John Deere Series 400 6076 Diesel Engines Technical Manual – PDF DOWNLOAD
DESCRIPTION:
John Deere Series 400 6076 Diesel Engines Technical Manual – PDF DOWNLOAD
FOREWORD:
This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
- This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Use this component technical manual in conjunction with the machine technical manual. An application listing in the introduction identifies product-model/component type-model relationship. See the machine technical manual for information on component removal and installation, and gaining access to the components.
- This manual is divided in two parts: repair and operation and tests. Repair sections contain necessary instructions to repair the component. Operation and tests sections help you identify the majority of routine failures quickly. Information is organized in groups for the various components requiring service instruction.
- At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values. Component Technical Manuals are concise service guides for specific components. Component technical manuals are written as stand-alone manuals covering multiple machine applications.
TABLE OF CONTENTS:
John Deere Series 400 6076 Diesel Engines Technical Manual – PDF DOWNLOAD
Group 00—Safety
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1
Group 01—General Information
Unified Inch Bolt and Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
Metric Bolt and Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . 01-2
Engine Model Designation . . . . . . . . . . . . . . 01-3
Engine Serial Number Plate Information . . . . . 01-4
Engine Application Chart . . . . . . . . . . . . . . . 01-5
Engine Application Chart . . . . . . . . . . . . . . . 01-6
Group 02—Fuels, Lubricants, and Coolant
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . 02-1
Lubricity of Diesel Fuels . . . . . . . . . . . . . . . 02-1
Engine Break-In Oil . . . . . . . . . . . . . . . . . . 02-2
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . 02-3
Oilscan and Coolscan . . . . . . . . . . . . . . . . . 02-4
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-4
Alternative and Synthetic Lubricants . . . . . . . 02-5
Engine Coolant Requirements . . . . . . . . . . . 02-5
Recommended Engine Coolant . . . . . . . . . . . 02-7
Engine Coolant Specifications . . . . . . . . . . . 02-8
Replenish Supplemental Coolant
Additives Between Coolant Changes . . . . 02-10
Operating in Tropical Conditions . . . . . . . . . 02-11
Flush and Service Cooling System . . . . . . . 02-12
Disposing of Coolant . . . . . . . . . . . . . . . . 02-13
Group 03—Engine Mounting
Engine Repair Stand . . . . . . . . . . . . . . . . . 03-1
Safety Precautions . . . . . . . . . . . . . . . . . . . 03-2
Install 400 Series Adapters on Repair
Stand . . . . . . . . . . . . . . . . . . . . . . . . . . 03-2
Engine Lifting Procedure . . . . . . . . . . . . . . . 03-3
Clean Engine . . . . . . . . . . . . . . . . . . . . . . 03-4
Disconnect Turbocharger Oil Inlet Line . . . . . 03-4
Mount Engine On Repair Stand . . . . . . . . . . 03-5
Page
Group 04—Engine Rebuild Guide
6076 Engine Disassembly Sequence . . . . . . . 04-1
Sealant Application Guidelines . . . . . . . . . . . 04-2
6076 Engine Assembly Sequence . . . . . . . . . 04-4
Group 05—Cylinder Head and Valves
Special or Essential Tools . . . . . . . . . . . . . . 05-1
Service Equipment and Tools . . . . . . . . . . . . 05-3
Other Material . . . . . . . . . . . . . . . . . . . . . . 05-4
Cylinder Head and Valves Specifications . . . . 05-5
Check and Adjust Valve Clearance . . . . . . . . 05-7
Check Valve Lift . . . . . . . . . . . . . . . . . . . . 05-9
Remove Cylinder Head . . . . . . . . . . . . . . . 05-10
Disassemble and Inspect Rocker Arm
Shaft Assembly . . . . . . . . . . . . . . . . . . 05-12
Assemble Rocker Arm Shaft Assembly . . . . 05-14
Measure Valve Recess . . . . . . . . . . . . . . . 05-14
Preliminary Cylinder Head and Valve
Checks . . . . . . . . . . . . . . . . . . . . . . . . 05-15
Remove Valve Assembly . . . . . . . . . . . . . . 05-16
Inspect and Measure Valve Springs . . . . . . 05-17
Inspect Valve Rotators and Wear Caps . . . . 05-17
Clean Valves . . . . . . . . . . . . . . . . . . . . . . 05-18
Inspect and Measure Valves . . . . . . . . . . . 05-18
Grind Valves . . . . . . . . . . . . . . . . . . . . . . 05-19
Inspect and Clean Cylinder Head . . . . . . . . 05-19
Check Cylinder Head Combustion Face
Flatness . . . . . . . . . . . . . . . . . . . . . . . 05-20
Measure Cylinder Head Thickness . . . . . . . 05-21
Clean Valve Guides . . . . . . . . . . . . . . . . . 05-22
Measure Valve Guides . . . . . . . . . . . . . . . 05-22
Knurl Valve Guides . . . . . . . . . . . . . . . . . 05-23
Clean and Inspect Valve Seats . . . . . . . . . 05-23
Measure Valve Seats . . . . . . . . . . . . . . . . 05-24
Grind Valve Seats . . . . . . . . . . . . . . . . . . 05-25
Remove Valve Seat Inserts and Measure
Bores . . . . . . . . . . . . . . . . . . . . . . . . . 05-26
Install Valve Seat Inserts . . . . . . . . . . . . . . 05-27
Inspect and Clean Cylinder Head Nozzle
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . 05-27
Clean and Inspect Push Rods . . . . . . . . . . 05-28
Inspect and Clean Ventilator Outlet Hose . . . 05-28
Clean and Inspect Top Deck of Cylinder
Block . . . . . . . . . . . . . . . . . . . . . . . . . 05-29
Measure Cylinder Liner Standout (Height
above Block) . . . . . . . . . . . . . . . . . . . . 05-30
Assemble Valve Assembly . . . . . . . . . . . . . 05-31
Install Cylinder Head . . . . . . . . . . . . . . . . 05-32
Cylinder Head Cap Screw Types . . . . . . . . 05-33
Clean, Inspect and Install Cylinder Head
Cap Screws . . . . . . . . . . . . . . . . . . . . . 05-34
Torque-To-Yield Special Flanged-Head
Cap Screws . . . . . . . . . . . . . . . . . . . . . 05-36
Install Rocker Arm Assembly . . . . . . . . . . . 05-37
Complete Final Assembly Of Injection
Pump Side . . . . . . . . . . . . . . . . . . . . . . 05-38
Complete Final Assembly On Exhaust
Manifold Side . . . . . . . . . . . . . . . . . . . . 05-39
Perform Engine Break-In . . . . . . . . . . . . . . 05-42
Group 10—Cylinder Block, Liners, Pistons and
Rods
Special or Essential Tools . . . . . . . . . . . . . . 10-1
Service Equipment and Tools . . . . . . . . . . . . 10-3
Other Material . . . . . . . . . . . . . . . . . . . . . . 10-3
Cylinder Block, Liners, Pistons, and Rods
Specifications . . . . . . . . . . . . . . . . . . . . . 10-4
Preliminary Liner, Piston, and Rod
Checks . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Remove Pistons and Connecting Rods . . . . . 10-9
Measure Cylinder Liner Standout (Height
above Block) . . . . . . . . . . . . . . . . . . . . 10-12
Remove Cylinder Liners . . . . . . . . . . . . . . 10-13
Deglazing Cylinder Liners . . . . . . . . . . . . . 10-14
Clean Cylinder Liners . . . . . . . . . . . . . . . . 10-15
Disassemble and Clean Piston . . . . . . . . . . 10-15
Visually Inspect Pistons . . . . . . . . . . . . . . . 10-16
Check Piston Ring Groove Wear . . . . . . . . 10-17
Measure Oil Control Ring Groove . . . . . . . . 10-18
Install Piston Pin in Piston Pin Bore . . . . . . 10-18
Visually Inspect Cylinder Liners . . . . . . . . . 10-19
Cylinder Liner Manufacturing Date Code
Explanation . . . . . . . . . . . . . . . . . . . . . 10-20
Measure Piston Skirt OD . . . . . . . . . . . . . . 10-21
Measure Cylinder Liner ID . . . . . . . . . . . . . 10-22
Measure Liner Flange Thickness . . . . . . . . 10-22
Inspect and Measure Connecting Rod
Bearings . . . . . . . . . . . . . . . . . . . . . . . 10-23
Inspect Rod and Cap . . . . . . . . . . . . . . . . 10-24
Page
Inspect Piston Pins and Bushings . . . . . . . . 10-26
Remove Piston Pin Bushing . . . . . . . . . . . . 10-27
Clean and Inspect Piston Pin Bushing
Bore in Rod . . . . . . . . . . . . . . . . . . . . . 10-27
Install Piston Pin Bushing in Connecting
Rod . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
Complete Disassembly of Cylinder Block
(If Required) . . . . . . . . . . . . . . . . . . . . . 10-29
Remove and Clean Piston Cooling
Orifices . . . . . . . . . . . . . . . . . . . . . . . . 10-29
Inspect and Clean Cylinder Block . . . . . . . . 10-30
Clean O-Ring Bore . . . . . . . . . . . . . . . . . . 10-32
Measure Cylinder Block . . . . . . . . . . . . . . 10-32
Install Piston Cooling Orifices and Gallery
Plugs . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
Recheck Cylinder Liner Standout (Height
above Block) . . . . . . . . . . . . . . . . . . . . 10-35
Install Liner Shims—If Required . . . . . . . . . 10-36
Install Cylinder Liner O-Rings and
Packings . . . . . . . . . . . . . . . . . . . . . . . 10-37
Install Cylinder Liners . . . . . . . . . . . . . . . . 10-38
Install Pistons and Connecting Rods . . . . . . 10-40
Torque-Turn Connecting Rod Cap Screws. . . 10-43
Check Engine Rotation for Excessive
Tightness . . . . . . . . . . . . . . . . . . . . . . . 10-43
Complete Final Assembly . . . . . . . . . . . . . 10-44
Group 15—Crankshaft, Main Bearings and
Flywheel
Special or Essential Tools . . . . . . . . . . . . . . 15-1
Service Equipment and Tools . . . . . . . . . . . . 15-4
Other Material . . . . . . . . . . . . . . . . . . . . . . 15-5
Crankshaft, Main Bearings, and Flywheel
Specifications . . . . . . . . . . . . . . . . . . . . . 15-6
Failure Analysis . . . . . . . . . . . . . . . . . . . . . 15-8
Remove Crankshaft Rear Oil Seal
Housing
(With Oil Seal Housing Installed) . . . . . . . . 15-9
Install Crankshaft Rear Oil Seal and
Wear Sleeve
(Without Engine Disassembly) . . . . . . . . . 15-11
Inspect Vibration Damper . . . . . . . . . . . . . 15-12
Check Crankshaft End Play . . . . . . . . . . . . 15-13
Remove Damper Pulley . . . . . . . . . . . . . . 15-14
Remove Front Oil Seal
(With Timing Gear Cover Installed on
Engine) . . . . . . . . . . . . . . . . . . . . . . 15-16
Remove Front Wear Sleeve
(With Timing Gear Cover Installed or
Removed) . . . . . . . . . . . . . . . . . . . . . 15-17
Install Front Wear Sleeve
(With Timing Gear Cover Installed) . . . . . 15-17
Install Front Oil Seal
(With Timing Gear Cover Installed) . . . . . 15-18
Replace Timing Gear Cover
(6076HRW33, 34, and 35 Engines)
—Engine Installed in Vehicle . . . . . . . . . . 15-19
Remove Timing Gear Cover . . . . . . . . . . . 15-20
Inspect, Measure and Repair Flywheel . . . . 15-20
Check Flywheel Housing Face Run-Out . . . . 15-21
Check Flywheel Face Flatness . . . . . . . . . . 15-21
Check Pilot Bearing Bore Concentricity . . . . 15-22
Remove Flywheel . . . . . . . . . . . . . . . . . . 15-22
Remove SAE 1 and SAE 2 Flywheel
Housing . . . . . . . . . . . . . . . . . . . . . . . . 15-23
Remove SAE 3 Flywheel Housing . . . . . . . . 15-23
Replace Flywheel Ring Gear . . . . . . . . . . . 15-24
Replace Rear Oil Seal Housing
(6076HRW33, 34, and 35 Engines)
—Engines Installed in Vehicle . . . . . . . . . 15-25
Remove Rear Oil Seal Housing and
Wear Sleeve
(With Engine Disassembled) . . . . . . . . . . 15-26
Remove Crankshaft Main Bearings . . . . . . . 15-27
Check Main Bearing Clearance . . . . . . . . . 15-28
Remove Crankshaft . . . . . . . . . . . . . . . . . 15-29
Inspect Crankshaft . . . . . . . . . . . . . . . . . . 15-30
Measure Assembled ID of Bearings And
OD Of Crankshaft Journals . . . . . . . . . . . 15-32
Main Bearing Cap Line Bore
Specifications . . . . . . . . . . . . . . . . . . . . 15-33
Crankshaft Grinding Guidelines . . . . . . . . . . 15-34
Thrust Bearing New Part Specifications . . . . 15-36
Crankshaft Grinding Specifications . . . . . . . 15-37
Replace Crankshaft Oil Pump Drive Gear . . . 15-38
Replace Crankshaft Gear . . . . . . . . . . . . . 15-39
Inspect Thrust Bearings . . . . . . . . . . . . . . 15-40
Remove and Clean Piston Cooling
Orifices . . . . . . . . . . . . . . . . . . . . . . . . 15-40
Install Main Bearings and Crankshaft . . . . . . 15-41
Install Crankshaft Rear Oil Seal Housing . . . 15-43
Check Oil Seal Housing Runout . . . . . . . . . 15-45
Crankshaft Rear Oil Seal And Wear
Sleeve Handling Precautions . . . . . . . . . . 15-46
Install Crankshaft Rear Oil Seal and
Wear Sleeve Assembly . . . . . . . . . . . . . 15-47
Install Timing Gear Cover . . . . . . . . . . . . . 15-48
Page
Install Front Wear Sleeve . . . . . . . . . . . . . 15-48
Install Front Oil Seal
(With Timing Gear Cover Installed) . . . . . 15-49
Install Damper Pulley Assembly . . . . . . . . . 15-49
Install SAE 3 Flywheel Housing . . . . . . . . . 15-50
Install Flywheel . . . . . . . . . . . . . . . . . . . . 15-51
Install SAE 1 and SAE 2 Flywheel
Housing . . . . . . . . . . . . . . . . . . . . . . . . 15-51
Complete Final Assembly . . . . . . . . . . . . . 15-52
Group 16—Camshaft and Timing Gear Train
Special or Essential Tools . . . . . . . . . . . . . . 16-1
Service Equipment and Tools . . . . . . . . . . . . 16-3
Other Material . . . . . . . . . . . . . . . . . . . . . . 16-3
Camshaft and Timing Gear Train
Specifications . . . . . . . . . . . . . . . . . . . . . 16-4
Check Valve Lift . . . . . . . . . . . . . . . . . . . . 16-6
Check Camshaft End Play . . . . . . . . . . . . . . 16-7
Remove Damper Pulley and Timing Gear
Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 16-7
Measure Camshaft Drive
Gear-to-Crankshaft Gear Backlash . . . . . . . 16-8
Remove Camshaft . . . . . . . . . . . . . . . . . . . 16-9
Remove Camshaft Gears . . . . . . . . . . . . . 16-11
Measure Thrust Washer Thickness . . . . . . . 16-11
Inspect and Measure Camshaft Followers . . . 16-12
Visually Inspect Camshaft . . . . . . . . . . . . . 16-12
Measure Camshaft Journal OD and
Bushing ID . . . . . . . . . . . . . . . . . . . . . . 16-13
Measure Camshaft Lobe Lift . . . . . . . . . . . 16-13
Install Camshaft Gears . . . . . . . . . . . . . . . 16-14
Service Camshaft Bushings using
JDG602 Adapter Set . . . . . . . . . . . . . . . 16-15
Service Camshaft Bushings using
JDG606 Adapter Set . . . . . . . . . . . . . . . 16-17
Install Camshaft . . . . . . . . . . . . . . . . . . . . 16-18
Install Thrust Washer and Timing Gear
Cover . . . . . . . . . . . . . . . . . . . . . . . . . 16-20
Install Front Oil Seal
(With Timing Gear Cover Installed) . . . . . 16-21
Complete Final Assembly . . . . . . . . . . . . . 16-22
Group 20—Lubrication System
Other Material . . . . . . . . . . . . . . . . . . . . . . 20-1
Lubrication System Specifications . . . . . . . . . 20-1
Drain Engine Oil and Remove Oil Pan . . . . . . 20-2
Oil Filter and Oil Conditioning Housing
Assembly . . . . . . . . . . . . . . . . . . . . . . . . 20-3
Continued on next page
Contents
CTM42 (24MAR95) iii 6076 Diesel Engines—S.N. (500000— )
160101
PN=440
110
115
199
INDX
Page
Remove Oil Filter and Oil Conditioning
Housing . . . . . . . . . . . . . . . . . . . . . . . . . 20-4
Inspect and Replace Oil Filter Adapter . . . . . . 20-4
Remove, Inspect, and Install Valves from
Oil Conditioning Housing . . . . . . . . . . . . . 20-5
Install Oil Filter and Oil Conditioning
Housing . . . . . . . . . . . . . . . . . . . . . . . . . 20-6
Remove Engine Oil Cooler . . . . . . . . . . . . . 20-7
Clean, Inspect, and Install Engine Oil
Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 20-8
Check Crankshaft Gear-To-Oil Pump
Drive Gear Backlash . . . . . . . . . . . . . . . . 20-9
Remove Engine Oil Pump . . . . . . . . . . . . . . 20-9
Inspect and Clean Oil Pump . . . . . . . . . . . 20-10
Check Drive Shaft End Play . . . . . . . . . . . 20-11
Check Drive Shaft Side Movement . . . . . . . 20-11
Check Pumping Gear Backlash . . . . . . . . . 20-12
Inspect Oil Pump Drive Gear . . . . . . . . . . . 20-12
Install Engine Oil Pump . . . . . . . . . . . . . . . 20-13
Install Oil Pan . . . . . . . . . . . . . . . . . . . . . 20-14
Tighten cap screws on front frame/oil
sump . . . . . . . . . . . . . . . . . . . . . . . . . 20-15
Group 25—Cooling System
Special or Essential Tools . . . . . . . . . . . . . . 25-1
Other Material . . . . . . . . . . . . . . . . . . . . . . 25-2
Cooling System Specifications . . . . . . . . . . . 25-3
Service Equipment and Tools . . . . . . . . . . . . 25-5
Replace Bearings in Standard Duty,
Adjustable Fan Drive Assembly . . . . . . . . . 25-6
Replace Bearings in Heavy Duty,
Adjustable Fan Drive Assembly . . . . . . . . . 25-8
Water Manifold Mounted Fixed Fan Drive
Assembly . . . . . . . . . . . . . . . . . . . . . . . 25-10
Replace Bearing in Injection Pump Drive
Gear Mounted Fan Drive . . . . . . . . . . . . 25-12
Inspect and Check Belt Tensioner Spring
Tension . . . . . . . . . . . . . . . . . . . . . . . . 25-13
Replace Belt Tensioner Assembly . . . . . . . . 25-14
Remove Water Pump . . . . . . . . . . . . . . . . 25-14
Disassemble Water Pump . . . . . . . . . . . . . 25-15
Inspect Water Pump Parts . . . . . . . . . . . . . 25-18
Assemble Water Pump . . . . . . . . . . . . . . . 25-19
Install Water Pump . . . . . . . . . . . . . . . . . . 25-21
Remove and Test Thermostats . . . . . . . . . . 25-22
Install Thermostats . . . . . . . . . . . . . . . . . . 25-23
Remove Water Manifold . . . . . . . . . . . . . . 25-23
Install Water Manifold . . . . . . . . . . . . . . . . 25-24
Remove Coolant Heater . . . . . . . . . . . . . . 25-24
Install Coolant Heater . . . . . . . . . . . . . . . . 25-25
Complete Final Assembly . . . . . . . . . . . . . 25-26
Page
Fan Belt Tension Specifications . . . . . . . . . 25-26
Group 30—Air Intake And Exhaust System
Special or Essential Tools . . . . . . . . . . . . . . 30-1
Other Material . . . . . . . . . . . . . . . . . . . . . . 30-2
Air Intake and Exhaust System
Specifications . . . . . . . . . . . . . . . . . . . . . 30-2
Extending Turbocharger Life . . . . . . . . . . . . 30-4
Remove Turbocharger . . . . . . . . . . . . . . . . 30-6
Turbocharger Failure Analysis . . . . . . . . . . . 30-8
Turbocharger Seven-Step Inspection . . . . . . 30-10
Perform Radial Bearing Clearance Test . . . . 30-15
Perform Axial Bearing End Play Test . . . . . . 30-16
Repair Turbocharger . . . . . . . . . . . . . . . . . 30-16
Disassemble Turbocharger . . . . . . . . . . . . 30-17
Clean and Inspect Turbine and
Compressor Housings . . . . . . . . . . . . . . 30-18
Replace Center Housing Assembly and
Assemble Turbocharger . . . . . . . . . . . . . 30-19
Prelube Turbocharger . . . . . . . . . . . . . . . . 30-20
Install Turbocharger . . . . . . . . . . . . . . . . . 30-20
Remove, Inspect, and Install Intake
Manifold . . . . . . . . . . . . . . . . . . . . . . . 30-22
Remove Vertically-Mounted Aftercooler
and Intake Manifold . . . . . . . . . . . . . . . . 30-23
Remove and Disassemble
Horizontally-Mounted Aftercooler
Assembly . . . . . . . . . . . . . . . . . . . . . . . 30-25
Inspect and Repair Aftercooler . . . . . . . . . . 30-26
Inspect and Repair Intake Manifold and
Cover . . . . . . . . . . . . . . . . . . . . . . . . . 30-26
Install Intake Manifold and
Vertically-Mounted Aftercooler . . . . . . . . . 30-27
Assemble and Install
Horizontally-Mounted Aftercooler
Assembly . . . . . . . . . . . . . . . . . . . . . . . 30-29
Remove, Inspect, and Install Exhaust
Manifold . . . . . . . . . . . . . . . . . . . . . . . 30-31
Group 35—Fuel System
Special or Essential Tools . . . . . . . . . . . . . . 35-1
Other Material . . . . . . . . . . . . . . . . . . . . . . 35-4
Diesel Fuel System Specifications . . . . . . . . . 35-4
Relieve Fuel System Pressure . . . . . . . . . . . 35-6
Replace Rectangular Fuel Filter Element . . . . 35-6
Replace Fuel Check Valve . . . . . . . . . . . . . 35-7
Remove Round Fuel Filter Element . . . . . . . . 35-8
Identification of fuel supply and fuel
injection pumps . . . . . . . . . . . . . . . . . . . 35-9
Remove Mechanical Fuel Supply Pump . . . . 35-10
Continued on next page
Contents
CTM42 (24MAR95) iv 6076 Diesel Engines—S.N. (500000— )
160101
PN=441
110
115
199
INDX
Page
Test Mechanical Fuel Supply Pump for
Leaks . . . . . . . . . . . . . . . . . . . . . . . . . 35-11
Disassemble Mechanical Fuel Supply
Pump (Nippondenso) . . . . . . . . . . . . . . . 35-12
Inspect and Repair Mechanical Fuel
Supply Pump (Nippondenso) . . . . . . . . . . 35-14
Assemble Mechanical Fuel Supply Pump
(Nippondenso) . . . . . . . . . . . . . . . . . . . 35-15
Disassemble Mechanical Fuel Supply
Pump (Robert Bosch) . . . . . . . . . . . . . . 35-16
Inspect and Repair Mechanical Fuel
Supply Pump (Robert Bosch) . . . . . . . . . 35-17
Assemble Mechanical Fuel Supply Pump
(Robert Bosch) . . . . . . . . . . . . . . . . . . . 35-18
Install Mechanical Fuel Supply Pump . . . . . 35-18
Remove and Install Electric Fuel Supply
Pump . . . . . . . . . . . . . . . . . . . . . . . . . 35-19
Clean or Replace Electric Fuel Supply
Pump Filter Screen . . . . . . . . . . . . . . . . 35-20
Repair Aneroid . . . . . . . . . . . . . . . . . . . . 35-21
Remove Hydraulic Aneroid Activator . . . . . . 35-21
Disassemble and Clean Hydraulic
Aneroid Activator Parts . . . . . . . . . . . . . 35-22
Assemble and Install Hydraulic Aneroid
Activator . . . . . . . . . . . . . . . . . . . . . . . 35-22
Service Injection Pump Overflow Valve . . . . 35-22
Remove and Install Fuel Shutoff Solenoid . . . 35-24
Identification of In-Line Injection Pumps . . . . 35-25
Remove In-Line Fuel Injection Pump . . . . . . 35-26
Install In-Line Fuel Injection Pump . . . . . . . 35-29
Remove Rotary Fuel Injection
Pump—Stanadyne DB4 . . . . . . . . . . . . . 35-33
Install Rotary Fuel Injection
Pump—Stanadyne DB4 . . . . . . . . . . . . . 35-34
Remove Fuel Injection Nozzles . . . . . . . . . 35-37
Diagnose Injection Nozzle Malfunction . . . . . 35-40
Test Fuel Injection Nozzles . . . . . . . . . . . . 35-42
Perform Opening Pressure Test . . . . . . . . . 35-43
Injection Nozzle Specifications . . . . . . . . . . 35-44
Perform Nozzle Leakage Test . . . . . . . . . . 35-45
Perform Chatter and Spray Pattern Test . . . 35-46
Disassemble Fuel Injection Nozzle . . . . . . . 35-47
Clean and Inspect Fuel Injection Nozzle
Assembly . . . . . . . . . . . . . . . . . . . . . . . 35-49
Perform Nozzle Slide Test . . . . . . . . . . . . . 35-50
Clean Spray Orifices . . . . . . . . . . . . . . . . . 35-50
Inspect Nozzle Holder . . . . . . . . . . . . . . . . 35-51
Inspect Gland Nut . . . . . . . . . . . . . . . . . . 35-53
Assemble Fuel Injection Nozzle . . . . . . . . . 35-54
Adjust Injection Nozzles . . . . . . . . . . . . . . 35-57
Page
Inspect and Clean Cylinder Head Nozzle
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . 35-58
Inspect and Clean Nozzle Seating
Surface . . . . . . . . . . . . . . . . . . . . . . . . 35-59
Install Fuel Injection Nozzles . . . . . . . . . . . 35-59
Group 100—Engine Tune-Up and Break-In
Effects of Altitude and Temperature on
Engine Performance . . . . . . . . . . . . . . . 100-1
Preliminary Engine Testing . . . . . . . . . . . . 100-2
General Tune-Up Recommendations . . . . . . 100-3
Dynamometer Test . . . . . . . . . . . . . . . . . . 100-4
Engine Break-In Guidelines . . . . . . . . . . . . 100-5
Perform Engine Break-In . . . . . . . . . . . . . . 100-6
Check Crankcase Ventilation System . . . . . . 100-7
Check Air Intake System . . . . . . . . . . . . . . 100-7
Check Exhaust System . . . . . . . . . . . . . . . 100-8
Check and Service Cooling System . . . . . . . 100-8
Check Electrical System . . . . . . . . . . . . . 100-10
Group 105—Engine System Operation and Test
Special or Essential Tools . . . . . . . . . . . . . 105-1
Engine Test Specifications . . . . . . . . . . . . . 105-3
Engine—Sectional View . . . . . . . . . . . . . . 105-4
General Engine Description . . . . . . . . . . . . 105-5
How the Lubrication System Works . . . . . . . 105-6
How the Cooling System Works . . . . . . . . 105-10
Head Gasket Joint Construction and
Operation . . . . . . . . . . . . . . . . . . . . . 105-12
Diagnosing Head Gasket Joint Failures . . . 105-14
Head Gasket Inspection and Repair
Sequence **M:CTM42,G105,18 -19- . . . . 105-17
Diagnosing Engine Malfunctions . . . . . . . . 105-18
Test Engine Compression Pressure . . . . . . 105-21
Check Engine Oil Pressure . . . . . . . . . . . 105-22
Inspect Thermostat and Test Opening
Temperature . . . . . . . . . . . . . . . . . . . 105-24
Group 110—Air Intake System Operation and
Test
Special or Essential Tools . . . . . . . . . . . . . 110-1
Air Intake and Exhaust System Test
Specifications . . . . . . . . . . . . . . . . . . . . 110-2
Diagnosing Air Intake Malfunctions . . . . . . . 110-3
How the Air Intake and Exhaust System
Works . . . . . . . . . . . . . . . . . . . . . . . . . 110-4
Air Cleaner Operation . . . . . . . . . . . . . . . . 110-4
Diagnosing Turbocharger Malfunctions . . . . . 110-6
How The Turbocharger Works . . . . . . . . . . 110-7
How The Turbocharger is Lubricated . . . . . . 110-7
How The Aftercooler Works—6076A
Engines . . . . . . . . . . . . . . . . . . . . . . . . 110-8
Check Intake Manifold Pressure
(Turbocharger Boost) . . . . . . . . . . . . . . . 110-9
Group 115—Fuel System Operation and Test
Special or Essential Tools . . . . . . . . . . . . . 115-1
Fuel System Test Specifications . . . . . . . . . 115-2
Check and Adjust Rotary fuel pump
Dynamic Timing . . . . . . . . . . . . . . . . . . 115-2
Fuel System Operation—In-Line Fuel
Injection Pump . . . . . . . . . . . . . . . . . . 115-10
Fuel System Operation—Rotary Fuel
Injection Pump . . . . . . . . . . . . . . . . . . 115-11
Diagnose Fuel System Malfunctions . . . . . 115-12
Mechanical Fuel Supply Pump Operation
Operation . . . . . . . . . . . . . . . . . . . . . 115-16
Diagnosing Mechanical Fuel Supply
Pump Malfunctions . . . . . . . . . . . . . . . 115-18
Test Mechanical Fuel Supply Pump for
Leaks . . . . . . . . . . . . . . . . . . . . . . . . 115-19
Check Mechanical Fuel Supply Pump
Operation . . . . . . . . . . . . . . . . . . . . . 115-20
Service Mechanical Fuel Supply Pump . . . 115-22
Electric Fuel Supply Pump Operation . . . . 115-23
Diagnose Electric Fuel Supply Pump
Malfunction . . . . . . . . . . . . . . . . . . . . 115-24
Test Electric Fuel Supply Pump Output
Pressure and Flow . . . . . . . . . . . . . . . 115-25
Fuel Shut-Off Solenoid Resistance Test . . . 115-27
Rectangular Fuel Filter Operation . . . . . . . 115-28
Round (Final) Fuel Filter Operation . . . . . . 115-28
Bleed the Fuel System . . . . . . . . . . . . . . 115-29
Diagnose In-Line Fuel Injection Pump
Malfunctions . . . . . . . . . . . . . . . . . . . . 115-32
In-Line Fuel Injection Pump Operation . . . . 115-33
Check Fast Idle Speed—In-Line Fuel
Injection Pump . . . . . . . . . . . . . . . . . . 115-34
Check and Adjust Engine Slow Idle
Speed—In-Line Fuel Injection Pump . . . . 115-35
Rotary Fuel Injection Pump
Operation—Stanadyne DB4 . . . . . . . . . 115-38
Diagnose Rotary Fuel Injection Pump
Malfunctions . . . . . . . . . . . . . . . . . . . . 115-40
Check and Adjust Engine Speeds on
Rotary Pump . . . . . . . . . . . . . . . . . . . 115-41
How the Aneroid Works—In-Line Injection
Pumps . . . . . . . . . . . . . . . . . . . . . . . 115-42
Diagnose Aneroid Malfunctions . . . . . . . . . 115-43
Page
How the Hydraulic Aneroid Activator
Works . . . . . . . . . . . . . . . . . . . . . . . . 115-44
Diagnose Malfunctions—Hydraulic
Aneroid Activator . . . . . . . . . . . . . . . . 115-45
Fuel Injection Nozzles—General
Information . . . . . . . . . . . . . . . . . . . . . 115-46
Fuel Injection Nozzle Operation . . . . . . . . 115-47
Diagnose Malfunctions—Fuel Injection
Nozzle . . . . . . . . . . . . . . . . . . . . . . . 115-48
Test Fuel Injection Nozzles (Engine
Running) . . . . . . . . . . . . . . . . . . . . . . 115-49
Fuel Drain Back Test Procedure . . . . . . . . 115-49
Group 199—Dealer Fabricated Tools
How to Make Tools . . . . . . . . . . . . . . . . . 199-1
Cylinder Liner Holding Fixture . . . . . . . . . . 199-1
Index
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