Komatsu 114 Series Diesel Engine Shop Manual SEBM020400 – PDF DOWNLOAD

Komatsu 114 Series Diesel Engine Shop Manual SEBM020400 – PDF DOWNLOAD

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Komatsu 114 Series Diesel Engine Shop Manual SEBM020400 – PDF DOWNLOAD

Language : English
Pages : 978
Downloadable : Yes
File Type : PDF
Size: 41.4 MB

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Komatsu 114 Series Diesel Engine Shop Manual SEBM020400 – PDF DOWNLOAD

The Komatsu 114 Series Diesel Engine Shop Manual SEBM020400 is a comprehensive guide that provides detailed information on the maintenance, repair, and overhaul of the 114 series engine. This engine is used in a variety of Komatsu equipment, including bulldozers, excavators, and other heavy equipment.

• The manual is organized into several sections, each covering a different aspect of the engine. The first section provides an overview of the engine, including its specifications and performance data. This section also includes a table of contents, a list of illustrations, and a list of symbols and abbreviations used throughout the manual.
• The second section of the manual covers engine inspection and measurement procedures. This section provides step-by-step instructions for checking and measuring various components of the engine, including the cylinder block, crankshaft, and connecting rods. The manual includes detailed illustrations to help the reader understand the procedures.
• The third section covers engine disassembly and assembly procedures. This section provides instructions for removing and installing various components of the engine, including the cylinder head, pistons, and crankshaft. The manual also includes torque specifications for each component.
• The fourth section covers engine testing and adjusting procedures. This section provides instructions for testing and adjusting various components of the engine, including the fuel injection system, the turbocharger, and the valve clearance. The manual includes detailed illustrations to help the reader understand the procedures.
• The fifth section covers engine maintenance procedures, including routine maintenance and inspections. This section provides instructions for maintaining the engine to ensure its continued performance and longevity.
• The sixth section covers engine troubleshooting and diagnosis procedures. This section provides instructions for diagnosing and troubleshooting various engine problems, including starting problems, low power output, and excessive smoke. The manual includes a troubleshooting chart and detailed illustrations to help the reader diagnose and fix the problem.
• Overall, the Komatsu 114 Series Diesel Engine Shop Manual SEBM020400 is an essential tool for anyone working on or maintaining this engine. The manual is available in print or digital formats, making it a convenient and accessible resource for mechanics and technicians. It is designed to be user-friendly and easy to understand, with clear instructions and detailed illustrations. With this manual, you can ensure that your Komatsu equipment is operating at its best and avoid costly repairs and downtime.

TABLE OF CONTENTS:

Komatsu 114 Series Diesel Engine Shop Manual SEBM020400 – PDF DOWNLOAD

COVER……………………………………………………………………………………. 1
PRODUCT PUBLICATIONS INFORMATION……………………………………………………………. 3
FOREWORD…………………………………………………………………………………. 5
ENGINE-EXPLODED VIEW BY GROUPS……………………………………………………………… 6
TABLE OF CONTENTS…………………………………………………………………………. 7
INTRODUCTION……………………………………………………………………………… 8
ABOUT THE MANUAL………………………………………………………………………. 9
HOW TO USE THIS MANUAL…………………………………………………………………. 10
TABLE OF CONTENTS………………………………………………………………….. 10
GROUP CONTENTS…………………………………………………………………….. 10
INDEX…………………………………………………………………………….. 10
METRIC INFORMATION…………………………………………………………………. 10
GENERIC SYMBOLS……………………………………………………………………….. 11
ILLUSTRATIONS…………………………………………………………………………. 12
GENERAL SAFETY INSTRUCTIONS…………………………………………………………….. 13
GENERAL REPAIR INSTRUCTIONS…………………………………………………………….. 14
GENERAL CLEANING INSTRUCTIONS…………………………………………………………… 15
SOLVENT AND ACID CLEANING…………………………………………………………… 15
STEAM CLEANING…………………………………………………………………….. 15
GLASS OR PLASTIC BEAD CLEANING………………………………………………………. 15
GLOSSARY OF TERMS……………………………………………………………………… 16
ENGINE AND COMPONENT IDENTIFICATION…………………………………………………………. 18
ENGINE IDENTIFICATION………………………………………………………………….. 19
ENGINE DATAPLATES………………………………………………………………….. 19
FUEL INJECTION PUMP DATAPLATE……………………………………………………….. 20
GENERAL ENGINE SPECIFICATIONS…………………………………………………………… 21
GENERAL ENGINE DATA………………………………………………………………… 21
LUBRICATION SYSTEM…………………………………………………………………. 21
COOLING SYSTEM…………………………………………………………………….. 22
INTAKE AIR AND EXHAUST SYSTEM……………………………………………………….. 22
FUEL SYSTEM……………………………………………………………………….. 22
ENGINE DIAGRAMS……………………………………………………………………….. 23
ENGINE DISASSEMBLY AND ASSEMBLY-GROUP 00…………………………………………………….. 26
ENGINE DISASSEMBLY AND ASSEMBLY-SERVICE TOOLS…………………………………………….. 29
GENERAL INFORMATION……………………………………………………………………. 33
DISASSEMBLY……………………………………………………………………….. 33
ASSEMBLY………………………………………………………………………….. 33
ENGINE LIFTING EQUIPMENT AND BRACKETS……………………………………………………. 34
ENGINE-PREPARATION FOR STEAM CLEANING……………………………………………………. 34
ENGINE-STEAM CLEANING………………………………………………………………….. 34
LUBRICATING OIL-DRAINING……………………………………………………………….. 35
COOLANT-DRAINING………………………………………………………………………. 35
COOLANT FILTER-REMOVAL…………………………………………………………………. 35
LUBRICATING OIL FILTER-REMOVAL………………………………………………………….. 35
FUEL FILTER-REMOVAL……………………………………………………………………. 36
FUEL FILTER HEAD-REMOVAL……………………………………………………………….. 36
FUEL LINES,LOW PRESSURE-REMOVAL…………………………………………………………. 36
FUEL TRANSFER PUMP-REMOVAL……………………………………………………………… 36
FUEL LINES,HIGH PRESSURE-REMOVAL………………………………………………………… 37
FUEL INJECTION PUMP SUPPLY LINE-REMOVAL………………………………………………….. 37
AFC TUBE-REMOVAL………………………………………………………………………. 37
TACHOMETER DRIVE-REMOVAL……………………………………………………………….. 38
FUEL INJECTION PUMP-REMOVAL…………………………………………………………….. 38
AIR COMPRESSOR-REMOVAL…………………………………………………………………. 39
FUEL PUMP SOLENOID-REMOVAL……………………………………………………………… 40
ENGINE-INSTALLATION ONTO ENGINE REBUILD STAND…………………………………………….. 40
TURBOCHARGER EXHAUST OUTLET CONNECTION-REMOVAL……………………………………………. 41
WASTEGATE ACTUATOR HOSE-REMOVAL…………………………………………………………. 41
CRANKCASE BREATHER TUBE-REMOVAL…………………………………………………………. 41
AIR CROSSOVER TUBE-REMOVAL……………………………………………………………… 42
INTAKE MANIFOLD COVER-REMOVAL…………………………………………………………… 42
AFTERCOOLER-REMOVAL……………………………………………………………………. 42
FUEL DRAIN MANIFOLD-REMOVAL…………………………………………………………….. 43
INJECTOR-REMOVAL………………………………………………………………………. 43
VALVE COVER-REMOVAL……………………………………………………………………. 43
ROCKER LEVER ASSEMBLY-REMOVAL…………………………………………………………… 44
PUSH ROD-REMOVAL………………………………………………………………………. 44
TURBOCHARGER OIL SUPPLY HOSE-REMOVAL…………………………………………………….. 45
TURBOCHARGER OIL DRAIN TUBE-REMOVAL……………………………………………………… 45
TURBOCHARGER-REMOVAL…………………………………………………………………… 45
EXHAUST MANIFOLD-REMOVAL……………………………………………………………….. 45
DRIVE BELT-REMOVAL…………………………………………………………………….. 46
BELT TENSIONER-REMOVAL…………………………………………………………………. 46
BELT TENSIONER BRACKET-REMOVAL………………………………………………………….. 46
ALTERNATOR BRACE-REMOVAL……………………………………………………………….. 46
ALTERNATOR-REMOVAL…………………………………………………………………….. 47
ALTERNATOR MOUNTING BRACKET-REMOVAL……………………………………………………… 47
COOLANT OUTLET CONNECTION-REMOVAL……………………………………………………….. 47
THERMOSTAT AND HOUSING-REMOVAL………………………………………………………….. 47
COOLANT VENT TUBE-REMOVAL………………………………………………………………. 48
COOLANT VENT PETCOCK-REMOVAL……………………………………………………………. 48
COOLANT VENT TUBE FITTING-REMOVAL……………………………………………………….. 48
CYLINDER HEAD-REMOVAL………………………………………………………………….. 48
LUBRICATING OIL COOLER-REMOVAL………………………………………………………….. 49
COOLANT INLET CONNECTION-REMOVAL………………………………………………………… 49
FAN HUB ASSEMBLY-REMOVAL……………………………………………………………….. 49
WATER PUMP-REMOVAL…………………………………………………………………….. 50
VIBRATION DAMPER-REMOVAL……………………………………………………………….. 50
GEAR COVER-REMOVAL…………………………………………………………………….. 51
SEAL,FRONT CRANKSHAFT-REMOVAL…………………………………………………………… 51
STARTING MOTOR-REMOVAL…………………………………………………………………. 51
COOLANT HEATER-REMOVAL…………………………………………………………………. 51
FLYWHEEL-REMOVAL………………………………………………………………………. 52
FLYWHEEL HOUSING-REMOVAL……………………………………………………………….. 52
LUBRICATING OIL PAN-REMOVAL…………………………………………………………….. 52
LUBRICATING OIL SUCTION TUBE-REMOVAL…………………………………………………….. 52
SEAL,REAR CRANKSHAFT-REMOVAL……………………………………………………………. 53
CAMSHAFT-REMOVAL………………………………………………………………………. 53
VALVE TAPPET-REMOVAL…………………………………………………………………… 54
LUBRICATING OIL PUMP GEAR BACKLASH-MEASUREMENT……………………………………………. 55
LUBRICATING OIL PUMP-REMOVAL……………………………………………………………. 56
ENGINE SUPPORT,FRONT-REMOVAL……………………………………………………………. 56
GEAR HOUSING-REMOVAL…………………………………………………………………… 56
CYLINDER LINER CARBON DEPOSITS-REMOVAL…………………………………………………… 57
PISTON ASSEMBLY-REMOVAL………………………………………………………………… 58
PISTON PIN-REMOVAL…………………………………………………………………….. 59
PISTON RING-REMOVAL……………………………………………………………………. 60
MAIN BEARING CAP-REMOVAL……………………………………………………………….. 60
MAIN BEARING(LOWER)-REMOVAL…………………………………………………………….. 61
CRANKSHAFT-REMOVAL…………………………………………………………………….. 61
MAIN BEARING(UPPER)-REMOVAL…………………………………………………………….. 61
PISTON COOLING NOZZLE-REMOVAL…………………………………………………………… 61
CYLINDER LINER PROTRUSION-CHECKING………………………………………………………. 62
CYLINDER LINER-REMOVAL…………………………………………………………………. 62
EXPANSION PLUG-REPLACEMENT……………………………………………………………… 63
EXPANSION PLUG-REMOVAL…………………………………………………………………. 64
CYLINDER BLOCK-REMOVAL FROM ENGINE REBUILD STAND………………………………………….. 64
ENGINE-ASSEMBLY……………………………………………………………………….. 64
CYLINDER LINER-INSTALLATION…………………………………………………………….. 65
VALVE TAPPET-INSTALLATION………………………………………………………………. 69
PISTON COOLING NOZZLE-INSTALLATION………………………………………………………. 70
MAIN BEARING(UPPER)-INSTALLATION………………………………………………………… 71
CRANKSHAFT-INSTALLATION………………………………………………………………… 72
MAIN BEARING(LOWER)-INSTALLATION………………………………………………………… 73
MAIN BEARING CAP-INSTALLATION…………………………………………………………… 73
SEAL,REAR CRANKSHAFT-INSTALLATION……………………………………………………….. 77
WEAR SLEEVE,REAR CRANKSHAFT SEAL-INSTALLATION…………………………………………….. 78
CONNECTING ROD BOLT-INSTALLATION………………………………………………………… 81
PISTON PIN-INSTALLATION………………………………………………………………… 81
PISTON RING END GAP-MEASUREMENT…………………………………………………………. 82
PISTON RING-INSTALLATION……………………………………………………………….. 83
PISTON ASSEMBLY-INSTALLATION……………………………………………………………. 85
GEAR HOUSING-INSTALLATION………………………………………………………………. 89
LUBRICATING OIL PUMP-INSTALLATION……………………………………………………….. 91
CAMSHAFT-INSTALLATION………………………………………………………………….. 92
WATER PUMP-INSTALLATION………………………………………………………………… 94
LUBRICATING OIL SUCTION TUBE-INSTALLATION………………………………………………… 95
LUBRICATING OIL PAN-INSTALLATION………………………………………………………… 95
TIMING PIN ASSEMBLY-INSTALLATION………………………………………………………… 96
FLYWHEEL HOUSING-INSTALLATION…………………………………………………………… 99
FLYWHEEL-INSTALLATION…………………………………………………………………..104
FLYWHEEL BORE RUNOUT MEASUREMENT…………………………………………………………106
FLYWHEEL FACE RUNOUT MEASUREMENT…………………………………………………………108
STARTING MOTOR-INSTALLATION……………………………………………………………..109
COOLANT HEATER-INSTALLATION……………………………………………………………..109
LUBRICATING OIL COOLER-INSTALLATION………………………………………………………111
LUBRICATING OIL FILTER-INSTALLATION………………………………………………………112
CYLINDER HEAD-INSTALLATION………………………………………………………………112
PUSH ROD-INSTALLATION…………………………………………………………………..116
ROCKER LEVER AND SHAFT-ASSEMBLY………………………………………………………….116
ROCKER LEVER ASSEMBLY-INSTALLATION……………………………………………………….118
VALVE CLEARANCE-ADJUSTMENT………………………………………………………………119
VALVE ARRANGEMENT………………………………………………………………………120
VALVE COVER-INSTALLATION………………………………………………………………..121
INJECTOR-INSTALLATION…………………………………………………………………..122
FUEL DRAIN MANIFOLD-INSTALLATION…………………………………………………………123
ENGINE LIFTING BRACKET-INSTALLATION………………………………………………………123
INTAKE MANIFOLD COVER-INSTALATION………………………………………………………..123
AFTERCOOLER-INSTALLATION………………………………………………………………..124
EXHAUST MANIFOLD-INSTALLATION……………………………………………………………124
TURBOCHARGER-INSTALLATION……………………………………………………………….125
TURBOCHARGER OIL DRAIN TUBE-INSTALLATION………………………………………………….126
TURBOCHARGER OIL SUPPLY HOSE-INSTALLATION…………………………………………………128
TURBOCHARGER EXHAUST OUTLET CONNECTION-INNSTALLATION……………………………………….129
AIR CROSSOVER TUBE-INSTALLATION………………………………………………………….129
THERMOSTAT AND HOUSING-INSTALLATION………………………………………………………129
COOLANT OUTLET CONNECTION-INSTALLATION……………………………………………………130
COOLANT FILTER-INSTALLATION……………………………………………………………..130
COOLANT VENT FITTING-INSTALLATION………………………………………………………..130
COOLANT VENT PETCOCK-INSTALLATION………………………………………………………..130
COOLANT VENT TUBE-INSTALLATION…………………………………………………………..131
COOLANT INLET CONNECTION-INSTALLATION…………………………………………………….131
ALTERNATOR MOUNTING BRACKET-INSTALLATION………………………………………………….131
ALTERNATOR-INSTALLATION…………………………………………………………………131
ALTERNATOR BRACE-INSTALLATION……………………………………………………………132
BELT TENSIONER BRACKET-INSTALLATION………………………………………………………133
BELT TENSIONER-INSTALLATION……………………………………………………………..133
FAN HUB ASSEMBLY-INSTALLATION……………………………………………………………134
FUEL INJECTION PUMP-INSTALLATION…………………………………………………………134
FUEL INJECTION PUMP SUPPLY LINE-INSTALLATION………………………………………………138
FUEL FILTER HEAD-INSTALLATION……………………………………………………………139
FUEL FILTER-INSTALLATION………………………………………………………………..139
FUEL LINES,HIGH PRESSURE-INSTALLATION…………………………………………………….140
AFC TUBE-INSTALLATION…………………………………………………………………..140
SEAL,FRONT CRANKSHAFT-INSTALLATION……………………………………………………….141
GEAR COVER-INSTALLATION…………………………………………………………………144
TACHOMETER DRIVE-INSTALLATION……………………………………………………………145
VIBRATION DAMPER-INSTALLATION……………………………………………………………145
DRIVE BELT-INSTALLATION…………………………………………………………………146
ENGINE SUPPORT,FRONT-INSTALLATION………………………………………………………..146
FUEL TRANSFER PUMP-INSTALLATION………………………………………………………….146
FUEL LINES,LOW PRESSURE-INSTALLATION……………………………………………………..147
FUEL PUMP SOLENOLD-INSTALLATION………………………………………………………….147
AIR COMPRESSOR-INSTALLATION……………………………………………………………..147
ENGINE ACCESSORIES-INSTALLATION………………………………………………………….149
CYLINDER BLOCK-GROUP 01…………………………………………………………………….150
CYLINDER BLOCK-SERVICE TOOLS…………………………………………………………….152
CYLINDER BLOCK-EXPLODED VIEW…………………………………………………………….155
CYLINDER BLOCK-GENERAL INFORMATION……………………………………………………….157
CAMSHAFT…………………………………………………………………………..157
CRANKSHAFT…………………………………………………………………………157
CYLINDER BLOCK……………………………………………………………………..157
CYLINDER LINER……………………………………………………………………..157
OIL SEALS………………………………………………………………………….157
PISTONS……………………………………………………………………………157
VIBRATION DAMPER……………………………………………………………………157
CONNECTING RODS…………………………………………………………………….157
CYLINDER BLOCK-PREPARATION FOR CLEANING…………………………………………………..158
CYLINDER BLOCK-DISASSEMBLY………………………………………………………………158
DOWEL PINS(CYLINDER HEAD)-REMOVAL………………………………………………………..159
CYLINDER BLOCK-CLEANING WITH SOLVENT……………………………………………………..160
CYLINDER BLOCK-CLEANING IN A HOT TANK…………………………………………………….163
CYLINDER BLOCK-INSPECTION FOR REUSE………………………………………………………164
EXPANSION PLUG-INSTALLATION……………………………………………………………..167
PIPE PLUG-INSTALLATION………………………………………………………………168
CAMSHAFT BORE EXPANSION PLUG INSTALLATION…………………………………………………169
CAMSHAFT BUSHING-REMOVAL………………………………………………………………..170
CAMSHAFT BUSHING BORE-CLEANING…………………………………………………………..171
CAMSHAFT BUSHING-INSTALLATION……………………………………………………………171
CYLINDER LINERS-CLEANING AND INSPECTION FOR REUSE………………………………………….172
CYLINDER LINERS-CLEANING…………………………………………………………….172
CYLINDER LINERS-INSPECTION…………………………………………………………..173
PISTONS-CLEANING AND INSPECTION FOR REUSE…………………………………………………175
PISTON RINGS-REMOVAL………………………………………………………………..175
PISTONS-CLEANING……………………………………………………………………175
PISTON-INSPECTION…………………………………………………………………..176
CRANKSHAFT-CLEANING AND INSPECTION FOR REUSE………………………………………………178
CRANKSHAFT-CLEANING…………………………………………………………………178
CRANKSHAFT-INSPECTION……………………………………………………………….179
CRANKSHAFT GEAR-REPLACEMENT……………………………………………………………..182
GENERAL INFORMATION…………………………………………………………………182
CRANKSHAFT GEAR-REMOVAL……………………………………………………………..182
CRANKSHAFT GEAR-INSPECTION…………………………………………………………..183
CRANKSHAFT GEAR-INSTALLATION…………………………………………………………184
MAIN BEARINGS-CLEANING AND INSPECTION FOR REUSE……………………………………………185
GENERAL INFORMATION…………………………………………………………………185
MAIN BEARINGS-CLEANING………………………………………………………………186
MAIN BEARINGS-INSPECTION…………………………………………………………….186
THRUST BEARINGS-INSPECTION…………………………………………………………..187
MAIN BEARING CAPS AND CAPSCREWS-CLEANING AND INSPECTION FOR REUSE……………………………187
CLEANING…………………………………………………………………………..187
INSPECTION…………………………………………………………………………188
CONNECTING ROD BEARINGS-CLEANING AND INSPECTION FOR REUSE…………………………………..188
CONNECTING ROD BEARINGS-CLEANING……………………………………………………..188
CONNECTING ROD BEARINGS-INSPECTION……………………………………………………188
CONNECTING RODS-CLEANING AND INSPECTION FOR REUSE………………………………………….189
CONNECTING RODS-CLEANING…………………………………………………………….189
CONNECTING RODS-INSPECTION…………………………………………………………..190
CONNECTING RODS-BEND AND TWIST INSPECTION…………………………………………………192
FIXTURE CALIBRATION…………………………………………………………………192
CONNECTING ROD ALIGNMENT-INSPECTION…………………………………………………..193
CONNECTING ROD TWIST-INSPECTION………………………………………………………193
CONNECTING ROD BUSHING-REPLACEMENT……………………………………………………….194
REMOVAL……………………………………………………………………………194
INSTALLATION……………………………………………………………………….196
MACHINING………………………………………………………………………….198
INSPECTION…………………………………………………………………………198
CAMSHAFT-CLEANING AND INSPECTION FOR REUSE………………………………………………..199
CAMSHAFT-CLEANING…………………………………………………………………..199
CAMSHAFT-INSPECTION…………………………………………………………………199
CAMSHAFT GEAR-INSPECTION…………………………………………………………….202
CAMSHAFT GEAR-REPLACEMENT……………………………………………………………….203
CAMSHAFT GEAR-REMOVAL……………………………………………………………….203
CAMSHAFT GEAR-CLEANING………………………………………………………………203
CAMSHAFT GEAR-INSPECTION…………………………………………………………….203
CAMSHAFT GEAR-INSTALLATION…………………………………………………………..205
GEAR HOUSING-CLEANING AND INSPECTION FOR REUSE…………………………………………….206
GEAR HOUSING-CLEANING……………………………………………………………….206
GEAR HOUSING-INSPECTION……………………………………………………………..206
ENGINE DATAPLATE-REPLACEMENT…………………………………………………………….208
ENGINE DATAPLATE-REMOVAL…………………………………………………………….208
ENGINE DATAPLATE-INSTALLATION………………………………………………………..208
GEAR COVER-CLEANING AND INSPECTION FOR REUSE………………………………………………209
GEAR COVER-CLEANING…………………………………………………………………209
GEAR COVER-INSPECTION……………………………………………………………….209
VIBRATION DAMPER-CLEANING AND CHECKING FOR REUSE…………………………………………..210
GENERAL INFORMATION…………………………………………………………………210
RUBBER VIBRATION DAMPER-CLEANING……………………………………………………..210
RUBBER ELEMENT VIBRATION DAMPER-INSPECTION…………………………………………….210
VISCOUS VIBRATION DAMPER-CLEANING…………………………………………………….211
VISCOUS VIBRATION DAMPER-INSPECTION…………………………………………………..211
REAR COVER-CLEANING AND INSPECTION……………………………………………………….212
CLEANING…………………………………………………………………………..212
INSPECTION…………………………………………………………………………213
CYLINDER HEAD CAPSCREWS-CLEANING AND INSPECTION FOR REUSE…………………………………..213
CLEANING…………………………………………………………………………..213
INSPECTION…………………………………………………………………………214
FREE LENGTH-MEASUREMENT……………………………………………………………..215
ENGINE LIFTING BRACKETS-CLEANING AND INSPECTION FOR REUSE…………………………………..215
CYLINDER HEAD-GROUP 02……………………………………………………………………..216
CYLINDER HEAD-SERVICE TOOLS……………………………………………………………..217
CYLINDER HEAD-EXPLODED VIEW……………………………………………………………..221
CYLINDER HEAD-GENERAL INFORMATION………………………………………………………..223
CYLINDER HEAD-CLEANING AND INSPECTION FOR REUSE……………………………………………224
HANDLING…………………………………………………………………………..224
CLEANING…………………………………………………………………………..224
INSPECTION…………………………………………………………………………225
CYLINDER HEAD-REBUILD…………………………………………………………………..226
DISASSEMBLY………………………………………………………………………..226
CLEANING…………………………………………………………………………..227
INSPECTION…………………………………………………………………………228
VALVE GUIDE-INSPECTION………………………………………………………………232
VALVE SEAT INSERT-INSPECTION…………………………………………………………233
VALVE SPRING-INSPECTION……………………………………………………………..234
VALVE STEM SEAL-INSPECTION…………………………………………………………..235
VALVE-INSPECTION……………………………………………………………………236
VALVE-GRINDING……………………………………………………………………..237
VALVE SEAT INSERT-GRINDING…………………………………………………………..238
ASSEMBLY…………………………………………………………………………..242
CYLINDER HEAD-VALVE GUIDE REPLACEMENT…………………………………………………….244
DISASSEMBLY………………………………………………………………………..244
INSPECTION…………………………………………………………………………245
ASSEMBLY…………………………………………………………………………..245
CYLINDER HEAD-VALVE SEAT INSERT REPLACEMENT……………………………………………….247
REMOVAL……………………………………………………………………………247
INSPECTION…………………………………………………………………………249
INSTALLATION……………………………………………………………………….249
CYLINDER HEAD-PRESSURE TESTING…………………………………………………………..250
CYLINDER HEAD-VACUUM TESTING VALVE SEATING………………………………………………..252
CYLINDER HEAD CAPSCREW-CLEANING AND INSPECTION…………………………………………….253
CLEANING…………………………………………………………………………..254
INSPECTION…………………………………………………………………………254
FREE LENGTH-MEASUREMENT…………………………………………………………………255
ROCKER LEVERS-GROUP 03……………………………………………………………………..256
ROCKER LEVER ASSEMBLY-EXPLODED VIEW………………………………………………………257
ROCKER LEVER ASSEMBLY-GENERAL INFORMATION…………………………………………………258
ROCKER LEVER ASSEMBLY-CLEANING AND INSPECTION……………………………………………..259
DISASSEMBLY………………………………………………………………………..259
CLEANING…………………………………………………………………………..260
INSPECTION…………………………………………………………………………260
ASSEMBLY…………………………………………………………………………..261
ROCKER ASSEMBLY OIL MANIFOLD-CLEANING AND INSPECTION FOR REUSE………………………………262
CLEANING…………………………………………………………………………..262
INSPECTION…………………………………………………………………………262
VALVE COVER-CLEANING AND INSPECTION FOR REUSE……………………………………………..263
CLEANING…………………………………………………………………………..263
INSPECTION…………………………………………………………………………263
CRANKCASE BREATHER TUBE-CLEANING AND INSPECTION FOR REUSE…………………………………..263
CLEANING AND INSPECTION……………………………………………………………..263
VALVE TAPPETS AND PUSH RODS-GROUP 04…………………………………………………………264
VALVE TAPPETS AND PUSH RODS-EXPLODED VIEW…………………………………………………265
VALVE TAPPETS AND PUSH RODS-GENERAL INFORMATION……………………………………………266
VALVE TAPPET CLEANING AND INSPECTION FOR REUSE…………………………………………….266
CLEANING…………………………………………………………………………..266
INSPECTION…………………………………………………………………………266
PUSH RODS-CLEANING AND INSPECTION FOR REUSE……………………………………………….267
CLEANING…………………………………………………………………………..267
INSPECTION…………………………………………………………………………267
FUEL SYSTEMS-GROUP 05………………………………………………………………………269
FUEL SYSTEM-GENERAL INFORMATION………………………………………………………….270
FUEL INJECTION PUMP…………………………………………………………………270
FUEL INJECTION PUMP-DATA TAG LOCATION…………………………………………………270
FUEL INJECTION PUMP-DATA TAG INFORMATION………………………………………………270
GOVERNOR-DATA TAG INFORMATION ……………………………………………………….271
DERIVATIVE FUEL INJECTION PUMP-DATA TAG INFORMATION…………………………………….271
FUEL SHUTOFF SOLENOID-WIRING REQUIREMENTS……………………………………………..271
FUEL TRANSFER PUMP-EXPLODED VIEW…………………………………………………………272
FUEL TRANSFER PUMP-REBUILD………………………………………………………………273
CLEANING…………………………………………………………………………..273
ASSEMBLY…………………………………………………………………………..273
RSV GOVERNOR FUEL SHUTOFF SOLENOID-ORIENTATION AND ADJUSTMENT……………………………….274
FUEL SHUTOFF SOLENOID-ORIENTATION…………………………………………………….274
FUEL SHUTOFF SOLENOID-ADJUSTMENT……………………………………………………..276
RQVK GOVERNOR FUEL SHUTOFF SOLENOID-ADJUSTMENT…………………………………………….277
SHUTDOWN LEVER OR SPRING-REPLACEMENT……………………………………………………..278
DIRECT LINK SHUTDOWN LEVER-REPLACEMENT……………………………………………………279
FUEL INJECTION PUMP GASKETS AND SEALS-REPLACEMENT………………………………………….280
INJECTORS AND FUEL LINES-GROUP 06……………………………………………………………281
INJECTORS AND FUEL LINES-SERVICE TOOLS……………………………………………………282
INJECTORS AND FUEL LINES-EXPLODED VIEW……………………………………………………283
INJECTORS AND FUEL LINES-EXPLODED VIEW……………………………………………………285
INJECTORS AND FUEL LINES-EXPLODED VIEW……………………………………………………286
INJECTORS AND FUEL LINES-GENERAL INFORMATION………………………………………………287
INJECTORS-CLEANING AND INSPECTION FOR REUSE……………………………………………….288
GENERAL INFORMATION…………………………………………………………………288
INJECTOR-DISASSEMBLY………………………………………………………………..288
INJECTOR-CLEANING AND INSPECTION……………………………………………………..290
INJECTOR-ASSEMBLY…………………………………………………………………..292
INJECTOR-SPRAY TESTING………………………………………………………………….293
INJECTOR-CHATTER TESTING………………………………………………………………..294
FUEL LINES,HIGH PRESSURE-CLEANING AND INSPECTION FOR REUSE………………………………….294
GENERAL INFORMATION…………………………………………………………………294
FUEL LINES-CLEANING AND INSPECTION……………………………………………………295
FUEL DRAIN MANIFOLD-INSPECTION…………………………………………………………..296
FUEL LINES,LOW PRESSURE-CLEANING AND INSPECTION FOR REUSE…………………………………..296
LUBRICATING OIL SYSTEM-GROUP 07……………………………………………………………..298
LUBRICATING OIL SYSTEM-SERVICE TOOLS……………………………………………………..299
LUBRICATING OIL SYSTEM-GENERAL INFORMATION………………………………………………..300
LUBRICATING OIL COOLER AND FILTER HEAD………………………………………………..300
OIL PRESSURE REGULATOR………………………………………………………………300
OIL FILTER HEAD…………………………………………………………………….300
OIL TEMPERATURE THERMOSTAT…………………………………………………………..300
LUBRICATING OIL PUMP………………………………………………………………..300
DIPSTICK…………………………………………………………………………..300
OIL PAN……………………………………………………………………………300
LUBRICATING OIL SYSTEM-EXPLODED VIEW……………………………………………………..301
LUBRICATING OIL PAN-CLEANING AND INSPECTION FOR REUSE………………………………………302
CLEANING…………………………………………………………………………..302
INSPECTION…………………………………………………………………………302
OIL COOLER ELEMENT-CLEANING AND INSPECTION FOR REUSE……………………………………….303
CLEANING…………………………………………………………………………..303
INSPECTION…………………………………………………………………………303
PRESSURE TEST………………………………………………………………………303
OIL PRESSURE REGULATING VALVE-CLEANING AND INSPECTION………………………………………304
DISASSEMBLY………………………………………………………………………..304
CLEANING…………………………………………………………………………..305
INSPECTION…………………………………………………………………………305
ASSEMBLY…………………………………………………………………………..305
OIL FILTER BYPASS VALVE-REPLACEMENT………………………………………………………306
OIL COOLER COVER-DISASSEMBLY AND ASSEMBLY…………………………………………………307
DISASSEMBLY………………………………………………………………………..307
CLEANING…………………………………………………………………………..307
ASSEMBLY…………………………………………………………………………..308
LUBRICATING OIL TEMPERATURE THERMOSTAT-CLEANING AND INSPECTION………………………………309
CLEANING…………………………………………………………………………..309
INSPECTION…………………………………………………………………………309
LUBRICATING OIL DIPSTICK-CALIBRATION……………………………………………………..310
LUBRICATING OIL PUMP-CLEANING AND INSPECTION FOR REUSE……………………………………..311
DISASSEMBLY………………………………………………………………………..311
CLEANING…………………………………………………………………………..312
INSPECTION…………………………………………………………………………312
COOLING SYSTEM-GROUP 08…………………………………………………………………….315
COOLING SYSTEM-SERVICE TOOLS…………………………………………………………….316
COOLING SYSTEM COMPONENTS-EXPLODED VIEW…………………………………………………..317
COOLING SYSTEM-GENERAL INFORMATION……………………………………………………….318
WATER PUMP…………………………………………………………………………318
THERMOSTATS………………………………………………………………………..318
PRESSURE CAPS………………………………………………………………………318
FAN HUB……………………………………………………………………………318
BELT TENSIONER……………………………………………………………………..318
COOLING FANS……………………………………………………………………….318
WATER PUMP ASSEMBLY-CLEANING AND INSPECTION FOR REUSE………………………………………320
CLEANING…………………………………………………………………………..320
INSPECTION…………………………………………………………………………320
THERMOSTAT HOUSING-CLEANING AND INSPECTION FOR REUSE……………………………………….321
CLEANING…………………………………………………………………………..321
INSPECTION…………………………………………………………………………321
THERMOSTAT-INSPECTION…………………………………………………………………..321
WATER OUTLET CONNECTION-CLEANING AND INSPECTION FOR REUSE…………………………………..322
FAN HUB-CLEANING AND INSPECTION FOR REUSE…………………………………………………322
CLEANING…………………………………………………………………………..322
INSPECTION…………………………………………………………………………323
FAN HUB-REBUILD………………………………………………………………………..323
DISASSEMBLY………………………………………………………………………..323
ASSEMBLY…………………………………………………………………………..324
BELT TENSIONER INSPECTION……………………………………………………………….325
COOLANT FILTER SHUTOFF VALVE-CLEANING AND INSPECTION FOR REUSE………………………………325
DISASSEMBLY………………………………………………………………………..325
CLEANING…………………………………………………………………………..326
ASSEMBLY…………………………………………………………………………..326
FAN-CLEANING AND INSPECTION FOR REUSE…………………………………………………….327
DRIVE UNITS-GROUP 09……………………………………………………………………….328
DRIVE UNITS-SERVICE TOOLS……………………………………………………………….329
ACCESSORY DRIVE ADAPTER-EXPLODED VIEW…………………………………………………….330
ACCESSORY DRIVE-GENERAL INFORMATION………………………………………………………331
ACCESSORY DRIVE ADAPTER……………………………………………………………..331
ACCESSORY DRIVE ADAPTER-CLEANING AND INSPECTION FOR REUSE…………………………………..332
CLEANING…………………………………………………………………………..332
INSPECTION…………………………………………………………………………332
ACCESSORY DRIVE ADAPTER-REBUILD………………………………………………………….332
DISASSEMBLY………………………………………………………………………..332
ASSEMBLY…………………………………………………………………………..333
AIR INTAKE SYSTEM-GROUP 10………………………………………………………………….335
AIR INTAKE SYSTEM-SERVICE TOOLS………………………………………………………….336
AIR INTAKE SYSTEM-EXPLODED VIEW………………………………………………………….337
AIR INTAKE SYSTEM-GENERAL INFORMATION…………………………………………………….339
TURBOCHARGER-CLEANING AND INSPECTION FOR REUSE…………………………………………….340
INSPECTION…………………………………………………………………………340
INTAKE MANIFOLD COVER-CLEANING AND INSPECTION FOR REUSE…………………………………….344
INSPECTION…………………………………………………………………………344
AFTERCOOLER ASSEMBLY-CLEANING AND INSPECTION FOR REUSE……………………………………..344
INSPECTION…………………………………………………………………………345
AFTERCOOLER ASSEMBLY-REBUILD…………………………………………………………….345
AIR TRANSFER PIPE-CLEANING AND INSPECTION FOR REUSE………………………………………..346
CLEANING…………………………………………………………………………..346
INSPECTION…………………………………………………………………………346
AIR CROSSOVER TUBE-CLEANING AND INSPECTION FOR REUSE……………………………………….346
CLEANING…………………………………………………………………………..346
INSPECTION…………………………………………………………………………346
CHARGE AIR COOLER(CAC)-CLEANING AND INSPECTION FOR REUSE……………………………………347
CLEANING…………………………………………………………………………..347
INSPECTION…………………………………………………………………………347
CHARGE AIR COOLER(CAC)-PRESSURE TESTING…………………………………………………..348
EXHAUST SYSTEM-GROUP 11…………………………………………………………………….350
EXHAUST MANIFOLD-EXPLODED VIEW…………………………………………………………..351
EXHAUST SYSTEM-GENERAL INFORMATION……………………………………………………….352
EXHAUST MANIFOLD……………………………………………………………………352
EXHAUST MANIFOLD-CLEANING AND INSPECTION FOR REUSE…………………………………………353
CLEANING…………………………………………………………………………..353
INSPECTION…………………………………………………………………………353
EXHAUST MANIFOLD TURBOCHARGER MOUNTING STUD-REPLACEMENT…………………………………….354
REMOVAL……………………………………………………………………………354
INSPECTION…………………………………………………………………………354
INSTALLATION……………………………………………………………………….354
EXHAUST MANIFOLD OUTLET CONNECTION-CLEANING AND INSPECTION FOR REUSE…………………………355
CLEANING…………………………………………………………………………..355
INSPECTION…………………………………………………………………………355
AIR EQUIPMENT-GROUP 12……………………………………………………………………..356
ELECTRICAL EQUIPMENT-GROUP 13……………………………………………………………….357
ENGINE TESTING-GROUP 14…………………………………………………………………….358
ENGINE TESTING-SERVICE TOOLS…………………………………………………………….359
ENGINE TESTING-COMPONENT IDENTIFICATION AND DIAGRAMS……………………………………….360
ENGINE TESTING-GENERAL INFORMATION……………………………………………………….362
IN-CHASSIS RUN-IN…………………………………………………………………..362
ENGINE DYNAMOMETER RUN-IN……………………………………………………………362
ENGINE TESTING-GENERAL SPECIFICATIONS…………………………………………………….363
BLOWBY MEASUREMENT……………………………………………………………………..364
ENGINE RUN-IN-GENERAL PROCEDURES…………………………………………………………365
ENGINE DYNAMOMETER TEST-INSTALLATION OF THE ENGINE…………………………………………366
ENGINE DYNAMOMETER TEST-ENGINE RUN-IN…………………………………………………….374
ENGINE DYNAMOMETER TEST-PERFORMANCE CHECKING………………………………………………378
GENERAL ENGINE TEST PROCEDURE-IN CHASSIS………………………………………………….380
ENGINE RUN-IN PROCEDURE-“IN-CHASSIS”……………………………………………………..385
FUEL INJECTION PUMP-IDLE SPEED ADJUSTMENT…………………………………………………386
RSV GOVERNOR……………………………………………………………………….386
RQV AND RQVK GOVERNOR……………………………………………………………….387
ENGINE PAINTING………………………………………………………………………..387
ENGINE STORAGE-SHORT TERM……………………………………………………………….388
ENGINE REMOVAL FROM SHORT TERM STORAGE………………………………………………..390
ENGINE STORAGE-LONG TERM………………………………………………………………..390
ENGINE REMOVAL FROM TERM STORAGE……………………………………………………..393
INSTRUMENTS AND CONTROLS-GROUP 15……………………………………………………………397
MOUNTING ADAPTATIONS-GROUP 16……………………………………………………………….398
MOUNTING ADAPTATIONS-SERVICE TOOLS……………………………………………………….399
MOUNTING ADAPTATIONS-EXPLODED VIEW……………………………………………………….400
MOUNTING ADAPTATIONS-GENERAL INFORMATION………………………………………………….401
FLYWHEEL HOUSING……………………………………………………………………401
FLYWHEEL AND RING GEAR………………………………………………………………401
FLYWHEEL-CLEANING AND INSPECTION FOR REUSE………………………………………………..402
CLEANING…………………………………………………………………………..402
INSPECTION…………………………………………………………………………402
FLEXPLATE ASSEMBLY-CLEANING AND INSPECTION FOR REUSE……………………………………….403
FLYWHEEL RING GEAR-REPLACEMENT…………………………………………………………..403
REMOVAL……………………………………………………………………………403
INSTALLATION……………………………………………………………………….403
FLYWHEEL HOUSING-CLEANING AND INSPECTION FOR REUSE…………………………………………404
CLEANING…………………………………………………………………………..404
INSPECTION…………………………………………………………………………404
FLYWHEEL HOUSING-ASSEMBLY(WET CLUTCH APPLICATION)………………………………………….405
ENGINE SUPPORT BRACKET,FRONT-CLEANING AND INSPECTION FOR REUSE………………………………406
CLEANING…………………………………………………………………………..406
INSPECTION…………………………………………………………………………406
SPECIFICATIONS AND TORQUE VALUES-GROUP 18…………………………………………………….407
ENGINE COMPONENTS-GENERAL INFORMATION…………………………………………………….408
COMPONENT SPECIFICATIONS AND TORQUE VALUES………………………………………………..409
ENGINE ASSEMBLY-SPECIFICATIONS……………………………………………………….409
ENGINE ASSEMBLY-TORQUE VALUES………………………………………………………..411
CYLINDER BLOCK-REBUILD SPECIFICATIONS…………………………………………………421
CYLINDER BLOCK-TORQUE VALUES…………………………………………………………427
CYLINDER HEAD-REBUILD SPECIFICATIONS………………………………………………….428
ROCKER LEVER ASSEMBLY-REBUILD SPECIFICATIONS………………………………………………432
VALVE TAPPET-REBUILD SPECIFICATIONS………………………………………………………432
FUEL SYSTEMS-REBUILD SPECIFICATIONS………………………………………………………432
FUEL SYSTEM SPECIFICATIONS…………………………………………………………..432
FUEL SHUTOFF SOLENOID ADJUSTMENT……………………………………………………..434
FUEL SYSTEM TORQUE VALUES……………………………………………………………434
FUEL INJECTION PUMP SEALING WASHER……………………………………………………434
LUBRICATING OIL SYSTEM SPECIFICATIONS…………………………………………………….437
LUBRICATING OIL SYSTEM TORQUE VALUES……………………………………………………..438
COOLING SYSTEM SPECIFICATIONS……………………………………………………………440
COOLING SYSTEM TORQUE VALUES…………………………………………………………441
AIR INTAKE SYSTEM SPECIFICATIONS……………………………………………………..442
AIR INTAKE SYSTEM TORQUE VALUES………………………………………………………442
EXHAUST SYSTEM SPECIFICATIONS……………………………………………………………444
EXHAUST SYSTEM TORQUE VALUES…………………………………………………………….444
AIR COMPRESSOR INSPECTION SPECIFICATIONS………………………………………………….444
AIR COMPRESSOR TORQUE VALUES…………………………………………………………….444
ELECTRICAL SYSTEM SPECIFICATIONS…………………………………………………………445
ELECTRICAL SYSTEM TORQUE VALUES………………………………………………………….445
ENGINE TESTING-TEST SPECIFICATIONS……………………………………………………….446
MOUNTING ADAPTATIONS SPECIFICATIONS………………………………………………………446
FLYWHEEL HOUSING(WET APPLICATION)…………………………………………………….446
FLYWHEEL RING GEAR INSTALLATION………………………………………………………447
MOUNTING ADAPTATIONS-TORQUE VALUES……………………………………………………….447
DRIVE BELT TENSION……………………………………………………………………..448
WEIGHT AND MEASURES-CONVERSION FACTORS……………………………………………………450
NEWTON-METER TO FOOT-POUND CONVERSION CHART……………………………………………….451
CAPSCREW MARKINGS AND TORQUE VALUES………………………………………………………452
CAPSCREW MARKINGS AND TORQUE VALUES-METRIC…………………………………………….453
CAPSCREW MARKINGS AND TORQUE VALUES-U.S. CUSTOMARY……………………………………..453
PIPE PLUG TORQUE VALUES…………………………………………………………………454
TAP-DRILL CHART-U.S. CUSTOMARY & METRIC…………………………………………………..455
INDEX…………………………………………………………………………………….456
COVER…………………………………………………………………………………….460
CONTENTS………………………………………………………………………………….461
PRODUCT PUBLICATIONS INFORMATION…………………………………………………………….462
TROUBLESHOOTING AND REPAIR MANUAL……………………………………………………………464
FOREWORD………………………………………………………………………………….465
TABLE OF CONTENTS………………………………………………………………………….466
INTRODUCTION………………………………………………………………………………467
ABOUT THE MANUAL……………………………………………………………………….468
HOW TO USE THIS MANUAL………………………………………………………………….468
TABLE OF CONTENTS…………………………………………………………………..468
INDEX……………………………………………………………………………..468
METRIC INFORMATION………………………………………………………………….468
GENERIC SYMBOLS………………………………………………………………………..469
ILLUSTRATIONS………………………………………………………………………….470
GENERAL SAFETY INSTRUCTIONS……………………………………………………………..471
GENERAL REPAIR INSTRUCTIONS……………………………………………………………..472
GENERAL CLEANING INSTRUCTIONS……………………………………………………………473
SOLVENT AND ACID CLEANING……………………………………………………………473
STEAM CLEANING……………………………………………………………………..473
GLASS OR PLASTIC BEAD CLEANING……………………………………………………….473
GLOSSARY OF TERMS………………………………………………………………………475
ENGINE AND COMPONENT IDENTIFICATION………………………………………………………….477
ENGINE IDENTIFICATION…………………………………………………………………..478
ENGINE DATAPLATES…………………………………………………………………..478
FUEL INJECTION PUMP DATAPLATE………………………………………………………..479
GENERAL ENGINE SPECIFICATIONS……………………………………………………………480
GENERAL ENGINE DATA…………………………………………………………………480
LUBRICATION SYSTEM………………………………………………………………….480
COOLING SYSTEM……………………………………………………………………..481
INTAKE AIR AND EXHAUST SYSTEM………………………………………………………..481
FUEL SYSTEM………………………………………………………………………..481
ELECTRICAL SYSTEM…………………………………………………………………..482
BATTERIES(SPECIFIC GRAVITY)………………………………………………………….482
ENGINE DIAGRAMS………………………………………………………………………..483
TROUBLESHOOTING LOGIC………………………………………………………………………486
SECTION T-TROUBLESHOOTING……………………………………………………………….487
PROCEDURES AND TECHNIQUES……………………………………………………………487
TROUBLESHOOTING SYMPTOMS CHARTS………………………………………………………….487
AIR COMPRESSOR OPERATES WITH EXCESSIVE NOISE…………………………………………..488
AIR COMPRESSOR PUMPING EXCESSIVE LUBRICATING OIL INTO AIR SYSTEM…………………………489
AIR COMPRESSOR AIR PRESSURE RISES SLOWLY………………………………………………490
AIR COMPRESSOR WILL NOT MAINTAIN ADEQUATE AIR PRESSURE(NOT PUMPING CONTINUOUSLY)…………..491
AIR COMPRESSOR WILL NOT PUMP AIR PRESSURE……………………………………………..492
AIR COMPRESSOR WILL NOT STOP PUMPING AIR………………………………………………493
ALTERNATOR NOT CHARGING OR INSUFFICIENT CHARGING……………………………………….494
COMPRESSION KNOCK…………………………………………………………………..495
COOLANT CONTAMINATED………………………………………………………………..496
COOLANT LOSS……………………………………………………………………….497
COOLANT TEMPERATURE ABOVE NORMAL-GRADUAL OVERHEAT………………………………………499
COOLANT TEMPERATURE ABOVE NORMAL-SUDDEN OVERHEAT……………………………………….502
COOLANT TEMPERATURE BELOW NORMAL……………………………………………………..504
ENGINE CRANKCASE GASES(BLOWBY)-EXCESSIVE………………………………………………505
ENGINE CRANKS,BUT WILL NOT START-NO SMOKE FROM EXHAUST………………………………….506
ENGINE DIFFICULT TO START OR WILL NOT START-EXHAUST SMOKE PRESENT………………………..509
ENGINE IDLE ROUGH,WARM ENGINE………………………………………………………..511
ENGINE MISFIRING……………………………………………………………………513
ENGINE POWER OUTPUT LOW……………………………………………………………..515
ENGINE NOISE EXCESSIVE………………………………………………………………519
ENGINE STARTS BUT WILL NOT KEEP RUNNING……………………………………………….520
ENGINE SURGES AT IDLE……………………………………………………………….521
ENGINE VIBRATION EXCESSIVE…………………………………………………………..522
ENGINE WILL NOT CRANK OR CRANKS SLOWLY………………………………………………..523
ENGINE WILL NOT REACH RATED SPEED WHEN LOADED………………………………………….524
ENGINE WILL NOT SHUT OFF…………………………………………………………….526
EXHAUST BLACK SMOKE EXCESSIVE UNDER LOAD………………………………………………527
EXHAUST WHITE SMOKE EXCESSIVE(WARM ENGINE)…………………………………………….529
FUEL CONSUMPTION EXCESSIVE…………………………………………………………..530
FUEL OR OIL LEAKING FROM EXHAUST MANIFOLD……………………………………………..531
LUBRICATING OIL CONTAMINATED…………………………………………………………532
LUBRICATING OIL CONSUMPTION EXCESSIVE…………………………………………………533
LUBRICATING OIL PRESSURE LOW…………………………………………………………535
LUBRICATING OIL PRESSURE HIGH………………………………………………………..537
ENGINE NOISE DIAGNOSTIC PROCEDURES-GENERAL INFORMATION………………………………….538
MAIN BEARING NOISE(REFER TO ENGINE NOISE EXCESSIVE-MAIN BEARING SYSTEM CHART)……………..538
CONNECTING ROD BEARING NOISE(REFER TO ENGINE NOISE EXCESSIVE-CONNECTING ROD SYMPTOM CHART)….538
PISTON NOISE(REFER TO ENGINE NOISE EXCESSIVE-PISTON SYMPTOM CHART)……………………….538
FUEL CONSUMPTION-GENERAL INFORMATION………………………………………………….538
FUEL CONSUMPTION-INDUSTRIAL CUSTOMER COMPLAINT FORM…………………………………….539
OIL CONSUMPTION…………………………………………………………………….540
COOLING SYSTEM…………………………………………………………………………….542
COOLING SYSTEM-GENERAL INFORMATION……………………………………………………….543
COOLING SYSTEM-FLOW DIAGRAMS…………………………………………………………….544
COOLING SYSTEM-SPECIFICATIONS……………………………………………………………546
COOLING SYSTEM-SERVICE TOOLS…………………………………………………………….547
COOLING SYSTEM-MAINTENANCE………………………………………………………………548
ANTIFREEZE…………………………………………………………………………548
ANTIFREEZE CONCENTRATION-CHECKING…………………………………………………….548
COOLING SYSTEM-DRAINING……………………………………………………………..548
ADDITIVE CONCENTRATION-CHECKING………………………………………………………548
COOLING SYSTEM-CLEANING……………………………………………………………..549
FILLING AND VENTING…………………………………………………………………553
COOLING SYSTEM-DIAGNOSING MALFUNCTIONS……………………………………………………554
RADIATOR CAP-PRESSURE TEST…………………………………………………………..555
COOLING SYSTEM-TEST FOR COMBUSTION GASES………………………………………………555
BELT TENSION……………………………………………………………………….559
COOLANT HOSE-INSPECTION……………………………………………………………..560
WATER PUMP-INSPECTION……………………………………………………………….560
WATER PUMP SEAL WEEP HOLE-INSPECTION………………………………………………….560
COOLANT PRESSURE-MEASUREMENT…………………………………………………………562
RADIATOR,FAN AND SHUTTERS……………………………………………………………562
THERMOSTAT OPERATION AND TESTING……………………………………………………..564
THERMOSTAT LEAKAGE AND OPENING TEMPERATURE-TESTING”IN-CHASSIS”…………………………..565
THERMOSTAT OPENING TEMPERATURE-TESTING”THERMOSTAT REMOVED”………………………………566
TEMPERATURE GAUGE OPERATION………………………………………………………….567
FUEL PUMP OVERFUELED………………………………………………………………..567
VEHICLE OVERLOADED………………………………………………………………….568
DRIVE BELT-REPLACEMENT………………………………………………………………….568
BELT TENSIONER-REPLACEMENT………………………………………………………………568
REMOVAL……………………………………………………………………………568
INSTALLATION……………………………………………………………………….569
FAN PULLEY-REPLACEMENT………………………………………………………………….569
REMOVAL AND INSTALLATION…………………………………………………………….569
FAN HUB-REPLACEMENT…………………………………………………………………….569
REMOVAL AND INSTALLATION…………………………………………………………….570
WATER PUMP-REPLACEMENT………………………………………………………………….570
REMOVAL……………………………………………………………………………570
CLEANING…………………………………………………………………………..571
INSTALLATION……………………………………………………………………….571
THERMOSTAT-REPLACEMENT………………………………………………………………….573
REMOVAL……………………………………………………………………………573
CLEANING…………………………………………………………………………..574
INSTALLATION……………………………………………………………………….574
LUBRICATING OIL SYSTEM……………………………………………………………………..577
LUBRICATING OIL SYSTEM-SERVICE TOOLS……………………………………………………..579
LUBRICATING OIL SYSTEM-GENERAL INFORMATION………………………………………………..580
LUBRICATING OIL SYSTEM-SPECIFICATIONS…………………………………………………….581
LUBRICATING OIL SYSTEM-FLOW DIAGRAM………………………………………………………582
LUBRICATING OIL LEAKS(EXTERNAL)-CHECKING………………………………………………….586
INTERNAL ENGINE DAMAGE-CHECKING………………………………………………………….587
LUBRICATING OIL ANALYSIS…………………………………………………………….587
LUBRICATING OIL FILTER INSPECTION…………………………………………………….587
LUBRICATING OIL SYSTEM-DIAGNOSING MALFUNTIONS……………………………………………..588
HIGH OIL PRESSURE…………………………………………………………………..588
OIL PRESSURE REGULATION VALVE………………………………………………………..588
LOW OIL PRESSURE……………………………………………………………………588
OIL LEVEL………………………………………………………………………….588
OIL FILTER…………………………………………………………………………589
OIL PRESSURE GAUGE-CHECKING………………………………………………………….589
OIL TEMPERATURE GAUGE-CHECKING……………………………………………………….590
OIL TEMPERATURE THERMOSTAT…………………………………………………………..590
OIL SUCTION TUBE……………………………………………………………………591
BEARINGS AND OIL PUMP……………………………………………………………….591
OIL DILUTION……………………………………………………………………….591
COOLANT DILUTED OIL…………………………………………………………………591
OIL COOLER…………………………………………………………………………592
AFTERCOOLER………………………………………………………………………..592
CYLINDER HEAD EXPANSION PLUGS………………………………………………………..593
CYLINDER LINER SEALS………………………………………………………………..593
CYLINDER HEAD GASKET………………………………………………………………..593
CRACKED CYLINDER HEAD……………………………………………………………….593
CRACKED CYLINDER LINER………………………………………………………………594
CRACKED CYLINDER BLOCK………………………………………………………………594
FUEL DILUTED OIL……………………………………………………………………594
FUEL TRANSFER PUMP………………………………………………………………….595
FUEL LEAKING BY PISTON RINGS…………………………………………………………595
INJECTION PUMP……………………………………………………………………..596
OIL LEAKS………………………………………………………………………….596
LUBRICATING OIL PAN-DRAINING…………………………………………………………….598
LUBRICATING OIL PAN-FILLING……………………………………………………………..598
LUBRICATING OIL LEVEL-CHECKING…………………………………………………………..599
LUBRICATING OIL FILTER-CHANGING………………………………………………………….600
LUBRICATING OIL DIPSTICK-CALIBRATION……………………………………………………..601
LUBRICATING OIL DIPSTICK TUBE-REPLACEMENT…………………………………………………602
REMOVAL……………………………………………………………………………602
INSTALLATION……………………………………………………………………….602
LUBRICATING OIL PRESSURE REGULATOR,VALVE AND SPRING-REPLACEMENT……………………………..603
REMOVAL……………………………………………………………………………603
CLEANING AND INSPECTION……………………………………………………………..603
INSTALLATION……………………………………………………………………….604
LUBRICATING OIL COOLER ELEMENT AND GASKET-REPLACEMENT………………………………………604
REMOVAL……………………………………………………………………………604
CLEANING AND INSPECTION……………………………………………………………..605
INSTALLATION……………………………………………………………………….606
LUBRICATING OIL TEMPERATURE THERMOSTAT-REPLACEMENT…………………………………………607
REMOVAL……………………………………………………………………………607
INSPECTION…………………………………………………………………………608
INSTALLATION……………………………………………………………………….609
LUBRICATING OIL PAN,SUCTION TUBE AND GASKET-REPLACEMENT…………………………………….609
OIL PAN -REMOVAL……………………………………………………………………609
CLEANING…………………………………………………………………………..609
SUCTION TUBE-REPLACEMENT…………………………………………………………….610
OIL PAN -INSTALLATION……………………………………………………………….610
LUBRICATING OIL PUMP-REPLACEMENT…………………………………………………………612
REMOVAL……………………………………………………………………………613
CLEANING AND INSPECTION……………………………………………………………..613
INSTALLATION……………………………………………………………………….616
COMBUSTION AIR SYSTEM………………………………………………………………………620
COMBUSTION AIR SYSTEM FLOW-GENERAL INFORMATION…………………………………………….622
AIR SYSTEM FLOW-DIAGRAMS………………………………………………………………..623
INTAKE AIR AND EXHAUST SYSTEM SPECIFICATIONS………………………………………………624
TURBOCHARGER BOOST PRESSURE SPECIFICATIONS………………………………………………..624
COMBUSTION AIR SYSTEM-SERVICE TOOLS………………………………………………………625
COMBUSTION AIR SYSTEM-DIAGNOSING MALFUNCTIONS……………………………………………..626
CLEAN AIR………………………………………………………………………….626
INTAKE AIR RESTRICTION-CHECKING………………………………………………………626
DAMAGE FROM NON-FILTERED AIR…………………………………………………………627
TURBOCHARGED ENGINES-AIR LEAKS,PRESSURE SIDE…………………………………………..627
TURBOCHARGED ENGINES-EXHAUST LEAKS……………………………………………………628
TURBOCHARGED BOOST PRESSURE-MEASUREMENT……………………………………………….628
MALFUNCTIONING TURBOCHARGER………………………………………………………….629
OIL CONSUMPTION AND LEAKS……………………………………………………………629
TURBOCHARGER NOISE………………………………………………………………….630
ROTOR ASSEMBLY CLEARANCE-MEASUREMENT………………………………………………….631
TURBOCHARGER WASTEGATE ACTUATOR-VISUAL INSPECTION………………………………………….632
TURBOCHARGER WASTEGATE ACTUATOR-FUNCTIONAL CHECKING………………………………………..633
TURBOCHARGER WASTEGATE ACTUATOR-REPLACEMENT……………………………………………….634
AIR REGULATOR WITH PRESSURE GAUGE…………………………………………………….634
TURBOCHARGER WASTEGATE ACTUATOR-CALIBRATION……………………………………………….636
EXHAUST RESTRICTION-MEASUREMENT………………………………………………………637
CHARGE AIR COOLER(CAC)-TROUBLESHOOTING……………………………………………………637
PRESSURE DROP-CHECKING………………………………………………………………637
CHECKING-AIR LEAK…………………………………………………………………..639
CHARGE AIR COOLER………………………………………………………………………640
CLEANING AND INSPECTION……………………………………………………………..640
AIR CROSSOVER TUBE-REPLACEMENT…………………………………………………………..641
REMOVAL AND INSTALLATION…………………………………………………………….641
INTAKE MANIFOLD COVER AND GASKET-REPLACEMENT………………………………………………642
REMOVAL……………………………………………………………………………642
CLEANING…………………………………………………………………………..643
INSTALLATION……………………………………………………………………….643
AFTERCOOLER AND GASKET-REPLACEMENT……………………………………………………….643
REMOVAL……………………………………………………………………………644
CLEANING…………………………………………………………………………..644
INSTALLATION……………………………………………………………………….644
TURBOCHARGER-REPLACEMENT………………………………………………………………..645
REMOVAL……………………………………………………………………………645
CLEANING AND INSPECTION……………………………………………………………..646
INSTALLATION……………………………………………………………………….647
EXHAUST MANIFOLD AND GASKETS-REPLACEMENT………………………………………………….649
REMOVAL……………………………………………………………………………649
CLEANING AND INSPECTION……………………………………………………………..650
INSTALLATION……………………………………………………………………….650
COMPRESSED AIR SYSTEM………………………………………………………………………652
COMPRESSED AIR SYSTEM GENERAL INFORMATION…………………………………………………653
COMPRESSED AIR SYSTEM SPECIFICATIONS……………………………………………………..654
COMPRESSED AIR SYSTEM FLOW DIAGRAMS………………………………………………………655
AIR COMPRESSOR CARBON BUILDUP-CHECKING……………………………………………………656
AIR COMPRESSOR GASKET LEAKS-CHECKING……………………………………………………..658
AIR GOVERNOR AND COMPRESSOR UNLOADER VALVE-CHECKING………………………………………..658
AIR GOVERNOR-CHECKING…………………………………………………………………..659
AIR COMPRESSOR-REPLACEMENT………………………………………………………………661
REMOVAL……………………………………………………………………………662
INSPECTION…………………………………………………………………………663
INSTALLATION……………………………………………………………………….663
FUEL SYSTEM……………………………………………………………………………….666
FUEL SYSTEM COMPONENTS AND FLOW………………………………………………………….668
FUEL SYSTEM SPECIFICATIONS………………………………………………………………669
FUEL SYSTEM -SERVICE TOOLS………………………………………………………………670
FUEL SYSTEM DIAGNOSING-MALFUNCTIONS………………………………………………………672
FUEL TRANSFER PUMP………………………………………………………………….672
AIR IN THE FUEL SYSTEM………………………………………………………………676
FUEL WATER SEPARATOR/FILTER UNIT……………………………………………………..678
FUEL INJECTION PUMP…………………………………………………………………679
GOVERNOR MALFUNCTIONS……………………………………………………………….679
AIR FUEL CONTROL(AFC)MALFUNCTIONS…………………………………………………….679
FUEL CONTROL LEVER TRAVEL AND ADJUSTMENT………………………………………………680
FUEL INJECTION PUMP IDLE ADJUSTMENT SCREWS…………………………………………….680
MANUAL SHUT DOWN LEVERS……………………………………………………………..680
ELECTRICAL SHUT DOWN DEVICES…………………………………………………………681
FUEL INJECTION PUMP TIMING…………………………………………………………..682
HIGH PRESSURE PUMP TIMING……………………………………………………………683
INJECTORS………………………………………………………………………….684
FUEL DRAIN MANIFOLD…………………………………………………………………685
LOW PRESSURE FUEL LINE-REPLACEMENT……………………………………………………….686
REMOVAL AND INSTALLATION…………………………………………………………….686
FUEL FILTER HEAD ADAPTER-REPLACEMENT……………………………………………………..686
REMOVAL AND INSTALLATION…………………………………………………………….686
FUEL TRANSFER PUMP-REPLACEMENT/REBUILD……………………………………………………687
REMOVAL……………………………………………………………………………687
REBUILD……………………………………………………………………………687
CLEANING…………………………………………………………………………..688
ASSEMBLY…………………………………………………………………………..688
CLEANING MOUNTING SURFACE……………………………………………………………689
INSTALLATION……………………………………………………………………….689
HIGH PRESSURE FUEL LINES-REPLACEMENT……………………………………………………..689
REMOVAL……………………………………………………………………………689
INSTALLATION……………………………………………………………………….690
FUEL DRAIN MANIFOLD-REPLACEMENT………………………………………………………….691
REMOVAL AND INSTALLATION…………………………………………………………….691
INJECTOR-REPLACEMENT……………………………………………………………………691
REMOVAL……………………………………………………………………………691
CLEANING AND INSPECTION……………………………………………………………..691
INSTALLATION……………………………………………………………………….692
FUEL SHUTOFF SOLENOID-REPLACEMENT………………………………………………………..693
RSV GOVERNOR FUEL SHUTOFF SOLENOID-REMOVAL…………………………………………….693
RSV GOVERNOR FUEL SHUTOFF SOLENOID-INSTALLATION………………………………………..694
DIRECT LINK SOLENOID,CYLINDER BLOCK MOUNTED……………………………………………694
RQVK GOVERNOR FUEL SHUTOFF SOLENOID-REMOVAL AND INSTALLATION…………………………….694
FUEL RETURN OVERFLOW VALVE-REPLACEMENT……………………………………………………695
AFC TUBE-REPLACEMENT……………………………………………………………………696
REMOVAL……………………………………………………………………………696
INSTALLATION……………………………………………………………………….696
FUEL INJECTION PUMP-REPLACEMENT………………………………………………………….696
REMOVAL……………………………………………………………………………697
INSTALLATION……………………………………………………………………….698
IDLE SPEED-ADJUSTMENT…………………………………………………………………..703
BOSCH RSV GOVERNOR………………………………………………………………….703
BOSCH RQVK GOVERNOR…………………………………………………………………704
INLINE FUEL INJECTION PUMP SPILL-PORT TIMING………………………………………………704
GOVERNOR LEVER POSITIONING…………………………………………………………..706
ELECTRICAL SYSTEM………………………………………………………………………….711
ELECTRICAL SYSTEM DESCRIPTION AND OPERATION……………………………………………….712
CRANKING MOTOR AND ELECTRICAL CIRCUITS………………………………………………..712
DELCO REMY MODEL 37MT/41MT STARTING MOTOR……………………………………………..713
DELCO REMY MODEL 42MT STARTING MOTOR………………………………………………….713
NIPPENDENSO MODEL F2 STARTING MOTOR…………………………………………………..714
NIPPENDENSO MODEL F2 BASIC CRANKING CURRENT FLOW……………………………………….714
DELCO REMY MODEL 15SI 116 ALTERNATOR(WIRING DIAGRAM)……………………………………715
BOSCH K1 MODEL ALTERNATOR(WIRING DIAGRAM)……………………………………………..715
NIPPONDENSO F4 STARTING MOTOR………………………………………………………..716
DELCO 42MT STARTING MOTOR……………………………………………………………716
ELECTRICAL SYSTEM-SPECIFICATIONS…………………………………………………………717
MINIMUM RECOMMENDED BATTERY CAPACITY………………………………………………….717
MAXIMUM ALLOWABLE RESISTANCE OF STARTING CIRCUIT……………………………………….717
WIRING SIZE RECOMMENDATIONS FOR STARTER SOLENOID AND FUEL SOLENOID CIRCUIT………………..718
ELECTRICAL SYSTEM-SERVICE TOOLS………………………………………………………….719
ELECTRICAL SYSTEM-DIAGNOSING MALFUNCTIONS…………………………………………………720
BATTERIES-CHECKING………………………………………………………………….720
STARTING CIRCUIT-CHECKING……………………………………………………………721
STARTING MOTOR SOLENOID AND STARTING MOTOR CHECKING…………………………………….724
ENGINE CRANKING SPEED TOO SLOW……………………………………………………….726
ALTERNATOR…………………………………………………………………………727
OIL PRESSURE SWITCH AND TEMPERATURE SENSOR-CHECKING…………………………………….730
COOLANT OR PAN HEATERS-CHECKING………………………………………………………731
STARTING MOTOR-REPLACEMENT………………………………………………………………731
REMOVAL AND INSTALLATION…………………………………………………………….732
ALTERNATOR-REPLACEMENT………………………………………………………………….732
REMOVAL……………………………………………………………………………732
INSTALLATION……………………………………………………………………….733
COOLANT TEMPERATURE SENSOR-REPLACEMENT……………………………………………………733
REMOVAL……………………………………………………………………………734
INSTALLATION……………………………………………………………………….734
ENGINE BLOCK AND COOLANT HEATER(750 AND 500 WATS)-REPLACEMENT……………………………….734
REMOVAL……………………………………………………………………………735
INSTALLATION……………………………………………………………………….735
LUBRICATING OIL PAN HEATER-REPLACEMENT……………………………………………………735
REMOVAL……………………………………………………………………………736
INSTALLATION……………………………………………………………………….736
LUBRICATING OIL PRESSURE SWITCH REPLACEMENT……………………………………………….736
REMOVAL……………………………………………………………………………736
INSTALLATION……………………………………………………………………….736
BASE ENGINE COMPONENTS……………………………………………………………………..737
BASE ENGINE COMPONENTS-SERVICE TOOLS……………………………………………………..740
BASE ENGINE COMPONENTS-GENERAL INFORMATION………………………………………………..745
ENGINE COMPRESSION-CHECKING……………………………………………………………..745
COMPRESSION GUAGE AND ADAPTER………………………………………………………..745
PISTON RING SEALING…………………………………………………………………746
INTAKE AND EXHAUST VALVE SEALING……………………………………………………..746
CYLINDER HEAD GASKET SEALING…………………………………………………………746
VALVE COVER-REPLACEMENT…………………………………………………………………747
REMOVAL……………………………………………………………………………747
CLEANING AND INSPECTION……………………………………………………………..748
INSTALLATION……………………………………………………………………….748
CRANKCASE BREATHER TUBE-REPLACEMENT………………………………………………………749
REMOVAL……………………………………………………………………………749
CLEANING AND INSPECTION……………………………………………………………..749
INSTALLATION……………………………………………………………………….750
ROCKER LEVER DIAGNOSING-MALFUNCTIONS……………………………………………………..750
VALVE LASH SPECIFICATIONS……………………………………………………………750
ROCKER LEVER-REPLACEMENT………………………………………………………………..751
REMOVAL……………………………………………………………………………751
DISASSEMBLY………………………………………………………………………..752
CLEANING AND INSPECTION……………………………………………………………..753
ASSEMBLY…………………………………………………………………………..754
INSTALLATION……………………………………………………………………….755
VALVE LASH-ADJUSTMENT…………………………………………………………………..756
VALVE ARRANGEMENT…………………………………………………………………..758
TIMING PIN ASSEMBLY-INSTALLATION…………………………………………………………759
PUSH ROD-REPLACEMENT……………………………………………………………………763
REMOVAL……………………………………………………………………………763
CLEANING AND INSPECTION……………………………………………………………..764
INSTALLATION……………………………………………………………………….765
CYLINDER HEAD-REPLACEMENT……………………………………………………………….766
GENERAL INFORMATION…………………………………………………………………766
DIAGNOSING MALFUNCTIONS……………………………………………………………..766
REMOVAL……………………………………………………………………………769
CYLINDER BLOCK/HEAD DECK-CLEANING AND INSPECTION……………………………………….770
CYLINDER HEAD-CLEANING AND INSPECTION…………………………………………………773
INSTALLATION……………………………………………………………………….778
CYLINDER HEAD-PRESSURE TEST……………………………………………………………..783
MAIN AND THRUST BEARINGS-REPLACEMENT……………………………………………………..784
GENERAL INFORMATION…………………………………………………………………784
DIAGNOSING MALFUNCTIONS……………………………………………………………..785
REMOVAL……………………………………………………………………………786
CLEANING AND INSPECTION……………………………………………………………..788
INSTALLATION……………………………………………………………………….790
CONNECTING ROD BEARINGS-REPLACEMENT………………………………………………………795
DIAGNOSING MALFUNCTIONS……………………………………………………………..795
REMOVAL……………………………………………………………………………796
CLEANING AND INSPECTION……………………………………………………………..797
INSTALLATION……………………………………………………………………….800
PISTON AND RINGS-REPLACEMENT…………………………………………………………….802
PISTON-GENERAL INFORMATION…………………………………………………………..802
PISTON AND RINGS-DIAGNOSING MALFUNCTIONS………………………………………………802
REMOVAL……………………………………………………………………………804
CLEANING AND INSPECTION……………………………………………………………..807
INSTALLATION……………………………………………………………………….812
CONNECTING RODS-REPLACEMENT……………………………………………………………..819
GENERAL INFORMATION…………………………………………………………………819
REMOVAL……………………………………………………………………………820
CLEANING AND INSPECTION……………………………………………………………..821
INSTALLATION……………………………………………………………………….823
CYLINDER LINERS-REPLACEMENT……………………………………………………………..825
GENERAL INFORMATION…………………………………………………………………825
REMOVAL……………………………………………………………………………825
CLEANING AND INSPECTION……………………………………………………………..829
INSTALLATION……………………………………………………………………….832
VIBRATION DAMPER-REPLACEMENT…………………………………………………………….839
GENERAL INFORMATION…………………………………………………………………839
RUBBER ELEMENT VIBRATION DAMPER-INSPECTION(IN-CHASSIS)………………………………….839
VISCOUS VIBRATION DAMPER-INSPECTION…………………………………………………..841
REMOVAL……………………………………………………………………………842
INSTALLATION……………………………………………………………………….843
GEAR COVER-REPLACEMENT………………………………………………………………….844
REMOVAL……………………………………………………………………………844
CLEANING AND INSPECTION……………………………………………………………..845
INSTALATION………………………………………………………………………..846
SEAL,FRONT CRANKSHAFT-REPLACEMENT………………………………………………………..848
GENERAL INFORMATION…………………………………………………………………848
REMOVAL AND INSTALLATION…………………………………………………………….849
WEAR SLEEVE,FRONT CRANKSHAFT-REPLACEMENT………………………………………………….849
REMOVAL……………………………………………………………………………849
CLEANING AND INSPECTION……………………………………………………………..850
INSTALLATION……………………………………………………………………….850
GEAR HOUSING-REPLACEMENT………………………………………………………………..853
GENERAL INFORMATION…………………………………………………………………853
REMOVAL……………………………………………………………………………854
CLEANING AND INSPECTION……………………………………………………………..855
INSTALLATION……………………………………………………………………….857
ENGINE DATAPLATE-REPLACEMENT…………………………………………………………….862
REMOVAL……………………………………………………………………………863
INSTALLATION……………………………………………………………………….863
CAMSHAFT-REPLACEMENT……………………………………………………………………864
GENERAL INFORMATION…………………………………………………………………864
REMOVAL……………………………………………………………………………866
CLEANING AND INSPECTION……………………………………………………………..869
INSTALLATION……………………………………………………………………….873
CAMSHAFT GEAR-REPLACEMENT……………………………………………………………….876
REMOVAL……………………………………………………………………………876
CLEANING AND INSPECTION……………………………………………………………..876
INSTALLATION……………………………………………………………………….878
VALVE TAPPET-REPLACEMENT………………………………………………………………..879
GENERAL INFORMATION…………………………………………………………………879
REMOVAL……………………………………………………………………………880
CLEANING AND INSPECTION……………………………………………………………..883
INSTALLATION……………………………………………………………………….884
CRANKSHAFT GEAR-REPLACEMENT……………………………………………………………..888
GENERAL INFORMATION…………………………………………………………………888
REMOVAL……………………………………………………………………………889
CLEANING AND INSPECTION……………………………………………………………..891
INSTALLATION……………………………………………………………………….892
FLYWHEEL-REPLACEMENT……………………………………………………………………895
REMOVAL……………………………………………………………………………895
CLEANING AND INSPECTION……………………………………………………………..896
INSTALLATION……………………………………………………………………….897
FLYWHEEL BORE RUNOUT MEASUREMENT……………………………………………………..899
FLYWHEEL FACE RUNOUT MEASUREMENT……………………………………………………..900
FLYWHEEL RING GEAR-REPLACEMENT…………………………………………………………..902
REMOVAL……………………………………………………………………………902
INSTALLATION……………………………………………………………………….902
FLYWHEEL HOUSING-REPLACEMENT…………………………………………………………….902
REMOVAL……………………………………………………………………………902
CLEANING AND INSPECTION……………………………………………………………..904
INSTALLATION(DRY CLUTCH APPLICATION)………………………………………………….905
CONCENTRICITY-CHECKING………………………………………………………………906
INSTALLATION(WET CLUTCH APPLICATION)………………………………………………….908
SEAL,REAR CRANKSHAFT-REPLACEMENT…………………………………………………………910
REMOVAL……………………………………………………………………………910
CLEANING AND INSPECTION……………………………………………………………..911
INSTALLATION……………………………………………………………………….912
WEAR SLEEVE,REAR CRANKSHAFT SEAL-REPLACEMENT………………………………………………913
REMOVAL……………………………………………………………………………913
CLEANING AND INSPECTION……………………………………………………………..915
INSTALLATION……………………………………………………………………….916
PIPE PLUG-REPLACEMENT…………………………………………………………………..919
REMOVAL……………………………………………………………………………919
CLEANING AND INSPECTION……………………………………………………………..919
INSTALLATION……………………………………………………………………….920
CUP PLUG-REPLACEMENT……………………………………………………………………920
REMOVAL……………………………………………………………………………920
CLEANING AND INSPECTION……………………………………………………………..921
INSTALLATION……………………………………………………………………….921
ENGINE TESTING…………………………………………………………………………….923
ENGINE TESTING-GENERAL INFORMATION……………………………………………………….924
ENGINE TESTING-GENERAL SPECIFICATIONS…………………………………………………….925
BLOWBY MEASUREMENT……………………………………………………………………..926
ENGINE TESTING-SERVICE TOOLS…………………………………………………………….927
GENERAL ENGINE TEST PROCEDURES…………………………………………………………..928
ENGINE RUN-IN PROCEDURE…………………………………………………………………930
ENGINE REMOVAL AND INSTALLATION……………………………………………………………..932
ENGINE REMOVAL AND INSTALLATION-GENERAL INFORMATION………………………………………..933
ENGINE-REMOVAL…………………………………………………………………………933
ENGINE MOUNT-INSPECTION…………………………………………………………………936
ENGINE-INSTALLATION…………………………………………………………………….936
THROTTLE CONTROL LEVER CONNECTION…………………………………………………….937
ENGINE COMPONENT SPECIFICATIONS……………………………………………………………..941
SPECIFICATION-GENERAL INFORMATION………………………………………………………..942
COMPONENT SPECIFICATIONS AND TORQUE VALUES………………………………………………..943
COOLING SYSTEM SPECIFICATIONS………………………………………………………..943
COOLING SYSTEM TORQUE VALUES…………………………………………………………943
LUBRICATING OIL SYSTEM SPECIFICATIONS…………………………………………………944
LUBRICATING OIL SYSTEM TORQUE VALUES………………………………………………….945
COMBUSTION AIR SYSTEM SPECIFICATIONS………………………………………………….947
COMBUSTION AIR SYSTEM TORQUE VALUES…………………………………………………..947
COMPRESSED AIR SYSTEM TORQUE VALUES…………………………………………………..948
FUEL SYSTEM SPECIFICATIONS…………………………………………………………..949
FUEL SHUTOFF SOLENOID ADJUSTMENT……………………………………………………..949
FUEL SYSTEM TORQUE VALUES……………………………………………………………950
ELECTRICAL SYSTEM SPECIFICATIONS……………………………………………………..953
ELECTRICAL SYSTEM TORQUE VALUES………………………………………………………953
BASE ENGINE COMPONENT SPECIFICATIONS………………………………………………….954
BASE ENGINE TORQUE VALUES……………………………………………………………965
DRIVE BELT TENSION……………………………………………………………………..967
WEIGHT AND MEASURES-CONVERSION FACTORS……………………………………………………969
NEWTON-METER TO FOOT-POUND CONVERSION CHART……………………………………………….970
CAPSCREW MARKINGS AND TORQUE VALUES………………………………………………………971
CAPSCREW MARKINGS AND TORQUE VALUES-METRIC…………………………………………….972
CAPSCREW MARKINGS AND TORQUE VALUES-U.S. CUSTOMARY……………………………………..973
PIPE PLUG TORQUE VALUES…………………………………………………………………974
INDEX…………………………………………………………………………………….975