1991 KOMATSU KDC 614 SERIES ENGINE SERVICE REPAIR MANUAL
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1991 KOMATSU KDC 614 SERIES ENGINE SERVICE REPAIR MANUAL
This manual contains complete rebuild specifications and information for the 614 Series engines. The repair procedures in this manual are based on the engine being installed on an approved engine stand. Some rebuild procedures require the use of special service tools. Make sure the correct tools are used as described in the procedures. When a specific brand name, number, or special tool is referenced in this manual, an equivalent product can be used in place of the recommended kern. A series of specific service manuals (Shop, Specification, Alternative Repair, and so forth) are available and can be ordered through your distributor using the form in Section L The specifications and rebuild information in this manual is based on the information in effect at the time of printing. Komatsu Dresser Co. reserves the right to make any changes at any time without obligation. If differences are found between your engine and the information in this manual, contact your KDC Distributor. The latest technology and the highest quality components are used to manufacture KDC engines. When replacement parts are needed, we recommend using only genuine KDC exchange parts.
TABLE OF CONTENTS:
1991 KOMATSU KDC 614 SERIES ENGINE SERVICE REPAIR MANUAL
Main Menu..................................................................... 0 Table of Contents............................................................. 5 Section i - 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 Table of Contents..................................................... 11 Group Contents........................................................ 11 Index................................................................. 11 Metric Information.................................................... 11 Illustrations............................................................. 13 Section E - Engine and Component Identification............................... 19 Engine Diagrams........................................................... 24 Engine Identification..................................................... 20 Engine Dataplate...................................................... 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...............................................138 Aftercooler - Installation............................................123 Air Compressor - Installation.........................................145 Air Crossover Tube - Installation.....................................127 Alternator Brace - Installation.......................................130 Alternator - Installation.............................................129 Alternator Mounting Bracket - Installation............................129 Belt Tensioner Bracket - Installation.................................131 Belt Tensioner - Installation.........................................131 Camshaft - Installation............................................... 91 Connecting Rod Bolt - Installation.................................... 80 Coolant Filter - Installation.........................................128 Coolant Heater - Installation.........................................108 Coolant Inlet Connection - Installation...............................129 Coolant Outlet Connection - Installation..............................128 Coolant Vent Fitting - Installation...................................128 Coolant Vent Petcock - Installation...................................128 Coolant Vent Tube - Installation......................................129 Crankcase Breather Tube - Installation................................121 Crankshaft - Installation............................................. 73 Cylinder Block - Installation onto Engine Rebuild Stand............... 65 Cylinder Head - Installation..........................................111 Cylinder Liner - Installation......................................... 66 Drive Belt - Installation.............................................144 Engine Lifting Bracket - Installation.................................122 Engine - Removal from the Rebuild Stand...............................131 Engine Support, Front - Installation..................................144 Exhaust Manifold - Installation.......................................123 Fan Hub Assembly - Installation.......................................132 Flywheel Bore Runout Measurement......................................105 Flywheel Face Runout Measurement......................................107 Flywheel Housing - Installation....................................... 98 Flywheel - Installation...............................................103 Fuel Drain Manifold - Installation....................................122 Fuel Filter Head - Installation.......................................137 Fuel Filter - Installation............................................137 Fuel Injection Pump - Installation....................................132 Fuel Injection Pump Supply Line - Installation........................136 Fuel Lines, High Pressure - Installation..............................138 Fuel Lines, Low Pressure - Installation...............................145 Fuel Pump Solenoid - Installation.....................................145 Fuel Transfer Pump - Installation.....................................144 Gear Cover - Installation.............................................142 Gear Housing - Installation........................................... 88 Injector - Installation...............................................121 Intake Manifold Cover - Installation..................................122 Lubricating Oil Cooler - Installation.................................110 Lubricating Oil Filter - Installation.................................111 Lubricating Oil Pan - Installation.................................... 94 Lubricating Oil Pump - Installation................................... 90 Lubricating Oil Suction Tube - Installation........................... 94 Main Bearing (Lower) - Installation................................... 73 Main Bearing (Upper) - Installation................................... 72 Main Bearing Cap - Installation....................................... 73 Piston Assembly - Installation........................................ 84 Piston Cooling Nozzle - Installation.................................. 71 Piston Pin - Installation............................................. 80 Piston Ring End Gap - Measurement..................................... 81 Piston Ring - Installation............................................ 82 Push Rod - Installation...............................................115 Rocker Lever and Shaft - Assembly.....................................115 Rocker Lever Assembly - Installation..................................117 Seal, Front Crankshaft - Installation.................................139 Seal, Rear Crankshaft - Installation.................................. 77 Starting Motor - Installation.........................................108 Tachometer Drive - Installation.......................................143 Thermostat and Housing - Installation.................................127 Timing Pin Assembly - Installation.................................... 95 Turbocharger Exhaust Outlet Connection Installation...................127 Turbocharger - Installation...........................................124 Turbocharger Oil Drain Tube - Installation............................125 Turbocharger Oil Supply Hose - Installation...........................126 Valve Arrangement.....................................................119 Valve Clearance - Adjustment..........................................118 Valve Cover - Installation............................................120 Valve Tappet - Installation........................................... 70 Vibration Damper - Installation.......................................143 Water Pump - Installation............................................. 93 Engine Accessories - Installation.....................................147 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 Tube - Removal........................................... 49 Coolant Vent Petcock - Removal........................................ 49 Coolant Vent Tube Fitting - 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.....................................................149 Camshaft Bore Expansion Plug - Installation...............................168 Camshaft Bushing Bore - Cleaning..........................................170 Camshaft Bushing - Installation...........................................170 Camshaft Bushing - Removal................................................169 Camshaft - Cleaning and Inspection for Reuse..............................197 Camshaft - Cleaning...................................................197 Camshaft Gear - Inspection............................................200 Camshaft - Inspection.................................................197 Camshaft Gear - Replacement...............................................201 Camshaft Gear - Cleaning..............................................201 Camshaft Gear - Inspection............................................201 Camshaft Gear - Installation..........................................203 Camshaft Gear - Removal...............................................201 Connecting Rod Bearings - Cleaning and Inspection for Reuse .............186 Connecting Rod Bearings - Cleaning ...................................186 Connecting Rod Bearings - Inspection .................................186 Connecting Rod Bushing - Replacement .....................................192 Inspection ...........................................................196 Installation .........................................................194 Machining ............................................................196 Removal...............................................................192 Connecting Rods - Bend and Twist Inspection..............................190 Connecting Rod Alignment - Inspection ................................191 Connecting Rod Twist - Inspection ....................................191 Fixture Calibration ..................................................190 Connecting Rods - Cleaning and Inspection for Reuse .....................187 Connecting Rods - Cleaning ...........................................187 Connecting Rods - Inspection .........................................188 Crankshaft - Cleaning and Inspection for Reuse............................176 Crankshaft - Cleaning.................................................176 Crankshaft - Inspection...............................................177 Crankshaft Gear - Replacement.............................................180 Crankshaft Gear - Inspection .........................................181 Crankshaft Gear - Installation .......................................182 Crankshaft Gear - Removal ...........................................180 General Information ..................................................180 Cylinder Block - Cleaning in a Hot Tank...................................162 Cylinder Block - Cleaning with Solvent....................................159 Cylinder Block - Disassembly..............................................157 Cylinder Block - Exploded View............................................154 Cylinder Block - General Information......................................156 Camshaft..............................................................156 Connecting Rods.......................................................156 Crankshaft............................................................156 Cylinder Block........................................................156 Cylinder Liner........................................................156 Oil Seals.............................................................156 Pistons...............................................................156 Vibration Damper......................................................156 Cylinder Block - Inspection For Reuse.....................................163 Cylinder Block - Preparation for Cleaning.................................157 Cylinder Block - Service Tools............................................151 Cylinder Head Capscrews - Cleaning and Inspection for Reuse .............211 Cleaning..............................................................211 Free Length - Measurement.............................................213 Inspection............................................................212 Cylinder Liners - Cleaning and Inspection for Reuse.......................171 Cylinder Liners - Cleaning............................................171 Cylinder Liners - Inspection..........................................172 Dowel Pins (Cylinder Head) - Removal......................................158 Engine Dataplate - Replacement ...........................................206 Engine Dataplate - Installation.......................................206 Engine Dataplate - Removal............................................206 Engine Lifting Brackets - Cleaning and Inspection for Reuse...............213 Expansion Plug - Installation.............................................166 Pipe Plug - Installation..............................................167 Gear Cover - Cleaning and Inspection for Reuse............................207 Gear Cover - Cleaning.................................................207 Gear Cover - Inspection...............................................207 Gear Housing - Cleaning and Inspection for Reuse..........................204 Gear Housing - Cleaning...............................................204 Gear Housing - Inspection.............................................204 Main Bearing Caps and Capscrews - Cleaning and Inspection for Reuse ......185 Cleaning .............................................................185 Inspection ...........................................................186 Main Bearings - Cleaning and Inspection for Reuse.......................183 General Information ..................................................183 Main Bearings - Cleaning .............................................184 Main Bearings - Inspection ...........................................184 Thrust Bearings - Inspection .........................................185 Pistons - Cleaning and Inspection for Reuse...............................174 Piston Rings - Removal................................................174 Pistons - Cleaning....................................................174 Pistons - Inspection..................................................175 Rear Cover - Cleaning and Inspection......................................210 Cleaning..............................................................210 Inspection............................................................211 Vibration Damper - Cleaning and Checking for Reuse........................208 General Information...................................................208 Rubber Element Vibration Damper - Inspection..........................208 Rubber Vibration Damper - Cleaning....................................208 Viscous Vibration Damper - Cleaning...................................209 Viscous Vibration Damper - Inspection.................................209 Cylinder Head - Group 02......................................................215 Cylinder Head Capscrew - Cleaning and Inspection..........................251 Cleaning..............................................................251 Inspection............................................................252 Cylinder Head - Cleaning and Inspection for Reuse ........................223 Cleaning..............................................................223 Handling..............................................................223 Inspection............................................................224 Cylinder Head - Exploded View.............................................220 Cylinder Head - General Information.......................................222 Cylinder Head - Pressure Testing..........................................248 Cylinder Head - Rebuild...................................................225 Assembly..............................................................240 Cleaning..............................................................226 Disassembly...........................................................225 Inspection............................................................227 Valve - Grinding......................................................235 Valve Guide - Inspection..............................................231 Valve - Inspection....................................................234 Valve Seat Insert - Grinding..........................................236 Valve Seat Insert - Inspection........................................232 Valve Spring - Inspection.............................................233 Valve Stem Seal - Inspection..........................................233 Cylinder Head - Service Tools.............................................216 Cylinder Head - Vacuum Testing Valve Seating..............................250 Cylinder Head - Valve Guide Replacement...................................242 Assembly..............................................................243 Disassembly...........................................................242 Inspection............................................................243 Cylinder Head - Valve Seat Insert Replacement.............................245 Inspection............................................................247 Installation..........................................................247 Removal...............................................................245 Free Length - Measurement.................................................253 Rocker Levers - Group 03......................................................255 Crankcase Breather Tube - Cleaning and Inspection for Reuse...............262 Cleaning and Inspection...............................................262 Rocker Assembly Oil Manifold - Cleaning . and Inspection for Reuse........261 Cleaning..............................................................261 Inspection............................................................261 Rocker Lever Assembly - Cleaning and Inspection...........................258 Assembly..............................................................260 Cleaning..............................................................259 Disassembly...........................................................258 Inspection............................................................259 Rocker Lever Assembly - Exploded View.....................................256 Rocker Lever Assembly - General Information...............................257 Valve Cover - Cleaning and Inspection for Reuse...........................262 Cleaning..............................................................262 Inspection............................................................262 Valve Tappets and Push Rods - Group 04........................................263 Push Rods - Reuse Cleaning and Inspection for.............................266 Cleaning..............................................................266 Inspection............................................................266 Valve Tappet Cleaning and Inspection for Reuse............................265 Cleaning..............................................................265 Inspection............................................................265 Valve Tappets and Push Rods - Exploded View...............................264 Valve Tappets and Push Rods - General Information.........................265 Fuel Systems - Group 05.......................................................269 Fuel Injection Pump Gaskets and Seals - Replacement.......................279 Fuel System - General Information.........................................270 Derivative Fuel Injection Pump - Data Tag Information.................271 Fuel Injection Pump...................................................270 Fuel Injection Pump - Data Tag Information............................270 Fuel Injection Pump - Data Tag Location...............................270 Fuel Shutoff Solenoid - Wiring Requirements...........................271 Governor - Data Tag Information.......................................271 Fuel Transfer Pump - Exploded View........................................272 Fuel Transfer Pump - Rebuild .............................................273 Cleaning..............................................................273 Assembly..............................................................273 RQVK Governor Fuel Shutoff Solenoid - Adjustment..........................277 RSV Governor Fuel Shutoff Solenoid - Orientation and Adjustment...........274 Fuel Shutoff Solenoid - Adjustment....................................276 Fuel Shutoff Solenoid - Orientation...................................274 Shutdown Lever or Spring - Replacement....................................278 Injectors and Fuel Lines - Group 06...........................................281 Fuel Drain Manifold - Inspection..........................................296 Fuel Lines, High Pressure - Cleaning and Inspection for Reuse.............294 Fuel Lines - Cleaning and Inspection..................................295 General Information...................................................294 Fuel Lines, Low Pressure - Cleaning and Inspection for Reuse..............296 Injector - Chatter Testing................................................294 Injector - Spray Testing..................................................293 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 and Fuel Lines - Service Tools..................................282 Injectors - Cleaning and Inspection for Reuse.............................288 General Information...................................................288 Injector - Assembly...................................................292 Injector - Cleaning and Inspection....................................290 Injector - Disassembly................................................288 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.....................................................317 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.................................319 Cooling System - General Information......................................320 Belt Tensioner........................................................320 Cooling Fans..........................................................320 Fan Hub...............................................................320 Pressure Caps.........................................................320 Thermostats...........................................................320 Water Pump............................................................320 Cooling System - Service Tools............................................318 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 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..................................................337 Aftercooler Assembly - Cleaning and Inspection for Reuse..................343 Inspection............................................................344 Aftercooler Assembly - Rebuild............................................344 Air Crossover Tube - Cleaning and Inspection for Reuse....................345 Cleaning..............................................................345 Inspection............................................................345 Air Intake System - Exploded View.........................................339 Air Intake System - General Information...................................340 Air Intake System - Service Tools.........................................338 Air Transfer Pipe - Cleaning and Inspection for Reuse.....................345 Cleaning..............................................................345 Inspection............................................................345 Intake Manifold Cover - Cleaning and Inspection for Reuse.................343 Inspection............................................................343 Turbocharger - Cleaning and Inspection for Reuse..........................341 Inspection............................................................341 Exhaust System - Group 11.....................................................347 Exhaust Manifold - Cleaning and Inspection for Reuse......................350 Cleaning..............................................................350 Inspection............................................................350 Exhaust Manifold - Exploded View..........................................348 Exhaust Manifold Outlet Connection - Cleaning and Inspection for Reuse....352 Cleaning..............................................................352 Inspection............................................................352 Exhaust Manifold Turbocharger Mounting Stud - Replacement.................351 Inspection............................................................351 Installation..........................................................351 Removal...............................................................351 Exhaust System - General Information......................................349 Exhaust Manifold......................................................349 Air Equipment - Group 12......................................................353 Electrical Equipment - Group 13...............................................355 Engine Testing - Group 14.....................................................357 Blowby Measurement........................................................363 Engine Dynamometer Test - Engine Run-In...................................373 Engine Dynamometer Test - Installation of the Engine......................365 Engine Dynamometer Test - Performance Checking............................377 Engine Painting ..........................................................382 Engine Run-In Procedure - "In-Chassis"....................................380 Engine Run-In - General Procedures........................................364 Engine Storage - Long Term................................................385 Engine Removal from Long Term Storage.................................388 Engine Storage - Short Term...............................................383 Engine Removal From Short Term Storage................................385 Engine Testing - Component Identification and Diagrams....................359 Engine Testing - General Information......................................361 Engine Dynamometer Run-in.............................................361 In-Chassis Run-In.....................................................361 Engine Testing - General Specifications...................................362 Engine Testing - Service Tools............................................358 Fuel Injection Pump - Idle Speed Adjustment...............................381 RSV Governor..........................................................381 RQV and RQVK Governor.................................................382 General Engine Test Procedure - In Chassis................................379 Instruments and Controls - Group 15...........................................393 Mounting Adaptations - Group 16...............................................395 Engine Support Bracket, Front - Cleaning and Inspection for Reuse.........403 Cleaning..............................................................403 Inspection............................................................403 Flexplate Assembly - Cleaning and Inspection for Reuse....................400 Flywheel - Cleaning and Inspection for Reuse..............................399 Cleaning..............................................................399 Inspection............................................................399 Flywheel Housing - Assembly (Wet Clutch Application)......................402 Flywheel Housing - Cleaning and Inspection for Reuse......................401 Cleaning..............................................................401 Inspection............................................................401 Flywheel Ring Gear - Replacement..........................................400 Installation..........................................................400 Removal...............................................................400 Mounting Adaptations - Exploded View......................................397 Mounting Adaptations - General Information................................398 Flywheel and Ring Gear................................................398 Flywheel Housing......................................................398 Mounting Adaptations - Service Tools......................................396 Section V - Specifications and Torque Values - Group 18.......................405 Air Compressor Inspection Specifications..................................441 Air Compressor Torque Values..............................................441 Capscrew Markings and Torque Values.......................................449 Capscrew Markings and Torque Values - Metric..........................450 Capscrew Markings and Torque Values - U.S. Customary..................450 Component Specifications and Torque Values................................407 Cylinder Block - Rebuild Specifications...............................419 Cylinder Block - Torque Values........................................425 Cylinder Head - Rebuild Specifications................................426 Engine Assembly - Specifications......................................407 Engine Assembly - Torque Values.......................................409 Cooling System Specifications.............................................437 Air Intake System Specifications......................................439 Air Intake System Torque Values.......................................439 Cooling System Torque Values..........................................438 Drive Belt Tension........................................................445 Electrical System Specifications..........................................442 Electrical System Torque Values...........................................442 Engine Components - General Information...................................406 Engine Testing - Test Specifications......................................443 Exhaust System Specifications.............................................441 Exhaust System Torque Values..............................................441 Fuel Systems - Rebuild Specifications.....................................429 Fuel Injection Pump Sealing Washer....................................431 Fuel Shutoff Solenoid Adjustment......................................431 Fuel System Specifications............................................429 Fuel System Torque Values.............................................431 Lubricating Oil System Specifications.....................................434 Lubricating Oil System Torque Values......................................435 Mounting Adaptations Specifications.......................................443 Flywheel Housing (Wet Application)....................................443 Flywheel Ring Gear Installation.......................................444 Mounting Adaptations - Torque Values......................................444 Newton-Meter to Foot-Pound Conversion Chart...............................448 Pipe Plug Torque Values...................................................451 Rocker Lever Assembly - Rebuild Specifications............................429 Tap-Drill - U.S. Customary & Metric.......................................452 Valve Tappet - Rebuild Specifications.....................................429 Weight and Measures - Conversion Factors..................................447 Section L - Service Literature................................................453 Index.........................................................................457
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