Content

Safety

• Introduction
• Prepare for the job
• Safety notices
• Keep work area clean
• Keep work area well ventilated
• Use proper eye and face protection
• Use lifting equipment safely
• Use compressed air and air tools safely
• Handle fuel safely
• Store volatile and hazardous materials safely
• Handle chemical products safely
• Service electrical components safely
• Dispose of waste materials safely

Specifications and general information

• General specifications
• Air intake and exhaust system specifications
• Electrical specifications
• Fuel system specifications
• Cooling system specifications
• Front cover, timing chain, and tensioner specifications
• Cylinder head, cams, and valve train specifications
• Tappet shim selection chart
• Lubrication system specifications
• Cylinder block, lower crankcase, and crankshaft specifications

Maintenance

• Engine oil level
• Change engine oil
• Oil filter
• Spark plugs

Theory of operation

• General engine operation
• Air intake, fuel, and exhaust
• Cooling system
• Front cover, timing chain, and tensioner
• Cylinder head and valve train
• Lubrication system
• Cylinder block and lower crankcase

Tests and adjustments

• Air intake and exhaust systems
• Cooling system
• Cylinder head, cams, and valve train
• Lubrication system

Diagnostic troubleshooting

• Troubleshooting

Repair

• Air intake and exhaust systems
• Electrical system
• Fuel system
• Cooling system
• Front cover, timing chain, and tensioner
• Cylinder head, cams, and valve train
• Lubrication system
• Cylinder block and lower crankcase

Tools and materials

• Special tools
• Required materials