Komatsu 114 Series Diesel Engine Shop Manual SEBM020400 – PDF DOWNLOAD
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DESCRIPTION:
Komatsu 114 Series Diesel Engine Shop Manual SEBM020400 – PDF DOWNLOAD
Foreword:
- This manual contains complete rebuild specifications and information for the 6D 114Е-1 Series engines.
The repair procedures in this manual are Ьased on the engine being installed оп 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 а specific brand пате, number, or special tool is referenced in this manual, an equivalent product can Ье used
in place of the recommended item. - А series of specific service manuals (Shop, Specification, Alternative Repair, and so forth) are availaЫe and can Ье
ordered through your distributor using the form in the front of this Ьооk.
The specifications and rebuild information in this rnanual is Ьased on the information in effect at the time of printing. - Kornatsu America lnternational Company reserves the right to make any changes at апу time without oЫigation. lf
differences are found Ьetween your engine and the information in this manual, contact your Komatsu Distributor. - The latest technology and the highest quality components are used to manufacture Komatsu engines. When replacement
parts are needed, we recommend using only genuine Komatsu exchange parts.
TABLE OF CONTENTS:
Komatsu 114 Series Diesel Engine Shop Manual SEBM020400 – PDF DOWNLOAD
COVER 1
PRODUCT PUBLICATIONS INFORMATION 3
FOREWORD 5
ENGINE-EXPLODED VIEW BY GROUPS 6
TABLE OF CONTENTS 7
INTRODUCTION 8
ABOUT THE MANUAL 9
HOW TO USE THIS MANUAL 10
TABLE OF CONTENTS 10
GROUP CONTENTS 10
INDEX 10
METRIC INFORMATION 10
GENERIC SYMBOLS 11
ILLUSTRATIONS 12
GENERAL SAFETY INSTRUCTIONS 13
GENERAL REPAIR INSTRUCTIONS 14
GENERAL CLEANING INSTRUCTIONS 15
SOLVENT AND ACID CLEANING 15
STEAM CLEANING 15
GLASS OR PLASTIC BEAD CLEANING 15
GLOSSARY OF TERMS 16
ENGINE AND COMPONENT IDENTIFICATION 18
ENGINE IDENTIFICATION 19
ENGINE DATAPLATES 19
FUEL INJECTION PUMP DATAPLATE 20
GENERAL ENGINE SPECIFICATIONS 21
GENERAL ENGINE DATA 21
LUBRICATION SYSTEM 21
COOLING SYSTEM 22
INTAKE AIR AND EXHAUST SYSTEM 22
FUEL SYSTEM 22
ENGINE DIAGRAMS 23
ENGINE DISASSEMBLY AND ASSEMBLY-GROUP 00 26
ENGINE DISASSEMBLY AND ASSEMBLY-SERVICE TOOLS 29
GENERAL INFORMATION 33
DISASSEMBLY 33
ASSEMBLY 33
ENGINE LIFTING EQUIPMENT AND BRACKETS 34
ENGINE-PREPARATION FOR STEAM CLEANING 34
ENGINE-STEAM CLEANING 34
LUBRICATING OIL-DRAINING 35
COOLANT-DRAINING 35
COOLANT FILTER-REMOVAL 35
LUBRICATING OIL FILTER-REMOVAL 35
FUEL FILTER-REMOVAL 36
FUEL FILTER HEAD-REMOVAL 36
FUEL LINES,LOW PRESSURE-REMOVAL 36
FUEL TRANSFER PUMP-REMOVAL 36
FUEL LINES,HIGH PRESSURE-REMOVAL 37
FUEL INJECTION PUMP SUPPLY LINE-REMOVAL 37
AFC TUBE-REMOVAL 37
TACHOMETER DRIVE-REMOVAL 38
FUEL INJECTION PUMP-REMOVAL 38
AIR COMPRESSOR-REMOVAL 39
FUEL PUMP SOLENOID-REMOVAL 40
ENGINE-INSTALLATION ONTO ENGINE REBUILD STAND 40
TURBOCHARGER EXHAUST OUTLET CONNECTION-REMOVAL 41
WASTEGATE ACTUATOR HOSE-REMOVAL 41
CRANKCASE BREATHER TUBE-REMOVAL 41
AIR CROSSOVER TUBE-REMOVAL 42
INTAKE MANIFOLD COVER-REMOVAL 42
AFTERCOOLER-REMOVAL 42
FUEL DRAIN MANIFOLD-REMOVAL 43
INJECTOR-REMOVAL 43
VALVE COVER-REMOVAL 43
ROCKER LEVER ASSEMBLY-REMOVAL 44
PUSH ROD-REMOVAL 44
TURBOCHARGER OIL SUPPLY HOSE-REMOVAL 45
TURBOCHARGER OIL DRAIN TUBE-REMOVAL 45
TURBOCHARGER-REMOVAL 45
EXHAUST MANIFOLD-REMOVAL 45
DRIVE BELT-REMOVAL 46
BELT TENSIONER-REMOVAL 46
BELT TENSIONER BRACKET-REMOVAL 46
ALTERNATOR BRACE-REMOVAL 46
ALTERNATOR-REMOVAL 47
ALTERNATOR MOUNTING BRACKET-REMOVAL 47
COOLANT OUTLET CONNECTION-REMOVAL 47
THERMOSTAT AND HOUSING-REMOVAL 47
COOLANT VENT TUBE-REMOVAL 48
COOLANT VENT PETCOCK-REMOVAL 48
COOLANT VENT TUBE FITTING-REMOVAL 48
CYLINDER HEAD-REMOVAL 48
LUBRICATING OIL COOLER-REMOVAL 49
COOLANT INLET CONNECTION-REMOVAL 49
FAN HUB ASSEMBLY-REMOVAL 49
WATER PUMP-REMOVAL 50
VIBRATION DAMPER-REMOVAL 50
GEAR COVER-REMOVAL 51
SEAL,FRONT CRANKSHAFT-REMOVAL 51
STARTING MOTOR-REMOVAL 51
COOLANT HEATER-REMOVAL 51
FLYWHEEL-REMOVAL 52
FLYWHEEL HOUSING-REMOVAL 52
LUBRICATING OIL PAN-REMOVAL 52
LUBRICATING OIL SUCTION TUBE-REMOVAL 52
SEAL,REAR CRANKSHAFT-REMOVAL 53
CAMSHAFT-REMOVAL 53
VALVE TAPPET-REMOVAL 54
LUBRICATING OIL PUMP GEAR BACKLASH-MEASUREMENT 55
LUBRICATING OIL PUMP-REMOVAL 56
ENGINE SUPPORT,FRONT-REMOVAL 56
GEAR HOUSING-REMOVAL 56
CYLINDER LINER CARBON DEPOSITS-REMOVAL 57
PISTON ASSEMBLY-REMOVAL 58
PISTON PIN-REMOVAL 59
PISTON RING-REMOVAL 60
MAIN BEARING CAP-REMOVAL 60
MAIN BEARING(LOWER)-REMOVAL 61
CRANKSHAFT-REMOVAL 61
MAIN BEARING(UPPER)-REMOVAL 61
PISTON COOLING NOZZLE-REMOVAL 61
CYLINDER LINER PROTRUSION-CHECKING 62
CYLINDER LINER-REMOVAL 62
EXPANSION PLUG-REPLACEMENT 63
EXPANSION PLUG-REMOVAL 64
CYLINDER BLOCK-REMOVAL FROM ENGINE REBUILD STAND 64
ENGINE-ASSEMBLY 64
CYLINDER LINER-INSTALLATION 65
VALVE TAPPET-INSTALLATION 69
PISTON COOLING NOZZLE-INSTALLATION 70
MAIN BEARING(UPPER)-INSTALLATION 71
CRANKSHAFT-INSTALLATION 72
MAIN BEARING(LOWER)-INSTALLATION 73
MAIN BEARING CAP-INSTALLATION 73
SEAL,REAR CRANKSHAFT-INSTALLATION 77
WEAR SLEEVE,REAR CRANKSHAFT SEAL-INSTALLATION 78
CONNECTING ROD BOLT-INSTALLATION 81
PISTON PIN-INSTALLATION 81
PISTON RING END GAP-MEASUREMENT 82
PISTON RING-INSTALLATION 83
PISTON ASSEMBLY-INSTALLATION 85
GEAR HOUSING-INSTALLATION 89
LUBRICATING OIL PUMP-INSTALLATION 91
CAMSHAFT-INSTALLATION 92
WATER PUMP-INSTALLATION 94
LUBRICATING OIL SUCTION TUBE-INSTALLATION 95
LUBRICATING OIL PAN-INSTALLATION 95
TIMING PIN ASSEMBLY-INSTALLATION 96
FLYWHEEL HOUSING-INSTALLATION 99
FLYWHEEL-INSTALLATION 104
FLYWHEEL BORE RUNOUT MEASUREMENT 106
FLYWHEEL FACE RUNOUT MEASUREMENT 108
STARTING MOTOR-INSTALLATION 109
COOLANT HEATER-INSTALLATION 109
LUBRICATING OIL COOLER-INSTALLATION 111
LUBRICATING OIL FILTER-INSTALLATION 112
CYLINDER HEAD-INSTALLATION 112
PUSH ROD-INSTALLATION 116
ROCKER LEVER AND SHAFT-ASSEMBLY 116
ROCKER LEVER ASSEMBLY-INSTALLATION 118
VALVE CLEARANCE-ADJUSTMENT 119
VALVE ARRANGEMENT 120
VALVE COVER-INSTALLATION 121
INJECTOR-INSTALLATION 122
FUEL DRAIN MANIFOLD-INSTALLATION 123
ENGINE LIFTING BRACKET-INSTALLATION 123
INTAKE MANIFOLD COVER-INSTALATION 123
AFTERCOOLER-INSTALLATION 124
EXHAUST MANIFOLD-INSTALLATION 124
TURBOCHARGER-INSTALLATION 125
TURBOCHARGER OIL DRAIN TUBE-INSTALLATION 126
TURBOCHARGER OIL SUPPLY HOSE-INSTALLATION 128
TURBOCHARGER EXHAUST OUTLET CONNECTION-INNSTALLATION 129
AIR CROSSOVER TUBE-INSTALLATION 129
THERMOSTAT AND HOUSING-INSTALLATION 129
COOLANT OUTLET CONNECTION-INSTALLATION 130
COOLANT FILTER-INSTALLATION 130
COOLANT VENT FITTING-INSTALLATION 130
COOLANT VENT PETCOCK-INSTALLATION 130
COOLANT VENT TUBE-INSTALLATION 131
COOLANT INLET CONNECTION-INSTALLATION 131
ALTERNATOR MOUNTING BRACKET-INSTALLATION 131
ALTERNATOR-INSTALLATION 131
ALTERNATOR BRACE-INSTALLATION 132
BELT TENSIONER BRACKET-INSTALLATION 133
BELT TENSIONER-INSTALLATION 133
FAN HUB ASSEMBLY-INSTALLATION 134
FUEL INJECTION PUMP-INSTALLATION 134
FUEL INJECTION PUMP SUPPLY LINE-INSTALLATION 138
FUEL FILTER HEAD-INSTALLATION 139
FUEL FILTER-INSTALLATION 139
FUEL LINES,HIGH PRESSURE-INSTALLATION 140
AFC TUBE-INSTALLATION 140
SEAL,FRONT CRANKSHAFT-INSTALLATION 141
GEAR COVER-INSTALLATION 144
TACHOMETER DRIVE-INSTALLATION 145
VIBRATION DAMPER-INSTALLATION 145
DRIVE BELT-INSTALLATION 146
ENGINE SUPPORT,FRONT-INSTALLATION 146
FUEL TRANSFER PUMP-INSTALLATION 146
FUEL LINES,LOW PRESSURE-INSTALLATION 147
FUEL PUMP SOLENOLD-INSTALLATION 147
AIR COMPRESSOR-INSTALLATION 147
ENGINE ACCESSORIES-INSTALLATION 149
CYLINDER BLOCK-GROUP 01 150
CYLINDER BLOCK-SERVICE TOOLS 152
CYLINDER BLOCK-EXPLODED VIEW 155
CYLINDER BLOCK-GENERAL INFORMATION 157
CAMSHAFT 157
CRANKSHAFT 157
CYLINDER BLOCK 157
CYLINDER LINER 157
OIL SEALS 157
PISTONS 157
VIBRATION DAMPER 157
CONNECTING RODS 157
CYLINDER BLOCK-PREPARATION FOR CLEANING 158
CYLINDER BLOCK-DISASSEMBLY 158
DOWEL PINS(CYLINDER HEAD)-REMOVAL 159
CYLINDER BLOCK-CLEANING WITH SOLVENT 160
CYLINDER BLOCK-CLEANING IN A HOT TANK 163
CYLINDER BLOCK-INSPECTION FOR REUSE 164
EXPANSION PLUG-INSTALLATION 167
PIPE PLUG-INSTALLATION 168
CAMSHAFT BORE EXPANSION PLUG INSTALLATION 169
CAMSHAFT BUSHING-REMOVAL 170
CAMSHAFT BUSHING BORE-CLEANING 171
CAMSHAFT BUSHING-INSTALLATION 171
CYLINDER LINERS-CLEANING AND INSPECTION FOR REUSE 172
CYLINDER LINERS-CLEANING 172
CYLINDER LINERS-INSPECTION 173
PISTONS-CLEANING AND INSPECTION FOR REUSE 175
PISTON RINGS-REMOVAL 175
PISTONS-CLEANING 175
PISTON-INSPECTION 176
CRANKSHAFT-CLEANING AND INSPECTION FOR REUSE 178
CRANKSHAFT-CLEANING 178
CRANKSHAFT-INSPECTION 179
CRANKSHAFT GEAR-REPLACEMENT 182
GENERAL INFORMATION 182
CRANKSHAFT GEAR-REMOVAL 182
CRANKSHAFT GEAR-INSPECTION 183
CRANKSHAFT GEAR-INSTALLATION 184
MAIN BEARINGS-CLEANING AND INSPECTION FOR REUSE 185
GENERAL INFORMATION 185
MAIN BEARINGS-CLEANING 186
MAIN BEARINGS-INSPECTION 186
THRUST BEARINGS-INSPECTION 187
MAIN BEARING CAPS AND CAPSCREWS-CLEANING AND INSPECTION FOR REUSE 187
CLEANING 187
INSPECTION 188
CONNECTING ROD BEARINGS-CLEANING AND INSPECTION FOR REUSE 188
CONNECTING ROD BEARINGS-CLEANING 188
CONNECTING ROD BEARINGS-INSPECTION 188
CONNECTING RODS-CLEANING AND INSPECTION FOR REUSE 189
CONNECTING RODS-CLEANING 189
CONNECTING RODS-INSPECTION 190
CONNECTING RODS-BEND AND TWIST INSPECTION 192
FIXTURE CALIBRATION 192
CONNECTING ROD ALIGNMENT-INSPECTION 193
CONNECTING ROD TWIST-INSPECTION 193
CONNECTING ROD BUSHING-REPLACEMENT 194
REMOVAL 194
INSTALLATION 196
MACHINING 198
INSPECTION 198
CAMSHAFT-CLEANING AND INSPECTION FOR REUSE 199
CAMSHAFT-CLEANING 199
CAMSHAFT-INSPECTION 199
CAMSHAFT GEAR-INSPECTION 202
CAMSHAFT GEAR-REPLACEMENT 203
CAMSHAFT GEAR-REMOVAL 203
CAMSHAFT GEAR-CLEANING 203
CAMSHAFT GEAR-INSPECTION 203
CAMSHAFT GEAR-INSTALLATION 205
GEAR HOUSING-CLEANING AND INSPECTION FOR REUSE 206
GEAR HOUSING-CLEANING 206
GEAR HOUSING-INSPECTION 206
ENGINE DATAPLATE-REPLACEMENT 208
ENGINE DATAPLATE-REMOVAL 208
ENGINE DATAPLATE-INSTALLATION 208
GEAR COVER-CLEANING AND INSPECTION FOR REUSE 209
GEAR COVER-CLEANING 209
GEAR COVER-INSPECTION 209
VIBRATION DAMPER-CLEANING AND CHECKING FOR REUSE 210
GENERAL INFORMATION 210
RUBBER VIBRATION DAMPER-CLEANING 210
RUBBER ELEMENT VIBRATION DAMPER-INSPECTION 210
VISCOUS VIBRATION DAMPER-CLEANING 211
VISCOUS VIBRATION DAMPER-INSPECTION 211
REAR COVER-CLEANING AND INSPECTION 212
CLEANING 212
INSPECTION 213
CYLINDER HEAD CAPSCREWS-CLEANING AND INSPECTION FOR REUSE 213
CLEANING 213
INSPECTION 214
FREE LENGTH-MEASUREMENT 215
ENGINE LIFTING BRACKETS-CLEANING AND INSPECTION FOR REUSE 215
CYLINDER HEAD-GROUP 02 216
CYLINDER HEAD-SERVICE TOOLS 217
CYLINDER HEAD-EXPLODED VIEW 221
CYLINDER HEAD-GENERAL INFORMATION 223
CYLINDER HEAD-CLEANING AND INSPECTION FOR REUSE 224
HANDLING 224
CLEANING 224
INSPECTION 225
CYLINDER HEAD-REBUILD 226
DISASSEMBLY 226
CLEANING 227
INSPECTION 228
VALVE GUIDE-INSPECTION 232
VALVE SEAT INSERT-INSPECTION 233
VALVE SPRING-INSPECTION 234
VALVE STEM SEAL-INSPECTION 235
VALVE-INSPECTION 236
VALVE-GRINDING 237
VALVE SEAT INSERT-GRINDING 238
ASSEMBLY 242
CYLINDER HEAD-VALVE GUIDE REPLACEMENT 244
DISASSEMBLY 244
INSPECTION 245
ASSEMBLY 245
CYLINDER HEAD-VALVE SEAT INSERT REPLACEMENT 247
REMOVAL 247
INSPECTION 249
INSTALLATION 249
CYLINDER HEAD-PRESSURE TESTING 250
CYLINDER HEAD-VACUUM TESTING VALVE SEATING 252
CYLINDER HEAD CAPSCREW-CLEANING AND INSPECTION 253
CLEANING 254
INSPECTION 254
FREE LENGTH-MEASUREMENT 255
ROCKER LEVERS-GROUP 03 256
ROCKER LEVER ASSEMBLY-EXPLODED VIEW 257
ROCKER LEVER ASSEMBLY-GENERAL INFORMATION 258
ROCKER LEVER ASSEMBLY-CLEANING AND INSPECTION 259
DISASSEMBLY 259
CLEANING 260
INSPECTION 260
ASSEMBLY 261
ROCKER ASSEMBLY OIL MANIFOLD-CLEANING AND INSPECTION FOR REUSE 262
CLEANING 262
INSPECTION 262
VALVE COVER-CLEANING AND INSPECTION FOR REUSE 263
CLEANING 263
INSPECTION 263
CRANKCASE BREATHER TUBE-CLEANING AND INSPECTION FOR REUSE 263
CLEANING AND INSPECTION 263
VALVE TAPPETS AND PUSH RODS-GROUP 04 264
VALVE TAPPETS AND PUSH RODS-EXPLODED VIEW 265
VALVE TAPPETS AND PUSH RODS-GENERAL INFORMATION 266
VALVE TAPPET CLEANING AND INSPECTION FOR REUSE 266
CLEANING 266
INSPECTION 266
PUSH RODS-CLEANING AND INSPECTION FOR REUSE 267
CLEANING 267
INSPECTION 267
FUEL SYSTEMS-GROUP 05 269
FUEL SYSTEM-GENERAL INFORMATION 270
FUEL INJECTION PUMP 270
FUEL INJECTION PUMP-DATA TAG LOCATION 270
FUEL INJECTION PUMP-DATA TAG INFORMATION 270
GOVERNOR-DATA TAG INFORMATION 271
DERIVATIVE FUEL INJECTION PUMP-DATA TAG INFORMATION 271
FUEL SHUTOFF SOLENOID-WIRING REQUIREMENTS 271
FUEL TRANSFER PUMP-EXPLODED VIEW 272
FUEL TRANSFER PUMP-REBUILD 273
CLEANING 273
ASSEMBLY 273
RSV GOVERNOR FUEL SHUTOFF SOLENOID-ORIENTATION AND ADJUSTMENT 274
FUEL SHUTOFF SOLENOID-ORIENTATION 274
FUEL SHUTOFF SOLENOID-ADJUSTMENT 276
RQVK GOVERNOR FUEL SHUTOFF SOLENOID-ADJUSTMENT 277
SHUTDOWN LEVER OR SPRING-REPLACEMENT 278
DIRECT LINK SHUTDOWN LEVER-REPLACEMENT 279
FUEL INJECTION PUMP GASKETS AND SEALS-REPLACEMENT 280
INJECTORS AND FUEL LINES-GROUP 06 281
INJECTORS AND FUEL LINES-SERVICE TOOLS 282
INJECTORS AND FUEL LINES-EXPLODED VIEW 283
INJECTORS AND FUEL LINES-EXPLODED VIEW 285
INJECTORS AND FUEL LINES-EXPLODED VIEW 286
INJECTORS AND FUEL LINES-GENERAL INFORMATION 287
INJECTORS-CLEANING AND INSPECTION FOR REUSE 288
GENERAL INFORMATION 288
INJECTOR-DISASSEMBLY 288
INJECTOR-CLEANING AND INSPECTION 290
INJECTOR-ASSEMBLY 292
INJECTOR-SPRAY TESTING 293
INJECTOR-CHATTER TESTING 294
FUEL LINES,HIGH PRESSURE-CLEANING AND INSPECTION FOR REUSE 294
GENERAL INFORMATION 294
FUEL LINES-CLEANING AND INSPECTION 295
FUEL DRAIN MANIFOLD-INSPECTION 296
FUEL LINES,LOW PRESSURE-CLEANING AND INSPECTION FOR REUSE 296
LUBRICATING OIL SYSTEM-GROUP 07 298
LUBRICATING OIL SYSTEM-SERVICE TOOLS 299
LUBRICATING OIL SYSTEM-GENERAL INFORMATION 300
LUBRICATING OIL COOLER AND FILTER HEAD 300
OIL PRESSURE REGULATOR 300
OIL FILTER HEAD 300
OIL TEMPERATURE THERMOSTAT 300
LUBRICATING OIL PUMP 300
DIPSTICK 300
OIL PAN 300
LUBRICATING OIL SYSTEM-EXPLODED VIEW 301
LUBRICATING OIL PAN-CLEANING AND INSPECTION FOR REUSE 302
CLEANING 302
INSPECTION 302
OIL COOLER ELEMENT-CLEANING AND INSPECTION FOR REUSE 303
CLEANING 303
INSPECTION 303
PRESSURE TEST 303
OIL PRESSURE REGULATING VALVE-CLEANING AND INSPECTION 304
DISASSEMBLY 304
CLEANING 305
INSPECTION 305
ASSEMBLY 305
OIL FILTER BYPASS VALVE-REPLACEMENT 306
OIL COOLER COVER-DISASSEMBLY AND ASSEMBLY 307
DISASSEMBLY 307
CLEANING 307
ASSEMBLY 308
LUBRICATING OIL TEMPERATURE THERMOSTAT-CLEANING AND INSPECTION 309
CLEANING 309
INSPECTION 309
LUBRICATING OIL DIPSTICK-CALIBRATION 310
LUBRICATING OIL PUMP-CLEANING AND INSPECTION FOR REUSE 311
DISASSEMBLY 311
CLEANING 312
INSPECTION 312
COOLING SYSTEM-GROUP 08 315
COOLING SYSTEM-SERVICE TOOLS 316
COOLING SYSTEM COMPONENTS-EXPLODED VIEW 317
COOLING SYSTEM-GENERAL INFORMATION 318
WATER PUMP 318
THERMOSTATS 318
PRESSURE CAPS 318
FAN HUB 318
BELT TENSIONER 318
COOLING FANS 318
WATER PUMP ASSEMBLY-CLEANING AND INSPECTION FOR REUSE 320
CLEANING 320
INSPECTION 320
THERMOSTAT HOUSING-CLEANING AND INSPECTION FOR REUSE 321
CLEANING 321
INSPECTION 321
THERMOSTAT-INSPECTION 321
WATER OUTLET CONNECTION-CLEANING AND INSPECTION FOR REUSE 322
FAN HUB-CLEANING AND INSPECTION FOR REUSE 322
CLEANING 322
INSPECTION 323
FAN HUB-REBUILD 323
DISASSEMBLY 323
ASSEMBLY 324
BELT TENSIONER INSPECTION 325
COOLANT FILTER SHUTOFF VALVE-CLEANING AND INSPECTION FOR REUSE 325
DISASSEMBLY 325
CLEANING 326
ASSEMBLY 326
FAN-CLEANING AND INSPECTION FOR REUSE 327
DRIVE UNITS-GROUP 09 328
DRIVE UNITS-SERVICE TOOLS 329
ACCESSORY DRIVE ADAPTER-EXPLODED VIEW 330
ACCESSORY DRIVE-GENERAL INFORMATION 331
ACCESSORY DRIVE ADAPTER 331
ACCESSORY DRIVE ADAPTER-CLEANING AND INSPECTION FOR REUSE 332
CLEANING 332
INSPECTION 332
ACCESSORY DRIVE ADAPTER-REBUILD 332
DISASSEMBLY 332
ASSEMBLY 333
AIR INTAKE SYSTEM-GROUP 10 335
AIR INTAKE SYSTEM-SERVICE TOOLS 336
AIR INTAKE SYSTEM-EXPLODED VIEW 337
AIR INTAKE SYSTEM-GENERAL INFORMATION 339
TURBOCHARGER-CLEANING AND INSPECTION FOR REUSE 340
INSPECTION 340
INTAKE MANIFOLD COVER-CLEANING AND INSPECTION FOR REUSE 344
INSPECTION 344
AFTERCOOLER ASSEMBLY-CLEANING AND INSPECTION FOR REUSE 344
INSPECTION 345
AFTERCOOLER ASSEMBLY-REBUILD 345
AIR TRANSFER PIPE-CLEANING AND INSPECTION FOR REUSE 346
CLEANING 346
INSPECTION 346
AIR CROSSOVER TUBE-CLEANING AND INSPECTION FOR REUSE 346
CLEANING 346
INSPECTION 346
CHARGE AIR COOLER(CAC)-CLEANING AND INSPECTION FOR REUSE 347
CLEANING 347
INSPECTION 347
CHARGE AIR COOLER(CAC)-PRESSURE TESTING 348
EXHAUST SYSTEM-GROUP 11 350
EXHAUST MANIFOLD-EXPLODED VIEW 351
EXHAUST SYSTEM-GENERAL INFORMATION 352
EXHAUST MANIFOLD 352
EXHAUST MANIFOLD-CLEANING AND INSPECTION FOR REUSE 353
CLEANING 353
INSPECTION 353
EXHAUST MANIFOLD TURBOCHARGER MOUNTING STUD-REPLACEMENT 354
REMOVAL 354
INSPECTION 354
INSTALLATION 354
EXHAUST MANIFOLD OUTLET CONNECTION-CLEANING AND INSPECTION FOR REUSE 355
CLEANING 355
INSPECTION 355
AIR EQUIPMENT-GROUP 12 356
ELECTRICAL EQUIPMENT-GROUP 13 357
ENGINE TESTING-GROUP 14 358
ENGINE TESTING-SERVICE TOOLS 359
ENGINE TESTING-COMPONENT IDENTIFICATION AND DIAGRAMS 360
ENGINE TESTING-GENERAL INFORMATION 362
IN-CHASSIS RUN-IN 362
ENGINE DYNAMOMETER RUN-IN 362
ENGINE TESTING-GENERAL SPECIFICATIONS 363
BLOWBY MEASUREMENT 364
ENGINE RUN-IN-GENERAL PROCEDURES 365
ENGINE DYNAMOMETER TEST-INSTALLATION OF THE ENGINE 366
ENGINE DYNAMOMETER TEST-ENGINE RUN-IN 374
ENGINE DYNAMOMETER TEST-PERFORMANCE CHECKING 378
GENERAL ENGINE TEST PROCEDURE-IN CHASSIS 380
ENGINE RUN-IN PROCEDURE-“IN-CHASSIS” 385
FUEL INJECTION PUMP-IDLE SPEED ADJUSTMENT 386
RSV GOVERNOR 386
RQV AND RQVK GOVERNOR 387
ENGINE PAINTING 387
ENGINE STORAGE-SHORT TERM 388
ENGINE REMOVAL FROM SHORT TERM STORAGE 390
ENGINE STORAGE-LONG TERM 390
ENGINE REMOVAL FROM TERM STORAGE 393
INSTRUMENTS AND CONTROLS-GROUP 15 397
MOUNTING ADAPTATIONS-GROUP 16 398
MOUNTING ADAPTATIONS-SERVICE TOOLS 399
MOUNTING ADAPTATIONS-EXPLODED VIEW 400
MOUNTING ADAPTATIONS-GENERAL INFORMATION 401
FLYWHEEL HOUSING 401
FLYWHEEL AND RING GEAR 401
FLYWHEEL-CLEANING AND INSPECTION FOR REUSE 402
CLEANING 402
INSPECTION 402
FLEXPLATE ASSEMBLY-CLEANING AND INSPECTION FOR REUSE 403
FLYWHEEL RING GEAR-REPLACEMENT 403
REMOVAL 403
INSTALLATION 403
FLYWHEEL HOUSING-CLEANING AND INSPECTION FOR REUSE 404
CLEANING 404
INSPECTION 404
FLYWHEEL HOUSING-ASSEMBLY(WET CLUTCH APPLICATION) 405
ENGINE SUPPORT BRACKET,FRONT-CLEANING AND INSPECTION FOR REUSE 406
CLEANING 406
INSPECTION 406
SPECIFICATIONS AND TORQUE VALUES-GROUP 18 407
ENGINE COMPONENTS-GENERAL INFORMATION 408
COMPONENT SPECIFICATIONS AND TORQUE VALUES 409
ENGINE ASSEMBLY-SPECIFICATIONS 409
ENGINE ASSEMBLY-TORQUE VALUES 411
CYLINDER BLOCK-REBUILD SPECIFICATIONS 421
CYLINDER BLOCK-TORQUE VALUES 427
CYLINDER HEAD-REBUILD SPECIFICATIONS 428
ROCKER LEVER ASSEMBLY-REBUILD SPECIFICATIONS 432
VALVE TAPPET-REBUILD SPECIFICATIONS 432
FUEL SYSTEMS-REBUILD SPECIFICATIONS 432
FUEL SYSTEM SPECIFICATIONS 432
FUEL SHUTOFF SOLENOID ADJUSTMENT 434
FUEL SYSTEM TORQUE VALUES 434
FUEL INJECTION PUMP SEALING WASHER 434
LUBRICATING OIL SYSTEM SPECIFICATIONS 437
LUBRICATING OIL SYSTEM TORQUE VALUES 438
COOLING SYSTEM SPECIFICATIONS 440
COOLING SYSTEM TORQUE VALUES 441
AIR INTAKE SYSTEM SPECIFICATIONS 442
AIR INTAKE SYSTEM TORQUE VALUES 442
EXHAUST SYSTEM SPECIFICATIONS 444
EXHAUST SYSTEM TORQUE VALUES 444
AIR COMPRESSOR INSPECTION SPECIFICATIONS 444
AIR COMPRESSOR TORQUE VALUES 444
ELECTRICAL SYSTEM SPECIFICATIONS 445
ELECTRICAL SYSTEM TORQUE VALUES 445
ENGINE TESTING-TEST SPECIFICATIONS 446
MOUNTING ADAPTATIONS SPECIFICATIONS 446
FLYWHEEL HOUSING(WET APPLICATION) 446
FLYWHEEL RING GEAR INSTALLATION 447
MOUNTING ADAPTATIONS-TORQUE VALUES 447
DRIVE BELT TENSION 448
WEIGHT AND MEASURES-CONVERSION FACTORS 450
NEWTON-METER TO FOOT-POUND CONVERSION CHART 451
CAPSCREW MARKINGS AND TORQUE VALUES 452
CAPSCREW MARKINGS AND TORQUE VALUES-METRIC 453
CAPSCREW MARKINGS AND TORQUE VALUES-U S CUSTOMARY 453
PIPE PLUG TORQUE VALUES 454
TAP-DRILL CHART-U S CUSTOMARY & METRIC 455
INDEX 456
COVER 460
CONTENTS 461
PRODUCT PUBLICATIONS INFORMATION 462
TROUBLESHOOTING AND REPAIR MANUAL 464
FOREWORD 465
TABLE OF CONTENTS 466
INTRODUCTION 467
ABOUT THE MANUAL 468
HOW TO USE THIS MANUAL 468
TABLE OF CONTENTS 468
INDEX 468
METRIC INFORMATION 468
GENERIC SYMBOLS 469
ILLUSTRATIONS 470
GENERAL SAFETY INSTRUCTIONS 471
GENERAL REPAIR INSTRUCTIONS 472
GENERAL CLEANING INSTRUCTIONS 473
SOLVENT AND ACID CLEANING 473
STEAM CLEANING 473
GLASS OR PLASTIC BEAD CLEANING 473
GLOSSARY OF TERMS 475
ENGINE AND COMPONENT IDENTIFICATION 477
ENGINE IDENTIFICATION 478
ENGINE DATAPLATES 478
FUEL INJECTION PUMP DATAPLATE 479
GENERAL ENGINE SPECIFICATIONS 480
GENERAL ENGINE DATA 480
LUBRICATION SYSTEM 480
COOLING SYSTEM 481
INTAKE AIR AND EXHAUST SYSTEM 481
FUEL SYSTEM 481
ELECTRICAL SYSTEM 482
BATTERIES(SPECIFIC GRAVITY) 482
ENGINE DIAGRAMS 483
TROUBLESHOOTING LOGIC 486
SECTION T-TROUBLESHOOTING 487
PROCEDURES AND TECHNIQUES 487
TROUBLESHOOTING SYMPTOMS CHARTS 487
AIR COMPRESSOR OPERATES WITH EXCESSIVE NOISE 488
AIR COMPRESSOR PUMPING EXCESSIVE LUBRICATING OIL INTO AIR SYSTEM 489
AIR COMPRESSOR AIR PRESSURE RISES SLOWLY 490
AIR COMPRESSOR WILL NOT MAINTAIN ADEQUATE AIR PRESSURE(NOT PUMPING CONTINUOUSLY) 491
AIR COMPRESSOR WILL NOT PUMP AIR PRESSURE 492
AIR COMPRESSOR WILL NOT STOP PUMPING AIR 493
ALTERNATOR NOT CHARGING OR INSUFFICIENT CHARGING 494
COMPRESSION KNOCK 495
COOLANT CONTAMINATED 496
COOLANT LOSS 497
COOLANT TEMPERATURE ABOVE NORMAL-GRADUAL OVERHEAT 499
COOLANT TEMPERATURE ABOVE NORMAL-SUDDEN OVERHEAT 502
COOLANT TEMPERATURE BELOW NORMAL 504
ENGINE CRANKCASE GASES(BLOWBY)-EXCESSIVE 505
ENGINE CRANKS,BUT WILL NOT START-NO SMOKE FROM EXHAUST 506
ENGINE DIFFICULT TO START OR WILL NOT START-EXHAUST SMOKE PRESENT 509
ENGINE IDLE ROUGH,WARM ENGINE 511
ENGINE MISFIRING 513
ENGINE POWER OUTPUT LOW 515
ENGINE NOISE EXCESSIVE 519
ENGINE STARTS BUT WILL NOT KEEP RUNNING 520
ENGINE SURGES AT IDLE 521
ENGINE VIBRATION EXCESSIVE 522
ENGINE WILL NOT CRANK OR CRANKS SLOWLY 523
ENGINE WILL NOT REACH RATED SPEED WHEN LOADED 524
ENGINE WILL NOT SHUT OFF 526
EXHAUST BLACK SMOKE EXCESSIVE UNDER LOAD 527
EXHAUST WHITE SMOKE EXCESSIVE(WARM ENGINE) 529
FUEL CONSUMPTION EXCESSIVE 530
FUEL OR OIL LEAKING FROM EXHAUST MANIFOLD 531
LUBRICATING OIL CONTAMINATED 532
LUBRICATING OIL CONSUMPTION EXCESSIVE 533
LUBRICATING OIL PRESSURE LOW 535
LUBRICATING OIL PRESSURE HIGH 537
ENGINE NOISE DIAGNOSTIC PROCEDURES-GENERAL INFORMATION 538
MAIN BEARING NOISE(REFER TO ENGINE NOISE EXCESSIVE-MAIN BEARING SYSTEM CHART) 538
CONNECTING ROD BEARING NOISE(REFER TO ENGINE NOISE EXCESSIVE-CONNECTING ROD SYMPTOM CHART) 538
PISTON NOISE(REFER TO ENGINE NOISE EXCESSIVE-PISTON SYMPTOM CHART) 538
FUEL CONSUMPTION-GENERAL INFORMATION 538
FUEL CONSUMPTION-INDUSTRIAL CUSTOMER COMPLAINT FORM 539
OIL CONSUMPTION 540
COOLING SYSTEM 542
COOLING SYSTEM-GENERAL INFORMATION 543
COOLING SYSTEM-FLOW DIAGRAMS 544
COOLING SYSTEM-SPECIFICATIONS 546
COOLING SYSTEM-SERVICE TOOLS 547
COOLING SYSTEM-MAINTENANCE 548
ANTIFREEZE 548
ANTIFREEZE CONCENTRATION-CHECKING 548
COOLING SYSTEM-DRAINING 548
ADDITIVE CONCENTRATION-CHECKING 548
COOLING SYSTEM-CLEANING 549
FILLING AND VENTING 553
COOLING SYSTEM-DIAGNOSING MALFUNCTIONS 554
RADIATOR CAP-PRESSURE TEST 555
COOLING SYSTEM-TEST FOR COMBUSTION GASES 555
BELT TENSION 559
COOLANT HOSE-INSPECTION 560
WATER PUMP-INSPECTION 560
WATER PUMP SEAL WEEP HOLE-INSPECTION 560
COOLANT PRESSURE-MEASUREMENT 562
RADIATOR,FAN AND SHUTTERS 562
THERMOSTAT OPERATION AND TESTING 564
THERMOSTAT LEAKAGE AND OPENING TEMPERATURE-TESTING”IN-CHASSIS” 565
THERMOSTAT OPENING TEMPERATURE-TESTING”THERMOSTAT REMOVED” 566
TEMPERATURE GAUGE OPERATION 567
FUEL PUMP OVERFUELED 567
VEHICLE OVERLOADED 568
DRIVE BELT-REPLACEMENT 568
BELT TENSIONER-REPLACEMENT 568
REMOVAL 568
INSTALLATION 569
FAN PULLEY-REPLACEMENT 569
REMOVAL AND INSTALLATION 569
FAN HUB-REPLACEMENT 569
REMOVAL AND INSTALLATION 570
WATER PUMP-REPLACEMENT 570
REMOVAL 570
CLEANING 571
INSTALLATION 571
THERMOSTAT-REPLACEMENT 573
REMOVAL 573
CLEANING 574
INSTALLATION 574
LUBRICATING OIL SYSTEM 577
LUBRICATING OIL SYSTEM-SERVICE TOOLS 579
LUBRICATING OIL SYSTEM-GENERAL INFORMATION 580
LUBRICATING OIL SYSTEM-SPECIFICATIONS 581
LUBRICATING OIL SYSTEM-FLOW DIAGRAM 582
LUBRICATING OIL LEAKS(EXTERNAL)-CHECKING 586
INTERNAL ENGINE DAMAGE-CHECKING 587
LUBRICATING OIL ANALYSIS 587
LUBRICATING OIL FILTER INSPECTION 587
LUBRICATING OIL SYSTEM-DIAGNOSING MALFUNTIONS 588
HIGH OIL PRESSURE 588
OIL PRESSURE REGULATION VALVE 588
LOW OIL PRESSURE 588
OIL LEVEL 588
OIL FILTER 589
OIL PRESSURE GAUGE-CHECKING 589
OIL TEMPERATURE GAUGE-CHECKING 590
OIL TEMPERATURE THERMOSTAT 590
OIL SUCTION TUBE 591
BEARINGS AND OIL PUMP 591
OIL DILUTION 591
COOLANT DILUTED OIL 591
OIL COOLER 592
AFTERCOOLER 592
CYLINDER HEAD EXPANSION PLUGS 593
CYLINDER LINER SEALS 593
CYLINDER HEAD GASKET 593
CRACKED CYLINDER HEAD 593
CRACKED CYLINDER LINER 594
CRACKED CYLINDER BLOCK 594
FUEL DILUTED OIL 594
FUEL TRANSFER PUMP 595
FUEL LEAKING BY PISTON RINGS 595
INJECTION PUMP 596
OIL LEAKS 596
LUBRICATING OIL PAN-DRAINING 598
LUBRICATING OIL PAN-FILLING 598
LUBRICATING OIL LEVEL-CHECKING 599
LUBRICATING OIL FILTER-CHANGING 600
LUBRICATING OIL DIPSTICK-CALIBRATION 601
LUBRICATING OIL DIPSTICK TUBE-REPLACEMENT 602
REMOVAL 602
INSTALLATION 602
LUBRICATING OIL PRESSURE REGULATOR,VALVE AND SPRING-REPLACEMENT 603
REMOVAL 603
CLEANING AND INSPECTION 603
INSTALLATION 604
LUBRICATING OIL COOLER ELEMENT AND GASKET-REPLACEMENT 604
REMOVAL 604
CLEANING AND INSPECTION 605
INSTALLATION 606
LUBRICATING OIL TEMPERATURE THERMOSTAT-REPLACEMENT 607
REMOVAL 607
INSPECTION 608
INSTALLATION 609
LUBRICATING OIL PAN,SUCTION TUBE AND GASKET-REPLACEMENT 609
OIL PAN -REMOVAL 609
CLEANING 609
SUCTION TUBE-REPLACEMENT 610
OIL PAN -INSTALLATION 610
LUBRICATING OIL PUMP-REPLACEMENT 612
REMOVAL 613
CLEANING AND INSPECTION 613
INSTALLATION 616
COMBUSTION AIR SYSTEM 620
COMBUSTION AIR SYSTEM FLOW-GENERAL INFORMATION 622
AIR SYSTEM FLOW-DIAGRAMS 623
INTAKE AIR AND EXHAUST SYSTEM SPECIFICATIONS 624
TURBOCHARGER BOOST PRESSURE SPECIFICATIONS 624
COMBUSTION AIR SYSTEM-SERVICE TOOLS 625
COMBUSTION AIR SYSTEM-DIAGNOSING MALFUNCTIONS 626
CLEAN AIR 626
INTAKE AIR RESTRICTION-CHECKING 626
DAMAGE FROM NON-FILTERED AIR 627
TURBOCHARGED ENGINES-AIR LEAKS,PRESSURE SIDE 627
TURBOCHARGED ENGINES-EXHAUST LEAKS 628
TURBOCHARGED BOOST PRESSURE-MEASUREMENT 628
MALFUNCTIONING TURBOCHARGER 629
OIL CONSUMPTION AND LEAKS 629
TURBOCHARGER NOISE 630
ROTOR ASSEMBLY CLEARANCE-MEASUREMENT 631
TURBOCHARGER WASTEGATE ACTUATOR-VISUAL INSPECTION 632
TURBOCHARGER WASTEGATE ACTUATOR-FUNCTIONAL CHECKING 633
TURBOCHARGER WASTEGATE ACTUATOR-REPLACEMENT 634
AIR REGULATOR WITH PRESSURE GAUGE 634
TURBOCHARGER WASTEGATE ACTUATOR-CALIBRATION 636
EXHAUST RESTRICTION-MEASUREMENT 637
CHARGE AIR COOLER(CAC)-TROUBLESHOOTING 637
PRESSURE DROP-CHECKING 637
CHECKING-AIR LEAK 639
CHARGE AIR COOLER 640
CLEANING AND INSPECTION 640
AIR CROSSOVER TUBE-REPLACEMENT 641
REMOVAL AND INSTALLATION 641
INTAKE MANIFOLD COVER AND GASKET-REPLACEMENT 642
REMOVAL 642
CLEANING 643
INSTALLATION 643
AFTERCOOLER AND GASKET-REPLACEMENT 643
REMOVAL 644
CLEANING 644
INSTALLATION 644
TURBOCHARGER-REPLACEMENT 645
REMOVAL 645
CLEANING AND INSPECTION 646
INSTALLATION 647
EXHAUST MANIFOLD AND GASKETS-REPLACEMENT 649
REMOVAL 649
CLEANING AND INSPECTION 650
INSTALLATION 650
COMPRESSED AIR SYSTEM 652
COMPRESSED AIR SYSTEM GENERAL INFORMATION 653
COMPRESSED AIR SYSTEM SPECIFICATIONS 654
COMPRESSED AIR SYSTEM FLOW DIAGRAMS 655
AIR COMPRESSOR CARBON BUILDUP-CHECKING 656
AIR COMPRESSOR GASKET LEAKS-CHECKING 658
AIR GOVERNOR AND COMPRESSOR UNLOADER VALVE-CHECKING 658
AIR GOVERNOR-CHECKING 659
AIR COMPRESSOR-REPLACEMENT 661
REMOVAL 662
INSPECTION 663
INSTALLATION 663
FUEL SYSTEM 666
FUEL SYSTEM COMPONENTS AND FLOW 668
FUEL SYSTEM SPECIFICATIONS 669
FUEL SYSTEM -SERVICE TOOLS 670
FUEL SYSTEM DIAGNOSING-MALFUNCTIONS 672
FUEL TRANSFER PUMP 672
AIR IN THE FUEL SYSTEM 676
FUEL WATER SEPARATOR/FILTER UNIT 678
FUEL INJECTION PUMP 679
GOVERNOR MALFUNCTIONS 679
AIR FUEL CONTROL(AFC)MALFUNCTIONS 679
FUEL CONTROL LEVER TRAVEL AND ADJUSTMENT 680
FUEL INJECTION PUMP IDLE ADJUSTMENT SCREWS 680
MANUAL SHUT DOWN LEVERS 680
ELECTRICAL SHUT DOWN DEVICES 681
FUEL INJECTION PUMP TIMING 682
HIGH PRESSURE PUMP TIMING 683
INJECTORS 684
FUEL DRAIN MANIFOLD 685
LOW PRESSURE FUEL LINE-REPLACEMENT 686
REMOVAL AND INSTALLATION 686
FUEL FILTER HEAD ADAPTER-REPLACEMENT 686
REMOVAL AND INSTALLATION 686
FUEL TRANSFER PUMP-REPLACEMENT/REBUILD 687
REMOVAL 687
REBUILD 687
CLEANING 688
ASSEMBLY 688
CLEANING MOUNTING SURFACE 689
INSTALLATION 689
HIGH PRESSURE FUEL LINES-REPLACEMENT 689
REMOVAL 689
INSTALLATION 690
FUEL DRAIN MANIFOLD-REPLACEMENT 691
REMOVAL AND INSTALLATION 691
INJECTOR-REPLACEMENT 691
REMOVAL 691
CLEANING AND INSPECTION 691
INSTALLATION 692
FUEL SHUTOFF SOLENOID-REPLACEMENT 693
RSV GOVERNOR FUEL SHUTOFF SOLENOID-REMOVAL 693
RSV GOVERNOR FUEL SHUTOFF SOLENOID-INSTALLATION 694
DIRECT LINK SOLENOID,CYLINDER BLOCK MOUNTED 694
RQVK GOVERNOR FUEL SHUTOFF SOLENOID-REMOVAL AND INSTALLATION 694
FUEL RETURN OVERFLOW VALVE-REPLACEMENT 695
AFC TUBE-REPLACEMENT 696
REMOVAL 696
INSTALLATION 696
FUEL INJECTION PUMP-REPLACEMENT 696
REMOVAL 697
INSTALLATION 698
IDLE SPEED-ADJUSTMENT 703
BOSCH RSV GOVERNOR 703
BOSCH RQVK GOVERNOR 704
INLINE FUEL INJECTION PUMP SPILL-PORT TIMING 704
GOVERNOR LEVER POSITIONING 706
ELECTRICAL SYSTEM 711
ELECTRICAL SYSTEM DESCRIPTION AND OPERATION 712
CRANKING MOTOR AND ELECTRICAL CIRCUITS 712
DELCO REMY MODEL 37MT/41MT STARTING MOTOR 713
DELCO REMY MODEL 42MT STARTING MOTOR 713
NIPPENDENSO MODEL F2 STARTING MOTOR 714
NIPPENDENSO MODEL F2 BASIC CRANKING CURRENT FLOW 714
DELCO REMY MODEL 15SI 116 ALTERNATOR(WIRING DIAGRAM) 715
BOSCH K1 MODEL ALTERNATOR(WIRING DIAGRAM) 715
NIPPONDENSO F4 STARTING MOTOR 716
DELCO 42MT STARTING MOTOR 716
ELECTRICAL SYSTEM-SPECIFICATIONS 717
MINIMUM RECOMMENDED BATTERY CAPACITY 717
MAXIMUM ALLOWABLE RESISTANCE OF STARTING CIRCUIT 717
WIRING SIZE RECOMMENDATIONS FOR STARTER SOLENOID AND FUEL SOLENOID CIRCUIT 718
ELECTRICAL SYSTEM-SERVICE TOOLS 719
ELECTRICAL SYSTEM-DIAGNOSING MALFUNCTIONS 720
BATTERIES-CHECKING 720
STARTING CIRCUIT-CHECKING 721
STARTING MOTOR SOLENOID AND STARTING MOTOR CHECKING 724
ENGINE CRANKING SPEED TOO SLOW 726
ALTERNATOR 727
OIL PRESSURE SWITCH AND TEMPERATURE SENSOR-CHECKING 730
COOLANT OR PAN HEATERS-CHECKING 731
STARTING MOTOR-REPLACEMENT 731
REMOVAL AND INSTALLATION 732
ALTERNATOR-REPLACEMENT 732
REMOVAL 732
INSTALLATION 733
COOLANT TEMPERATURE SENSOR-REPLACEMENT 733
REMOVAL 734
INSTALLATION 734
ENGINE BLOCK AND COOLANT HEATER(750 AND 500 WATS)-REPLACEMENT 734
REMOVAL 735
INSTALLATION 735
LUBRICATING OIL PAN HEATER-REPLACEMENT 735
REMOVAL 736
INSTALLATION 736
LUBRICATING OIL PRESSURE SWITCH REPLACEMENT 736
REMOVAL 736
INSTALLATION 736
BASE ENGINE COMPONENTS 737
BASE ENGINE COMPONENTS-SERVICE TOOLS 740
BASE ENGINE COMPONENTS-GENERAL INFORMATION 745
ENGINE COMPRESSION-CHECKING 745
COMPRESSION GUAGE AND ADAPTER 745
PISTON RING SEALING 746
INTAKE AND EXHAUST VALVE SEALING 746
CYLINDER HEAD GASKET SEALING 746
VALVE COVER-REPLACEMENT 747
REMOVAL 747
CLEANING AND INSPECTION 748
INSTALLATION 748
CRANKCASE BREATHER TUBE-REPLACEMENT 749
REMOVAL 749
CLEANING AND INSPECTION 749
INSTALLATION 750
ROCKER LEVER DIAGNOSING-MALFUNCTIONS 750
VALVE LASH SPECIFICATIONS 750
ROCKER LEVER-REPLACEMENT 751
REMOVAL 751
DISASSEMBLY 752
CLEANING AND INSPECTION 753
ASSEMBLY 754
INSTALLATION 755
VALVE LASH-ADJUSTMENT 756
VALVE ARRANGEMENT 758
TIMING PIN ASSEMBLY-INSTALLATION 759
PUSH ROD-REPLACEMENT 763
REMOVAL 763
CLEANING AND INSPECTION 764
INSTALLATION 765
CYLINDER HEAD-REPLACEMENT 766
GENERAL INFORMATION 766
DIAGNOSING MALFUNCTIONS 766
REMOVAL 769
CYLINDER BLOCK/HEAD DECK-CLEANING AND INSPECTION 770
CYLINDER HEAD-CLEANING AND INSPECTION 773
INSTALLATION 778
CYLINDER HEAD-PRESSURE TEST 783
MAIN AND THRUST BEARINGS-REPLACEMENT 784
GENERAL INFORMATION 784
DIAGNOSING MALFUNCTIONS 785
REMOVAL 786
CLEANING AND INSPECTION 788
INSTALLATION 790
CONNECTING ROD BEARINGS-REPLACEMENT 795
DIAGNOSING MALFUNCTIONS 795
REMOVAL 796
CLEANING AND INSPECTION 797
INSTALLATION 800
PISTON AND RINGS-REPLACEMENT 802
PISTON-GENERAL INFORMATION 802
PISTON AND RINGS-DIAGNOSING MALFUNCTIONS 802
REMOVAL 804
CLEANING AND INSPECTION 807
INSTALLATION 812
CONNECTING RODS-REPLACEMENT 819
GENERAL INFORMATION 819
REMOVAL 820
CLEANING AND INSPECTION 821
INSTALLATION 823
CYLINDER LINERS-REPLACEMENT 825
GENERAL INFORMATION 825
REMOVAL 825
CLEANING AND INSPECTION 829
INSTALLATION 832
VIBRATION DAMPER-REPLACEMENT 839
GENERAL INFORMATION 839
RUBBER ELEMENT VIBRATION DAMPER-INSPECTION(IN-CHASSIS) 839
VISCOUS VIBRATION DAMPER-INSPECTION 841
REMOVAL 842
INSTALLATION 843
GEAR COVER-REPLACEMENT 844
REMOVAL 844
CLEANING AND INSPECTION 845
INSTALATION 846
SEAL,FRONT CRANKSHAFT-REPLACEMENT 848
GENERAL INFORMATION 848
REMOVAL AND INSTALLATION 849
WEAR SLEEVE,FRONT CRANKSHAFT-REPLACEMENT 849
REMOVAL 849
CLEANING AND INSPECTION 850
INSTALLATION 850
GEAR HOUSING-REPLACEMENT 853
GENERAL INFORMATION 853
REMOVAL 854
CLEANING AND INSPECTION 855
INSTALLATION 857
ENGINE DATAPLATE-REPLACEMENT 862
REMOVAL 863
INSTALLATION 863
CAMSHAFT-REPLACEMENT 864
GENERAL INFORMATION 864
REMOVAL 866
CLEANING AND INSPECTION 869
INSTALLATION 873
CAMSHAFT GEAR-REPLACEMENT 876
REMOVAL 876
CLEANING AND INSPECTION 876
INSTALLATION 878
VALVE TAPPET-REPLACEMENT 879
GENERAL INFORMATION 879
REMOVAL 880
CLEANING AND INSPECTION 883
INSTALLATION 884
CRANKSHAFT GEAR-REPLACEMENT 888
GENERAL INFORMATION 888
REMOVAL 889
CLEANING AND INSPECTION 891
INSTALLATION 892
FLYWHEEL-REPLACEMENT 895
REMOVAL 895
CLEANING AND INSPECTION 896
INSTALLATION 897
FLYWHEEL BORE RUNOUT MEASUREMENT 899
FLYWHEEL FACE RUNOUT MEASUREMENT 900
FLYWHEEL RING GEAR-REPLACEMENT 902
REMOVAL 902
INSTALLATION 902
FLYWHEEL HOUSING-REPLACEMENT 902
REMOVAL 902
CLEANING AND INSPECTION 904
INSTALLATION(DRY CLUTCH APPLICATION) 905
CONCENTRICITY-CHECKING 906
INSTALLATION(WET CLUTCH APPLICATION) 908
SEAL,REAR CRANKSHAFT-REPLACEMENT 910
REMOVAL 910
CLEANING AND INSPECTION 911
INSTALLATION 912
WEAR SLEEVE,REAR CRANKSHAFT SEAL-REPLACEMENT 913
REMOVAL 913
CLEANING AND INSPECTION 915
INSTALLATION 916
PIPE PLUG-REPLACEMENT 919
REMOVAL 919
CLEANING AND INSPECTION 919
INSTALLATION 920
CUP PLUG-REPLACEMENT 920
REMOVAL 920
CLEANING AND INSPECTION 921
INSTALLATION 921
ENGINE TESTING 923
ENGINE TESTING-GENERAL INFORMATION 924
ENGINE TESTING-GENERAL SPECIFICATIONS 925
BLOWBY MEASUREMENT 926
ENGINE TESTING-SERVICE TOOLS 927
GENERAL ENGINE TEST PROCEDURES 928
ENGINE RUN-IN PROCEDURE 930
ENGINE REMOVAL AND INSTALLATION 932
ENGINE REMOVAL AND INSTALLATION-GENERAL INFORMATION 933
ENGINE-REMOVAL 933
ENGINE MOUNT-INSPECTION 936
ENGINE-INSTALLATION 936
THROTTLE CONTROL LEVER CONNECTION 937
ENGINE COMPONENT SPECIFICATIONS 941
SPECIFICATION-GENERAL INFORMATION 942
COMPONENT SPECIFICATIONS AND TORQUE VALUES 943
COOLING SYSTEM SPECIFICATIONS 943
COOLING SYSTEM TORQUE VALUES 943
LUBRICATING OIL SYSTEM SPECIFICATIONS 944
LUBRICATING OIL SYSTEM TORQUE VALUES 945
COMBUSTION AIR SYSTEM SPECIFICATIONS 947
COMBUSTION AIR SYSTEM TORQUE VALUES 947
COMPRESSED AIR SYSTEM TORQUE VALUES 948
FUEL SYSTEM SPECIFICATIONS 949
FUEL SHUTOFF SOLENOID ADJUSTMENT 949
FUEL SYSTEM TORQUE VALUES 950
ELECTRICAL SYSTEM SPECIFICATIONS 953
ELECTRICAL SYSTEM TORQUE VALUES 953
BASE ENGINE COMPONENT SPECIFICATIONS 954
BASE ENGINE TORQUE VALUES 965
DRIVE BELT TENSION 967
WEIGHT AND MEASURES-CONVERSION FACTORS 969
NEWTON-METER TO FOOT-POUND CONVERSION CHART 970
CAPSCREW MARKINGS AND TORQUE VALUES 971
CAPSCREW MARKINGS AND TORQUE VALUES-METRIC 972
CAPSCREW MARKINGS AND TORQUE VALUES-U S CUSTOMARY 973
PIPE PLUG TORQUE VALUES 974
INDEX 975
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