tech@diesel.org
The TechCert exams, developed by A.D.S. in cooperation with the National Institute for Automotive Excellence
(ASE), are offered at more than 700 sites throughout the U.S., and at 11 test centers in Canada.
9140 Ward Parkway ♦ Kansas City, Missouri 64114 U.S.A.

Tel. 816.444.3500 ♦ Fax. 816.444.0330
e-mail: david@diesel.org ♦ http://www.diesel.org
Effective January 1, 2001
Association of Diesel Specialists

TechCert Program
SPECIFICATIONS FOR DIESEL ENGINE DIAGNOSTICS TEST (TC7)
Questions Percentage
Content Area in Test of Test
A. General Diesel Engine Diagnosis 13 26.0%
B. Starting and Charging Systems Diagnosis 4 8.0%
C. Air Induction and Exhaust Systems Diagnosis 4 8.0%
D. Cooling and Lubrication Systems Diagnosis 4 8.0%
E. Fuel Systems Diagnosis 25 50.0%
1. Fuel Supply System (7)
2. Mechanical Fuel System Diagnosis (8)
3. Electronic Fuel System Diagnosis (10)
50 100.0%
*Note: There will be 50 additional questions on the May 2001 TC7 test that are
included for statisitcal research purposes only. Your answers to these questions will
not affect your score, but since you do not know which they are, you should answer all
questions in the test.
DIESEL ENGINE DIAGNOSTICS TASK LIST (TC7)
A. General Diesel Engine Diagnosis (13 Questions)
Task 1 - Verify customer complaint, requirements and/or expectations.
Task 2 - Verify vehicle application, usage, and service history.
Task 3 - Determine that components are correct for the application.
Task 4 - Inspect tamper-resistant seals; determine warranty status.
Task 5 - Inspect for missing, modified or damaged components; verify correct

installation.
Task 6 - Determine fuel condition, level, quality and/or contamination.
Task 7 - Perform visual inspection.
Task 8 - Identify oil, coolant, air, and fuel leaks.
Task 9 - Observe exhaust for smoke, color, odor; determine needed service.
Task 10 - Determine the presence and effects of parasitic loads.
Task 11 - Diagnose engine-related noise and vibration problems.
Task 12 - Perform road/performance test, if applicable.
Task 13 - Perform compression test; determine needed repairs.
Task 14 - Perform cylinder leakage test; determine needed repairs.
Task 15 - Perform crankcase pressure test; determine needed repairs.
Task 16 - Check engine overhead settings (includes intake/exhaust valves, bridges

and injectors).
Task 17 - Perform exhaust port temperature test; determine needed repairs.

Task 18 - Locate and utilize relevant service information, vehicle information and
diagnostic tools.
Task 19 - Inspect installation and verify operation of vacuum pumps and air
compressors.
Task 20 - Inspect and repair as necessary wires, harnesses, connectors, terminals,

splices and/or grounds.
B. Starting and Charging Systems Diagnosis (4 Questions)
Task 1 - Inspect and test condition of battery(s) and cables; determine needed
service.
Task 2 - Check engine cranking speed; determine needed service.
Task 3 -Test charging system output; determine needed service.
Task 4 - Inspect and test operation of glow plug system and/or preheat system;
determine needed service.
Task 5 - Inspect and test operation of starting fluid system; determine needed
service.
Task 6 - Perform starting system voltage drop test; determine needed service.
Task 7 - Inspect and test shutdown system components; determine needed service.
Task 8 - Inspect condition and routing of charging system cables and wiring;
Task 9 - Inspect condition and routing of starting system cables and wiring;
Task 10 - Test for presence and effects of parasitic loads; determine needed
service.
Task 11 - Inspect condition and alignment of belts, pulleys and idlers.

C. Air Induction and Exhaust Systems Diagnosis (4 Questions)
Task 1 - Inspect air intake ducts, piping, clamps, hoses, and filters; check for air
restrictions and leaks.
Task 2 - Check for modifications and installed aftermarket accessories.
Task 3 - Check for missing or loose sound insulation.
Task 4 - Inspect and test wastegate and EGR system, if applicable.
Task 5 - Inspect turbocharger and test boost pressure.
Task 6 - Inspect and test charge air coolers.
Task 7 - Inspect exhaust system manifolds, piping, muffler, catalytic converter, and
clamps; determine needed service.
Task 8 - Perform exhaust back pressure test.
Task 9 - Inspect and test engine compression and exhaust brakes; determine
needed service.
D. Cooling and Lubrication Systems Diagnosis (4 Questions)
Task 1 - Check oil and coolant levels, condition, and/or contamination.
Task 2 - Perform lube oil aeration test, if applicable.
Task 3 - Verify engine oil pressure and temperature, check operation of pressure
sensor, gauge and sending unit.
Task 4 - Check operation of fan hub, fan, fan clutch, fan shroud, mechanical and
electrical controls.
Task 5 - Verify engine operating temperature; check operation of temperature

Task 6 - Perform cooling system pressure test.
Task 7 - Inspect cooling system, water pump, thermostat(s), pressure cap, radiator,
recovery tank, belts, hoses, and clamps.
Task 8 - Inspect for air flow restrictions and obstructions.

Task 9 - Inspect radiator shutter and controls.
Task 10 - Diagnose oil consumption problems; determine needed service.
E. Fuel Systems Diagnosis (25 Questions)
1. Fuel Supply System (7 Questions)
Task 1 - Check fuel level in tank.
Task 2 - Determine fuel quality and condition; inspect for contamination.
Task 3 - Inspect fuel tanks, vents, caps, mounts, valves, screens, crossover system,
supply and return lines and fittings.
Task 4 - Inspect, clean, and test fuel supply pump, pump drive, screens fuel/water
separators/indicators, filters, heaters, coolers, and mounting hardware.
Task 5 - Check fuel system for air leaks and restrictions; determine needed service.
Task 6 - Prime and bleed fuel system; check primer pump.
Task 7 - Inspect and test, low pressure regulator systems (check valves, pressure
regulator valves, overflow valves, and restrictive fittings).
Task 8 - Inspect and test fuel shut-down devices and controls, including engine
protection shut-down devices, circuits and sensors.
2. Mechanical Fuel System Diagnosis (8 Questions)

NOTE: Tasks in this section may apply to the following types of fuel injection
systems: distributor/rotary, inline, rail, and unit injector.
Task 1 - Inspect throttle and shut-off linkage/cable and controls.
Task 2 - Check injection pump-to-engine timing.

diagnostic tools.
Task 4 - Diagnose no-start/ hard-starting, surging, rough operation, misfiring, low

power, slow deceleration, slow acceleration, stalling, and shutdown problems;
Task 5 - Diagnose fuel economy/consumption problems; determine needed service.
Task 6 - Inspect high pressure injector lines/pipes for routing and damage.
Task 7 - Determine the need for fuel injector performance testing.
3. Electronic Fuel System Diagnosis (10 Questions)

systems: Rotary/Distributor with Electronic Diesel Control (EDC); Inline with
EDC, Electronic Unit Injectors (EUI), Hydraulic Electronic Unit Injector (HEUI),
Electronic Unit Pumps, common rail and other rail-type systems.
Task 2 - Check injection pump to engine timing.

power, slow deceleration, slow acceleration, stalling, and slow shutdown problems;
Task 6 - Determine appropriate electronic engine control diagnostic procedures

based on vehicle data, operational complaint, and service information.
Task 7 - Locate, utilize and /or interpret relevant service information, vehicle
information and diagnostic tools.
Task 8 - Inspect and test for missing, modified, damaged or incorrect engine control
components and programmed parameters (factory and customer).
Task 9 - Interpret diagnostic tool data to determine control system condition.

Task 10 - Establish relative importance and accuracy of displayed data.
Task 11 - Test and confirm operation of electrical/electronic circuits not displayed on

diagnostic tools.
Task 12 - Diagnose performance complaints caused by non-engine electronic

control system problems.
Task 13 - Perform digital multimeter (DMM) tests on circuits.

Task 14 - Test input sensors/circuits using displayed data.
Task 15 - Test output actuators/circuits using displayed data.
Task 16 - Test fuel system temperatures and delivery rates.

Test Specifications - TC1
(Diesel Engine Theory & Operation)
A. Principles of Operation 12 24.0%
B. Engine Systems 24 48.0%

1. Fuel System (6)
2. Lubrication and Cooling Systems (4)
3. Cranking and Charging Systems (4)
4. Intake, Exhaust, and Emissions Systems (4)
5. Starting Aid Systems (2)
6. Engine Control Systems (4)
C. Shop Practices 14 28.0%

1. Precision Measurement (3)
2. Electrical/Electronic Principles (4)
3. Tools and Equipment (3)
4. Safety (4)
Total 50* 100.0%
*Note: There could be up to ten additional pre-test questions. Your answers to these pre-test
questions will not affect your score, but since you do not know which they are, you should
answer all questions in the test.
The following pages list the tasks covered in each content area. These task descrip-
tions offer detailed information to technicians preparing for the test, and to persons who may
be instructing diesel fuel system specialists. The task lists may also serve as guidelines for
question writers, reviewers, and test assemblers.
It should be noted that the number of questions in each content area may not equal
the number of tasks listed. Some of the tasks are complex and broad in scope and may be
covered by several questions. Other tasks are simple and narrow in scope; one question may
cover several tasks. The main purpose for listing the tasks is to describe accurately what is
done on the job, not to make each task correspond to a particular test question.
4
Task List - TC1
A. Principles of Operation (12 questions)
Task 1 - Identify the four diesel engine operating events.

Task 2 - Explain the differences between two-stroke and four-stroke operation.
Task 3 - Explain the differences between diesel and gasoline engine performance character-
istics.
Task 4 - Explain the differences between diesel and gasoline fuels and additives.
Task 5 - Explain the differences between diesel and gasoline engine components and mainte-
nance characteristics.
Task 6 - Identify measurement units of engine performance (HP, KW).
Task 7 - Define engine torque characteristics (torque curve, peak torque, torque rise).
Task 8 - Measure fuel and oil consumption rates.
Task 9 - Determine engine operation efficiency by exhaust characteristics, engine noises, op-
erating temperatures, and pressures.
Task 10 - Determine the effects of altitude and ambient temperature on engine performance.
Task 11 - Identify the effects of cold temperatures on engine starting.
Task 12 - Explain the differences between direct and indirect injection.
B. Engine Systems (24 questions)
1. Fuel System (6 questions)

Task 1 - Identify the components of the various types of fuel supply systems (internal and
external supply pumps).
Task 2 - Describe the function of each component in the low pressure system.
Task 3 - Identify the low pressure fuel supply paths.
Task 4 - Identify the types of problems found in the fuel supply system.
Task 5 - Identify the operating principles and components of the rotary high pressure fuel
system.
Task 6 - Identify the operating principles and components of the rail high pressure fuel sys-
tem.
Task 7 - Identify the operating principles and components of the inline high pressure fuel
system.
Task 8 - Identify the types of diesel fuel injectors.
Task 9 - Identify the components of the different types of diesel fuel injectors.
Task 10 - Explain the operation of the different types of diesel fuel injectors.
Task 11 - Identify the proper safety precautions to use when working on diesel high pressure
fuel systems.
2. Lubrication and Cooling Systems (4 questions)

Task 1 - Explain the purpose(s) of the engine lubrication system.
Task 2 - Identify lubrication flow path(s).
Task 3 - Identify cause(s) of low lubrication system pressure.
Task 4 - Explain the purpose(s) of the engine cooling system.
Task 5 - Identify the purpose and function of cooling system components.
Task 6 - Explain the purpose and operation of the fan clutch.
Task 7 - Explain the purpose of cooling system additives.
Task 8 - Identify the purpose and function of lubrication system components.
5
3. Cranking and Charging Systems (4 questions)
Task 1 - Identify types of engine cranking systems (electric, air, hydraulic, spring).
Task 2 - Explain the purpose and function of cranking system components.
Task 3 - Determine the effects of cranking speed on engine starting.
Task 4 - Explain the purpose and function of charging system components.
Task 5 - Explain the purpose and function of the battery.
Task 6 - Determine if battery is adequate to crank engine.
4. Intake, Exhaust and Emissions Systems (4 questions)

Task 1 - Explain the purpose and function of the air intake system components.
Task 2 - Explain the purpose and function of the exhaust system components.
Task 3 - Explain the differences between naturally aspirated and forced air induction sys-
tems.
Task 4 - Explain the differences between turbochargers, superchargers, and scavenger pumps
(blowers).
Task 5 - Explain the purpose and function of diesel engine emissions systems components
such as sensors, actuators, and electronic engine controls (CPU, ECU, ECM).
5. Starting Aid Systems (2 questions)

Task 1 - Explain the purpose, applications, and functions, of diesel engine starting aid sys-
tems and components.
Task 2 - Explain the advantages and limitations of the various starting aid systems.
6. Engine Control Systems (4 questions)

Task 1 - Explain the purpose, function, and types of diesel governor systems.
Task 2 - Identify the purpose and components of diesel engine electronic fuel control sys-
tems.
Task 3 - Identify and explain the operation of normal and emergency engine shutdown and
failsafe systems.
C. Shop Practices (14 questions)
1. Precision Measurement (3 questions)

Task 1 - Demonstrate the ability to use and read metric and SAE micrometers, calipers, and
other precision measuring devices.
Task 2 - Identify correct abbrevations for measurement terms such as millimeters, inchs,
KPA, PSI, pounds/feet, and Newton meters.
Task 3 - Read and interpret measurement conversion charts.
2. Electrical/Electronic Principles (4 questions)

Task 1 - Demonstrate a basic understanding of electrical/ electronic principles (voltage, AC
and DC current, and resistance).
Task 2 - Demonstrate the ability to measure voltage, AC and DC current, and resistance us-
ing multi-meters, oscilloscopes, and scan tools.
3. Tools and Equipment (3 questions)

Task 1 - Demonstrate an understanding of fastener selection and applications.
Task 2 - Demonstrate the ability to use hand, bench, and special application tools.
Task 3 - Read and follow manufacturers’ recommended instructions and procedures.
4. Safety (4 questions)
Task 1 - Recognize the need for safety clothing, equipment, and procedures.
Task 2 - Read, understand, and apply Materials’ Safety Data Sheet (MSDS) information.
6
Sample Questions - TC1
1. Technician A says that a diesel engine develops more torque at low rpm than a gasoline
engine of similar size.
Technician B says that a diesel engine develops maximum horsepower at a higher rpm
than a gasoline engine of similar size.
Who is right?
(A) A only (C) Both A and B

(B) B only (D) Neither A nor B
2. Which of these statements is true about a fuel supply pump?
(A) It draws fuel from the fuel tank.

(B) It lubricates the fuel injection pump.
(C) It removes water from the fuel.
(D) It removes water from the fuel system.
3. Technician A says that a low power complaint could be caused by injection pump tim-
ing.
Technician B says that a low power complaint could be caused by a worn governor.
Who is right?

4. The primary purpose of the cooling system is to:
(A) Warm up the engine gradually in cold weather.

(B) Cool the engine turbocharger.
(C) Provide piston cooling.
(D) Remove unwanted heat from the engine.
5. Which scale on a multimeter is used to measure resistance?
(A) Millivolt
(B) Milliamp
(C) Ohm
(D) Volts
5. C 4. D 3. C 1. A 2. A
Answer Key:
7
Study Materials - TC1
“Automotive Handbook” by Bosch,
Emphasis on chapter titled Internal Combustion Engines – Diesel Engine
“Diesel Fuel Injection – An Overview” by Bosch
Diesel Fuels, emissions, diesel engine operation, mixture formation, injection systems
“Diesel Pre-Tech” by Bosch
A complete overview of diesel theory and injection equipment – a must for the complete ba-
sics.
“Diesel Basics” video by Bosch
P/N STVV DB
“Metrics in the Shop” video by Bosch
P/N STVV Metrics
Publisher: Robert Bosch Corporation
(800) YES-BOSCH
Robert Bosch Corporation provides a comprehensive selection of training aids and reference
material for diesel fuel injection systems. For a complete catalog of training aids available,
please ask for publication “Access – a catalog of learning tools” when calling Bosch at (800)
YES-BOSCH
“Diesel Fundamentals, Service and Repair” by Bill Toboldt

Emphasis on Chapter 8 – Fuel Injectors and Injection Systems
Publisher: The Goodheart-Wilcox Company, Inc.
“Introduction to Internal Combustion Engines, Second Edition” by Richard Stone

Emphasis on Chapter 5 – Compression Ignition Engines
Publisher: Society of Automotive Engineers, Inc.
“Diesel Fuel Systems” by Robert N. Brady

Emphasis on entire book
Publisher: Reston Publishing Co., Inc.
“An Introduction to Compact and Automotive Diesels” by Edward Ralbovsky

Emphasis on Chapters 5 through 9, covering basic diesel fuel systems, pumps, injectors, test-
ing and operation
Publisher: Delmar Publishers
“Advanced Engine Technology” by Heinz Hiesler

Emphasis on Chapter 6, section 6.7, however entire book is valuable
Co-Published: SAE and Edward Arnold
8
“Diesel Fuel Injection System – Basic Course” by Denso
TMZG-11 (990005-1650) June 1994
Publisher: Denso Sales California, Inc.
3900 Via Oro Avenue
Long Beach, CA 90810
(310) 513-8529
“Agricultural and Automotive Diesel Mechanics” by Gene L. Davis

Emphasis on Chapter “Understanding the Diesel Concept”
Publisher: Prentice Hall
“Technical Review, Diesel Fuels” by Chevron Products Company

Discusses emissions and fuel technology
Publisher: Chevron Products Company
575 Market Street
San Francisco, CA 94105
E-mail address – Fueltek@chevron.com
“Automotive Engines” by Tim Giles

Publisher: Automotive Engines Rebuilders Assn.
330 Lexington Drive
Buffalo Grove, IL 60089
(708) 541-6550
“Fundamentals of Service-Engines” by John Deere

Emphasis on entire book, P/N FOS 3007B
Publisher: Deere & Company Service Training
Dept. F
John Deere Road
Moline, IL 61265
(800) 522-7448
“Diesel Engine & Fuel System Repair” by John Dagel

Publisher: John Wiley and Sons, Inc.
605 Third Avenue
New York, NY 10158-0012
“Truck and Diesel Repair Manual”

Publisher: Motor Publications
224 W. 57th Street
New York, NY 1001
9
Cummins Engine Company, Inc.
1000 Fifth Street, Box 3005
Columbus, IN 47202-3005
(812) 377-5000
Cummins offers training courses on Engine Tune-up and Overhaul; PT Fuel System Rebuild
& Calibration; Engine Familiarization, Theory & Maintenance and Parts Management.
For details on course locations, schedules and costs, contact: Cummins Atlantic, Inc., 3700
North Interstate 85, Charlotte, NC 28206 (704) 596-7401
Caterpillar, Inc.
Engine Division, Service Training
Bldg. JJ, 600 W. Washington Street
East Peoria, IL 61630
Caterpillar has training material available. It is listed in the Caterpillar Materials Catalog,
available from Caterpillar by requesting Form No. LECQ3811. Caterpillar Engine Division
Service Training charges a nominal fee for this information; please contact Caterpillar for
the fee amount. Send your request along with your check to Attn: Supervisor, Service Train-
ing, at the above address.
The 262-page book includes all information available from Caterpillar that can be ordered
through your local dealer. Many Caterpillar dealers have on-site training programs available,
for which a fee is charged. For further information, contact the training department of your
local Caterpillar dealer.
Other references include:

AlliedSignal Turbocharging Systems Stanadyne Automotive Corp.
3201 West Lomita Blvd. Diesel Systems Division
Torrance, CA 90505 92 Deerfield Road
(800) 642-7738 Windsor, CT 06095
(203) 525-0821
AMBAC International
P. O. Box 85 ZEXEL USA Corporation
Columbia, SC 29203 2001-110th Street, Suite 200
(803) 735-1400 Grand Prairie, TX 75050
(214) 602-2360
Deutz Corporation
3883 Steve Reynolds Blvd.
Norcross, GA 30093
(404) 564-7250
Holset Engineering Company
(see Cummins Engine Company, Inc.)
Lucas Aftermarket Operations
P. O. Box 7079
Troy, MI 48007-7079
(248) 288-2000
BorgWarner Automotive Turbo Systems
(Schwitzer)
6040 W. 62nd Street
Indianapolis, IN 46278
(317) 328-3100
10
(Distributor Fuel Injection)
A. Product Receipt and Examination 4 6.7%

B. Pretest and Evaluation 6 10.0%
C. Disassembly, Cleaning, and Inspection 11 18.3%
D. Assembly and Static Adjustments 17 28.3%
E. Testing and Calibration 21 35.0%
F. Product Completion 1 1.7%
Total 60* 100.0%
answer all questions in the test. The five-year Recertification Test will cover the same con-
tent areas as those listed above; however, the number of questions in each content area of the
Recertification Test will be reduced by about one-half.
Task List - TC2

A. Product Receipt and Examination (4 questions)
Task 1 - Document and qualify customer’s complaint.
Task 2 - Identify pump model, part number, date code, and serial number; obtain appropriate
specifications and service information.
Task 3 - Conduct visual inspection for external damage, missing parts, and wear; inspect
wiring and electrical connectors.
Task 4 - Inspect tamper resistant seals.
Task 5 - Determine warranty status.
B. Pretest and Evaluation (6 questions)
Task 1 - Remove top/side cover; inspect for contamination; evaluate fuel condition.
Task 2 - Check for ease of pump rotation.
11
Task 3 - Check drive shaft axial and radial play.
Task 4 - Prepare pump for pretesting, where applicable.
Task 5 - Pretest pump; evaluate results.
C. Disassembly, Cleaning, and Inspection (11 questions)
Task 1 - Disassemble pump; determine probable cause of failure.
Task 2 - Organize and clean components.
Task 3 - Evaluate condition of housing and drive mechanism; determine need for repair/re-
placement.
Task 4 - Evaluate hydraulic head assembly and related components; determine need for re-
pair/replacement.
Task 5 - Evaluate transfer/supply pump group; determine need for repair/replacement.
Task 6 - Evaluate governor group; determine need for repair/replacement.
Task 7 - Evaluate advance group; determine need for repair/replacement.
Task 8 - Evaluate plunger activating device; determine need for repair/replacement.
Task 9 - Evaluate ancillary devices and electrical components; determine need for repair/
replacement.
Task 10 - Determine repairability; complete repair estimate; get repair approval.
D. Assembly and Static Adjustments (17 questions)
Task 1 - Assemble, adjust, and install ancillary devices.
Task 2 - Assemble and adjust plunger activating device.
Task 3 - Assemble and adjust advance group.
Task 4 - Assemble and adjust governor group.
Task 5 - Assemble and adjust transfer/supply pump group.
Task 6 - Assemble and adjust hydraulic head assembly and related components.
Task 7 - Install drive group.
E. Testing and Calibration (21 questions)
(Includes mechanical and electrical/electronic controls.).
Task 1 - Determine appropriate test equipment, condition (ISO standards), and procedure;
mount injection pump.
Task 2 - Check and adjust plunger position.
Task 3 - Check and adjust pump timing; verify timing marks.
Task 4 - Check and adjust transfer/supply pump pressure.
Task 5 - Check and adjust advance mechanism.
Task 6 - Check and adjust all fuel delivery points.
Task 7 - Check and adjust fuel shut-off device(s).
Task 8 - Check and adjust manifold pressure compensator.
Task 9 - Check and adjust cold start device(s).
Task 10 - Check and adjust altitude compensation device(s).
Task 11 - Check and adjust ancillary devices.
Task 12 - Check and adjust governor regulation.
Task 13 - Check and adjust emission control devices.
Task 14 - Perform leak test.
F. Product Completion (1 question)
Task 1 - Install manufacturers’ approved tamper resistant devices.
Task 2 - Install protective caps.
Task 3 - Dry and paint injection pump assembly according to standard shop practices.
Task 4 - Modify/install name plate.
Task 5 - Package injection pump; include any special instruction sheets.
Task 6 - Complete/document necessary repair data and warranty records.
12
1. An engine with a Lucas DPA pump surges. The most likely cause is:
(A) Blocked metering port.

(B) Tight metering valve.
(C) Misaligned governor weight thrust sleeve.
(D) Worn governor weights.
2. During inspection of a Stanadyne pump the leaf spring should be checked for:
(A) Flexibility
(B) Tension
(C) Wear
(D) Spring rate
3. Technician A says that incorrect plunger spring pretension can cause excessive wear of
the camplate and rollers.
Technician B says that incorrect plunger spring pretension can cause fuel delivery prob-
lems at high speeds.
Who is right?

4. Improper transfer rotor phasing will cause:
(A) Hard hot-engine starting

(B) White smoke at full load rpm.
(C) Excessive carbon buildup in the exhaust system.
(D) Irregular exhaust beat at idle.
Question 5 is not like the ones above. It contains the word EXCEPT. For this question,
look for the choice that could NOT cause the described situation. Read the entire question
carefully before choosing your answer.
5. An engine with a VE pump has slow deceleration after running at high speed. All of
these could be the cause EXCEPT:
(A) Worn governor flyweights.

(B) An incorrect prestroke setting.
(C) An incorrect MS dimension.
(D) Sticking control levers.
5. B 4. D 3. C 1. B 2. C
Answer Key:
13
“Agricultural and Automotive Diesel Mechanics” by Gene L. Davis
Emphasis on Chapter – Servicing the Fuel System
Publisher: Prentice Hall
“Automotive Handbook” by Bosch

Emphasis on Chapters – Fuel Injection – Distributor Pumps
“VE Pump” video by Bosch
P/N STVV VE
(800) YES-BOSCH
“The 6.2 Liter Diesel Engine” by General Motors

16015.05-2 High Pressure Fuel Delivery System
Publisher: GM Publication
“Operation and Instruction Manual Model DM Pump” by Stanadyne Diesel Systems

Emphasis on Chapters General, Section 1, 8, 9, 10, 11
“Operation and Instruction Manual Model DB2 Pump” by Stanadyne Diesel Systems
Emphasis on Chapters General, Section 1, 8, 9
“Operation and Instruction Manual Model DB4 Pump” by Stanadyne Diesel Systems
Emphasis on Chapters General, Section 1
The following materials are available from Stanadyne Diesel Systems:
“Pencil Nozzles” P/N 99002
“Conventional Injectors”P/N 99118
“Model DB2” P/N 99009
“Model DB” P/N 99523
“Model DB4” P/N 99689
“Model DS” P/N 99646
Publisher: Stanadyne Automotive Corp.
Diesel Systems Division
92 Deerfield Road
Windsor, CT 06095
(203) 525-0821
“Fuel Injection Pump – Distributor (VE) Type Pump” by Denso

PMZG-04 (990005-1470) December 1987
“Fuel Injection Pump – Distributor (VE) Type Pump” by Denso
P5ZG-01 (990005-1670) June 1994
3900 Via Oro Avenue
(310) 513-8529
14
“Distributor Fuel Pump Model 100” by AMBAC
P/N - ADS 202 & ADS 1101
Publisher: AMBAC International
P. O. Box 85
Columbia, SC 29203
(803) 735-1400
“VE Distributor Fuel Pump” by Bosch

P/N 103, 104, 105 STCA VE text or audiscan products
Publisher: Cybern Film Systems, Inc.
7527 West Touhy Ave.
Chicago, IL 60648
“Lucas/CAV Training Program – DPA Distributor Pump” by Lucas

P/N ADS 1001 text or audiscan
“DP 200 Glossy Brochure” by Lucas
No Part Number Assigned
“DP 201 Fuel Injection Pump” by Lucas
P/N XNB101 (EN)
“DP 200 Series Fuel Pump Special Features” by Lucas
P/N XNB105 (EN)
“DPS Fuel Injection Pump – Principles of Operation” by Lucas
P/N XPB105 (EN)
“DPS Fuel Injection Pump” by Lucas
P/N XNB104 (EN)
“DPA Fuel Injection Pump Mechanically Governed” by Lucas
XNB134 (EN)
“DPA Pump Hydraulically Governed” by Lucas
P/N C2129E
“DPA RotoDiesel” by Lucas
P/N LEX3606
Publisher: Lucas Aftermarket Operations
1624 Meijer Drive
Troy, MI 48084
(248) 280-8284
Note: Lucas information is only available to Lucas Authorized Shops.
15
(Inline Fuel Injection)
A. Product Receipt 7 11.7%

B. Inspection/Pretest 6 10.0%
C. Disassembly 4 6.7%
D. Inspection/Reconditioning 8 13.3%
E. Reassembly 11 18.3%
F. Testing and Calibration 22 36.7%
G. Product Completion 2 3.3%
Total 60* 100.0%
tent areas as those listed above. However, the number of questions in each content area of
the Recertification Test will be reduced by about one-half.
Task List - TC3

A. Product Receipt (7 questions)
Task 1 - Record pump model/serial number and pump application.
Task 2 - Determine customer complaint/need; identify related/ other symptoms.
Task 3 - Inspect tamper resistant seals.
Task 4 - Conduct visual inspection for external damage, missing parts, and wear; inspect
wiring and electrical connectors.
Task 5 - Remove and retain all non-pump parts.
Task 6 - Perform preliminary oil/fuel contamination inspection.
16
B. Inspection/Pretest (6 questions)
Task 1 - Select appropriate manufacturers’ service tools and publications, i.e. specifications,
parts list/bulletins, and technical bulletins.
Task 2 - Verify pump application.
Task 3 - Clean pump exterior.
Task 4 - Pull covers if applicable; check for seized/damaged parts; check electrical wiring
and connectors.
Task 5 - Install pump on test stand; perform pretest; record test data.
Test 6 - Evaluate test data; determine repairs.
C. Disassembly (4 questions)
Task 1 - Remove and disassemble governor and ancillary devices, i.e. supply pump, aneroid/
boost compensators, overflow valve, timing devices, wiring and connectors, etc.
Task 2 - Disassemble injection pump.
Task 3 - Organize and clean parts.
D. Inspection/Reconditioning (8 questions)
Task 1 - Measure/inspect parts for wear/damage.
Task 2 - Evaluate wear/damage; record condition.
Task 3 - Determine product update requirements.
Task 4 - Determine repairability.
Task 5 - Replace/recondition parts as necessary.
E. Reassembly (11 questions)
Task 1 - Organize parts.
Task 2 - Assemble injection pump; perform static pressure test; make necessary static adjust-
ments.
Task 3 - Reassemble governor to injection pump; perform necessary static adjustments.
Task 4 - Reassemble ancillary devices to injection pump; perform necessary static adjust-
ments.
F. Testing and Calibration (22 questions)
(Includes mechanical and electrical/electronic controls.).
Task 1 - Determine appropriate test equipment, condition (ISO standards), and procedure;
mount injection pump.
Task 2 - Perform all tests as outlined in test specifications.
Task 3 - Perform dynamic adjustments as required; record data.
Task 4 - Check for fuel leaks; repair as necessary.
Task 5 - Remove injection pump from test stand.
G. Product Completion (2 questions)
Task 1 - Install manufacturers’ approved tamper resistant devices.
Task 3 - Dry and paint injection pump assembly according to standard shop practices.
Task 4 - Modify/install name plate.
Task 5 - Package injection pump; include any special instruction sheets.
Task 6 - Complete/document necessary repair data and warranty records.
17
1. The fuel injection quantity of one cylinder is 30cc (30cm3) lower than the others, and
there is lube oil dilution. Which of these is the most likely cause?
(A) Worn plunger and barrel.

(B) Worn delivery valve.
(C) Cracked delivery valve
(D) Seized plunger and barrel.
2. An inline pump will not meet specs during the phasing operation.
Technician A says that wrong shim thickness could be the cause.
Technician B says that incorrect pump rotation could be the cause.
Who is right?

3. A customer complains of engine run-away. Which of these could be the cause?
(A) Excessive feed pump pressure.

(B) Excessive overflow valve opening pressure.
(C) A broken shut off cable.
(D) A stuck control rack.
4. Technician A says that lift to port closure is the first step in pump calibration.
Technician B says that phasing is the last step in pump calibration.
Who is right?

5. During calibration of a rebuilt inline injection pump, starting fuel is too low. Which of
these is the most likely cause?
(A) Incorrect test nozzles.

(B) Leaking delivery valve gaskets
(C) Worn plungers and barrels.
(D) Worn camshaft lobes.
5. C 4. A 3. D 1. A 2. C
Answer Key:
18
“(A) type pump & governor” by Denso
P/N P5ZGR-07 (990005-1770) June 1994
“EP-20 (NF) type pump” by Denso
P/N P5ZGN-01 (990005-1660) May 1993
“EP-11 (NE) type pump/RSUV governor” by Denso
P/N PPMZG-15 (990005-1610) July 1990
“(P) type pump” by Denso
P/N MIP-088 (99005-1350) July 1988
“EP-9 (NB) type pump” by Denso
P/N MIP-096 (990005-1410) July 1988
“PF and PR type pump” by Denso
P/N MIP-033 (990009-5100) July 1983
“Pneumatic Governor” by Denso
P/N MIP-094 (990005-1390) September 1986
“RSV type governor” by Denso
P/N MIP-054 (990009-5190) April 1982
“RU/RUV type governor” by Denso
P/N MIP-014 (990009-5040) September 1981
“R722 type governor” by Denso
P/N MIP-009 (99009-5090) March 1980
“R801/R901 type governor” by Denso
P/N P5ZGP-05 (990005-1710) June 1994
“R801 type governor” by Denso
P/N MIP-089 (990005-1360) June 1983
3900 Via Oro Avenue
(310) 513-8529
“Minimec Principles of Operation” by Lucas

P/N C2127E
“8 Cylinder Minimec” by Lucas
P/N C/P31T
“Minimec with Leaf Spring Governor” by Lucas
P/N C/P32E
19
“Simms Minimec” by Lucas
P/N P29E
“Simms Minimec - Reverse Linkage Governor” by Lucas
P/N P29E Sup. 2
“Boost Control Unit Series 0-50” by Lucas
P/N C2137/EN
1624 Meijer Drive
Troy, MI 48084
(248) 280-8284
Note: Lucas information is only available to Authorized Lucas Repair Shops.
The following videos are available from Bosch:

“A-Pump” P/N STVV A
“MW Pump” P/N STVV MW
“P-Pump” P/N STVV P
“RQV Governor” P/N STVV RQV
“RQV… K Governor” P/N STVV RQVK
“RSV Governor” P/N STVV RSV
“RW Governor” P/N STVV RW
(800) YES-BOSCH
29
(Rail Fuel Injection)
A. Problem Diagnosis 12 20.0%

B. Disassembly 5 8.3%
C. Inspection 8 13.3%
D. Assembly 10 16.7%
1. Pumps (6)
2. Injectors (4)
E. Calibration 25 41.7%
1. Pumps (19)
2. Injectors (6)
Total 60* 100.0%
tent areas as those listed above.
Task List - TC4

Task 1 - Listen to customer’s complaint, i.e. engine noises, exhaust quality, engine operation,
power, acceleration/deceleration, and shut down problems; determine if problem is
fuel system related.
Task 2 - Determine fuel system component compatibility and operation; use CPL/Type.
Task 3 - Review past maintenance documents; obtain manufacturer’s calibration code data.
Task 4 - Determine repairability/needed repairs.
Task 5 - Visually inspect for evidence of tampering or damage.
21
B. Disassembly (5 questions)
Task 1 - Disassemble fuel system components in accordance with manufacturer’s proce-
dures, using required tools and fixtures.
Task 2 - Identify, sort, and clean individual parts.
Task 3 - Remove all gaskets, o-rings, and seals.
C. Inspection (8 questions)
Task 1 - Evaluate all parts for obvious wear.
Task 2 - Test and measure all key components.
Task 3 - Determine serviceability of components; replace as necessary.
Task 4 - Lap surfaces as needed.
D. Assembly (10 questions)
1. Pumps (6 questions)
Task 1 - Assemble pump in accordance with manufacturer’s procedures, using required tools
and fixtures.
Task 2 - Make static adjustments as needed.
2. Injectors (4 questions)
Task 1 - Check spray pattern; clean or replace injectors as needed.
Task 2 - Leak test; repair as needed.
Task 3 - Assemble injectors in accordance with manufacturer’s procedures, using required
tools and fixtures.
Task 4 - Set plunger travel.
E. Calibration (25 questions)
1. Pumps (19 questions)
Task 1 - Mount pump using appropriate fixtures; determine pump rotation.
Task 2 - Prime pump; check integrity of seals.
Task 3 - Set test stand to pump’s rated speed.
Task 4 - Adjust pump flow rate.
Task 5 - Set throttle leakage.
Task 6 - Set throttle travel.
Task 7 - Check and adjust rail pressure.
Task 8 - Make necessary governor adjustments (Automotive, VS, MVS, SVS, and road speed).
Task 9 - Adjust air fuel control (AFC) settings.
Task 10 - Remove pump from text fixture; tamperproof pump.
Task 11 - Record calibration results.
2. Injectors (6 questions)
Task 1 - Mount injector using appropriate fixtures.
Task 2 - Check flow; adjust as needed.
Task 3 - Remove injector from test fixture.
Task 4 - Set step timing control (STC) injector total travel.
22
1. A customer brings in a recently rebuilt AFC pump with the governor plunger seized to
the governor barrel.
Technician A says that an improperly fitted governor plunger could be the cause.
Technician B says that engine overspeeding could be the cause.
Who is right?

2. The PT fuel pump governor plunger tang is twisted off and the gear pump drive shaft is
broken. Which of these is the most likely cause?
(A) Engine overspeeding.

(B) Winter fuel blend.
(C) Engine lugging.
(D) Low sulfur fuel.
3. Technician A says that flange style injectors use cup gaskets of different thickness to in-
crease the height of the plunger.
Technician B says that “B” style injectors use cup gaskets of different thickness to
maintain the plunger and metering orifice relationship.
Who is right?

4. During calibration, the check point #1 rail pressure is found to be below specs. Which
of these should the technician do next?
(A) Change the torque shim spring thickness.

(B) Check the gear pump pressure.
(C) Replace the governor plunger.
(D) Check the weigh assist setting.
5. Technician A says that the throttle leakage adjustment will affect the engine decelera-
tion rate.
Technician B says that the throttle leakage adjustment will affect the peak torque fuel
rate.
Who is right?

5. A 4. B 3. B 1. C 2. A
Answer Key:
23
“Cummins PT Fuel Systems Rebuilding & Calibrating Instructions” by Cummins
P/N 3379084-02
“Cummins Pace Control Systems Preliminary Manual” by Cummins
Covers pacer pump calibration & repairs
P/N 3810319
“Cummins PT Injector Manual” by Cummins
Covers repair & calibration of Flange, PTB, PTC, PTD & Top Stop Injectors
P/N 3379071-06
“Cummins Shop Manual PT (type D) Top Stop Injector” by Cummins
P/N 3810344
“Cummins Step Timing Control Shop Manual” by Cummins
Covers repair & calibration of STC Injectors
P/N 3810313
“Cummins PT (type R) Rebuild and Calibration Instructions” by Cummins
P/N 3379101-02
Publisher: Cummins Engine Company, Inc.
(812) 377-5000
Note: You must be a subscriber to the “Cummins Rack System of Information” in order to
obtain the majority of publications shown above. Most Fuel Injection Shops subscribe to this
service and have this information readily available to their technicians.
24
(Turbochargers/Blowers)
A. On-Engine Troubleshooting 15 25.0%
B. Turbocharger/Blower Removal and Receipt 6 10.0%
C. Disassembly, Inspection, and Component Rework 23 38.3%
1. Turbochargers (20)
2. Blowers (3)
D. Reassembly 10 16.7%
1. Turbochargers (7)
2. Blowers (3)
E. Installation and Startup 6 10.0%
Total 60* 100.0%
Task List - TC5

A. On-Engine Troubleshooting (15 questions)
Task 1 - Listen to customer complaints/concerns/requests.
Task 2 - Perform visual inspection of air, oil, cooling and exhaust systems for leaks.
Task 3 - Check wastegate/EGR operation if applicable.
Task 4 - Verify turbocharger/blower application.
Task 5 - Follow manufacturers’ recommended safety procedures.
Task 6 - Run engine; listen for noises; check smoke color and quantity under acceleration,
deceleration and steady load conditions.
Task 7 - Load test engine; check for air and exhaust restrictions; check boost pressure.
Task 8 - Check crankcase pressure (blowby) restrictions according to manufacturer’s recom-
mendations.
Task 9 - Remove turbocharger air intake ducting; check compressor wheel for damage, rub-
bing, and contamination; check end play.
25
Task 10 - Remove blower air intake ducting; visually inspect rotor and housing for damage/
wear.
B. Removal and Receipt (6 questions)
Task 1 - Remove turbocharger/blower; inspect oil feed/drain lines and fittings, air inlet duct-
ing, exhaust manifold, and air cleaner condition.
Task 2 - Record customer complaints.
Task 3 - Identify turbocharger/blower; record part number and serial number; verify applica-
tion.
Task 4 - Perform visual exterior inspection; determine repairability.
Task 5 - Determine warranty status, i.e. in-service date, mileage/hours.
C. Disassembly, Inspection, and Component Rework (23 questions)
1. Turbochargers (20 questions)
Task 1 - Mark turbine and compressor housings for orientation (index); remove housings and
inspect for serviceability.
Task 2 - Determine repairability of center section (cartridge).
Task 3 - Disassemble center section (cartridge).
Task 5 - Inspect/measure parts; determine serviceability in accordance with manufacturer’s
specifications; repair/rework as required.
Task 6 - Verify and record cause of failure.
2. Blowers (3 questions)
Task 1 - Mark end plates, housing, rotors, and gears for location and orientation.
Task 2 - Disassemble blower; visually inspect rotors, end plates, gears and housing; deter-
mine reusability.
Task 4 - Inspect/measure parts; determine serviceability in accordance with manufacturer’s
specifications; repair/rework as required.
Task 5 - Verify and record cause of failure.
D. Reassembly (10 questions)
1. Turbochargers (7 questions)
Task 2 - Reassemble center section (cartridge); perform static checks following manufactur-
ers specifications and procedures.
Task 3 - Install and orient (index) turbine and compressor housings; set wastegate if appli-
cable.
Task 4 - Perform final inspection; install nameplate.
Task 5 - Install protective caps; package turbocharger with appropriate gaskets, lines and fit-
tings; include installation and start-up instructions.
Task 6 - Complete necessary shop and warranty records.
2. Blowers (3 questions)
Task 2 - Reassemble blower.
Task 3 - Measure rotor clearances and end play; adjust as required.
Task 4 - Package blower with appropriate gaskets, lines and fittings; include installation and
start-up instructions.
Task 5 - Complete necessary shop and warranty records.
E. Installation and Startup (6 questions)
Task 1 - Install turbocharger/blower in accordance with manufacturer’s procedures.
Task 2 - Prelube turbocharger/blower in accordance with manufacturers’ recommendations.
Task 3 - Run engine to operating temperature; check for leaks; verify repair.
26
1. Inspection reveals a bent turbine shaft. Which of these is the most likely cause?
(A) Hot shutdown.

(B) Improper disassembly.
(C) Excessive oil change intervals
(D) Worn thrust bearings.
2. Technician A says that damage on the wiping edge of a rotor must not exceed 1/16" in
depth.
Technician B says that damage on the wiping edge of a rotor must not exceed 3/4 of the
rotor length.
Who is right?
3. Oil is leaking past the rotor seals on an inline 71 series blower. Which of these is the
LEAST likely cause?
(A) Improper application.

(B) Wrong mounting gasket.
(C) High air box pressure.
(D) Restricted air filter.
4. Which of these is the correct procedure to use when installing a V-71 blower:
(A) Tighten the blower housing bolts to 30-35 lbs. ft. of torque, and then torque
the blower-to-block endplate bolts to 40-45 lbs. ft.
(B) Tighten the blower-to-block endplate bolts to 40-45 lbs. ft. torque, and then
torque the blower housing-to-block side angle bolts to 30-35 lbs. ft.
(C) Install both the blower housing bolts and the blower block bolts finger tight,
and then torque, in clockwise rotation, to 40-45 lbs. ft.
(D) Install and torque the blower housing bolts and the side angle bolts to
50 to 60 lbs. ft., and then install the blower block end plate and torque it
to 30 to 40 lbs. ft.
5. A turbocharged engine is producing too much boost. Which of these is the most likely
cause?
(A) A plugged air intake.

(B) A loose exhaust manifold.
(C) A bad wastegate.
(D) An overfueling condition.
5. C 4. B 3. A 1. B 2. A
Answer Key:
27
“Charge Air Fundamentals” by AlliedSignal (Garrett)
P/N GA9500
Publisher: AlliedSignal Turbocharging Systems
3201 West Lomita Blvd.
Torrance, CA 90505
(800) 642-7738
“Turbocharging Workshop Manual” by Holset

Publisher: Holset Aftermarket
4155 Quest Way Drive
Memphis, TN 38115
(800) 888-1862
“Introduction to Turbochargers” by BorgWarner (Schwitzer)

P/N C0030
Publisher: BorgWarner Automotive Turbo Systems (Schwitzer)
6040 W. 62nd Street
Indianapolis, IN 46278
(704) 684-4137
“Blowers – Inline 71 Series Service Manual” by Detroit Diesel

Section 3.4 – Blowers
Publishers: Detroit Diesel
13400 Outer Drive, West
Detroit, MI 48239-4001
(313) 592-5000
28
(Injectors/Unit Injectors)
A. Product Receipt 12 20.0%
B. Pretest and Evaluation 13 21.7%
C. Disassembly, Inspection and Reconditioning 15 25.0%
D. Reassembly, Testing, and Product Completion 20 33.3%
Total 60* 100.0%
29
Task List - TC6
Test 1 - Determine customer’s complaint and requested service.

Test 2 - Identify and record product number, date code, application and operation of me-
chanical and electronic injectors.
Test 3 - Visually inspect; record condition as received.
Test 4 - Determine warranty status.
B. Pretest and Evaluation (13 questions)
Task 1 - Clean exterior of fuel injector.

Task 2 - Perform pretests as required , i.e. pressure, spray pattern/atomization, chatter, leak-
age, travel settings, calibration flow rate, rack free test, and electrical resistance
checks; record test data.
Task 3 - Evaluate test results; determine serviceability.
C. Disassembly, Inspection and Reconditioning (15 questions)
Task 1 - Disassemble fuel injector in accordance with manufacturers procedures.

Task 2 - Clean, inspect/measure, and test components in accordance with manufacturers pro-
cedures.
Task 3 - Recondition/replace components in accordance with manufacturers’ procedures.
D. Reassembly, Testing, and Product Completion (20 questions)
Task 1 - Organize/match components.

Task 2 - Assemble/test components in accordance with manufacturers’ procedures.
Task 3 - Test and adjust fuel injector in accordance with manufacturers’ procedures.
Task 4 - Record test data.
Task 6 - Relabel assembly in accordance with manufacturers’ procedures.
30
1. A nozzle with the stamping “DLLA150S633” is a:
(A) Pintle–type nozzle.

(B) Hole–type nozzle.
(C) Orifice plate nozzle.
(D) Low dead volume nozzle.
2. When measured, the nozzle valve (needle) lift is found to be excessive.
Technician A says that the nozzle should be replaced.
Technician B says that the nozzle will fail the back leakage check.
Who is right?

3. A customer complains of white smoke.
Technician A says that a stuck–open pintle could be the cause.
Technician B says that excessive seat leakage could be the cause.
Who is right?

4. Technician A says that the opening pressure of a KC nozzle holder assembly can be
adjusted by a screw.
Technician B says that the opening pressure of a KB nozzle holder assembly can be
adjusted by changing shims.
Who is right?
5. While prechecking a nozzle holder assembly, the opening pressure is too low. Which of
these is the most likely cause?
(A) Excessive nozzle valve clearance.

(B) A leaking pressure face.
(C) A missing edge filter.
(D) A worn nozzle holder spindle.
5. D 4. D 3. A 1. B 2. A
Answer Key:
31
“Nozzle Holders and Nozzles” video by Bosch
P/N STVV IN
(800) YES-BOSCH
“Pencil Nozzle” by Stanadyne

P/N 99002
“Conventional Injectors” by Stanadyne
P/N 99118
Publisher: Stanadyne Automotive Systems
Diesel Systems Division
92 Deerfield Road
Windsor, CT 06095
(203) 525-0821
“Nozzle Holder Assemblies Servicing” by AMBAC

P/N 4079/84
Publisher: AMBAC International
P. O. Box 85
Columbia, SC 29203
(803) 735-1400
“Diesel Pre-Tech” by Bosch

Reference Module 6, titled Injector Operation, Service and Testing
(800) YES-BOSCH
“Diesel Fuel Injectors” by Lucas

P/N XNB115 (EN)
P. O. Box 7079
Troy, MI 48007-7079
(248) 288-2000
“Nozzle/Nozzle Holder Service Manual” by Denso

P/N MIP-018 (7712-1001) December 1977
3900 Via Oro Avenue
(310) 513-8529
32
“Detroit Diesel Series 53 Unit Injectors Service Repair Manual” by Detroit Diesel
P/N 6SE202
Publisher: Detroit Diesel
13400 Outer Drive, West
Detroit, MI 48239-4001
(313) 592-5000
“PT Injectors” by Cummins

P/N 3379071-06
“PT (Type D) Top Stop Injectors” by Cummins
P/N 3810344
“PTD and STC Step Timing Control Injectors” by Cummins
P/N 3810313
Publisher: Cummins Engine Company, Inc.
(812) 377-5000
33
P.O. Box 26487
Overland Park, KS 66225
Telephone - 913.851.9840
Fax - 913.851.4023
E-mail - tech@diesel.org
Web Site - http://www.diesel.org
Printed in U.S.A.
Effective January 1, 2001
Association of Diesel Specialists

TechCert Program
SPECIFICATIONS FOR DIESEL ENGINE DIAGNOSTICS TEST (TC7)
A. General Diesel Engine Diagnosis 13 26.0%
B. Starting and Charging Systems Diagnosis 4 8.0%
C. Air Induction and Exhaust Systems Diagnosis 4 8.0%
D. Cooling and Lubrication Systems Diagnosis 4 8.0%
E. Fuel Systems Diagnosis 25 50.0%
1. Fuel Supply System (7)
2. Mechanical Fuel System Diagnosis (8)
3. Electronic Fuel System Diagnosis (10)
50 100.0%
*Note: There will be 50 additional questions on the May 2001 TC7 test that are
included for statisitcal research purposes only. Your answers to these questions will
not affect your score, but since you do not know which they are, you should answer all
questions in the test.
DIESEL ENGINE DIAGNOSTICS TASK LIST (TC7)
A. General Diesel Engine Diagnosis (13 Questions)
Task 1 - Verify customer complaint, requirements and/or expectations.
Task 2 - Verify vehicle application, usage, and service history.
Task 3 - Determine that components are correct for the application.
Task 4 - Inspect tamper-resistant seals; determine warranty status.
Task 5 - Inspect for missing, modified or damaged components; verify correct

installation.
Task 6 - Determine fuel condition, level, quality and/or contamination.
Task 7 - Perform visual inspection.
Task 8 - Identify oil, coolant, air, and fuel leaks.
Task 9 - Observe exhaust for smoke, color, odor; determine needed service.
Task 10 - Determine the presence and effects of parasitic loads.
Task 11 - Diagnose engine-related noise and vibration problems.
Task 12 - Perform road/performance test, if applicable.
Task 13 - Perform compression test; determine needed repairs.
Task 14 - Perform cylinder leakage test; determine needed repairs.
Task 15 - Perform crankcase pressure test; determine needed repairs.
Task 16 - Check engine overhead settings (includes intake/exhaust valves, bridges

and injectors).
Task 17 - Perform exhaust port temperature test; determine needed repairs.

diagnostic tools.
Task 19 - Inspect installation and verify operation of vacuum pumps and air
compressors.
Task 20 - Inspect and repair as necessary wires, harnesses, connectors, terminals,

splices and/or grounds.
B. Starting and Charging Systems Diagnosis (4 Questions)
Task 1 - Inspect and test condition of battery(s) and cables; determine needed
service.
Task 2 - Check engine cranking speed; determine needed service.
Task 3 -Test charging system output; determine needed service.
Task 4 - Inspect and test operation of glow plug system and/or preheat system;
Task 5 - Inspect and test operation of starting fluid system; determine needed
service.
Task 6 - Perform starting system voltage drop test; determine needed service.
Task 7 - Inspect and test shutdown system components; determine needed service.
Task 8 - Inspect condition and routing of charging system cables and wiring;
Task 9 - Inspect condition and routing of starting system cables and wiring;
Task 10 - Test for presence and effects of parasitic loads; determine needed
service.
Task 11 - Inspect condition and alignment of belts, pulleys and idlers.

C. Air Induction and Exhaust Systems Diagnosis (4 Questions)
Task 1 - Inspect air intake ducts, piping, clamps, hoses, and filters; check for air
restrictions and leaks.
Task 2 - Check for modifications and installed aftermarket accessories.
Task 3 - Check for missing or loose sound insulation.
Task 4 - Inspect and test wastegate and EGR system, if applicable.
Task 5 - Inspect turbocharger and test boost pressure.
Task 6 - Inspect and test charge air coolers.
Task 7 - Inspect exhaust system manifolds, piping, muffler, catalytic converter, and
clamps; determine needed service.
Task 8 - Perform exhaust back pressure test.
Task 9 - Inspect and test engine compression and exhaust brakes; determine
needed service.
D. Cooling and Lubrication Systems Diagnosis (4 Questions)
Task 1 - Check oil and coolant levels, condition, and/or contamination.
Task 2 - Perform lube oil aeration test, if applicable.
Task 3 - Verify engine oil pressure and temperature, check operation of pressure
Task 4 - Check operation of fan hub, fan, fan clutch, fan shroud, mechanical and
electrical controls.
Task 5 - Verify engine operating temperature; check operation of temperature

Task 6 - Perform cooling system pressure test.
Task 7 - Inspect cooling system, water pump, thermostat(s), pressure cap, radiator,
recovery tank, belts, hoses, and clamps.
Task 8 - Inspect for air flow restrictions and obstructions.

Task 9 - Inspect radiator shutter and controls.
Task 10 - Diagnose oil consumption problems; determine needed service.
E. Fuel Systems Diagnosis (25 Questions)
1. Fuel Supply System (7 Questions)
Task 1 - Check fuel level in tank.
Task 2 - Determine fuel quality and condition; inspect for contamination.
Task 3 - Inspect fuel tanks, vents, caps, mounts, valves, screens, crossover system,
supply and return lines and fittings.
Task 4 - Inspect, clean, and test fuel supply pump, pump drive, screens fuel/water
separators/indicators, filters, heaters, coolers, and mounting hardware.
Task 5 - Check fuel system for air leaks and restrictions; determine needed service.
Task 6 - Prime and bleed fuel system; check primer pump.
Task 7 - Inspect and test, low pressure regulator systems (check valves, pressure
regulator valves, overflow valves, and restrictive fittings).
Task 8 - Inspect and test fuel shut-down devices and controls, including engine
protection shut-down devices, circuits and sensors.
2. Mechanical Fuel System Diagnosis (8 Questions)

systems: distributor/rotary, inline, rail, and unit injector.
Task 2 - Check injection pump-to-engine timing.

diagnostic tools.

power, slow deceleration, slow acceleration, stalling, and shutdown problems;
3. Electronic Fuel System Diagnosis (10 Questions)

systems: Rotary/Distributor with Electronic Diesel Control (EDC); Inline with
EDC, Electronic Unit Injectors (EUI), Hydraulic Electronic Unit Injector (HEUI),
Electronic Unit Pumps, common rail and other rail-type systems.
Task 2 - Check injection pump to engine timing.

power, slow deceleration, slow acceleration, stalling, and slow shutdown problems;
Task 6 - Determine appropriate electronic engine control diagnostic procedures

based on vehicle data, operational complaint, and service information.
Task 7 - Locate, utilize and /or interpret relevant service information, vehicle
information and diagnostic tools.
Task 8 - Inspect and test for missing, modified, damaged or incorrect engine control
components and programmed parameters (factory and customer).
Task 9 - Interpret diagnostic tool data to determine control system condition.

Task 10 - Establish relative importance and accuracy of displayed data.
Task 11 - Test and confirm operation of electrical/electronic circuits not displayed on

diagnostic tools.
Task 12 - Diagnose performance complaints caused by non-engine electronic

control system problems.
Task 13 - Perform digital multimeter (DMM) tests on circuits.

Task 14 - Test input sensors/circuits using displayed data.
Task 15 - Test output actuators/circuits using displayed data.
Task 16 - Test fuel system temperatures and delivery rates.

Tim Reggio Certification Committee Chair Gerhardt's, Inc., Jefferson, La

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Introduction

It should be noted several manufacturers will not release internal publications to

Good luck in your preparation for the TechCert exams!

Contact: David Fehling FOR IMMEDIATE RELEASE:

A.D.S. TO OFFER NEW DIESEL ENGINE DIAGNOSTICS TEST

♦ General Diesel Engine Diagnosis,

9140 Ward Parkway ♦ Kansas City, Missouri 64114 U.S.A.

Association of Diesel Specialists

SPECIFICATIONS FOR DIESEL ENGINE DIAGNOSTICS TEST (TC7)

A. General Diesel Engine Diagnosis (13 Questions)

Task 1 - Verify customer complaint, requirements and/or expectations.

Task 2 - Verify vehicle application, usage, and service history.

Task 3 - Determine that components are correct for the application.

Task 4 - Inspect tamper-resistant seals; determine warranty status.

Task 5 - Inspect for missing, modified or damaged components; verify correct

Task 6 - Determine fuel condition, level, quality and/or contamination.

Task 7 - Perform visual inspection.

Task 8 - Identify oil, coolant, air, and fuel leaks.

Task 10 - Determine the presence and effects of parasitic loads.

Task 11 - Diagnose engine-related noise and vibration problems.

Task 12 - Perform road/performance test, if applicable.

Task 13 - Perform compression test; determine needed repairs.

Task 14 - Perform cylinder leakage test; determine needed repairs.

Task 15 - Perform crankcase pressure test; determine needed repairs.

Task 16 - Check engine overhead settings (includes intake/exhaust valves, bridges

Task 17 - Perform exhaust port temperature test; determine needed repairs.

Task 20 - Inspect and repair as necessary wires, harnesses, connectors, terminals,

B. Starting and Charging Systems Diagnosis (4 Questions)

Task 2 - Check engine cranking speed; determine needed service.

Task 3 -Test charging system output; determine needed service.

Task 11 - Inspect condition and alignment of belts, pulleys and idlers.

Task 2 - Check for modifications and installed aftermarket accessories.

Task 3 - Check for missing or loose sound insulation.

Task 4 - Inspect and test wastegate and EGR system, if applicable.

Task 5 - Inspect turbocharger and test boost pressure.

Task 6 - Inspect and test charge air coolers.

Task 8 - Perform exhaust back pressure test.

D. Cooling and Lubrication Systems Diagnosis (4 Questions)

Task 1 - Check oil and coolant levels, condition, and/or contamination.

Task 2 - Perform lube oil aeration test, if applicable.

Task 5 - Verify engine operating temperature; check operation of temperature

Task 8 - Inspect for air flow restrictions and obstructions.

Task 10 - Diagnose oil consumption problems; determine needed service.

E. Fuel Systems Diagnosis (25 Questions)

1. Fuel Supply System (7 Questions)

Task 1 - Check fuel level in tank.

Task 2 - Determine fuel quality and condition; inspect for contamination.

Task 6 - Prime and bleed fuel system; check primer pump.

2. Mechanical Fuel System Diagnosis (8 Questions)

Task 1 - Inspect throttle and shut-off linkage/cable and controls.

Task 2 - Check injection pump-to-engine timing.

Task 4 - Diagnose no-start/ hard-starting, surging, rough operation, misfiring, low

Task 5 - Diagnose fuel economy/consumption problems; determine needed service.

Task 7 - Determine the need for fuel injector performance testing.

3. Electronic Fuel System Diagnosis (10 Questions)

Task 1 - Inspect throttle and shut-off linkage/cable and controls.

Task 2 - Check injection pump to engine timing.

Task 3 - Diagnose no-start/ hard-starting, surging, rough operation, misfiring, low

Task 4 - Diagnose fuel economy/consumption problems; determine needed service.

Task 6 - Determine appropriate electronic engine control diagnostic procedures

Task 9 - Interpret diagnostic tool data to determine control system condition.

Task 11 - Test and confirm operation of electrical/electronic circuits not displayed on

Task 12 - Diagnose performance complaints caused by non-engine electronic