Komatsu S6D114E-1 SA6D114E-1 SAA6D114E-1 Series Engine Shop Manual CEBM000601 – PDF DOWNLOAD

Komatsu S6D114E-1 SA6D114E-1 SAA6D114E-1 Series Engine Shop Manual CEBM000601 – PDF DOWNLOAD

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Komatsu S6D114E-1 SA6D114E-1 SAA6D114E-1 Series Engine Shop Manual CEBM000601 – PDF DOWNLOAD

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Pages : 975
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File Type : PDF
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Komatsu S6D114E-1 SA6D114E-1 SAA6D114E-1 Series Engine Shop Manual CEBM000601 – PDF DOWNLOAD

The Komatsu S6D114E-1, SA6D114E-1, and SAA6D114E-1 Series Engine Shop Manual CEBM000601 is a comprehensive guidebook that provides technical information and instructions on how to operate, maintain, and repair the Komatsu S6D114E-1, SA6D114E-1, and SAA6D114E-1 diesel engines. These engines are commonly used in heavy equipment such as excavators, bulldozers, and other heavy machinery.

• The manual is divided into several sections, each providing detailed information on specific topics. These sections include specifications, structure and function, testing and adjusting, disassembly and assembly, maintenance, and troubleshooting.
• The specifications section of the manual provides detailed information on the engine’s physical and operational characteristics, including its dimensions, weight, performance, and power output. It also provides information on the engine’s cooling system, fuel system, and lubrication system.
• The structure and function section of the manual provides an overview of the engine’s internal components and their functions. This section includes detailed diagrams and descriptions of the engine’s various components, such as the cylinder block, cylinder head, crankshaft, pistons, and valves.
• The testing and adjusting section of the manual provides instructions on how to test and adjust the engine’s various components to ensure they are functioning correctly. This section includes detailed procedures for testing and adjusting the engine’s fuel injection system, valve clearances, and oil pressure.
• The disassembly and assembly section of the manual provides step-by-step instructions on how to disassemble and reassemble the engine’s various components. This section includes detailed diagrams and photographs to guide the user through the process.
• The maintenance section of the manual provides information on routine maintenance tasks that should be performed to keep the engine in good working condition. This section includes instructions on how to perform tasks such as changing the engine oil and replacing the air filter.
• The troubleshooting section of the manual provides guidance on how to diagnose and resolve common issues that may arise with the engine. This section includes a list of common symptoms and their likely causes, as well as step-by-step instructions for troubleshooting and resolving each issue.
• Overall, the Komatsu S6D114E-1, SA6D114E-1, and SAA6D114E-1 Series Engine Shop Manual CEBM000601 is an essential resource for anyone who works with or operates machinery that utilizes these engine series. It provides a wealth of technical information, detailed instructions, and troubleshooting guidance that can help keep the engine running smoothly and extend its lifespan. The manual is designed to be user-friendly and easy to understand, with clear and concise language and illustrations to guide the user through each process. Whether you are a mechanic or an equipment operator, this manual will provide you with the information you need to keep your Komatsu engine in good working order.

TABLE OF CONTENTS:

Komatsu S6D114E-1 SA6D114E-1 SAA6D114E-1 Series Engine Shop Manual CEBM000601 – PDF DOWNLOAD

MAIN MENU………………………………………………………………………………………. 0
CONTENTS……………………………………………………………………………………….. 2
SHOP MANUAL…………………………………………………………………………………….. 5
Table of Contents……………………………………………………………………………. 8
Introduction………………………………………………………………………………… 9
About the Manual…………………………………………………………………………. 10
General Cleaning Instructions……………………………………………………………… 16
Solvent and Acid Cleaning……………………………………………………………… 16
Steam Cleaning……………………………………………………………………….. 16
General Repair Instructions……………………………………………………………….. 15
General Safety Instructions……………………………………………………………….. 14
Generic Symbols………………………………………………………………………….. 12
Glossary of Terms………………………………………………………………………… 17
How To Use This Manual……………………………………………………………………. 11
Group Contents……………………………………………………………………….. 11
Index……………………………………………………………………………….. 11
Metric Information……………………………………………………………………. 11
Table of Contents…………………………………………………………………….. 11
Illustrations……………………………………………………………………………. 13
Engine and Component Identification……………………………………………………………. 19
Engine Diagrams………………………………………………………………………….. 24
Engine Identification…………………………………………………………………….. 20
Engine Dataplates…………………………………………………………………….. 20
Fuel Injection Pump Dataplate………………………………………………………….. 21
General Engine Specifications……………………………………………………………… 22
Cooling System……………………………………………………………………….. 23
Fuel System………………………………………………………………………….. 23
General Engine Data…………………………………………………………………… 22
Intake Air and Exhaust System………………………………………………………….. 23
Lubrication System……………………………………………………………………. 22
Engine Disassembly and Assembly – Group 00……………………………………………………… 27
Engine – Assembly………………………………………………………………………… 65
AFC Tube – Installation………………………………………………………………..141
Aftercooler – Installation……………………………………………………………..125
Air Compressor – Installation…………………………………………………………..148
Air Crossover Tube – Installation……………………………………………………….130
Alternator Brace – Installation…………………………………………………………133
Alternator – Installation………………………………………………………………132
Alternator Mounting Bracket – Installation……………………………………………….132
Belt Tensioner Bracket – Installation……………………………………………………134
Belt Tensioner – Installation…………………………………………………………..134
Camshaft – Installation……………………………………………………………….. 93
Connecting Rod Bolt – Installation……………………………………………………… 82
Coolant Filter – Installation…………………………………………………………..131
Coolant Heater – Installation…………………………………………………………..110
Coolant Inlet Connection – Installation………………………………………………….132
Coolant Outlet Connection – Installation…………………………………………………131
Coolant Vent Fitting – Installation……………………………………………………..131
Coolant Vent Petcock – Installation……………………………………………………..131
Coolant Vent Tube – Installation………………………………………………………..132
Crankcase Breather Tube – Installation…………………………………………………..123
Crankshaft – Installation……………………………………………………………… 73
Cylinder Block – Installation onto Engine Rebuild Stand…………………………………… 65
Cylinder Head Installation……………………………………………………………..113
Cylinder Liner – Installation………………………………………………………….. 66
Drive Belt – Installation………………………………………………………………147
Engine Lifting Bracket – Installation……………………………………………………124
Engine – Removal from the Rebuild Stand………………………………………………….134
Engine Support, Front – Installation…………………………………………………….147
Exhaust Manifold – Installation…………………………………………………………125
Fan Hub Assembly – Installation…………………………………………………………135
Flywheel Bore Runout Measurement………………………………………………………..107
Flywheel Face Runout Measurement………………………………………………………..109
Flywheel Housing – Installation…………………………………………………………100
Flywheel – Installation………………………………………………………………..105
Fuel Drain Manifold – Installation………………………………………………………124
Fuel Filter Head – Installation…………………………………………………………140
Fuel Filter – Installation……………………………………………………………..140
Fuel Injection Pump – Installation………………………………………………………135
Fuel Injection Pump Supply Line – Installation……………………………………………139
Fuel Lines, High Pressure – Installation…………………………………………………141
Fuel Lines, Low Pressure – Installation………………………………………………….148
Fuel Pump Solenoid – Installation……………………………………………………….148
Fuel Transfer Pump – Installation……………………………………………………….147
Gear Cover – Installation………………………………………………………………145
Gear Housing – Installation……………………………………………………………. 90
Injector – Installation………………………………………………………………..123
Intake Manifold Cover – Installation…………………………………………………….124
Lubricating Oil Cooler – Installation……………………………………………………112
Lubricating Oil Filter – Installation……………………………………………………113
Lubricating Oil Pan – Installation……………………………………………………… 96
Lubricating Oil Pump – Installation…………………………………………………….. 92
Lubricating Oil Suction Tube – Installation……………………………………………… 96
Main Bearing (Lower) – Installation…………………………………………………….. 74
Main Bearing (Upper) – Installation…………………………………………………….. 72
Main Bearing Cap – Installation………………………………………………………… 74
Piston Assembly – Installation…………………………………………………………. 86
Piston Cooling Nozzle – Installation……………………………………………………. 71
Piston Pin – Installation……………………………………………………………… 82
Piston Ring End Gap – Measurement………………………………………………………. 83
Piston Ring – Installation…………………………………………………………….. 84
Push Rod – Installation………………………………………………………………..117
Rocker Lever and Shaft – Assembly……………………………………………………….117
Rocker Lever Assembly – Installation…………………………………………………….119
Seal, Front Crankshaft – Installation……………………………………………………142
Seal, Rear Crankshaft – Installation……………………………………………………. 78
Starting Motor – Installation…………………………………………………………..110
Tachometer Drive – Installation…………………………………………………………146
Thermostat and Housing – Installation……………………………………………………130
Timing Pin Assembly – Installation……………………………………………………… 97
Turbocharger Exhaust Outlet Connection – Installation……………………………………..130
Turbocharger – Installation…………………………………………………………….126
Turbocharger Oil Drain Tube – Installation……………………………………………….127
Turbocharger Oil Supply Hose – Installation………………………………………………129
Valve Arrangement……………………………………………………………………..121
Valve Clearance – Adjustment……………………………………………………………120
Valve Cover – Installation……………………………………………………………..122
Valve Tappet – Installation……………………………………………………………. 70
Vibration Damper – Installation…………………………………………………………146
Water Pump – Installation……………………………………………………………… 95
Wear Sleeve, Rear Crankshaft Seal – Installation…………………………………………. 79
Engine Accessories – Installation……………………………………………………….150
Engine – Disassembly……………………………………………………………………… 35
AFC Tube – Removal……………………………………………………………………. 38
Aftercooler – Removal…………………………………………………………………. 43
Air Compressor – Removal………………………………………………………………. 40
Air Crossover Tube – Removal…………………………………………………………… 43
Alternator Brace – Removal…………………………………………………………….. 47
Alternator Mounting Bracket – Removal…………………………………………………… 48
Alternator – Removal………………………………………………………………….. 48
Belt Tensioner Bracket – Removal……………………………………………………….. 47
Belt Tensioner – Removal………………………………………………………………. 47
Camshaft – Removal……………………………………………………………………. 54
Coolant – Draining……………………………………………………………………. 36
Coolant Filter – Removal………………………………………………………………. 36
Coolant Heater – Removal………………………………………………………………. 52
Coolant Inlet Connection – Removal……………………………………………………… 50
Coolant Outlet Connection – Removal…………………………………………………….. 48
Coolant Vent Petcock – Removal…………………………………………………………. 49
Coolant Vent Tube Fitting – Removal…………………………………………………….. 49
Coolant Vent Tube – Removal……………………………………………………………. 49
Crankcase Breather Tube – Removal………………………………………………………. 42
Crankshaft – Removal………………………………………………………………….. 62
Cylinder Head – Removal……………………………………………………………….. 49
Cylinder Liner Carbon Deposits – Removal………………………………………………… 58
Cylinder Liner Protrusion – Checking……………………………………………………. 63
Cylinder Liner – Removal………………………………………………………………. 63
Drive Belt – Removal………………………………………………………………….. 47
Engine – Installation onto Engine Rebuild Stand………………………………………….. 41
Engine Lifting Equipment and Brackets…………………………………………………… 35
Engine – Preparation for Steam Cleaning…………………………………………………. 35
Engine – Steam Cleaning……………………………………………………………….. 35
Engine Support, Front – Removal………………………………………………………… 57
Exhaust Manifold – Removal…………………………………………………………….. 46
Expansion Plug – Removal………………………………………………………………. 65
Expansion Plug – Replacement…………………………………………………………… 64
Fan Hub Assembly – Removal…………………………………………………………….. 50
Flywheel Housing – Removal…………………………………………………………….. 53
Flywheel – Removal……………………………………………………………………. 53
Fuel Drain Manifold – Removal………………………………………………………….. 44
Fuel Filter Head – Removal…………………………………………………………….. 37
Fuel Filter – Removal…………………………………………………………………. 37
Fuel Injection Pump – Removal………………………………………………………….. 39
Fuel Injection Pump Supply Line – Removal……………………………………………….. 38
Fuel Lines, High Pressure – Removal…………………………………………………….. 38
Fuel Lines, Low Pressure – Removal……………………………………………………… 37
Fuel Pump Solenoid – Removal…………………………………………………………… 41
Fuel Transfer Pump – Removal…………………………………………………………… 37
Gear Cover – Removal………………………………………………………………….. 52
Gear Housing – Removal………………………………………………………………… 57
Injector – Removal……………………………………………………………………. 44
Intake Manifold Cover – Removal………………………………………………………… 43
Lubricating Oil Cooler – Removal……………………………………………………….. 50
Lubricating Oil – Draining…………………………………………………………….. 36
Lubricating Oil Filter – Removal……………………………………………………….. 36
Lubricating Oil Pan – Removal………………………………………………………….. 53
Lubricating Oil Pump Gear Backlash – Measurement…………………………………………. 56
Lubricating Oil Pump – Removal…………………………………………………………. 57
Lubricating Oil Suction Tube – Removal………………………………………………….. 53
Main Bearing (Lower) – Removal…………………………………………………………. 62
Main Bearing (Upper) – Removal…………………………………………………………. 62
Main Bearing Cap – Removal…………………………………………………………….. 61
Piston Assembly – Removal……………………………………………………………… 59
Piston Cooling Nozzle – Removal………………………………………………………… 62
Piston Pin – Removal………………………………………………………………….. 60
Piston Ring – Removal…………………………………………………………………. 61
Push Rod – Removal……………………………………………………………………. 45
Rocker Lever Assembly – Removal………………………………………………………… 45
Seal, Front Crankshaft – Removal……………………………………………………….. 52
Seal, Rear Crankshaft – Removal………………………………………………………… 54
Starting Motor – Removal………………………………………………………………. 52
Tachometer Drive – Removal…………………………………………………………….. 39
Thermostat and Housing – Removal……………………………………………………….. 48
Turbocharger Exhaust Outlet Connection – Removal…………………………………………. 42
Turbocharger Oil Drain Tube – Removal…………………………………………………… 46
Turbocharger Oil Supply Hose – Removal………………………………………………….. 46
Turbocharger – Removal………………………………………………………………… 46
Valve Cover – Removal…………………………………………………………………. 44
Valve Tappet – Removal………………………………………………………………… 55
Vibration Damper – Removal…………………………………………………………….. 51
Wastegate Actuator Hose – Removal………………………………………………………. 42
Water Pump – Removal………………………………………………………………….. 51
Cylinder Block – Removal from Engine Rebuild Stand……………………………………….. 65
Engine Disassembly and Assembly – Service Tools……………………………………………… 30
General Information………………………………………………………………………. 34
Disassembly………………………………………………………………………….. 34
Assembly…………………………………………………………………………….. 34
Cylinder Block – Group 01……………………………………………………………………..151
Camshaft Bore Expansion Plug – Installation………………………………………………….170
Camshaft Bushing Bore – Cleaning……………………………………………………………172
Camshaft Bushing – Installation…………………………………………………………….172
Camshaft Bushing – Removal…………………………………………………………………171
Camshaft – Cleaning and Inspection for Reuse…………………………………………………200
Camshaft – Cleaning……………………………………………………………………200
Camshaft Gear – Inspection……………………………………………………………..203
Camshaft – Inspection………………………………………………………………….200
Camshaft Gear – Replacement………………………………………………………………..204
Camshaft Gear – Cleaning……………………………………………………………….204
Camshaft Gear – Inspection……………………………………………………………..204
Camshaft Gear – Installation……………………………………………………………206
Camshaft Gear – Removal………………………………………………………………..204
Connecting Rod Bearings – Cleaning and Inspection for Reuse……………………………………189
Connecting Rod Bearings – Cleaning………………………………………………………189
Connecting Rod Bearings – Inspection…………………………………………………….189
Connecting Rod Bushing – Replacement………………………………………………………..195
Inspection……………………………………………………………………………199
Installation………………………………………………………………………….197
Machining…………………………………………………………………………….199
Removal………………………………………………………………………………195
Connecting Rods – Bend and Twist Inspection………………………………………………….193
Connecting Rod Alignment – Inspection……………………………………………………194
Connecting Rod Twist – Inspection……………………………………………………….194
Fixture Calibration……………………………………………………………………193
Connecting Rods – Cleaning and Inspection for Reuse…………………………………………..190
Connecting Rods – Cleaning……………………………………………………………..190
Connecting Rods – Inspection……………………………………………………………191
Crankshaft – Cleaning and Inspection for Reuse……………………………………………….179
Crankshaft – Cleaning………………………………………………………………….179
Crankshaft – Inspection………………………………………………………………..180
Crankshaft Gear – Replacement………………………………………………………………183
Crankshaft Gear – Inspection……………………………………………………………184
Crankshaft Gear – Installation………………………………………………………….185
Crankshaft Gear – Removal………………………………………………………………183
General Information……………………………………………………………………183
Cylinder Block – Cleaning in a Hot Tank……………………………………………………..164
Cylinder Block – Cleaning with Solvent………………………………………………………161
Cylinder Block – Disassembly……………………………………………………………….159
Cylinder Block – Exploded View……………………………………………………………..156
Cylinder Block – General Information………………………………………………………..158
Camshaft……………………………………………………………………………..158
Connecting Rods……………………………………………………………………….158
Crankshaft……………………………………………………………………………158
Cylinder Block………………………………………………………………………..158
Cylinder Liner………………………………………………………………………..158
Oil Seals…………………………………………………………………………….158
Pistons………………………………………………………………………………158
Vibration Damper………………………………………………………………………158
Cylinder Block – Inspection For Reuse……………………………………………………….165
Cylinder Block – Preparation for Cleaning……………………………………………………159
Cylinder Block – Service Tools……………………………………………………………..153
Cylinder Head Capscrews – Cleaning and Inspection for Reuse……………………………………214
Cleaning……………………………………………………………………………..214
Free Length – Measurement………………………………………………………………216
Inspection……………………………………………………………………………215
Cylinder Liners – Cleaning and Inspection for Reuse…………………………………………..173
Cylinder Liners – Cleaning……………………………………………………………..173
Cylinder Liners – Inspection……………………………………………………………174
Dowel Pins (Cylinder Head) – Removal………………………………………………………..160
Engine Dataplate – Replacement……………………………………………………………..209
Engine Dataplate – Installation…………………………………………………………209
Engine Dataplate – Removal……………………………………………………………..209
Engine Lifting Brackets – Cleaning and Inspection for Reuse……………………………………216
Expansion Plug – Installation………………………………………………………………168
Pipe Plug – Installation……………………………………………………………….169
Gear Cover – Cleaning and Inspection for Reuse……………………………………………….210
Gear Cover – Cleaning………………………………………………………………….210
Gear Cover – Inspection………………………………………………………………..210
Gear Housing – Cleaning and Inspection for Reuse……………………………………………..207
Gear Housing – Cleaning………………………………………………………………..207
Gear Housing – Inspection………………………………………………………………207
Main Bearing Caps and Capscrews – Cleaning and Inspection for Reuse…………………………….188
Cleaning……………………………………………………………………………..188
Inspection……………………………………………………………………………189
Main Bearings – Cleaning and Inspection for Reuse…………………………………………….186
General Information……………………………………………………………………186
Main Bearings – Cleaning……………………………………………………………….187
Main Bearings – Inspection……………………………………………………………..187
Thrust Bearings – Inspection……………………………………………………………188
Pistons – Cleaning and Inspection for Reuse………………………………………………….176
Piston Rings – Removal…………………………………………………………………176
Pistons – Cleaning…………………………………………………………………….176
Pistons – Inspection…………………………………………………………………..177
Rear Cover – Cleaning and Inspection………………………………………………………..213
Cleaning……………………………………………………………………………..213
Inspection……………………………………………………………………………214
Vibration Damper – Cleaning and Checking for Reuse……………………………………………211
General Information……………………………………………………………………211
Rubber Element Vibration Damper – Inspection……………………………………………..211
Rubber Vibration Damper – Cleaning………………………………………………………211
Viscous Vibration Damper – Cleaning……………………………………………………..212
Viscous Vibration Damper – Inspection……………………………………………………212
Cylinder Head – Group 02………………………………………………………………………217
Cylinder Head Capscrew – Cleaning and Inspection for Reuse…………………………………….254
Cleaning……………………………………………………………………………..255
Inspection……………………………………………………………………………255
Cylinder Head – Cleaning and Inspection for Reuse…………………………………………….225
Cleaning……………………………………………………………………………..225
Handling……………………………………………………………………………..225
Inspection……………………………………………………………………………226
Cylinder Head – Exploded View………………………………………………………………222
Cylinder Head – General Information…………………………………………………………224
Cylinder Head – Pressure Testing……………………………………………………………251
Cylinder Head – Rebuild……………………………………………………………………227
Assembly……………………………………………………………………………..243
Cleaning……………………………………………………………………………..228
Disassembly…………………………………………………………………………..227
Inspection……………………………………………………………………………229
Valve – Grinding………………………………………………………………………238
Valve Guide – Inspection……………………………………………………………….233
Valve – Inspection…………………………………………………………………….237
Valve Seat Insert – Grinding……………………………………………………………239
Valve Seat Insert – Inspection………………………………………………………….234
Valve Spring – Inspection………………………………………………………………235
Valve Stem Seal – Inspection……………………………………………………………236
Cylinder Head – Service Tools………………………………………………………………218
Cylinder Head – Vacuum Testing Valve Seating…………………………………………………253
Cylinder Head – Valve Guide Replacement……………………………………………………..245
Assembly……………………………………………………………………………..246
Disassembly…………………………………………………………………………..245
Inspection……………………………………………………………………………246
Cylinder Head – Valve Seat Insert Replacement………………………………………………..248
Inspection……………………………………………………………………………250
Installation………………………………………………………………………….250
Removal………………………………………………………………………………248
Free Length – Measurement………………………………………………………………….256
Rocker Levers – Group 03………………………………………………………………………257
Crankcase Breather Tube – Cleaning and Inspection for Reuse……………………………………264
Cleaning and Inspection………………………………………………………………..264
Rocker Assembly Oil Manifold – Cleaning and Inspection for Reuse……………………………….263
Cleaning……………………………………………………………………………..263
Inspection……………………………………………………………………………263
Rocker Lever Assembly – Cleaning and Inspection………………………………………………260
Assembly……………………………………………………………………………..262
Cleaning……………………………………………………………………………..261
Disassembly…………………………………………………………………………..260
Inspection……………………………………………………………………………261
Rocker Lever Assembly – Exploded View……………………………………………………….258
Rocker Lever Assembly – General Information………………………………………………….259
Valve Cover – Cleaning and Inspection for Reuse………………………………………………264
Cleaning……………………………………………………………………………..264
Inspection……………………………………………………………………………264
Valve Tappets and Push Rods – Group 04………………………………………………………….265
Push Rods – Cleaning and Inspection for Reuse………………………………………………..268
Cleaning……………………………………………………………………………..268
Inspection……………………………………………………………………………268
Valve Tappet Cleaning and Inspection for Reuse……………………………………………….267
Cleaning……………………………………………………………………………..267
Inspection……………………………………………………………………………267
Valve Tappets and Push Rods – Exploded View………………………………………………….266
Valve Tappets and Push Rods – General Information…………………………………………….267
Fuel Systems – Group 05……………………………………………………………………….270
Direct Link Shutdown Lever – Replacement…………………………………………………….280
Fuel Injection Pump Gaskets and Seals – Replacement…………………………………………..281
Fuel System – General Information…………………………………………………………..271
Fuel Injection Pump……………………………………………………………………271
Fuel Injection Pump – Data Tag Location………………………………………………….271
Fuel Injection Pump – Data Tag Information……………………………………………….271
Governor – Data Tag Information…………………………………………………………272
Derivative Fuel Injection Pump – Data Tag Information……………………………………..272
Fuel Shutoff Solenoid – Wiring Requirements………………………………………………272
Fuel Transfer Pump – Exploded View………………………………………………………….273
Fuel Transfer Pump – Rebuild……………………………………………………………….274
Assembly……………………………………………………………………………..274
Cleaning……………………………………………………………………………..274
RSV Governor Fuel Shutoff Solenoid – Orientation and Adjustment………………………………..275
Fuel Shutoff Solenoid – Orientation……………………………………………………..275
Fuel Shutoff Solenoid – Adjustment………………………………………………………277
RQVK Governor Fuel Shutoff Solenoid – Adjustment……………………………………………..278
Shutdown Lever or Spring – Replacement………………………………………………………279
Injectors and Fuel Lines – Group 06…………………………………………………………….282
Fuel Drain Manifold – Inspection……………………………………………………………297
Fuel Lines, High Pressure – Cleaning and Inspection for Reuse………………………………….295
General Information……………………………………………………………………295
Fuel Lines – Cleaning and Inspection…………………………………………………….296
Fuel Lines, Low Pressure – Cleaning and Inspection for Reuse…………………………………..297
Injector – Chatter Testing…………………………………………………………………295
Injector – Spray Testing…………………………………………………………………..294
Injectors and Fuel Lines – Exploded View…………………………………………………….284
Injectors and Fuel Lines – Exploded View…………………………………………………….286
Injectors and Fuel Lines – Exploded View…………………………………………………….287
Injectors and Fuel Lines – General Information……………………………………………….288
Injectors and Fuel Lines – Service Tools…………………………………………………….283
Injectors – Cleaning and Inspection for Reuse………………………………………………..289
General Information……………………………………………………………………289
Injector – Assembly……………………………………………………………………293
Injector – Cleaning and Inspection………………………………………………………291
Injector – Disassembly…………………………………………………………………289
Lubricating Oil System – Group 07………………………………………………………………299
Lubricating Oil Dipstick – Calibration………………………………………………………311
Lubricating Oil Pan – Cleaning and Inspection for Reuse……………………………………….303
Cleaning……………………………………………………………………………..303
Inspection……………………………………………………………………………303
Lubricating Oil Pump – Cleaning and Inspection for Reuse………………………………………312
Cleaning……………………………………………………………………………..313
Disassembly…………………………………………………………………………..312
Inspection……………………………………………………………………………313
Lubricating Oil System – Exploded View………………………………………………………302
Lubricating Oil System – General Information…………………………………………………301
Dipstick……………………………………………………………………………..301
Lubricating Oil Cooler and Filter Head…………………………………………………..301
Lubricating Oil Pump…………………………………………………………………..301
Oil Filter Head……………………………………………………………………….301
Oil Pan………………………………………………………………………………301
Oil Pressure Regulator…………………………………………………………………301
Oil Temperature Thermostat……………………………………………………………..301
Lubricating Oil System – Service Tools………………………………………………………300
Lubricating Oil Temperature Thermostat – Cleaning and Inspection……………………………….310
Cleaning……………………………………………………………………………..310
Inspection……………………………………………………………………………310
Oil Cooler Cover – Disassembly and Assembly………………………………………………….308
Assembly……………………………………………………………………………..309
Cleaning……………………………………………………………………………..308
Disassembly…………………………………………………………………………..308
Oil Cooler Element – Cleaning and Inspection for Reuse………………………………………..304
Cleaning……………………………………………………………………………..304
Inspection……………………………………………………………………………304
Pressure Test…………………………………………………………………………304
Oil Filter Bypass Valve – Replacement……………………………………………………….307
Oil Pressure Regulating Valve – Cleaning and Inspection……………………………………….305
Assembly……………………………………………………………………………..306
Cleaning……………………………………………………………………………..306
Disassembly…………………………………………………………………………..305
Inspection……………………………………………………………………………306
Cooling System – Group 08……………………………………………………………………..316
Belt Tensioner Inspection………………………………………………………………….326
Coolant Filter Shutoff Valve – Cleaning and Inspection for Reuse……………………………….326
Assembly……………………………………………………………………………..327
Cleaning……………………………………………………………………………..327
Disassembly…………………………………………………………………………..326
Cooling System Components – Exploded View……………………………………………………318
Cooling System – General Information………………………………………………………..319
Belt Tensioner………………………………………………………………………..319
Cooling Fans………………………………………………………………………….319
Fan Hub………………………………………………………………………………319
Pressure Caps…………………………………………………………………………319
Thermostats…………………………………………………………………………..319
Water Pump……………………………………………………………………………319
Cooling System – Service Tools……………………………………………………………..317
Fan – Cleaning and Inspection for Reuse……………………………………………………..328
Fan Hub – Cleaning and Inspection for Reuse………………………………………………….323
Cleaning……………………………………………………………………………..323
Inspection……………………………………………………………………………324
Fan Hub – Rebuild…………………………………………………………………………324
Assembly……………………………………………………………………………..325
Disassembly…………………………………………………………………………..324
Thermostat Housing – Cleaning and Inspection for Reuse………………………………………..322
Cleaning……………………………………………………………………………..322
Inspection……………………………………………………………………………322
Thermostat – Inspection……………………………………………………………………322
Water Outlet Connection – Cleaning and Inspection for Reuse……………………………………323
Water Pump Assembly – Cleaning and Inspection for Reuse……………………………………….321
Cleaning……………………………………………………………………………..321
Inspection……………………………………………………………………………321
Drive Units – Group 09………………………………………………………………………..329
Accessory Drive Adapter – Cleaning and Inspection for Reuse……………………………………333
Cleaning……………………………………………………………………………..333
Inspection……………………………………………………………………………333
Accessory Drive Adapter – Exploded View……………………………………………………..331
Accessory Drive Adapter – Rebuild…………………………………………………………..333
Assembly……………………………………………………………………………..334
Disassembly…………………………………………………………………………..333
Accessory Drive – General Information……………………………………………………….332
Accessory Drive Adapter………………………………………………………………..332
Drive Units – Service Tools………………………………………………………………..330
Air Intake System – Group 10…………………………………………………………………..336
Aftercooler Assembly – Cleaning and Inspection for Reuse………………………………………345
Inspection……………………………………………………………………………346
Aftercooler Assembly – Rebuild …………………………………………………………….346
Air Crossover Tube – Cleaning and Inspection for Reuse………………………………………..347
Cleaning……………………………………………………………………………..347
Inspection……………………………………………………………………………347
Air Intake System – Exploded View…………………………………………………………..338
Air Intake System – General Information……………………………………………………..340
Inspection……………………………………………………………………………341
Air Intake System – Service Tools…………………………………………………………..337
Air Transfer Pipe – Cleaning and Inspection for Reuse…………………………………………347
Cleaning……………………………………………………………………………..347
Inspection……………………………………………………………………………347
Charge Air Cooler (CAC) – Cleaning and Inspection for Reuse……………………………………348
Cleaning……………………………………………………………………………..348
Inspection……………………………………………………………………………348
Charge Air Cooler (CAC) – Pressure Testing…………………………………………………..349
Intake Manifold Cover – Cleaning and Inspection for Reuse……………………………………..345
Inspection……………………………………………………………………………345
Turbocharger – Cleaning and Inspection for Reuse……………………………………………..341
Inspection……………………………………………………………………………341
Exhaust System – Group 11……………………………………………………………………..351
Exhaust Manifold – Cleaning and Inspection for Reuse………………………………………….354
Cleaning……………………………………………………………………………..354
Inspection……………………………………………………………………………354
Exhaust Manifold – Exploded View……………………………………………………………352
Exhaust Manifold Outlet Connection – Cleaning and Inspection for Reuse………………………….356
Cleaning……………………………………………………………………………..356
Inspection……………………………………………………………………………356
Exhaust Manifold Turbocharger Mounting Stud – Replacement……………………………………..355
Inspection……………………………………………………………………………355
Installation………………………………………………………………………….355
Removal………………………………………………………………………………355
Exhaust System – General Information………………………………………………………..353
Exhaust Manifold………………………………………………………………………353
Air Equipment – Group 12………………………………………………………………………357
Electrical Equipment – Group 13………………………………………………………………..358
Engine Testing – Group 14……………………………………………………………………..359
Blowby Measurement………………………………………………………………………..365
Engine Dynamometer Test – Engine Run-In……………………………………………………..375
Engine Dynamometer Test – Installation of the Engine………………………………………….367
Engine Dynamometer Test – Performance Checking……………………………………………….379
Engine Painting…………………………………………………………………………..388
Engine Run-In Procedure – “In-Chassis”………………………………………………………386
Engine Run-In – General Procedures………………………………………………………….366
Engine Storage – Long Term…………………………………………………………………391
Engine Removal from Long Term Storage……………………………………………………394
Engine Storage – Short Term………………………………………………………………..389
Engine Removal From Short Term Storage…………………………………………………..391
Engine Testing – Component Identification and Diagrams………………………………………..361
Engine Testing – General Information………………………………………………………..363
Engine Dynamometer Run-in………………………………………………………………363
In-Chassis Run-In……………………………………………………………………..363
Engine Testing – General Specifications……………………………………………………..364
Engine Testing – Service Tools……………………………………………………………..360
Fuel Injection Pump – Idle Speed Adjustment………………………………………………….387
RSV Governor………………………………………………………………………….387
RQV and RQVK Governor………………………………………………………………….388
General Engine Test Procedure – In Chassis…………………………………………………..381
Instruments and Controls – Group 15…………………………………………………………….398
Mounting Adaptations – Group 16………………………………………………………………..399
Engine Support Bracket, Front – Cleaning and Inspection for Reuse………………………………407
Cleaning……………………………………………………………………………..407
Inspection……………………………………………………………………………407
Flexplate Assembly – Cleaning and Inspection for Reuse………………………………………..404
Flywheel – Cleaning and Inspection for Reuse…………………………………………………403
Cleaning……………………………………………………………………………..403
Inspection……………………………………………………………………………403
Flywheel Housing – Assembly (Wet Clutch Application)………………………………………….406
Flywheel Housing – Cleaning and Inspection for Reuse………………………………………….405
Cleaning……………………………………………………………………………..405
Inspection……………………………………………………………………………405
Flywheel Ring Gear – Replacement……………………………………………………………404
Installation………………………………………………………………………….404
Removal………………………………………………………………………………404
Mounting Adaptations – Exploded View………………………………………………………..401
Mounting Adaptations – General Information…………………………………………………..402
Flywheel and Ring Gear…………………………………………………………………402
Flywheel Housing………………………………………………………………………402
Mounting Adaptations – Service Tools………………………………………………………..400
Specifications and Torque Values – Group 18……………………………………………………..408
Air Compressor Inspection Specifications…………………………………………………….445
Air Compressor Torque Values……………………………………………………………….445
Capscrew Markings and Torque Values…………………………………………………………453
Capscrew Markings and Torque Values – Metric……………………………………………..454
Capscrew Markings and Torque Values – U.S. Customary………………………………………454
Component Specifications and Torque Values…………………………………………………..410
Cylinder Block – Rebuild Specifications………………………………………………….422
Cylinder Block – Torque Values………………………………………………………….428
Cylinder Head – Rebuild Specifications…………………………………………………..429
Engine Assembly – Specifications………………………………………………………..410
Engine Assembly – Torque Values…………………………………………………………412
Cooling System Specifications………………………………………………………………441
Air Intake System Specifications………………………………………………………..443
Air Intake System Torque Values…………………………………………………………443
Cooling System Torque Values……………………………………………………………442
Drive Belt Tension………………………………………………………………………..449
Electrical System Specifications……………………………………………………………446
Electrical System Torque Values…………………………………………………………….446
Engine Components – General Information……………………………………………………..409
Engine Testing – Test Specifications………………………………………………………..447
Exhaust System Specifications………………………………………………………………445
Exhaust System Torque Values……………………………………………………………….445
Fuel Systems – Rebuild Specifications……………………………………………………….433
Fuel Injection Pump Sealing Washer………………………………………………………435
Fuel Shutoff Solenoid Adjustment………………………………………………………..435
Fuel System Specifications……………………………………………………………..433
Fuel System Torque Values………………………………………………………………435
Lubricating Oil System Specifications……………………………………………………….438
Lubricating Oil System Torque Values………………………………………………………..439
Mounting Adaptations – Torque Values………………………………………………………..448
Mounting Adaptations Specifications…………………………………………………………447
Flywheel Housing (Wet Application)………………………………………………………447
Flywheel Ring Gear Installation…………………………………………………………448
Newton-Meter to Foot-Pound Conversion Chart………………………………………………….452
Pipe Plug Torque Values……………………………………………………………………455
Rocker Lever Assembly – Rebuild Specifications……………………………………………….433
Tap-Drill – U.S. Customary & Metric…………………………………………………………456
Valve Tappet – Rebuild Specifications……………………………………………………….433
Weight and Measures – Conversion Factors…………………………………………………….451
Index……………………………………………………………………………………….457
TROUBLESHOOTING AND REPAIR MANUAL………………………………………………………………….461
Table of Contents…………………………………………………………………………….463
Introduction…………………………………………………………………………………464
About the Manual………………………………………………………………………….465
General Cleaning Instructions………………………………………………………………470
Solvent and Acid Cleaning………………………………………………………………470
Steam Cleaning………………………………………………………………………..470
General Repair Instructions………………………………………………………………..469
General Safety Instructions………………………………………………………………..468
Generic Symbols…………………………………………………………………………..466
Glossary of Terms…………………………………………………………………………472
How To Use This Manual…………………………………………………………………….465
Index………………………………………………………………………………..465
Metric Information…………………………………………………………………….465
Table of Contents……………………………………………………………………..465
Illustrations…………………………………………………………………………….467
Engine and Component Identification…………………………………………………………….474
Engine Identification……………………………………………………………………..475
Engine Dataplates……………………………………………………………………..475
Fuel Injection Pump Dataplate…………………………………………………………..476
General Engine Specifications………………………………………………………………477
General Engine Data……………………………………………………………………477
Lubrication System…………………………………………………………………….477
Cooling System………………………………………………………………………..478
Intake Air and Exhaust System…………………………………………………………..478
Fuel System…………………………………………………………………………..478
Electrical System……………………………………………………………………..479
Batteries (Specific Gravity)……………………………………………………………479
Engine Diagrams…………………………………………………………………………..480
Troubleshooting Logic…………………………………………………………………………483
Section T – Troubleshooting………………………………………………………………..484
Procedures and Techniques………………………………………………………………484
Troubleshooting Symptoms Charts…………………………………………………………….484
Air Compressor Operates with Excessive Noise……………………………………………..485
Air Compressor Pumping Excessive Lubricating Oil into Air System……………………………486
Air Compressor Air Pressure Rises Slowly…………………………………………………487
Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously)…………….488
Air Compressor Will Not Pump Air Pressure………………………………………………..489
Air Compressor Will Not Stop Pumping Air…………………………………………………490
Alternator Not Charging or Insufficient Charging………………………………………….491
Compression Knock……………………………………………………………………..492
Coolant Contaminated…………………………………………………………………..493
Coolant Loss………………………………………………………………………….494
Coolant Temperature Above Normal – Gradual Overheat……………………………………….496
Coolant Temperature Above Normal – Sudden Overheat………………………………………..499
Coolant Temperature Below Normal………………………………………………………..501
Engine Crankcase Gases (Blowby) – Excessive………………………………………………502
Engine Cranks, But Will Not Start – No Smoke from Exhaust………………………………….503
Engine Difficult to Start or Will Not Start – Exhaust Smoke Present…………………………505
Engine Idle Rough, Warm Engine………………………………………………………….507
Engine Misfiring………………………………………………………………………509
Engine Power Output Low………………………………………………………………..511
Engine Noise Excessive…………………………………………………………………515
Engine Starts But Will Not Keep Running………………………………………………….516
Engine Surges at Idle………………………………………………………………….517
Engine Vibration Excessive……………………………………………………………..518
Engine Will Not Crank or Cranks Slowly…………………………………………………..519
Engine Will Not Reach Rated Speed When Loaded…………………………………………….520
Engine Will Not Shut Off……………………………………………………………….522
Exhaust Black Smoke Excessive Under Load…………………………………………………523
Exhaust White Smoke Excessive (Warm Engine)………………………………………………525
Fuel Consumption Excessive……………………………………………………………..526
Fuel or Oil Leaking from Exhaust Manifold………………………………………………..527
Lubricating Oil Contaminated……………………………………………………………528
Lubricating Oil Consumption Excessive……………………………………………………529
Lubricating Oil Pressure Low……………………………………………………………531
Lubricating Oil Pressure High…………………………………………………………..533
Engine Noise Diagnostic Procedures – General Information…………………………………..534
Main Bearing Noise (Refer to Engine Noise Excessive – Main bearing System Chart)……………..534
Connecting Rod Bearing Noise (Refer to Engine Noise Excessive – Connecting Rod Symptom Chart)….534
Piston Noise (Refer to Engine Noise Excessive – Piston Symptom Chart)……………………….534
Fuel Consumption – General Information…………………………………………………..534
Fuel Consumption – Industrial Customer Complaint Form……………………………………..535
Oil Consumption……………………………………………………………………….536
Cooling System……………………………………………………………………………….538
Belt Tensioner – Replacement……………………………………………………………….564
Installation………………………………………………………………………….565
Removal………………………………………………………………………………564
Removal and Installation……………………………………………………………….565
Cooling System – Diagnosing Malfunctions…………………………………………………….550
Belt Tension………………………………………………………………………….555
Coolant Hose – Inspection………………………………………………………………556
Coolant Pressure – Measurement………………………………………………………….558
Cooling System – Test for Combustion Gases……………………………………………….551
Fuel Pump Overfueled…………………………………………………………………..563
Radiator Cap – Pressure Test……………………………………………………………551
Radiator, Fan and Shutters……………………………………………………………..558
Temperature Gauge Operation…………………………………………………………….563
Thermostat Leakage and Opening Temperature – Testing “In-Chassis”…………………………..561
Thermostat Opening Temperature – Testing “Thermostat Removed”………………………………562
Thermostat Operation and Testing………………………………………………………..560
Vehicle Overloaded…………………………………………………………………….564
Water Pump – Inspection………………………………………………………………..556
Water Pump Seal Weep Hole – Inspection…………………………………………………..556
Cooling System – Flow Diagrams……………………………………………………………..540
Cooling System – General Information………………………………………………………..539
Cooling System – Maintenance……………………………………………………………….544
Additive Concentration – Checking……………………………………………………….544
Antifreeze……………………………………………………………………………544
Antifreeze Concentration – Checking……………………………………………………..544
Cooling System – Cleaning………………………………………………………………545
Cooling System – Draining………………………………………………………………544
Filling and Venting……………………………………………………………………549
Cooling System – Service Tools……………………………………………………………..543
Cooling System – Specifications…………………………………………………………….542
Drive Belt – Replacement…………………………………………………………………..564
Fan Hub – Replacement……………………………………………………………………..565
Removal and Installation……………………………………………………………….566
Fan Pulley – Replacement…………………………………………………………………..565
Removal and Installation……………………………………………………………….565
Thermostat – Replacement…………………………………………………………………..569
Cleaning……………………………………………………………………………..570
Installation………………………………………………………………………….570
Removal………………………………………………………………………………569
Water Pump – Replacement…………………………………………………………………..566
Cleaning……………………………………………………………………………..567
Installation………………………………………………………………………….567
Removal………………………………………………………………………………566
Lubricating Oil System………………………………………………………………………..573
Internal Engine Damage – Checking…………………………………………………………..583
Lubricating Oil Analysis……………………………………………………………….583
Lubricating Oil Filter Inspection……………………………………………………….583
Lubricating Oil Cooler Element and Gasket – Replacement……………………………………….600
Cleaning and Inspection………………………………………………………………..601
Installation………………………………………………………………………….602
Removal………………………………………………………………………………600
Lubricating Oil Dipstick – Calibration………………………………………………………597
Lubricating Oil Dipstick Tube – Replacement………………………………………………….598
Installation………………………………………………………………………….598
Removal………………………………………………………………………………598
Lubricating Oil Filter – Changing…………………………………………………………..596
Lubricating Oil Leaks (External) – Checking………………………………………………….582
Lubricating Oil Level – Checking……………………………………………………………595
Lubricating Oil Pan – Draining……………………………………………………………..594
Lubricating Oil Pan – Filling………………………………………………………………594
Lubricating Oil Pan, Suction Tube and Gasket – Replacement…………………………………….605
Cleaning……………………………………………………………………………..605
Oil Pan – Installation…………………………………………………………………606
Oil Pan – Removal……………………………………………………………………..605
Suction Tube – Replacement……………………………………………………………..606
Lubricating Oil Pressure Regulator, Valve and Spring – Replacement……………………………..599
Cleaning and Inspection………………………………………………………………..599
Removal………………………………………………………………………………599
Installation………………………………………………………………………….600
Lubricating Oil Pump – Replacement………………………………………………………….608
Cleaning and Inspection………………………………………………………………..609
Installation………………………………………………………………………….612
Removal………………………………………………………………………………609
Lubricating Oil System – Diagnosing Malfunctions……………………………………………..584
Aftercooler…………………………………………………………………………..588
Bearings and Oil Pump………………………………………………………………….587
Coolant Diluted Oil……………………………………………………………………587
Cracked Cylinder Block…………………………………………………………………590
Cracked Cylinder Head………………………………………………………………….589
Cracked Cylinder Liner…………………………………………………………………590
Cylinder Head Expansion Plugs…………………………………………………………..589
Cylinder Head Gasket…………………………………………………………………..589
Cylinder Liner Seals…………………………………………………………………..589
Fuel Diluted Oil………………………………………………………………………590
Fuel Leaking by Piston Rings……………………………………………………………591
Fuel Transfer Pump…………………………………………………………………….591
High Oil Pressure……………………………………………………………………..584
Injection Pump………………………………………………………………………..592
Low Oil Pressure………………………………………………………………………584
Oil Cooler……………………………………………………………………………588
Oil Dilution………………………………………………………………………….587
Oil Filter……………………………………………………………………………585
Oil Leaks…………………………………………………………………………….592
Oil Level…………………………………………………………………………….584
Oil Pressure Gauge – Checking…………………………………………………………..585
Oil Pressure Regulating Valve…………………………………………………………..584
Oil Suction Tube………………………………………………………………………587
Oil Temperature Gauge – Checking………………………………………………………..586
Oil Temperature Thermostat……………………………………………………………..586
Lubricating Oil System – Flow Diagram……………………………………………………….578
Lubricating Oil System – General Information…………………………………………………576
Lubricating Oil System – Service Tools………………………………………………………575
Lubricating Oil System – Specifications……………………………………………………..577
Lubricating Oil Temperature Thermostat – Replacement………………………………………….603
Inspection……………………………………………………………………………604
Installation………………………………………………………………………….605
Removal………………………………………………………………………………603
Air Combustion System Repair…………………………………………………………………..616
Aftercooler and Gasket – Replacement………………………………………………………..639
Removal………………………………………………………………………………640
Cleaning……………………………………………………………………………..640
Installation………………………………………………………………………….640
Air Crossover Tube – Replacement……………………………………………………………637
Removal and installation……………………………………………………………….637
Air System Flow – Diagrams…………………………………………………………………619
Charge Air Cooler…………………………………………………………………………636
Cleaning and inspection………………………………………………………………..636
Charge Air Cooler (CAC) – Troubleshooting……………………………………………………633
Pressure Drop – Checking……………………………………………………………….633
Checking – Air Leak……………………………………………………………………635
Combustion Air System – Diagnosing Malfunctions………………………………………………622
Clean Air…………………………………………………………………………….622
Intake Air Restriction – Checking……………………………………………………….622
Damage From Non-filtered Air……………………………………………………………623
Turbocharged Engines – Air Leaks, Pressure Side…………………………………………..623
Turbocharged Engines – Exhaust Leaks…………………………………………………….624
Turbocharger Boost Pressure – Measurement………………………………………………..624
Malfunctioning Turbocharger…………………………………………………………….625
Oil Consumption and Leaks………………………………………………………………625
Turbocharger Noise…………………………………………………………………….626
Rotor Assembly Clearance – Measurement…………………………………………………..627
Combustion Air System Flow – General Information……………………………………………..618
Combustion Air System – Service Tools……………………………………………………….621
Exhaust Manifold and Gaskets – Replacement…………………………………………………..645
Removal………………………………………………………………………………645
Cleaning and Inspection………………………………………………………………..646
Installation………………………………………………………………………….646
Intake Air and Exhaust System Specifications…………………………………………………620
Intake Manifold Cover and Gasket – Replacement……………………………………………….638
Removal………………………………………………………………………………638
Cleaning……………………………………………………………………………..639
Installation………………………………………………………………………….639
Turbocharger Boost Pressure Specifications…………………………………………………..620
Turbocharger – Replacement…………………………………………………………………641
Removal………………………………………………………………………………641
Cleaning and Inspection………………………………………………………………..642
Installation………………………………………………………………………….643
Turbocharger Wastegate Actuator – Calibration………………………………………………..632
Exhaust Restriction – Measurement……………………………………………………….633
Turbocharger Wastegate Actuator – Functional Checking…………………………………………629
Turbocharger Wastegate Actuator – Replacement………………………………………………..630
Air regulator with pressure gauge……………………………………………………….630
Turbocharger Wastegate Actuator – Visual Inspection…………………………………………..628
Compressed Air System Repair…………………………………………………………………..648
Air Compressor Carbon Buildup – Checking…………………………………………………….652
Air Compressor Gasket Leaks – Checking………………………………………………………654
Air Compressor – Replacement……………………………………………………………….657
Inspection……………………………………………………………………………659
Installation………………………………………………………………………….659
Removal………………………………………………………………………………658
Air Governor and Compressor Unloader Valve – Checking…………………………………………654
Air Governor – Checking……………………………………………………………………655
Compressed Air System Flow Diagrams…………………………………………………………651
Compressed Air System General Information……………………………………………………649
Compressed Air System Specifications………………………………………………………..650
Fuel System………………………………………………………………………………….662
AFC Tube – Replacement…………………………………………………………………….692
Removal………………………………………………………………………………692
Installation………………………………………………………………………….692
Fuel Drain Manifold – Replacement…………………………………………………………..687
Removal and Installation……………………………………………………………….687
Fuel Filter Head Adapter – Replacement………………………………………………………682
Removal and Installation……………………………………………………………….682
Fuel Injection Pump – Replacement…………………………………………………………..692
Removal………………………………………………………………………………693
Installation………………………………………………………………………….694
Fuel Return Overflow Valve – Replacement…………………………………………………….691
Fuel Shutoff Solenoid – Replacement…………………………………………………………689
RSV Governor Fuel Shutoff Solenoid – Removal……………………………………………..689
RSV Governor Fuel Shutoff Solenoid – Installation…………………………………………690
Direct Link Solenoid, Cylinder Block Mounted……………………………………………..690
RQVK Governor Fuel Shutoff Solenoid – Removal and Installation……………………………..690
Fuel System Components and Flow…………………………………………………………….664
Fuel System Diagnosing – Malfunctions……………………………………………………….668
Fuel Transfer Pump…………………………………………………………………….668
Air in the Fuel System…………………………………………………………………672
Fuel Water Separator/Filter Unit………………………………………………………..674
Fuel Injection Pump……………………………………………………………………675
Governor Malfunctions………………………………………………………………….675
Air Fuel Control (AFC) Malfunctions……………………………………………………..675
Fuel Control Lever Travel and Adjustment…………………………………………………676
Fuel Injection Pump Idle Adjustment Screws……………………………………………….676
Manual Shut Down Levers………………………………………………………………..676
Electrical Shut Down Devices……………………………………………………………677
Fuel Injection Pump Timing……………………………………………………………..678
High Pressure Fuel Lines……………………………………………………………….679
Injectors…………………………………………………………………………….680
Fuel Drain Manifold……………………………………………………………………681
Fuel System – Service Tools………………………………………………………………..666
Fuel System Specifications…………………………………………………………………665
Fuel Transfer Pump – Replacement/Rebuild…………………………………………………….683
Removal………………………………………………………………………………683
Rebuild………………………………………………………………………………683
Cleaning……………………………………………………………………………..684
Assembly……………………………………………………………………………..684
Cleaning Mounting Surface………………………………………………………………685
Installation………………………………………………………………………….685
High Pressure Fuel Lines – Replacement………………………………………………………685
Removal………………………………………………………………………………685
Installation………………………………………………………………………….686
Idle Speed – Adjustment……………………………………………………………………699
Bosch RSV Governor…………………………………………………………………….699
Bosch RQVK Governor……………………………………………………………………700
Injector – Replacement…………………………………………………………………….687
Removal………………………………………………………………………………687
Cleaning and Inspection………………………………………………………………..687
Installation………………………………………………………………………….688
Inline Fuel Injection Pump Spill-Port Timing…………………………………………………700
Governor Lever Positioning……………………………………………………………..702
Low Pressure Fuel Line – Replacement………………………………………………………..682
Removal and Installation……………………………………………………………….682
Electrical System…………………………………………………………………………….707
Alternator – Replacement…………………………………………………………………..728
Installation………………………………………………………………………….729
Removal………………………………………………………………………………728
Coolant Temperature Sensor – Replacement…………………………………………………….729
Installation………………………………………………………………………….730
Removal………………………………………………………………………………730
Electrical System Description and Operation………………………………………………….708
Bosch Kl Model Alternator (Wiring Diagram)……………………………………………….711
Cranking Motor and Electrical Circuits…………………………………………………..708
Delco 42MT Starting Motor………………………………………………………………712
Delco Remy Model 15SI 116 Alternator (Wiring Diagram)……………………………………..711
Delco Remy Model 37MT/41MT Starting Motor………………………………………………..709
Delco Remy Model 42MT Starting Motor…………………………………………………….709
Nippondenso F4 Starting Motor…………………………………………………………..712
Nippendenso Model F2 Starting Motor……………………………………………………..710
Nippendenso Model F2 Basic Cranking Current Flow………………………………………….710
Electrical System – Diagnosing Malfunctions………………………………………………….716
Alternator……………………………………………………………………………723
Batteries – Checking…………………………………………………………………..716
Coolant or Pan Heaters – Checking……………………………………………………….727
Engine Cranking Speed Too Slow………………………………………………………….722
Oil Pressure Switch and Temperature Sensor – Checking……………………………………..726
Starting Circuit – Checking…………………………………………………………….717
Starting Motor Solenoid and Starting Motor……………………………………………….720
Electrical System – Service Tools…………………………………………………………..715
Electrical System – Specifications………………………………………………………….713
Maximum Allowable Resistance of Starting Circuit………………………………………….713
Minimum Recommended Battery Capacity…………………………………………………….713
Wiring Size Recommendations for Starter Solenoid and Fuel Solenoid Circuit…………………..714
Engine Block and Coolant Heater (750 and 500 Wats) – Replacement……………………………….730
Installation………………………………………………………………………….731
Removal………………………………………………………………………………731
Lubricating Oil Pan Heater – Replacement…………………………………………………….731
Installation………………………………………………………………………….732
Removal………………………………………………………………………………732
Lubricating Oil Pressure Switch – Replacement………………………………………………..732
Installation………………………………………………………………………….732
Removal………………………………………………………………………………732
Starting Motor – Replacement……………………………………………………………….727
Removal and Installation……………………………………………………………….728
Base Engine Components………………………………………………………………………..733
Base Engine Components – General Information…………………………………………………741
Base Engine Components – Service Tools………………………………………………………736
Camshaft – Replacement…………………………………………………………………….860
General Information……………………………………………………………………860
Removal………………………………………………………………………………862
Cleaning and Inspection………………………………………………………………..865
Installation………………………………………………………………………….869
Camshaft Gear – Replacement………………………………………………………………..872
Removal………………………………………………………………………………872
Cleaning and Inspection………………………………………………………………..872
Installation………………………………………………………………………….874
Connecting Rod Bearings – Replacement……………………………………………………….791
Diagnosing Malfunctions………………………………………………………………..791
Removal………………………………………………………………………………792
Cleaning and Inspection………………………………………………………………..793
Installation………………………………………………………………………….796
Connecting Rods – Replacement………………………………………………………………815
General Information……………………………………………………………………815
Removal………………………………………………………………………………816
Cleaning and Inspection………………………………………………………………..817
Installation………………………………………………………………………….819
Crankcase Breather Tube – Replacement……………………………………………………….745
Removal………………………………………………………………………………745
Cleaning and Inspection………………………………………………………………..745
Installation………………………………………………………………………….746
Crankshaft Gear – Replacement………………………………………………………………884
General Information……………………………………………………………………884
Removal………………………………………………………………………………885
Cleaning and Inspection………………………………………………………………..887
Installation………………………………………………………………………….888
Cup Plug – Replacement…………………………………………………………………….916
Removal………………………………………………………………………………916
Cleaning and Inspection………………………………………………………………..917
Installation………………………………………………………………………….917
Cylinder Head – Pressure Test………………………………………………………………779
Cylinder Head – Replacement………………………………………………………………..762
General Information……………………………………………………………………762
Diagnosing Malfunctions………………………………………………………………..762
Removal………………………………………………………………………………765
Cylinder Block/Head Deck Cleaning and Inspection………………………………………….766
Cylinder Head – Cleaning and Inspection………………………………………………….769
Installation………………………………………………………………………….774
Cylinder Liners – Replacement………………………………………………………………821
General Information……………………………………………………………………821
Removal………………………………………………………………………………821
Cleaning and Inspection………………………………………………………………..825
Installation………………………………………………………………………….828
Engine Compression – Checking………………………………………………………………741
Compression Gauge and Adapter…………………………………………………………..741
Piston Ring Sealing……………………………………………………………………742
Intake and Exhaust Valve Sealing………………………………………………………..742
Cylinder Head Gasket Sealing……………………………………………………………742
Engine Dataplate – Replacement……………………………………………………………..858
Removal………………………………………………………………………………859
Installation………………………………………………………………………….859
Flywheel – Replacement…………………………………………………………………….891
Removal………………………………………………………………………………891
Cleaning and Inspection………………………………………………………………..892
Installation………………………………………………………………………….893
Flywheel Bore Runout Measurement………………………………………………………..895
Flywheel Face Runout Measurement………………………………………………………..896
Flywheel Housing – Replacement……………………………………………………………..898
Removal………………………………………………………………………………898
Cleaning and Inspection………………………………………………………………..900
Installation (Dry Clutch Application)……………………………………………………901
Concentricity – Checking……………………………………………………………….902
Installation (Wet Clutch Application)……………………………………………………904
Flywheel Ring Gear – Replacement……………………………………………………………898
Removal………………………………………………………………………………898
Installation………………………………………………………………………….898
Gear Cover – Replacement…………………………………………………………………..840
Removal………………………………………………………………………………840
Cleaning and Inspection………………………………………………………………..841
Installation………………………………………………………………………….842
Gear Housing – Replacement…………………………………………………………………849
General Information……………………………………………………………………849
Removal………………………………………………………………………………850
Cleaning and Inspection………………………………………………………………..851
Installation………………………………………………………………………….853
Main and Thrust Bearings – Replacement………………………………………………………780
General Information……………………………………………………………………780
Diagnosing Malfunctions………………………………………………………………..781
Removal………………………………………………………………………………782
Cleaning and Inspection………………………………………………………………..784
Installation………………………………………………………………………….786
Pipe Plug – Replacement……………………………………………………………………915
Removal………………………………………………………………………………915
Cleaning and Inspection………………………………………………………………..915
Installation………………………………………………………………………….916
Pistons and Rings – Replacement…………………………………………………………….798
Piston – General Information……………………………………………………………798
Piston and Rings – Diagnosing Malfunctions……………………………………………….798
Removal………………………………………………………………………………800
Cleaning and Inspection………………………………………………………………..803
Installation………………………………………………………………………….808
Push Rod – Replacement…………………………………………………………………….759
Removal………………………………………………………………………………759
Cleaning and Inspection………………………………………………………………..760
Installation………………………………………………………………………….761
Rocker Lever – Replacement…………………………………………………………………747
Removal………………………………………………………………………………747
Disassembly…………………………………………………………………………..748
Cleaning and Inspection………………………………………………………………..749
Assembly……………………………………………………………………………..750
Installation………………………………………………………………………….751
Rocker Lever Diagnosing – Malfunctions………………………………………………………746
Valve Lash Specifications………………………………………………………………746
Seal, Front Crankshaft – Replacement………………………………………………………..844
General Information……………………………………………………………………844
Removal and Installation……………………………………………………………….845
Seal, Rear Crankshaft – Replacement…………………………………………………………906
Removal………………………………………………………………………………906
Cleaning and Inspection………………………………………………………………..907
Installation………………………………………………………………………….908
Timing Pin Assembly – Installation………………………………………………………….755
Valve Cover – Replacement………………………………………………………………….743
Removal………………………………………………………………………………743
Cleaning and Inspection………………………………………………………………..744
Installation………………………………………………………………………….744
Valve Lash – Adjustment……………………………………………………………………752
Valve Arrangement……………………………………………………………………..754
Valve Tappet – Replacement…………………………………………………………………875
General Information……………………………………………………………………875
Removal………………………………………………………………………………876
Cleaning and Inspection………………………………………………………………..879
Installation………………………………………………………………………….880
Vibration Damper – Replacement……………………………………………………………..835
General Information……………………………………………………………………835
Rubber Element Vibration Damper – Inspection (In-Chassis)………………………………….835
Viscous Vibration Damper – Inspection……………………………………………………837
Removal………………………………………………………………………………838
Installation………………………………………………………………………….839
Wear Sleeve, Front Crankshaft – Replacement………………………………………………….845
Removal………………………………………………………………………………845
Cleaning and Inspection………………………………………………………………..846
Installation………………………………………………………………………….846
Wear Sleeve, Rear Crankshaft Seal – Replacement………………………………………………909
Removal………………………………………………………………………………909
Cleaning and Inspection………………………………………………………………..911
Installation………………………………………………………………………….912
Engine Testing……………………………………………………………………………….919
Blowby Measurement………………………………………………………………………..922
Engine Run-in Procedure……………………………………………………………………926
Engine Testing – General Information………………………………………………………..920
Engine Testing – General Specifications……………………………………………………..921
Engine Testing – Service Tools……………………………………………………………..923
General Engine Test Procedures……………………………………………………………..924
Engine Removal and Installation………………………………………………………………..928
Engine – Installation……………………………………………………………………..932
Throttle Control Lever Connection……………………………………………………….933
Engine Mount – Inspection………………………………………………………………….932
Engine Removal and Installation – General Information…………………………………………929
Engine – Removal………………………………………………………………………….929
Engine Component Specifications………………………………………………………………..937
Capscrew Markings and Torque Values…………………………………………………………967
Capscrew Markings and Torque Values – Metric……………………………………………..968
Capscrew Markings and Torque Values – U.S. Customary………………………………………969
Component Specifications and Torque Values…………………………………………………..939
Base Engine Component Specifications…………………………………………………….950
Base Engine Torque Values………………………………………………………………961
Combustion Air System Specifications…………………………………………………….943
Combustion Air System Torque Values……………………………………………………..943
Compressed Air System Torque Values……………………………………………………..944
Cooling System Specifications…………………………………………………………..939
Cooling System Torque Values……………………………………………………………939
Electrical System Specifications………………………………………………………..949
Electrical System Torque Values…………………………………………………………949
Fuel Shutoff solenoid Adjustment………………………………………………………..945
Fuel System Specifications……………………………………………………………..945
Fuel System Torque Values………………………………………………………………946
Lubricating Oil System Specifications……………………………………………………940
Lubricating Oil System Torque Values…………………………………………………….941
Drive Belt Tension………………………………………………………………………..963
Newton-Meter to Foot-Pound Conversion Chart………………………………………………….966
Pipe Plug Torque Values……………………………………………………………………970
Specification – General Information…………………………………………………………938
Weight and Measures – Conversion Factors…………………………………………………….965
Index……………………………………………………………………………………….971