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John Deere 300 3029 4039 4045 6059 6068 Series Engine Components Technical Manual CTM8
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John Deere 300 3029 4039 4045 6059 6068 Series Engine Components Technical Manual CTM8
Size: 25.81 MB
Format: PDF
Language: English
Brand: John Deere
Type of Machine: Engine
Type of Manual: Components Technical Manual
Model: John Deere 300 3029 4039 4045 6059 6068 Series Engine
Part Number: CTM8
Number of Pages: 505 Pages
Contents:
Safety
Handle Fluids Safely—Avoid Fires
Prevent Battery Explosions
Prepare For Emergencies
Prevent Acid Burns
Avoid High-Pressure Fluids
Wear Protective Clothing
Service Machines Safely
Work In Ventilated Area
Work In Clean Area
Remove Paint Before Welding Or Heating
Avoid Heating Near Pressurized Fluid Lines
Illuminate Work Area Safely
Use Proper Lifting Equipment
Practice Safe Maintenance
Use Proper Tools
Dispose Of Waste Properly
Live With Safety
General Information
Unified Inch Bolt And Cap Screw Torque Values
Metric Bolt And Cap Screw Torque Values
Engine Model Designation
Engine Serial Number Plate Information
Engine Application Charjohn Deere Agricultural Equipment
Engine Application Charjohn Deere Industrial Equipment
Engine Application Charjohn Deere Industrial Equipment—Continued
Engine Application Charoem Applications
Fuels, Lubricants, And Coolant
Diesel Fuel
Lubricity Of Diesel Fuels
Engine Break-In Oil
Diesel Engine Oil
Alternative And Synthetic Lubricants
Oilscan® And Coolscan™
Grease
Engine Coolant Requirements
Engine Coolant Requirements—Continued
Recommended Engine Coolant
Engine Coolant Specifications
Engine Coolant Specifications—Continued
Replenishing Supplemental Coolant Additives (Sca’s) Between Coolant Changes
Operating In Tropical Conditions
Flush And Service Cooling System
Disposing Of Coolant
Engine Mounting
Engine Repair Stand
Safety Precautions
Install 300 Series Adapters On Repair Stand
Engine Lifting Procedure
Clean Engine
Mount Engine On Repair Stand
Disconnect Turbocharger Oil Inlet Line
Engine Rebuild Guide
Engine Disassembly Sequence
Sealant Application Guidelines
Sealant Application Guidelines—Continued
Engine Assembly Sequence
Cylinder Head And Valves
Special Or Essential Tools
Cylinder Head And Valves Specifications
Cylinder Head And Valves Specifications—Continued
Cylinder Head And Valves Specifications—Continued
Check And Adjust Valve Clearance
Measure Valve Lift
Remove Cylinder Head
Disassemble And Inspect Rocker Arm Assembly
Assemble Rocker Arm Assembly
Inspect, Measure, And Assemble Camshaft Followers
Check Valve Recess In Cylinder Head
Preliminary Cylinder Head And Valve Checks
Remove Valve Assembly
Inspect And Measure Valve Springs
Inspect Valve Rotators
Clean Valves
Inspect And Measure Valves
Grind Valves
Inspect And Clean Cylinder Head
Check Cylinder Head Flatness
Measure Cylinder Head Thickness
Clean Injection Nozzle Bores
Clean Valve Guides
Measure Valve Guides
Knurl Valve Guides
Clean And Inspect Valve Seats
Grind Valve Seats
Remove Valve Seat Inserts
Measure Valve Seat Bore In Cylinder Head
Install Valve Seat Inserts
Install Valves
Clean And Inspect Cylinder Head Cap Screws
Inspect And Clean Exhaust Manifold
Clean And Inspect Top Deck Of Cylinder Block
Measure Cylinder Liner Standou(Height Above Block)
Install Cylinder Head
Torque-Turn Method For Proper Torque
Install Rocker Arm Assembly
Inspect And Clean Ventilator Outlet Hose
Install Rocker Arm Cover
Complete Final Assembly
Perform Engine Break-In
Cylinder Block, Liners, Pistons, And Rods
Special Or Essential Tools
Other Material
Cylinder Block, Liners, Pistons, And Rods Specifications
Cylinder Block, Liners, Pistons, And Rods Specifications—Continued
Cylinder Block, Liners, Pistons, And Rods Specifications—Continued
Cylinder Block, Liners, Pistons, And Rods Specifications—Continued
Cylinder Block, Liners, Pistons, And Rods Specifications—Continued
Remove Pistons And Connecting Rods
Remove Cylinder Liners
Complete Disassembly Of Cylinder Block (If Required)
Preliminary Liner, Piston And Rod Checks
Disassemble Piston And Rod Assembly
Clean Pistons
Visually Inspect Pistons
Clean Cylinder Liners
Visually Inspect Cylinder Liners
Check Piston Ring Groove Wear
Measure Piston Pin Bore
Measure Piston Skirt
Determine Piston-To-Liner Clearance
Deglaze Cylinder Liners
Replace Piston And Liner Sets
Inspect And Measure Connecting Rod Bearings
Inspect Rod And Cap
Inspect Piston Pins And Bushings
Remove Piston Pin Bushing
Clean And Inspect Connecting Rod Pin Bore
Install Piston Pin Bushing In Connecting Rod
Inspect And Clean Cylinder Block
Clean Cylinder Liner O-Ring Bore
Measure Cylinder Block Main Bearing Bore
Measure Camshaft Follower Bore
Measure Camshaft Bearing Bore
Measure Balancer Shaft Bore—4-Cylinder Engines
Measure Cylinder Block Top Deck Flatness
Inspect Piston Cooling Orifices
Measure Liner Flange Thickness
Measure Cylinder Liner Standout (Height Above Block)
Install Cylinder Liner O-Rings And Packings
Install Cylinder Liner
Assemble Piston And Connecting Rod
Install Piston Rings
Install Piston And Connecting Rod Assembly
Torque-Turn Connecting Rod Cap Screws
Check Engine Rotation For Excessive Tightness
Measure Piston Protrusion
Complete Final Assembly
Crankshaft, Main Bearings, And Flywheel
Special Or Essential Tools
Other Material
Crankshaft, Main Bearings, And Flywheel Specifications
Crankshaft, Main Bearings, And Flywheel Specifications—Continued
Crankshaft, Main Bearings, And Flywheel Specifications—Continued
Crankshaft And Main Bearing Failure Analysis
Inspect Vibration Damper (6-Cylinder Engine)
Remove Pulley Or Vibration Damper Pulley
Install Pulley Or Vibration Damper Pulley
Checking Vibration Damper Or Pulley (Engine With Front Pto)
Removing Vibration Damper Or Pulley (Engine With Front Pto)
Installing Vibration Damper Or Pulley (Engine With Front Pto)
Replace Front Crankshaft Oil Seal (Without Removing Timing Gear Cover)
Check Crankshaft End Play
Inspect Flywheel
Check Flywheel Housing Face Runout
Check Flywheel Face Flatness
Remove Flywheel
Replace Flywheel Ring Gear
Replace Pilot Bearing In Flywheel—3029, 4039, 4045 Engines (If Equipped)
Install Flywheel
Crankshaft Rear Oil Seal And Wear Sleeve General Information
Remove Two-Piece Crankshaft Rear Oil Seal And Wear Sleeve (Without Removing Flywheel Housing)
Remove Unitized (Non-Separable) Crankshaft Rear Oil Seal And Wear Sleeve
Install Crankshaft Rear Oil Seal And Wear Sleeve
Remove Flywheel Housing
Remove Crankshaft Main Bearings
Check Main Bearing Clearance
Remove And Install Crankshaft Gear (Crankshaft Installed In Engine)
Remove Crankshaft
Remove Crankshaft Rear Wear Sleeve (Crankshaft Removed From Engine)
Inspect Crankshaft
Measure Main Bearing Id And Crankshaft Journal Od
Measure Main Thrust Journal Width And Thrust Bearing Width
Crankshaft Grinding Guidelines
Crankshaft Grinding Guidelines—Continued
Crankshaft Grinding Specifications
Measure Assembled Id Of Main Bearing Caps
Inspect Piston Cooling Orifices
Install Main And Thrust Bearing Inserts In Block
Install Crankshaft
Install Flywheel Housing
Complete Final Assembly
Camshaft, Balancer Shafts, And Timing Gear Train
Special Or Essential Tools
Other Materials
Camshaft, Balancer Shafts, And Timing Gear Train Specifications
Camshaft, Balancer Shafts, And Timing Gear Train Specifications—Continued
Camshaft, Balancer Shafts, And Timing Gear Train Specifications—Continued
Camshaft, Balancer Shafts, And Timing Gear Train Specifications—Continued
Camshaft, Balancer Shafts, And Timing Gear Train Specifications—Continued
Left-Hand (Crankshaft-Driven) Auxiliary Gear Drive Specifications
Measure Valve Lift
Remove Timing Gear Cover
Remove And Install Camshaft Bushing With Front Plate Installed Camshaft Gear-Driven Auxiliary Drive Engines, Serial No. (138541— )
Remove Auxiliary Drive Gears (Engines With Auxiliary Gear Drive Option)
Measure Camshaft End Play
Measure Balancer Shaft End Play (4-Cylinder Engines)
Measure Idler Gear End Play
Measure Timing Gear Backlash
Remove Camshaft
Visually Inspect Camshaft
Measure Camshaft Thrust Plate Clearance
Inspect And Measure Camshaft Bearing Bore Id And Journal Od
Measure Camshaft Lobe Height
Remove And Install Camshaft Gear
Inspect Camshaft Followers
Replace Tachometer Drive Gear
Remove And Install Camshaft Bushing With Front Plate Removed Engine Serial No. ( —138540)
Remove Balancer Shafts—If Equipped (4-Cylinder Engines)
Inspect And Measure Balancer Shaft Bushings And Journals
Remove And Install Balancer Shaft Bushings (4-Cylinder Engines)
Install Oversize Balancer Shaft Bushings In Cylinder Block (4039 Engines)
Inspect Balancer Shaft Gears And Thrust Plates
Remove And Install Balancer Shaft Gears
Removing Balancer Shaft
Remove Cylinder Block Front Plate
Measure Idler Gear Bushing And Shaft
Remove And Install Idler Gear Bushings
Remove Lower And Upper Idler Shafts
Clean And Inspect Front Plate
Replace Engine Front Plate
Transfer Fuel Injection Pump Timing Mark Onto Replacement Front Plate
Install Idler Shaft Spring Pins
Install Upper Idler Shaft In Front Plate
Install Lower Idler Shaft In Front Plate
Install Engine Front Plate
Install And Time Balancer Shafts—If Equipped (4-Cylinder Engines)
Install And Time Camshaft And Fuel Injection Pump
Clean And Inspect Timing Gear Cover
Install Ball Bearings And Dowels (Engines With Crankshaft-Driven Auxiliary Gear Drive Option)
Install Drive Gear (Engines With Crankshaft-Driven Auxiliary Gear Drive Option)
Install Timing Gear Cover
Install Crankshaft Front Oil Seal
Install Idler Gear And Output Gear (Engines With Auxiliary Gear Drive Option)
Complete Final Assembly
Lubrication System
Special Or Essential Tools
Other Material
Lubrication System Specifications
Lubrication System Specifications—Continued
Lubrication System Specifications—Continued
General Lubrication System Information
Oil Cooler Identification
Remove, Inspect, And Install Standard-Flow Oil Cooler
Remove And Install High-Flow Oil Cooler
Replacing Standard Oil Cooler/Oil Filter Housings
Remove, Inspect, And Install Oil Bypass Valve—3029, 4039, And 6059 Engines And 4045 And 6068 Engines With Common Lube Block*
Remove And Install Oil Bypass Valve—4045 And 6068 Engines With Pre-Common Lube Block*
Remove And Install Oil Pressure Regulating Valve And Seat—3029, 4039, And 6059 Engines And 4045 And 6068 Engines With Common Lube Block*
Remove, Inspect, And Install Oil Pressure Regulating Valve—4045 And 6068 Engines With Pre-Common Lube Block*
Remove And Install Oil Filter Nipple—3029, 4039, 6059 Engines
Remove And Install Oil Pan Mounted Oil Fill/Dipstick Tube
Remove, Install, And Adjust Dipstick Nipple
General Oil Pump Information
Replace Oil Pump Pick-Up Tube Assembly
Remove Standard Capacity Oil Pump
Inspect And Measure Clearances (Standard Capacity Oil Pump)
Complete Standard Capacity Oil Pump Disassembly
Assemble Standard Capacity Oil Pump
Install Standard Capacity Oil Pump
Remove High Capacity Oil Pump
Inspect And Measure Clearances (High Capacity Oil Pump)
Complete High Capacity Oil Pump Disassembly
Assemble High Capacity Oil Pump
Install High Capacity Oil Pump
Install Oil Pan
Cooling System
Special Or Essential Tools
Service Equipment And Tools
Other Material
Cooling System Specifications
Cooling System Specifications—Continued
Cooling System Specifications—Continued
Cooling System Specifications—Continued
Cooling System Specifications—Continued
Cooling System Specifications—Continued
Cooling System Specifications—Continued
Cooling System Specifications—Continued
Cooling System Specifications—Continued
Remove, Test, And Install Thermostats
Remove And Install Water Manifold/Thermostat Housing
General Water Pump Information
Remove Water Pump
Disassemble Low Flow, Standard-Duty High Flow, And Modular Style Water Pumps
Disassemble Heavy-Duty High Flow Water Pump
Inspect And Clean Water Pump Parts
Assemble Low Flow, Standard-Duty High Flow, And Modular Style Water Pumps
Assemble Heavy-Duty High Flow Water Pump
Checking Water Pump Cap Screw Protrusion
Install Water Pump
Inspect And Install Fan Blade Assembly
Remove Coolant Heater—If Equipped
Install Coolant Heater—If Equipped
Air Intake And Exhaust System
Air Intake And Exhaust System Specifications
Air Intake And Exhaust System Specifications—Continued
Extending Turbocharger Life
Remove Turbocharger
Turbocharger Failure Analysis
Turbocharger Seven-Step Inspection
Perform Radial Bearing Clearance Test
Perform Axial Bearing End Play Test
Repair Turbocharger
Disassemble And Inspect Turbocharger
Replace Center Housing And Rotating Assembly
Prelube Turbocharger
Install Turbocharger
Turbocharger Break-In
Remove, Inspect And Install Intake Manifold
Remove, Inspect And Install Exhaust Manifold
Aftercooler Assembly
Remove And Install Aftercooler
Inspect And Repair Aftercooler
Fuel System
Special Or Essential Tools
Fuel System Specifications
Fuel System Specifications—Continued
Fuel System Specifications—Continued
Relieve Fuel System Pressure
Replace Primary Fuel Filter/Water Separator And Final Fuel Filter
Primary Fuel Filter/Water Separator Assembly
Replace Rectangular Fuel Filter Element
Replace Round Fuel Filter Element
Remove Fuel Supply Pump
Bench Test Fuel Supply Pump
Install Fuel Supply Pump
Fuel Injection Pump Timing
Remove Stanadyne Model Db2 Injection Pump With Non-Retained Drive Shaft
Repair Stanadyne Fuel Injection Pump
Remove Stanadyne Db2 Non-Retained Injection Pump Drive Shaft From Engine
Install Non-Retained Drive Shaft In Stanadyne Db2 Injection Pump (If Removed From Engine)
Install Stanadyne Model Db2 Injection Pump With Non-Retained Drive Shaft
Remove Stanadyne Model Db2 (With Retained Drive Shaft) And Db4 Injection Pump
Inspect Injection Pump Drive Gear I.D. And Shaft O.D.
Repair Stanadyne Fuel Injection Pump
Install Stanadyne Model Db2 (With Retained Drive Shaft) And Db4 Injection Pump
Remove Stanadyne Model Dm4 Fuel Injection Pump
Repair Stanadyne Fuel Injection Pump
Install Stanadyne Model Dm4 Fuel Injection Pump
Remove Lucas Cav Fuel Injection Pump
Repair Lucas Cav Fuel Injection Pump
Install Lucas Cav Fuel Injection Pump
Aneroid Replacement
Aneroid Field Adjustment
Aneroid Workshop Adjustment
Replace Engine Front Plate
Transfer Fuel Injection Pump Timing Mark Onto Replacement Front Plate
Remove Fuel Injection Nozzles
Clean Fuel Injection Nozzle Bore
Clean Injection Nozzles
Diagnose Injection Nozzle Malfunction
Diagnose Injection Nozzle Malfunction—Continued
Test Injection Nozzles
Disassemble Injection Nozzles
Inspect And Clean Nozzle Body
Inspect And Clean Valve And Valve Seat
Inspect Valve Adjusting Mechanism
Assemble Injection Nozzles
Adjust Fuel Injection Nozzles
Install Seals On Injection Nozzle
Install Injection Nozzles
Engine Tune-Up And Break-In
Effects Of Altitude And Temperature On Engine Performance
Preliminary Engine Testing
General Tune-Up Recommendations
Dynamometer Test
Dynamometer Test Specifications
Dynamometer Test Specifications—Continued
Dynamometer Test Specifications—Continued
Dynamometer Test Specifications—Continued
Dynamometer Test Specifications—Continued
Engine Break-In Guidelines
Perform Engine Break-In
Check Crankcase Ventilation System
Check Air Intake System
Check Exhaust System
Check And Service Cooling System
Check Electrical System
Engine System Operation And Tests
Special Or Essential Tools
Engine Test Specifications
Engine—Sectional View
General Engine Description
How The Engine Lubrication System Works
How The Engine Lubrication System Works—Continued
How The Cooling System Works
How The Cooling System Works—Continued
How The Crankshaft Gear-Driven Auxiliary Drive Works
Head Gasket Joint Construction And Operation
Diagnosing Head Gasket Joint Failures
Head Gasket Inspection And Repair Sequence
Diagnosing Engine Malfunctions
Diagnosing Engine Malfunctions—Continued
Diagnosing Engine Malfunctions—Continued
Test Engine Compression Pressure
Check Engine Oil Pressure
Measure Engine Crankcase Pressure (Blow-By)
Pressure Test Cooling System And Radiator Cap
Inspect Thermostat And Test Opening Temperature
Air Intake System Operation And Tests
Special Or Essential Tools
Air Intake And Exhaust System Test Specifications
Diagnosing Air Intake Malfunctions
How The Air Intake And Exhaust System Works
Air Cleaner Operation
Diagnosing Turbocharger Malfunctions
Turbocharger Operation
How The Turbocharger Is Lubricated
Check Intake Manifold Pressure (Turbocharger Boost)
Air Filter Restriction Indicator Switch Test
Fuel System Operation And Tests
Special Or Essential Tools
Fuel System Test Specifications
Fuel System Test Specifications—Continued
Fuel Injection Pump Specifications*
Fuel Injection Pump Specifications*—Continued
Fuel Injection Pump Specifications*—Continued
Fuel Injection Pump Specifications*—Continued
Fuel Injection Pump Specifications*—Continued
Check And Adjust Injection Pump Dynamic Timing Using Jt07158 Time Trac Kit
Fuel System Operation
Fuel System Operation—Continued
Diagnose Fuel System Malfunctions
Diagnose Fuel System Malfunctions—Continued
Diagnose Fuel System Malfunctions—Continued
Diagnose Fuel System Malfunctions—Continued
Fuel Supply Pump Operation—If Equipped
Diagnose Fuel Supply Pump Malfunction—If Equipped
Measure Fuel Supply Pump Pressure—If Equipped
Rectangular Final Fuel Filter Operation
Round (Primary) Fuel Filter/Water Separator Operation
Bleed The Fuel System
Stanadyne Fuel Injection Pump Operation
Lucas Cav Fuel Injection Pump Operation
Diagnose Fuel Injection Pump Malfunctions
Check And Adjust Engine Speeds On Lucas Cav Pump
Adjust Variable Speed On Generator Set Engines (Lucas Cav Pumps Only)
Check And Adjust Engine Speeds On Stanadyne Pump
Adjust Variable Speed (Droop) On Generator Set Engines (3—5% Govenor Regulation)—Stanadyne Db2, Db4, Dm4 Injection Pumps
Changing Gen Set Engine Rated Speed From 1800 Rpm To 1300 Rpm—Stanadyne Db2, Db4, Dm4 Injection Pumps
Fuel Injection Nozzles—General Information And Operation
Diagnose Malfunction—Fuel Injection Nozzle
Test Fuel Injection Nozzles (Engine Running)
Fuel Drain Back Test Procedure
Dealer Fabricated Tools
How To Make Tools
Dfrg2—Injection Pump Front Plate Timing Mark Transfer Tool
Dfrg3—Cylinder Liner Holding Fixture
Index
A
Additives
Coolant
Aftercooler
Assembly
Inspect
Remove And Install
Repair
Air Cleaner Operation
Air Intake System
Diagnostics
General Information
Inspect
Specifications
Test Specifications
Altitude Compensation
Aneroid
Field Adjustment
Replacement
Workshop Adjustment
Application Chart
Auxiliary Drive
Bearings
Dowels
Drive Gear
Gears, Remove
General Description
Idler Gear
Output Gear
Specifications
B
Balancer Shaft
Bushing Bore, Measure
Bushings, Inspect
Bushings, Install
Bushings, Measure
Bushings, Oversize
Bushings, Remove
End Play
Gears, Inspect
Gears, Install
Gears, Remove
Install
Journals, Inspect And Measure
Remove
Specifications
Thrust Plates, Inspect
Time
Balancer Shafts
Removal
Bearing
Main, Install
Bearing Bore
Camshaft
Camshaft, Measure
Main Bearing Bore, Measure
Main Cap, Measure
Bearing, Pilot
Replace
Bearings
Auxiliary Gear Drive
Connecting Rod, Inspect
Connecting Rod, Measure
Connecting Rod, Specifications
Failure Analysis
Main Thrust, Clearance
Main, Oil Clearance
Main, Oil Clearance, Measure
Main, Specifications
Bearings, Crankshaft
Main, Remove
Block, Cylinder
Clean
Inspect
Liner O-Ring Bore, Clean
Main Bearing Bore, Measure
Top Deck, Clean And Inspect
Top Deck, Measure
Break-In Engine Oil
Break-In, Engine
Guidelines
Perform
Bushing Bore
Balancer Shaft, Measure
Camshaft
Bushings
Balancer Shaft, Inspect
Balancer Shaft, Install
Balancer Shaft, Measure
Balancer Shaft, Oversize
Balancer Shaft, Remove
Camshaft
Idler Gear, Install
Idler Gear, Measure
Idler Gear, Remove
Piston Pin, Inspect
Bypass Valve, Oil Pressure
Inspect
Install
Install
Remove
Remove
C
Camshaft
Bearing Bore
Bearing Bore, Measure
Bushing, Install
Bushing, Remove
End Play
End Play
Followers, Assemble
Followers, Inspect
Followers, Inspect
Followers, Measure
Gear, Install
Gear, Remove
Inspect
Install
Journal Od
Lobe Height
Remove
Specifications
Thrust Plate, Clearance
Time
Camshaft Bushings Remove And Install
Camshaft Followers
Bore, Measure
Cap Screws, Connecting Rod
Torque-Turn
Composite Material Timing Gear Cover
Installation
Compression Pressure Test
Connecting Rod
Assemble
Bearings, Inspect
Bearings, Measure
Cap, Inspect
Disassemble
Inspect
Pin Bore, Clean
Pin Bore, Inspect
Remove
Specifications
Connecting Rod And Piston Assembly
Install
Connecting Rod Cap Screws
Torque-Turn
Connecting Rods
Failure Analysis
Preliminary Checks
Coolant
Additives
Disposing
Heater, Install
Heater, Remove
Products
Recommended
Requirements
Tropical
Coolant, Engine
Coolant, Engine
Specifications
Cooler, Oil
High-Flow, Install
High-Flow, Remove
Identification
Standard-Flow, Inspect
Standard-Flow, Install
Standard-Flow, Remove
Cooling System
Check
Flow Diagram
Flow Diagram
Flush And Service
General Description
General Description
Pressure Test
Service
Specifications
Cover
Rocker Arm, Install
Timing Gear, Clean
Timing Gear, Inspect
Timing Gear, Install
Timing Gear, Remove
Crankcase
Blow-By
Ventilation System, Inspect
Ventilator Hose, Clean And Inspect
Crankshaft
End Play
End Play
Front Oil Seal, Install
Grinding Guidelines
Grinding Guidelines
Grinding Specifications
Inspect
Install
Main Bearing Journal, Measure
Pulley, Install
Pulley, Remove
Rear Oil Seal, General Information
Rear Oil Seal, Two-Piece, Install
Rear Oil Seal, Two-Piece, Remove
Rear Oil Seal, Unitized, Install
Rear Oil Seal, Unitized, Remove
Rear Wear Sleeve, Remove
Remove
Specifications
Thrust Bearing, Clearance
5/6-Piece Thrust Bearing Inst.
Crankshaft Gear
Remove And Install
Crankshaft Main Bearings
Remove
Cylinder Block
Clean
Inspect
Liner O-Ring Bore, Clean
Main Bearing Bore, Measure
Specifications
Top Deck, Clean And Inspect
Top Deck, Measure
Cylinder Head
Cap Screws, Clean And Inspect
Cap Screws, Torque-Turn Method
Failure Analysis
Flatness
Injection Nozzle Bores
Inspect And Clean
Install
Preliminary Checks
Remove
Specifications
Thickness
Valve Guides, Clean
Valve Guides, Knurl
Valve Guides, Measure
Valve Recess
Valve Seat Bore, Measure
Valve Seat Inserts, Install
Valve Seat Inserts, Remove
Valve Seats, Clean And Inspect
Valve Seats, Grind
Valves, Install
Valves, Remove
Cylinder Head Gasket
Failure Diagnostics
Joint Construction
Joint Operation
Cylinder Liner
Clean
Deglaze
Height Standout
Inspect
Install
O-Ring Bore, Clean
O-Rings
Packings
Remove
Replace
Specifications
Standout
Cylinder Liners
Failure Analysis
Preliminary Checks
D
Damper, Vibration
Inspect
Install
Remove
Diagnostics
Air Intake System
Engine
Fuel Injection Nozzles
Fuel Injection Pump
Fuel Supply Pump
Fuel System
Head Gasket Failure
Diesel Engine Oil
Diesel Fuel
Diesel Fuel
Lubricity
Dipstick Nipple
Adjust
Install
Remove
Droop Speed
Adjustment
Dynamometer Test
Procedure
Specifications
E
Electrical System
Check
Service
Elevations
Compensation Guideline
Engine
Applications
Assembly Sequence
Blow-By
Check For Excessive Tightness
Cleaning
Compression Pressure Test
Coolant
Coolant
Diagnostics
Disassembly Sequence
Dynamometer Test
General Description
Lifting Procedure
Mounting
Oil Pressure, Check
Preliminary Testing
Repair Stand
Sectional View
Serial Number Plate
Speed, Droop Adjustment
Speeds, Gen Set, Change
Test Specifications
Engine Break-In
Perform
Engine Break-In Guidelines
Engine Coolant
Disposing
Products
Requirements
Specifications
Engine Oil
Break-In
Diesel
Engine Speeds
Check And Adjust
Exhaust Manifold
Clean And Inspect
Remove And Install
Exhaust System
General Information
Inspect
Specifications
F
Failure Analysis
Head Gasket
Fan
Inspect
Install
Final Fuel Filter
Replace
Flywheel
Face Flatness
Inspect
Install
Pilot Bearing, Replace
Remove
Ring Gear, Replace
Specifications
Flywheel Housing
Face Runout
Install
Remove
Followers, Camshaft
Inspect
Front Plate
Clean
Inspect
Install
Remove
Replace
Replace
Timing Mark, Transfer
Timing Mark, Transfer
Fuel
Diesel
Lubricity
Fuel Filter
Replace
Replace
Fuel Filter, Final
Operation
Fuel Filter, Primary
Operation
Fuel Injection Nozzles
Adjustment
Assemble
Clean
Diagnosis
Diagnostics
Disassembly
General Information
Install
Operation
Remove
Test, Engine Running
Fuel Injection Pump
Install, Stanadyne Db2
Aneroid Field Adjustment
Aneroid Workshop Adjustment
Diagnostics
Install
Install, Lucas Cav
Install, Stanadyne Db2/Db4
Install, Stanadyne Dm4
Operation, Lucas Cav
Operation, Stanadyne
Remove, Lucas Cav
Remove, Stanadyne Db2
Remove, Stanadyne Db2
Remove, Stanadyne Db2/Db4
Remove, Stanadyne Dm4
Repair, Lucas Cav Dpa2
Repair, Stanadyne
Repair, Stanadyne
Repair, Stanadyne
Specifications
Time
Timing
Fuel Supply Pump
Bench Test
Diagnostics
Install
Operation
Remove
Test
Fuel System
Bleed
Diagnostics
Fuel Drain Back Test
Operation
Specifications
Test Specifications
G
Gear
Auxiliary Drive, Idler Gear
Auxiliary Drive, Output Gear
Auxiliary Drive, Remove
Backlash
Balancer Shaft, Inspect
Balancer Shaft, Install
Balancer Shaft, Remove
Camshaft, Remove And Install
Flywheel Ring, Replace
Idler, Bushings, Install
Idler, Bushings, Measure
Idler, Bushings, Remove
Idler, End Play
Specifications
Tachometer Drive, Replace
Gear Cover
Clean
Inspect
Install
Remove
Gear Drive, Auxiliary
Bearings
Dowels
Drive Gear
General Description
Gear, Crankshaft
Remove And Install
Gen Set Engine Speeds
Change, From 1800—1300 Rpm
General Information
Lubrication System
Oil Pump
Water Pump
Grease
Extreme Pressure And Multipurpose
H
Head, Cylinder
Cap Screws, Clean And Inspect
Cap Screws, Torque-Turn Method
Failure Analysis
Flatness
Gasket Failure Diagnostics
Gasket Joint Construction
Gasket Joint Operation
Injection Nozzle Bores
Inspect And Clean
Install
Preliminary Checks
Remove
Thickness
Valve Guides, Clean
Valve Guides, Knurl
Valve Guides, Measure
Valve Seat Bore, Measure
Valve Seat Inserts, Install
Valve Seat Inserts, Remove
Valve Seats, Clean And Inspect
Valve Seats, Grind
Valves, Install
Valves, Remove
Heater, Coolant
Install
Remove
Housing, Flywheel
Face Runout
I
Idler Gear
Bushings, Install
Bushings, Measure
Bushings, Remove
End Play
Shaft, Measure
Shaft, Remove
Idler Shaft
Lower, Install
Spring Pins, Install
Upper, Install
Inch Torque Values
Injection Nozzle
Adjustment
Assemble
Bore, Clean
Clean
Disassembly
Install
Remove
Seals, Install
Test
Injection Nozzle Bores
Clean
Injection Nozzles
Diagnosis
Test, Engine Running
Injection Pump
Dynamic Timing
Install
Time
Inserts In Block, Main Bearing
Install
Intake Manifold
Pressure, Check
Remove And Install
Intake, Air System
Inspect
J
Journals, Balancer Shaft
Inspect And Measure
L
Liner, Cylinder
Clean
Deglaze
Height Standout
Inspect
Install
O-Rings
Packings
Remove
Replace
Specifications
Standout
Liners, Cylinder
Failure Analysis
Preliminary Checks
Lubricant
Alternative
Synthetic
Lubrication System
Flow Diagram
General Description
General Information
Specifications
M
Main Bearing
Block Bore, Measure
Cap Bore, Measure
Oil Clearance
Oil Clearance, Measure
Specifications
Main Bearing Inserts In Block
Install
Main Thrust Bearing
Clearance
Manifold, Exhaust
Clean And Inspect
Remove And Install
Manifold, Intake
Remove And Install
Manifold, Water
Install
Remove
Mechanical Tachometer
Drive Gear, Replace
Metric Torque Values
N
Nipple
Dipstick, Adjust
Dipstick, Install
Dipstick, Remove
Oil Filter, Install
Oil Filter, Remove
Nozzle Body
Inspect And Clean
Nozzle Bore
Clean
Nozzle Seals
Install
Nozzle Valve
Inspect And Clean
Nozzle Valve Adjusting Mechanism
Inspect
Nozzle Valve Seat
Inspect And Clean
Nozzles, Fuel Injection
Diagnosis
Test, Engine Running
O
Oil Bypass Valve
Inspect
Install
Install
Remove
Remove
Oil Cooler
Bracket Replacement
High-Flow, Install
High-Flow, Remove
Identification
Standard-Flow, Inspect
Standard-Flow, Install
Standard-Flow, Remove
Oil Filter Nipple
Install
Remove
Oil Pan
Install
Oil Pressure
Check
Oil Pressure Regulating Valve
Inspect
Install
Install
Remove
Remove
Oil Pump
Assemble
General Information
High Capacity, Assemble
High Capacity, Clearances
High Capacity, Disassemble
High Capacity, Inspect
High Capacity, Install
High Capacity, Remove
Standard Capacity, Clearances
Standard Capacity, Disassemble
Standard Capacity, Install
Standard Capacity, Remove
Oil Pump Pick-Up Tube
Replacement (On Standard Oil Pump)
Oil Seal, Crankshaft Rear
General Information
Two-Piece, Install
Two-Piece, Remove
Unitized, Install
Oil Seal, Front Crankshaft
Install
Oil Seal, Rear Crankshaft
Unitized, Remove
Orifices, Piston Cooling
Inspect
P
Pan, Oil
Install
Pilot Bearing
Replace
Pin Bore, Connecting Rod
Clean
Inspect
Pin, Piston
Inspect
Piston And Connecting Rod Assembly
Install
Piston Cooling Orifices
Inspect
Inspect
Piston Pin
Bushings, Inspect
Inspect
Inspect
Install
Remove
Piston Pin Bore
Measure
Piston Pin Bushing
Install
Remove
Piston Protrusion
Measure
Piston Ring Groove Wear
Check
Piston Rings
Install
Remove
Pistons
Assemble
Clean
Disassemble
Failure Analysis
Inspect
Preliminary Checks
Remove
Replace
Specifications
Plate, Front
Clean
Inspect
Install
Remove
Replace
Pulley For Front Pto
Inspection
Removal
Pump, Fuel Injection
Install
Time
Pump, Oil
General Information
High Capacity, Assemble
High Capacity, Clearances
High Capacity, Disassemble
High Capacity, Inspect
High Capacity, Install
High Capacity, Remove
Standard Capacity, Clearances
Standard Capacity, Disassemble
Standard Capacity, Install
Standard Capacity, Remove
Pump, Water
Clean
General Information
Heavy Duty High Flow, Assemble
Heavy Duty High Flow, Disassemble
Inspect
Install
Low Flow, Assemble
Modular Style, Assemble
Modular Style, Disassemble
Modular Style, Disassemble
Modular Style, Disassemble
Remove
Std. Duty High Flow, Assemble
R
Radiator Cap
Pressure Test
Radiator, Cap
Pressure Test
Regulating Valve, Oil Pressure
Inspect
Install
Install
Remove
Remove
Ring Gear, Flywheel
Replace
Rings, Piston
Install
Remove
Rocker Arm Assembly
Assemble
Disassemble
Inspect
Install
Rocker Arm Cover
Install
Rods, Connecting
Failure Analysis
Preliminary Checks
S
Seal, Crankshaft Front Oil
Install
Seal, Crankshaft Rear Oil
General Information
Two-Piece, Install
Two-Piece, Remove
Unitized, Install
Unitized, Remove
Sealant Application Guidelines
Serial Number Plate
Shaft
Balancer, Install
Balancer, Remove
Balancer, Time
Idler Gear, Measure
Idler Gear, Remove
Lower Idler Gear, Install
Upper Idler Gear, Install
Specifications
Air Intake System
Air Intake System Test
Auxiliary Drive
Balancer Shaft
Camshaft
Connecting Rods
Coolant
Cooling System
Crankshaft
Crankshaft Grinding
Cylinder Block
Cylinder Head And Valves
Cylinder Liners
Dynamometer Test
Engine Test
Exhaust System
Flywheel
Fuel Injection Pump
Fuel System
Fuel System
Lubrication System
Main Bearings
Pistons
Timing Gear Train
Spring Pins, Idler Shaft
Install
Synthetic Lubricants
T
Tachometer Drive Gear
Replace
Temperature Compensation
Thermostat
Inspect And Test
Thermostat Housing
Install
Remove
Thermostats
Install
Remove
Test
Thrust Plate
Balancer Shaft, Inspect
Camshaft, Clearance
Timing
Fuel Injection Pump
Timing Gear
Backlash
Timing Gear Cover
Clean
Inspect
Install
Remove
Timing Mark
Transfer
Transfer
Torque Values
Inch
Metric
Torque-Turn Method
Connecting Rod Cap Screws
Cylinder Head Cap Screws
Tune-Up
General Recommendations
Preliminary Engine Testing
Turbocharger
Boost Pressure, Check
Break-In
Center Housing, Replace
Diagnostics
Disassemble And Inspect
Extending Life
Failure Analysis
Install
Lubrication
Measure Axial Bearing End Play
Measure Radial Bearing Clearance
Operation
Prelube
Remove
Seven-Step Inspection
V
Valve
Clearance, Check And Adjust
Guides, Clean
Guides, Knurl
Guides, Measure
Lift
Lift
Recess
Rotators, Inspect
Rotators, Install
Rotators, Remove
Seat Bore, Measure
Seat Inserts, Install
Seat Inserts, Remove
Seats, Clean And Inspect
Seats, Grind
Springs, Inspect
Springs, Install
Springs, Measure
Springs, Remove
Stem Seals, Install
Stem Seals, Remove
Valves
Clean
Failure Analysis
Grind
Inspect
Install
Measure
Preliminary Checks
Remove
Specifications
Ventilation System
Inspect
Ventilator Outlet Hose
Clean And Inspect
Vibration Damper
Inspect
Install
Remove
W
Water Manifold
Install
Remove
Water Pump
Clean
General Information
Heavy Duty High Flow, Assemble
Heavy Duty High Flow, Disassemble
Inspect
Install
Low Flow, Assemble
Low Flow, Disassemble
Modular Style, Assemble
Modular Style, Disassemble
Remove
Std. Duty High Flow, Assemble
Std. Duty High Flow, Disassemble
Water Pump Cap Screw Protrusion
Checking
Water Pump Cap Screw Protrusion, Checking
Water Separator Filter
Replace
Wear Sleeve, Rear Crankshaft
Remove
Page Numbers
Size: 25.81 MB
Format: PDF
Language: English
Brand: John Deere
Type of Machine: Engine
Type of Manual: Components Technical Manual
Model: John Deere 300 3029 4039 4045 6059 6068 Series Engine
Part Number: CTM8
Number of Pages: 505 Pages
Contents:
Safety
Handle Fluids Safely—Avoid Fires
Prevent Battery Explosions
Prepare For Emergencies
Prevent Acid Burns
Avoid High-Pressure Fluids
Wear Protective Clothing
Service Machines Safely
Work In Ventilated Area
Work In Clean Area
Remove Paint Before Welding Or Heating
Avoid Heating Near Pressurized Fluid Lines
Illuminate Work Area Safely
Use Proper Lifting Equipment
Practice Safe Maintenance
Use Proper Tools
Dispose Of Waste Properly
Live With Safety
General Information
Unified Inch Bolt And Cap Screw Torque Values
Metric Bolt And Cap Screw Torque Values
Engine Model Designation
Engine Serial Number Plate Information
Engine Application Charjohn Deere Agricultural Equipment
Engine Application Charjohn Deere Industrial Equipment
Engine Application Charjohn Deere Industrial Equipment—Continued
Engine Application Charoem Applications
Fuels, Lubricants, And Coolant
Diesel Fuel
Lubricity Of Diesel Fuels
Engine Break-In Oil
Diesel Engine Oil
Alternative And Synthetic Lubricants
Oilscan® And Coolscan™
Grease
Engine Coolant Requirements
Engine Coolant Requirements—Continued
Recommended Engine Coolant
Engine Coolant Specifications
Engine Coolant Specifications—Continued
Replenishing Supplemental Coolant Additives (Sca’s) Between Coolant Changes
Operating In Tropical Conditions
Flush And Service Cooling System
Disposing Of Coolant
Engine Mounting
Engine Repair Stand
Safety Precautions
Install 300 Series Adapters On Repair Stand
Engine Lifting Procedure
Clean Engine
Mount Engine On Repair Stand
Disconnect Turbocharger Oil Inlet Line
Engine Rebuild Guide
Engine Disassembly Sequence
Sealant Application Guidelines
Sealant Application Guidelines—Continued
Engine Assembly Sequence
Cylinder Head And Valves
Special Or Essential Tools
Cylinder Head And Valves Specifications
Cylinder Head And Valves Specifications—Continued
Cylinder Head And Valves Specifications—Continued
Check And Adjust Valve Clearance
Measure Valve Lift
Remove Cylinder Head
Disassemble And Inspect Rocker Arm Assembly
Assemble Rocker Arm Assembly
Inspect, Measure, And Assemble Camshaft Followers
Check Valve Recess In Cylinder Head
Preliminary Cylinder Head And Valve Checks
Remove Valve Assembly
Inspect And Measure Valve Springs
Inspect Valve Rotators
Clean Valves
Inspect And Measure Valves
Grind Valves
Inspect And Clean Cylinder Head
Check Cylinder Head Flatness
Measure Cylinder Head Thickness
Clean Injection Nozzle Bores
Clean Valve Guides
Measure Valve Guides
Knurl Valve Guides
Clean And Inspect Valve Seats
Grind Valve Seats
Remove Valve Seat Inserts
Measure Valve Seat Bore In Cylinder Head
Install Valve Seat Inserts
Install Valves
Clean And Inspect Cylinder Head Cap Screws
Inspect And Clean Exhaust Manifold
Clean And Inspect Top Deck Of Cylinder Block
Measure Cylinder Liner Standou(Height Above Block)
Install Cylinder Head
Torque-Turn Method For Proper Torque
Install Rocker Arm Assembly
Inspect And Clean Ventilator Outlet Hose
Install Rocker Arm Cover
Complete Final Assembly
Perform Engine Break-In
Cylinder Block, Liners, Pistons, And Rods
Special Or Essential Tools
Other Material
Cylinder Block, Liners, Pistons, And Rods Specifications
Cylinder Block, Liners, Pistons, And Rods Specifications—Continued
Cylinder Block, Liners, Pistons, And Rods Specifications—Continued
Cylinder Block, Liners, Pistons, And Rods Specifications—Continued
Cylinder Block, Liners, Pistons, And Rods Specifications—Continued
Remove Pistons And Connecting Rods
Remove Cylinder Liners
Complete Disassembly Of Cylinder Block (If Required)
Preliminary Liner, Piston And Rod Checks
Disassemble Piston And Rod Assembly
Clean Pistons
Visually Inspect Pistons
Clean Cylinder Liners
Visually Inspect Cylinder Liners
Check Piston Ring Groove Wear
Measure Piston Pin Bore
Measure Piston Skirt
Determine Piston-To-Liner Clearance
Deglaze Cylinder Liners
Replace Piston And Liner Sets
Inspect And Measure Connecting Rod Bearings
Inspect Rod And Cap
Inspect Piston Pins And Bushings
Remove Piston Pin Bushing
Clean And Inspect Connecting Rod Pin Bore
Install Piston Pin Bushing In Connecting Rod
Inspect And Clean Cylinder Block
Clean Cylinder Liner O-Ring Bore
Measure Cylinder Block Main Bearing Bore
Measure Camshaft Follower Bore
Measure Camshaft Bearing Bore
Measure Balancer Shaft Bore—4-Cylinder Engines
Measure Cylinder Block Top Deck Flatness
Inspect Piston Cooling Orifices
Measure Liner Flange Thickness
Measure Cylinder Liner Standout (Height Above Block)
Install Cylinder Liner O-Rings And Packings
Install Cylinder Liner
Assemble Piston And Connecting Rod
Install Piston Rings
Install Piston And Connecting Rod Assembly
Torque-Turn Connecting Rod Cap Screws
Check Engine Rotation For Excessive Tightness
Measure Piston Protrusion
Complete Final Assembly
Crankshaft, Main Bearings, And Flywheel
Special Or Essential Tools
Other Material
Crankshaft, Main Bearings, And Flywheel Specifications
Crankshaft, Main Bearings, And Flywheel Specifications—Continued
Crankshaft, Main Bearings, And Flywheel Specifications—Continued
Crankshaft And Main Bearing Failure Analysis
Inspect Vibration Damper (6-Cylinder Engine)
Remove Pulley Or Vibration Damper Pulley
Install Pulley Or Vibration Damper Pulley
Checking Vibration Damper Or Pulley (Engine With Front Pto)
Removing Vibration Damper Or Pulley (Engine With Front Pto)
Installing Vibration Damper Or Pulley (Engine With Front Pto)
Replace Front Crankshaft Oil Seal (Without Removing Timing Gear Cover)
Check Crankshaft End Play
Inspect Flywheel
Check Flywheel Housing Face Runout
Check Flywheel Face Flatness
Remove Flywheel
Replace Flywheel Ring Gear
Replace Pilot Bearing In Flywheel—3029, 4039, 4045 Engines (If Equipped)
Install Flywheel
Crankshaft Rear Oil Seal And Wear Sleeve General Information
Remove Two-Piece Crankshaft Rear Oil Seal And Wear Sleeve (Without Removing Flywheel Housing)
Remove Unitized (Non-Separable) Crankshaft Rear Oil Seal And Wear Sleeve
Install Crankshaft Rear Oil Seal And Wear Sleeve
Remove Flywheel Housing
Remove Crankshaft Main Bearings
Check Main Bearing Clearance
Remove And Install Crankshaft Gear (Crankshaft Installed In Engine)
Remove Crankshaft
Remove Crankshaft Rear Wear Sleeve (Crankshaft Removed From Engine)
Inspect Crankshaft
Measure Main Bearing Id And Crankshaft Journal Od
Measure Main Thrust Journal Width And Thrust Bearing Width
Crankshaft Grinding Guidelines
Crankshaft Grinding Guidelines—Continued
Crankshaft Grinding Specifications
Measure Assembled Id Of Main Bearing Caps
Inspect Piston Cooling Orifices
Install Main And Thrust Bearing Inserts In Block
Install Crankshaft
Install Flywheel Housing
Complete Final Assembly
Camshaft, Balancer Shafts, And Timing Gear Train
Special Or Essential Tools
Other Materials
Camshaft, Balancer Shafts, And Timing Gear Train Specifications
Camshaft, Balancer Shafts, And Timing Gear Train Specifications—Continued
Camshaft, Balancer Shafts, And Timing Gear Train Specifications—Continued
Camshaft, Balancer Shafts, And Timing Gear Train Specifications—Continued
Camshaft, Balancer Shafts, And Timing Gear Train Specifications—Continued
Left-Hand (Crankshaft-Driven) Auxiliary Gear Drive Specifications
Measure Valve Lift
Remove Timing Gear Cover
Remove And Install Camshaft Bushing With Front Plate Installed Camshaft Gear-Driven Auxiliary Drive Engines, Serial No. (138541— )
Remove Auxiliary Drive Gears (Engines With Auxiliary Gear Drive Option)
Measure Camshaft End Play
Measure Balancer Shaft End Play (4-Cylinder Engines)
Measure Idler Gear End Play
Measure Timing Gear Backlash
Remove Camshaft
Visually Inspect Camshaft
Measure Camshaft Thrust Plate Clearance
Inspect And Measure Camshaft Bearing Bore Id And Journal Od
Measure Camshaft Lobe Height
Remove And Install Camshaft Gear
Inspect Camshaft Followers
Replace Tachometer Drive Gear
Remove And Install Camshaft Bushing With Front Plate Removed Engine Serial No. ( —138540)
Remove Balancer Shafts—If Equipped (4-Cylinder Engines)
Inspect And Measure Balancer Shaft Bushings And Journals
Remove And Install Balancer Shaft Bushings (4-Cylinder Engines)
Install Oversize Balancer Shaft Bushings In Cylinder Block (4039 Engines)
Inspect Balancer Shaft Gears And Thrust Plates
Remove And Install Balancer Shaft Gears
Removing Balancer Shaft
Remove Cylinder Block Front Plate
Measure Idler Gear Bushing And Shaft
Remove And Install Idler Gear Bushings
Remove Lower And Upper Idler Shafts
Clean And Inspect Front Plate
Replace Engine Front Plate
Transfer Fuel Injection Pump Timing Mark Onto Replacement Front Plate
Install Idler Shaft Spring Pins
Install Upper Idler Shaft In Front Plate
Install Lower Idler Shaft In Front Plate
Install Engine Front Plate
Install And Time Balancer Shafts—If Equipped (4-Cylinder Engines)
Install And Time Camshaft And Fuel Injection Pump
Clean And Inspect Timing Gear Cover
Install Ball Bearings And Dowels (Engines With Crankshaft-Driven Auxiliary Gear Drive Option)
Install Drive Gear (Engines With Crankshaft-Driven Auxiliary Gear Drive Option)
Install Timing Gear Cover
Install Crankshaft Front Oil Seal
Install Idler Gear And Output Gear (Engines With Auxiliary Gear Drive Option)
Complete Final Assembly
Lubrication System
Special Or Essential Tools
Other Material
Lubrication System Specifications
Lubrication System Specifications—Continued
Lubrication System Specifications—Continued
General Lubrication System Information
Oil Cooler Identification
Remove, Inspect, And Install Standard-Flow Oil Cooler
Remove And Install High-Flow Oil Cooler
Replacing Standard Oil Cooler/Oil Filter Housings
Remove, Inspect, And Install Oil Bypass Valve—3029, 4039, And 6059 Engines And 4045 And 6068 Engines With Common Lube Block*
Remove And Install Oil Bypass Valve—4045 And 6068 Engines With Pre-Common Lube Block*
Remove And Install Oil Pressure Regulating Valve And Seat—3029, 4039, And 6059 Engines And 4045 And 6068 Engines With Common Lube Block*
Remove, Inspect, And Install Oil Pressure Regulating Valve—4045 And 6068 Engines With Pre-Common Lube Block*
Remove And Install Oil Filter Nipple—3029, 4039, 6059 Engines
Remove And Install Oil Pan Mounted Oil Fill/Dipstick Tube
Remove, Install, And Adjust Dipstick Nipple
General Oil Pump Information
Replace Oil Pump Pick-Up Tube Assembly
Remove Standard Capacity Oil Pump
Inspect And Measure Clearances (Standard Capacity Oil Pump)
Complete Standard Capacity Oil Pump Disassembly
Assemble Standard Capacity Oil Pump
Install Standard Capacity Oil Pump
Remove High Capacity Oil Pump
Inspect And Measure Clearances (High Capacity Oil Pump)
Complete High Capacity Oil Pump Disassembly
Assemble High Capacity Oil Pump
Install High Capacity Oil Pump
Install Oil Pan
Cooling System
Special Or Essential Tools
Service Equipment And Tools
Other Material
Cooling System Specifications
Cooling System Specifications—Continued
Cooling System Specifications—Continued
Cooling System Specifications—Continued
Cooling System Specifications—Continued
Cooling System Specifications—Continued
Cooling System Specifications—Continued
Cooling System Specifications—Continued
Cooling System Specifications—Continued
Remove, Test, And Install Thermostats
Remove And Install Water Manifold/Thermostat Housing
General Water Pump Information
Remove Water Pump
Disassemble Low Flow, Standard-Duty High Flow, And Modular Style Water Pumps
Disassemble Heavy-Duty High Flow Water Pump
Inspect And Clean Water Pump Parts
Assemble Low Flow, Standard-Duty High Flow, And Modular Style Water Pumps
Assemble Heavy-Duty High Flow Water Pump
Checking Water Pump Cap Screw Protrusion
Install Water Pump
Inspect And Install Fan Blade Assembly
Remove Coolant Heater—If Equipped
Install Coolant Heater—If Equipped
Air Intake And Exhaust System
Air Intake And Exhaust System Specifications
Air Intake And Exhaust System Specifications—Continued
Extending Turbocharger Life
Remove Turbocharger
Turbocharger Failure Analysis
Turbocharger Seven-Step Inspection
Perform Radial Bearing Clearance Test
Perform Axial Bearing End Play Test
Repair Turbocharger
Disassemble And Inspect Turbocharger
Replace Center Housing And Rotating Assembly
Prelube Turbocharger
Install Turbocharger
Turbocharger Break-In
Remove, Inspect And Install Intake Manifold
Remove, Inspect And Install Exhaust Manifold
Aftercooler Assembly
Remove And Install Aftercooler
Inspect And Repair Aftercooler
Fuel System
Special Or Essential Tools
Fuel System Specifications
Fuel System Specifications—Continued
Fuel System Specifications—Continued
Relieve Fuel System Pressure
Replace Primary Fuel Filter/Water Separator And Final Fuel Filter
Primary Fuel Filter/Water Separator Assembly
Replace Rectangular Fuel Filter Element
Replace Round Fuel Filter Element
Remove Fuel Supply Pump
Bench Test Fuel Supply Pump
Install Fuel Supply Pump
Fuel Injection Pump Timing
Remove Stanadyne Model Db2 Injection Pump With Non-Retained Drive Shaft
Repair Stanadyne Fuel Injection Pump
Remove Stanadyne Db2 Non-Retained Injection Pump Drive Shaft From Engine
Install Non-Retained Drive Shaft In Stanadyne Db2 Injection Pump (If Removed From Engine)
Install Stanadyne Model Db2 Injection Pump With Non-Retained Drive Shaft
Remove Stanadyne Model Db2 (With Retained Drive Shaft) And Db4 Injection Pump
Inspect Injection Pump Drive Gear I.D. And Shaft O.D.
Repair Stanadyne Fuel Injection Pump
Install Stanadyne Model Db2 (With Retained Drive Shaft) And Db4 Injection Pump
Remove Stanadyne Model Dm4 Fuel Injection Pump
Repair Stanadyne Fuel Injection Pump
Install Stanadyne Model Dm4 Fuel Injection Pump
Remove Lucas Cav Fuel Injection Pump
Repair Lucas Cav Fuel Injection Pump
Install Lucas Cav Fuel Injection Pump
Aneroid Replacement
Aneroid Field Adjustment
Aneroid Workshop Adjustment
Replace Engine Front Plate
Transfer Fuel Injection Pump Timing Mark Onto Replacement Front Plate
Remove Fuel Injection Nozzles
Clean Fuel Injection Nozzle Bore
Clean Injection Nozzles
Diagnose Injection Nozzle Malfunction
Diagnose Injection Nozzle Malfunction—Continued
Test Injection Nozzles
Disassemble Injection Nozzles
Inspect And Clean Nozzle Body
Inspect And Clean Valve And Valve Seat
Inspect Valve Adjusting Mechanism
Assemble Injection Nozzles
Adjust Fuel Injection Nozzles
Install Seals On Injection Nozzle
Install Injection Nozzles
Engine Tune-Up And Break-In
Effects Of Altitude And Temperature On Engine Performance
Preliminary Engine Testing
General Tune-Up Recommendations
Dynamometer Test
Dynamometer Test Specifications
Dynamometer Test Specifications—Continued
Dynamometer Test Specifications—Continued
Dynamometer Test Specifications—Continued
Dynamometer Test Specifications—Continued
Engine Break-In Guidelines
Perform Engine Break-In
Check Crankcase Ventilation System
Check Air Intake System
Check Exhaust System
Check And Service Cooling System
Check Electrical System
Engine System Operation And Tests
Special Or Essential Tools
Engine Test Specifications
Engine—Sectional View
General Engine Description
How The Engine Lubrication System Works
How The Engine Lubrication System Works—Continued
How The Cooling System Works
How The Cooling System Works—Continued
How The Crankshaft Gear-Driven Auxiliary Drive Works
Head Gasket Joint Construction And Operation
Diagnosing Head Gasket Joint Failures
Head Gasket Inspection And Repair Sequence
Diagnosing Engine Malfunctions
Diagnosing Engine Malfunctions—Continued
Diagnosing Engine Malfunctions—Continued
Test Engine Compression Pressure
Check Engine Oil Pressure
Measure Engine Crankcase Pressure (Blow-By)
Pressure Test Cooling System And Radiator Cap
Inspect Thermostat And Test Opening Temperature
Air Intake System Operation And Tests
Special Or Essential Tools
Air Intake And Exhaust System Test Specifications
Diagnosing Air Intake Malfunctions
How The Air Intake And Exhaust System Works
Air Cleaner Operation
Diagnosing Turbocharger Malfunctions
Turbocharger Operation
How The Turbocharger Is Lubricated
Check Intake Manifold Pressure (Turbocharger Boost)
Air Filter Restriction Indicator Switch Test
Fuel System Operation And Tests
Special Or Essential Tools
Fuel System Test Specifications
Fuel System Test Specifications—Continued
Fuel Injection Pump Specifications*
Fuel Injection Pump Specifications*—Continued
Fuel Injection Pump Specifications*—Continued
Fuel Injection Pump Specifications*—Continued
Fuel Injection Pump Specifications*—Continued
Check And Adjust Injection Pump Dynamic Timing Using Jt07158 Time Trac Kit
Fuel System Operation
Fuel System Operation—Continued
Diagnose Fuel System Malfunctions
Diagnose Fuel System Malfunctions—Continued
Diagnose Fuel System Malfunctions—Continued
Diagnose Fuel System Malfunctions—Continued
Fuel Supply Pump Operation—If Equipped
Diagnose Fuel Supply Pump Malfunction—If Equipped
Measure Fuel Supply Pump Pressure—If Equipped
Rectangular Final Fuel Filter Operation
Round (Primary) Fuel Filter/Water Separator Operation
Bleed The Fuel System
Stanadyne Fuel Injection Pump Operation
Lucas Cav Fuel Injection Pump Operation
Diagnose Fuel Injection Pump Malfunctions
Check And Adjust Engine Speeds On Lucas Cav Pump
Adjust Variable Speed On Generator Set Engines (Lucas Cav Pumps Only)
Check And Adjust Engine Speeds On Stanadyne Pump
Adjust Variable Speed (Droop) On Generator Set Engines (3—5% Govenor Regulation)—Stanadyne Db2, Db4, Dm4 Injection Pumps
Changing Gen Set Engine Rated Speed From 1800 Rpm To 1300 Rpm—Stanadyne Db2, Db4, Dm4 Injection Pumps
Fuel Injection Nozzles—General Information And Operation
Diagnose Malfunction—Fuel Injection Nozzle
Test Fuel Injection Nozzles (Engine Running)
Fuel Drain Back Test Procedure
Dealer Fabricated Tools
How To Make Tools
Dfrg2—Injection Pump Front Plate Timing Mark Transfer Tool
Dfrg3—Cylinder Liner Holding Fixture
Index
A
Additives
Coolant
Aftercooler
Assembly
Inspect
Remove And Install
Repair
Air Cleaner Operation
Air Intake System
Diagnostics
General Information
Inspect
Specifications
Test Specifications
Altitude Compensation
Aneroid
Field Adjustment
Replacement
Workshop Adjustment
Application Chart
Auxiliary Drive
Bearings
Dowels
Drive Gear
Gears, Remove
General Description
Idler Gear
Output Gear
Specifications
B
Balancer Shaft
Bushing Bore, Measure
Bushings, Inspect
Bushings, Install
Bushings, Measure
Bushings, Oversize
Bushings, Remove
End Play
Gears, Inspect
Gears, Install
Gears, Remove
Install
Journals, Inspect And Measure
Remove
Specifications
Thrust Plates, Inspect
Time
Balancer Shafts
Removal
Bearing
Main, Install
Bearing Bore
Camshaft
Camshaft, Measure
Main Bearing Bore, Measure
Main Cap, Measure
Bearing, Pilot
Replace
Bearings
Auxiliary Gear Drive
Connecting Rod, Inspect
Connecting Rod, Measure
Connecting Rod, Specifications
Failure Analysis
Main Thrust, Clearance
Main, Oil Clearance
Main, Oil Clearance, Measure
Main, Specifications
Bearings, Crankshaft
Main, Remove
Block, Cylinder
Clean
Inspect
Liner O-Ring Bore, Clean
Main Bearing Bore, Measure
Top Deck, Clean And Inspect
Top Deck, Measure
Break-In Engine Oil
Break-In, Engine
Guidelines
Perform
Bushing Bore
Balancer Shaft, Measure
Camshaft
Bushings
Balancer Shaft, Inspect
Balancer Shaft, Install
Balancer Shaft, Measure
Balancer Shaft, Oversize
Balancer Shaft, Remove
Camshaft
Idler Gear, Install
Idler Gear, Measure
Idler Gear, Remove
Piston Pin, Inspect
Bypass Valve, Oil Pressure
Inspect
Install
Install
Remove
Remove
C
Camshaft
Bearing Bore
Bearing Bore, Measure
Bushing, Install
Bushing, Remove
End Play
End Play
Followers, Assemble
Followers, Inspect
Followers, Inspect
Followers, Measure
Gear, Install
Gear, Remove
Inspect
Install
Journal Od
Lobe Height
Remove
Specifications
Thrust Plate, Clearance
Time
Camshaft Bushings Remove And Install
Camshaft Followers
Bore, Measure
Cap Screws, Connecting Rod
Torque-Turn
Composite Material Timing Gear Cover
Installation
Compression Pressure Test
Connecting Rod
Assemble
Bearings, Inspect
Bearings, Measure
Cap, Inspect
Disassemble
Inspect
Pin Bore, Clean
Pin Bore, Inspect
Remove
Specifications
Connecting Rod And Piston Assembly
Install
Connecting Rod Cap Screws
Torque-Turn
Connecting Rods
Failure Analysis
Preliminary Checks
Coolant
Additives
Disposing
Heater, Install
Heater, Remove
Products
Recommended
Requirements
Tropical
Coolant, Engine
Coolant, Engine
Specifications
Cooler, Oil
High-Flow, Install
High-Flow, Remove
Identification
Standard-Flow, Inspect
Standard-Flow, Install
Standard-Flow, Remove
Cooling System
Check
Flow Diagram
Flow Diagram
Flush And Service
General Description
General Description
Pressure Test
Service
Specifications
Cover
Rocker Arm, Install
Timing Gear, Clean
Timing Gear, Inspect
Timing Gear, Install
Timing Gear, Remove
Crankcase
Blow-By
Ventilation System, Inspect
Ventilator Hose, Clean And Inspect
Crankshaft
End Play
End Play
Front Oil Seal, Install
Grinding Guidelines
Grinding Guidelines
Grinding Specifications
Inspect
Install
Main Bearing Journal, Measure
Pulley, Install
Pulley, Remove
Rear Oil Seal, General Information
Rear Oil Seal, Two-Piece, Install
Rear Oil Seal, Two-Piece, Remove
Rear Oil Seal, Unitized, Install
Rear Oil Seal, Unitized, Remove
Rear Wear Sleeve, Remove
Remove
Specifications
Thrust Bearing, Clearance
5/6-Piece Thrust Bearing Inst.
Crankshaft Gear
Remove And Install
Crankshaft Main Bearings
Remove
Cylinder Block
Clean
Inspect
Liner O-Ring Bore, Clean
Main Bearing Bore, Measure
Specifications
Top Deck, Clean And Inspect
Top Deck, Measure
Cylinder Head
Cap Screws, Clean And Inspect
Cap Screws, Torque-Turn Method
Failure Analysis
Flatness
Injection Nozzle Bores
Inspect And Clean
Install
Preliminary Checks
Remove
Specifications
Thickness
Valve Guides, Clean
Valve Guides, Knurl
Valve Guides, Measure
Valve Recess
Valve Seat Bore, Measure
Valve Seat Inserts, Install
Valve Seat Inserts, Remove
Valve Seats, Clean And Inspect
Valve Seats, Grind
Valves, Install
Valves, Remove
Cylinder Head Gasket
Failure Diagnostics
Joint Construction
Joint Operation
Cylinder Liner
Clean
Deglaze
Height Standout
Inspect
Install
O-Ring Bore, Clean
O-Rings
Packings
Remove
Replace
Specifications
Standout
Cylinder Liners
Failure Analysis
Preliminary Checks
D
Damper, Vibration
Inspect
Install
Remove
Diagnostics
Air Intake System
Engine
Fuel Injection Nozzles
Fuel Injection Pump
Fuel Supply Pump
Fuel System
Head Gasket Failure
Diesel Engine Oil
Diesel Fuel
Diesel Fuel
Lubricity
Dipstick Nipple
Adjust
Install
Remove
Droop Speed
Adjustment
Dynamometer Test
Procedure
Specifications
E
Electrical System
Check
Service
Elevations
Compensation Guideline
Engine
Applications
Assembly Sequence
Blow-By
Check For Excessive Tightness
Cleaning
Compression Pressure Test
Coolant
Coolant
Diagnostics
Disassembly Sequence
Dynamometer Test
General Description
Lifting Procedure
Mounting
Oil Pressure, Check
Preliminary Testing
Repair Stand
Sectional View
Serial Number Plate
Speed, Droop Adjustment
Speeds, Gen Set, Change
Test Specifications
Engine Break-In
Perform
Engine Break-In Guidelines
Engine Coolant
Disposing
Products
Requirements
Specifications
Engine Oil
Break-In
Diesel
Engine Speeds
Check And Adjust
Exhaust Manifold
Clean And Inspect
Remove And Install
Exhaust System
General Information
Inspect
Specifications
F
Failure Analysis
Head Gasket
Fan
Inspect
Install
Final Fuel Filter
Replace
Flywheel
Face Flatness
Inspect
Install
Pilot Bearing, Replace
Remove
Ring Gear, Replace
Specifications
Flywheel Housing
Face Runout
Install
Remove
Followers, Camshaft
Inspect
Front Plate
Clean
Inspect
Install
Remove
Replace
Replace
Timing Mark, Transfer
Timing Mark, Transfer
Fuel
Diesel
Lubricity
Fuel Filter
Replace
Replace
Fuel Filter, Final
Operation
Fuel Filter, Primary
Operation
Fuel Injection Nozzles
Adjustment
Assemble
Clean
Diagnosis
Diagnostics
Disassembly
General Information
Install
Operation
Remove
Test, Engine Running
Fuel Injection Pump
Install, Stanadyne Db2
Aneroid Field Adjustment
Aneroid Workshop Adjustment
Diagnostics
Install
Install, Lucas Cav
Install, Stanadyne Db2/Db4
Install, Stanadyne Dm4
Operation, Lucas Cav
Operation, Stanadyne
Remove, Lucas Cav
Remove, Stanadyne Db2
Remove, Stanadyne Db2
Remove, Stanadyne Db2/Db4
Remove, Stanadyne Dm4
Repair, Lucas Cav Dpa2
Repair, Stanadyne
Repair, Stanadyne
Repair, Stanadyne
Specifications
Time
Timing
Fuel Supply Pump
Bench Test
Diagnostics
Install
Operation
Remove
Test
Fuel System
Bleed
Diagnostics
Fuel Drain Back Test
Operation
Specifications
Test Specifications
G
Gear
Auxiliary Drive, Idler Gear
Auxiliary Drive, Output Gear
Auxiliary Drive, Remove
Backlash
Balancer Shaft, Inspect
Balancer Shaft, Install
Balancer Shaft, Remove
Camshaft, Remove And Install
Flywheel Ring, Replace
Idler, Bushings, Install
Idler, Bushings, Measure
Idler, Bushings, Remove
Idler, End Play
Specifications
Tachometer Drive, Replace
Gear Cover
Clean
Inspect
Install
Remove
Gear Drive, Auxiliary
Bearings
Dowels
Drive Gear
General Description
Gear, Crankshaft
Remove And Install
Gen Set Engine Speeds
Change, From 1800—1300 Rpm
General Information
Lubrication System
Oil Pump
Water Pump
Grease
Extreme Pressure And Multipurpose
H
Head, Cylinder
Cap Screws, Clean And Inspect
Cap Screws, Torque-Turn Method
Failure Analysis
Flatness
Gasket Failure Diagnostics
Gasket Joint Construction
Gasket Joint Operation
Injection Nozzle Bores
Inspect And Clean
Install
Preliminary Checks
Remove
Thickness
Valve Guides, Clean
Valve Guides, Knurl
Valve Guides, Measure
Valve Seat Bore, Measure
Valve Seat Inserts, Install
Valve Seat Inserts, Remove
Valve Seats, Clean And Inspect
Valve Seats, Grind
Valves, Install
Valves, Remove
Heater, Coolant
Install
Remove
Housing, Flywheel
Face Runout
I
Idler Gear
Bushings, Install
Bushings, Measure
Bushings, Remove
End Play
Shaft, Measure
Shaft, Remove
Idler Shaft
Lower, Install
Spring Pins, Install
Upper, Install
Inch Torque Values
Injection Nozzle
Adjustment
Assemble
Bore, Clean
Clean
Disassembly
Install
Remove
Seals, Install
Test
Injection Nozzle Bores
Clean
Injection Nozzles
Diagnosis
Test, Engine Running
Injection Pump
Dynamic Timing
Install
Time
Inserts In Block, Main Bearing
Install
Intake Manifold
Pressure, Check
Remove And Install
Intake, Air System
Inspect
J
Journals, Balancer Shaft
Inspect And Measure
L
Liner, Cylinder
Clean
Deglaze
Height Standout
Inspect
Install
O-Rings
Packings
Remove
Replace
Specifications
Standout
Liners, Cylinder
Failure Analysis
Preliminary Checks
Lubricant
Alternative
Synthetic
Lubrication System
Flow Diagram
General Description
General Information
Specifications
M
Main Bearing
Block Bore, Measure
Cap Bore, Measure
Oil Clearance
Oil Clearance, Measure
Specifications
Main Bearing Inserts In Block
Install
Main Thrust Bearing
Clearance
Manifold, Exhaust
Clean And Inspect
Remove And Install
Manifold, Intake
Remove And Install
Manifold, Water
Install
Remove
Mechanical Tachometer
Drive Gear, Replace
Metric Torque Values
N
Nipple
Dipstick, Adjust
Dipstick, Install
Dipstick, Remove
Oil Filter, Install
Oil Filter, Remove
Nozzle Body
Inspect And Clean
Nozzle Bore
Clean
Nozzle Seals
Install
Nozzle Valve
Inspect And Clean
Nozzle Valve Adjusting Mechanism
Inspect
Nozzle Valve Seat
Inspect And Clean
Nozzles, Fuel Injection
Diagnosis
Test, Engine Running
O
Oil Bypass Valve
Inspect
Install
Install
Remove
Remove
Oil Cooler
Bracket Replacement
High-Flow, Install
High-Flow, Remove
Identification
Standard-Flow, Inspect
Standard-Flow, Install
Standard-Flow, Remove
Oil Filter Nipple
Install
Remove
Oil Pan
Install
Oil Pressure
Check
Oil Pressure Regulating Valve
Inspect
Install
Install
Remove
Remove
Oil Pump
Assemble
General Information
High Capacity, Assemble
High Capacity, Clearances
High Capacity, Disassemble
High Capacity, Inspect
High Capacity, Install
High Capacity, Remove
Standard Capacity, Clearances
Standard Capacity, Disassemble
Standard Capacity, Install
Standard Capacity, Remove
Oil Pump Pick-Up Tube
Replacement (On Standard Oil Pump)
Oil Seal, Crankshaft Rear
General Information
Two-Piece, Install
Two-Piece, Remove
Unitized, Install
Oil Seal, Front Crankshaft
Install
Oil Seal, Rear Crankshaft
Unitized, Remove
Orifices, Piston Cooling
Inspect
P
Pan, Oil
Install
Pilot Bearing
Replace
Pin Bore, Connecting Rod
Clean
Inspect
Pin, Piston
Inspect
Piston And Connecting Rod Assembly
Install
Piston Cooling Orifices
Inspect
Inspect
Piston Pin
Bushings, Inspect
Inspect
Inspect
Install
Remove
Piston Pin Bore
Measure
Piston Pin Bushing
Install
Remove
Piston Protrusion
Measure
Piston Ring Groove Wear
Check
Piston Rings
Install
Remove
Pistons
Assemble
Clean
Disassemble
Failure Analysis
Inspect
Preliminary Checks
Remove
Replace
Specifications
Plate, Front
Clean
Inspect
Install
Remove
Replace
Pulley For Front Pto
Inspection
Removal
Pump, Fuel Injection
Install
Time
Pump, Oil
General Information
High Capacity, Assemble
High Capacity, Clearances
High Capacity, Disassemble
High Capacity, Inspect
High Capacity, Install
High Capacity, Remove
Standard Capacity, Clearances
Standard Capacity, Disassemble
Standard Capacity, Install
Standard Capacity, Remove
Pump, Water
Clean
General Information
Heavy Duty High Flow, Assemble
Heavy Duty High Flow, Disassemble
Inspect
Install
Low Flow, Assemble
Modular Style, Assemble
Modular Style, Disassemble
Modular Style, Disassemble
Modular Style, Disassemble
Remove
Std. Duty High Flow, Assemble
R
Radiator Cap
Pressure Test
Radiator, Cap
Pressure Test
Regulating Valve, Oil Pressure
Inspect
Install
Install
Remove
Remove
Ring Gear, Flywheel
Replace
Rings, Piston
Install
Remove
Rocker Arm Assembly
Assemble
Disassemble
Inspect
Install
Rocker Arm Cover
Install
Rods, Connecting
Failure Analysis
Preliminary Checks
S
Seal, Crankshaft Front Oil
Install
Seal, Crankshaft Rear Oil
General Information
Two-Piece, Install
Two-Piece, Remove
Unitized, Install
Unitized, Remove
Sealant Application Guidelines
Serial Number Plate
Shaft
Balancer, Install
Balancer, Remove
Balancer, Time
Idler Gear, Measure
Idler Gear, Remove
Lower Idler Gear, Install
Upper Idler Gear, Install
Specifications
Air Intake System
Air Intake System Test
Auxiliary Drive
Balancer Shaft
Camshaft
Connecting Rods
Coolant
Cooling System
Crankshaft
Crankshaft Grinding
Cylinder Block
Cylinder Head And Valves
Cylinder Liners
Dynamometer Test
Engine Test
Exhaust System
Flywheel
Fuel Injection Pump
Fuel System
Fuel System
Lubrication System
Main Bearings
Pistons
Timing Gear Train
Spring Pins, Idler Shaft
Install
Synthetic Lubricants
T
Tachometer Drive Gear
Replace
Temperature Compensation
Thermostat
Inspect And Test
Thermostat Housing
Install
Remove
Thermostats
Install
Remove
Test
Thrust Plate
Balancer Shaft, Inspect
Camshaft, Clearance
Timing
Fuel Injection Pump
Timing Gear
Backlash
Timing Gear Cover
Clean
Inspect
Install
Remove
Timing Mark
Transfer
Transfer
Torque Values
Inch
Metric
Torque-Turn Method
Connecting Rod Cap Screws
Cylinder Head Cap Screws
Tune-Up
General Recommendations
Preliminary Engine Testing
Turbocharger
Boost Pressure, Check
Break-In
Center Housing, Replace
Diagnostics
Disassemble And Inspect
Extending Life
Failure Analysis
Install
Lubrication
Measure Axial Bearing End Play
Measure Radial Bearing Clearance
Operation
Prelube
Remove
Seven-Step Inspection
V
Valve
Clearance, Check And Adjust
Guides, Clean
Guides, Knurl
Guides, Measure
Lift
Lift
Recess
Rotators, Inspect
Rotators, Install
Rotators, Remove
Seat Bore, Measure
Seat Inserts, Install
Seat Inserts, Remove
Seats, Clean And Inspect
Seats, Grind
Springs, Inspect
Springs, Install
Springs, Measure
Springs, Remove
Stem Seals, Install
Stem Seals, Remove
Valves
Clean
Failure Analysis
Grind
Inspect
Install
Measure
Preliminary Checks
Remove
Specifications
Ventilation System
Inspect
Ventilator Outlet Hose
Clean And Inspect
Vibration Damper
Inspect
Install
Remove
W
Water Manifold
Install
Remove
Water Pump
Clean
General Information
Heavy Duty High Flow, Assemble
Heavy Duty High Flow, Disassemble
Inspect
Install
Low Flow, Assemble
Low Flow, Disassemble
Modular Style, Assemble
Modular Style, Disassemble
Remove
Std. Duty High Flow, Assemble
Std. Duty High Flow, Disassemble
Water Pump Cap Screw Protrusion
Checking
Water Pump Cap Screw Protrusion, Checking
Water Separator Filter
Replace
Wear Sleeve, Rear Crankshaft
Remove
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