Content

Introduction

• About the manual
• Definition of terms
• General cleaning instructions
• How to use the manual
• Illustrations
• Symbols

Engine identification

• Automotive engine specifications
• Engine diagrams
• Fuel pump dataplate (nameplate)
• Non-automotive engine specifications

Troubleshooting

Cooling system repair

• Beit tensioner
• Coolant
• Coolant system components and flow
• Coolant system malfunctions
• Cooling system specifications
• Drive belt
• Expansion plugs
• Fan hub
• Fan pulley
• Thermostat
• Water pump

Lubricating oil system repair

• Diagnosing lubricating system malfunctions
• Expansion plug
• Flow diagrams - lubricating system
• General information
• High lubricating oil pressure
• Low lubricating oil pressure
• Lubricating oil cooler element and / or gasket
• Lubricating oil leaks
• Lubricating oil pan, suction tube and / or gaskets
• Lubricating oil pressure regulator valve / spring
• Lubricating oil pump
• Lubrication for the power components
• Lubrication for the turbocharger
• Specifications - lubricating oil system

Air combustion system repair

• Aftercooler amd gasket
• Air crossover tube
• Air system flow
• Charge air cooler
• Combustion air system
• Combustion air system flow
• Exhaust manifold and gaskets
• Intake air and exhaust system specifications
• Intake manifold cover and gasket
• Turbocharger
• Rotor assembly clearance
• Turbocharger boost pressure specifications
• Turbocharger wastegate actuator
• Turbocharger wastegate actuator boost capsule
• Turbocharger wastegate capsule
• Turbocharger wastegate functional
• Turbocharger wastegate valve assembly

Compressed air system repair

• Air compressor
• Air governor
• Air governor and compressor unloader valve
• Carbon buildup, air compressor
• Compressed air system
• Row diagrams - compressed air system
• Gasket leaks, air compressor
• Specifications - compressor air system

Fuel system repair

• Air fuel control tube
• Back leakage valve and sealing washer
• Cold start timing advance system
• External pump leaks
• Fuel drain menifoki
• Fuel filter
• Fuel injection pump
• Fuel shut off solenoid
• Fuel shut off valve
• Fuel system - service tools
• Fuel system components and flow
• Fuel system identification
• Fuel system specifications
• Fuel transfer pump
• Fuel water separator / filter unit
• General information - fuel systems
• High pressure fuel line
• Idle speed adjustment
• Injector
• KSB wiring harness
• Low pressure fuel line
• Fuel injection pump
• Low pressure fuel line
• Pressure relief valve
• Shut down solenoid

Electrical system repair

• Alternator
• Battery checking
• Battery terminal connections
• Block water heater replacement
• Service tools
• Flow diagrams
• General information
• Intake manifold heater
• Lubricating oil pressure switch
• Oil pan heater
• Specifications
• Starting circuit
• Temperature sensor
• White smoke

Base engine components system repair

• Base engine components
• Camshaft and tappet
• Camshaft gear
• Connecting rod bearing
• Connecting rods
• Crankshaft gear
• Cylinder bore deglaze
• Cylinder head
• Exhaust manifold
• Expansion plug
• Flywheel housing
• Flywheel / ring gear
• Front seal
• Gear cover
• Gear housing or gasket
• Main bearing
• Piston and rings
• Piston pin
• Rear seal
• Rocker levers and push rods
• Timing pin
• Turbocharger
• Valves
• Vibration damper / crank pulley
• Wear sleeve, rear crankshaft seal

Engine testing and run-in

Engine removal and installation

Specifications and torque values

• Capscrew markings and torque values
• Component specifications and torque values
• Drive belt tension
• Newton-meter to foot-pound conversion chart
• Pipe plug torque values
• Tap-drill chart - U.S. Customary and metric
• Weight and measures - conversion factors

Component manufacturers

Additional service literature

Index