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Diesel Engine Index
3
Index
Introduction
About the Manual................................................... 4
How to Use the Manual ......................................... 4
Illustrations............................................................. 6
Symbols................................................................. 5
Engine Identification
Engine Diagrams ................................................... 9
Engine Views.......................................................9
Engine Identification .............................................. 7
Engine Dataplate................................................. 7
Specifications......................................................... 8
Troubleshooting Symptoms
Procedures and Techniques .................................20
Troubleshooting Symptoms Charts.......................20
Coolant Contamination.......................................34
Coolant Loss.......................................................35
Coolant Temperature above Normal...................38
Engine Cranks But Will Not Start
(No Exhaust Smoke) ..........................................22
Engine Difficult to Start or Will Not Start
(Exhaust Smoke) (Continued) ............................24
Engine Difficult to Start or Will Not Start
(Exhaust Smoke)................................................23
Engine Has Poor Respones ...............................25
Engine Power Output Low (Continued)..............29
Engine Power Output Low..................................28
Engine Runs Rough or Misfires..........................27
Engine Stops During Operation..........................26
Engine Vibration Excessive ................................41
Engine Will Not Crank or Cranks Slowly ............21
Excessive Exhaust (Black Smoke).....................30
Excessive Noise (Continued) .............................40
Excessive Noise .................................................39
Fuel consumption Is Excessive ..........................33
Lubricating Oil Consumption Excessive .............31
Lubricating Oil Contaminated .............................32
Lubricating Oil Pressure Is Low..........................36
Oil Level Rises....................................................37
Complete Engine
Complete Engine ..................................................42
Engine Assembly................................................61
Engine Disassembly...........................................42
Engine Testing
Complete Engine.................................................. 89
Measuring Compression Pressure..................... 89
Testing and Adjusting the Fan Belt Tansion ....... 91
Fuel System ......................................................... 92
Checking and Adjusting Fuel Injection Timing ... 92
Injector ................................................................. 95
Assembly ........................................................... 98
Disassembly....................................................... 97
Testing................................................................ 95
Lubricating System.............................................100
Measuring Oil Pressure ...................................100
Rocker Levers...................................................... 87
Adjusting Valve Clearance................................. 87
Specifications
Camshaft and Camshaft Bushing ......................105
Capscrew Markings and Torque Values - Metric 115
Capscrew Markings and Torque Values - U.S.
Customary.......................................................... 116
Capscrew Markings and Torque Values.............115
Connecting Rod, Piston Ring and Piston Pin..... 111
Crankshaft.......................................................... 106
Cylinder Block ....................................................104
Cylinder Head ....................................................103
Cylinder..............................................................109
Flywheel.............................................................108
Fraction, Decimal, Millimeter Conversions......... 117
Newton-Meter to Foot-Pound Conversion
Chart ..................................................................118
Oil Pump ............................................................112
Pipe Plug Torque Values ....................................118
Piston .................................................................110
Regulator Valve..................................................113
Rocker Arm Shaft, Push Rod and Tappets......... 102
Tap-Drill Chart - U.S. Customary and Metric......119
Thermostat.........................................................114
Timing Gear........................................................107
Valves, Valve Guides, and Springs ....................101
Weight and Measures - Conversion Factors...... 120
Special Tool
Special Tool List .................................................121