1991 KOMATSU KDC 614 SERIES ENGINE SERVICE REPAIR MANUAL – PDF DOWNLOAD

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1991 KOMATSU KDC 614 SERIES ENGINE SERVICE REPAIR MANUAL

1991 KOMATSU KDC 614 SERIES ENGINE SERVICE REPAIR MANUAL – PDF DOWNLOAD:

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DESCRIPTION:

1991 KOMATSU KDC 614 SERIES ENGINE SERVICE REPAIR MANUAL

This manual contains complete rebuild specifications and information for the 614 Series engines. The repair procedures in this manual are based on the engine being installed on 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 a specific brand name, number, or special tool is referenced in this manual, an equivalent product can be used in place of the recommended kern. A series of specific service manuals (Shop, Specification, Alternative Repair, and so forth) are available and can be ordered through your distributor using the form in Section L The specifications and rebuild information in this manual is based on the information in effect at the time of printing. Komatsu Dresser Co. reserves the right to make any changes at any time without obligation. If differences are found between your engine and the information in this manual, contact your KDC Distributor. The latest technology and the highest quality components are used to manufacture KDC engines. When replacement parts are needed, we recommend using only genuine KDC exchange parts.

TABLE OF CONTENTS:

1991 KOMATSU KDC 614 SERIES ENGINE SERVICE REPAIR MANUAL

Main Menu.....................................................................  0
Table of Contents.............................................................  5
Section i - Introduction......................................................  9
	About the Manual.......................................................... 10
	General Cleaning Instructions............................................. 16
		Solvent and Acid Cleaning............................................. 16
		Steam Cleaning........................................................ 16
	General Repair Instructions............................................... 15
	General Safety Instructions............................................... 14
	Generic Symbols........................................................... 12
	Glossary of Terms......................................................... 17
	How To Use This Manual.................................................... 11
		Table of Contents..................................................... 11
		Group Contents........................................................ 11
		Index................................................................. 11
		Metric Information.................................................... 11
	Illustrations............................................................. 13
Section E - Engine and Component Identification............................... 19
	Engine Diagrams........................................................... 24
	Engine Identification..................................................... 20
		Engine Dataplate...................................................... 20
		Fuel Injection Pump Dataplate......................................... 21
	General Engine Specifications............................................. 22
		Cooling System........................................................ 23
		Fuel System........................................................... 23
		General Engine Data................................................... 22
		Intake Air and Exhaust System......................................... 23
		Lubrication System.................................................... 22
Engine Disassembly and Assembly - Group 00.................................... 27
	Engine - Assembly......................................................... 65
		AFC Tube - Installation...............................................138
		Aftercooler - Installation............................................123
		Air Compressor - Installation.........................................145
		Air Crossover Tube - Installation.....................................127
		Alternator Brace - Installation.......................................130
		Alternator - Installation.............................................129
		Alternator Mounting Bracket - Installation............................129
		Belt Tensioner Bracket - Installation.................................131
		Belt Tensioner - Installation.........................................131
		Camshaft - Installation............................................... 91
		Connecting Rod Bolt - Installation.................................... 80
		Coolant Filter - Installation.........................................128
		Coolant Heater - Installation.........................................108
		Coolant Inlet Connection - Installation...............................129
		Coolant Outlet Connection - Installation..............................128
		Coolant Vent Fitting - Installation...................................128
		Coolant Vent Petcock - Installation...................................128
		Coolant Vent Tube - Installation......................................129
		Crankcase Breather Tube - Installation................................121
		Crankshaft - Installation............................................. 73
		Cylinder Block - Installation onto Engine Rebuild Stand............... 65
		Cylinder Head - Installation..........................................111
		Cylinder Liner - Installation......................................... 66
		Drive Belt - Installation.............................................144
		Engine Lifting Bracket - Installation.................................122
		Engine - Removal from the Rebuild Stand...............................131
		Engine Support, Front - Installation..................................144
		Exhaust Manifold - Installation.......................................123
		Fan Hub Assembly - Installation.......................................132
		Flywheel Bore Runout Measurement......................................105
		Flywheel Face Runout Measurement......................................107
		Flywheel Housing - Installation....................................... 98
		Flywheel - Installation...............................................103
		Fuel Drain Manifold - Installation....................................122
		Fuel Filter Head - Installation.......................................137
		Fuel Filter - Installation............................................137
		Fuel Injection Pump - Installation....................................132
		Fuel Injection Pump Supply Line - Installation........................136
		Fuel Lines, High Pressure - Installation..............................138
		Fuel Lines, Low Pressure - Installation...............................145
		Fuel Pump Solenoid - Installation.....................................145
		Fuel Transfer Pump - Installation.....................................144
		Gear Cover - Installation.............................................142
		Gear Housing - Installation........................................... 88
		Injector - Installation...............................................121
		Intake Manifold Cover - Installation..................................122
		Lubricating Oil Cooler - Installation.................................110
		Lubricating Oil Filter - Installation.................................111
		Lubricating Oil Pan - Installation.................................... 94
		Lubricating Oil Pump - Installation................................... 90
		Lubricating Oil Suction Tube - Installation........................... 94
		Main Bearing (Lower) - Installation................................... 73
		Main Bearing (Upper) - Installation................................... 72
		Main Bearing Cap - Installation....................................... 73
		Piston Assembly - Installation........................................ 84
		Piston Cooling Nozzle - Installation.................................. 71
		Piston Pin - Installation............................................. 80
		Piston Ring End Gap - Measurement..................................... 81
		Piston Ring - Installation............................................ 82
		Push Rod - Installation...............................................115
		Rocker Lever and Shaft - Assembly.....................................115
		Rocker Lever Assembly - Installation..................................117
		Seal, Front Crankshaft - Installation.................................139
		Seal, Rear Crankshaft - Installation.................................. 77
		Starting Motor - Installation.........................................108
		Tachometer Drive - Installation.......................................143
		Thermostat and Housing - Installation.................................127
		Timing Pin Assembly - Installation.................................... 95
		Turbocharger Exhaust Outlet Connection Installation...................127
		Turbocharger - Installation...........................................124
		Turbocharger Oil Drain Tube - Installation............................125
		Turbocharger Oil Supply Hose - Installation...........................126
		Valve Arrangement.....................................................119
		Valve Clearance - Adjustment..........................................118
		Valve Cover - Installation............................................120
		Valve Tappet - Installation........................................... 70
		Vibration Damper - Installation.......................................143
		Water Pump - Installation............................................. 93
		Engine Accessories - Installation.....................................147
	Engine - Disassembly...................................................... 35
		AFC Tube - Removal.................................................... 38
		Aftercooler - Removal................................................. 43
		Air Compressor - Removal.............................................. 40
		Air Crossover Tube - Removal.......................................... 43
		Alternator Brace - Removal............................................ 47
		Alternator Mounting Bracket - Removal................................. 48
		Alternator - Removal.................................................. 48
		Belt Tensioner Bracket - Removal...................................... 47
		Belt Tensioner - Removal.............................................. 47
		Camshaft - Removal.................................................... 54
		Coolant - Draining.................................................... 36
		Coolant Filter - Removal.............................................. 36
		Coolant Heater - Removal.............................................. 52
		Coolant Inlet Connection - Removal.................................... 50
		Coolant Outlet Connection - Removal................................... 48
		Coolant Vent Tube - Removal........................................... 49
		Coolant Vent Petcock - Removal........................................ 49
		Coolant Vent Tube Fitting - Removal................................... 49
		Crankcase Breather Tube - Removal..................................... 42
		Crankshaft - Removal.................................................. 62
		Cylinder Head - Removal............................................... 49
		Cylinder Liner Carbon Deposits - Removal.............................. 58
		Cylinder Liner Protrusion - Checking.................................. 63
		Cylinder Liner - Removal.............................................. 63
		Drive Belt - Removal.................................................. 47
		Engine - Installation onto Engine Rebuild Stand....................... 41
		Engine Lifting Equipment and Brackets................................. 35
		Engine - Preparation for Steam Cleaning............................... 35
		Engine - Steam Cleaning............................................... 35
		Engine Support, Front - Removal....................................... 57
		Exhaust Manifold - Removal............................................ 46
		Expansion Plug - Removal.............................................. 65
		Expansion Plug - Replacement.......................................... 64
		Fan Hub Assembly - Removal............................................ 50
		Flywheel Housing - Removal............................................ 53
		Flywheel - Removal.................................................... 53
		Fuel Drain Manifold - Removal......................................... 44
		Fuel Filter Head - Removal............................................ 37
		Fuel Filter - Removal................................................. 37
		Fuel Injection Pump - Removal......................................... 39
		Fuel Injection Pump Supply Line - Removal............................. 38
		Fuel Lines, High Pressure - Removal................................... 38
		Fuel Lines, Low Pressure - Removal.................................... 37
		Fuel Pump Solenoid - Removal.......................................... 41
		Fuel Transfer Pump - Removal.......................................... 37
		Gear Cover - Removal.................................................. 52
		Gear Housing - Removal................................................ 57
		Injector - Removal.................................................... 44
		Intake Manifold Cover - Removal....................................... 43
		Lubricating Oil Cooler - Removal...................................... 50
		Lubricating Oil - Draining............................................ 36
		Lubricating Oil Filter - Removal...................................... 36
		Lubricating Oil Pan - Removal......................................... 53
		Lubricating Oil Pump Gear Backlash - Measurement...................... 56
		Lubricating Oil Pump - Removal........................................ 57
		Lubricating Oil Suction Tube - Removal................................ 53
		Main Bearing (Lower) - Removal........................................ 62
		Main Bearing (Upper) - Removal........................................ 62
		Main Bearing Cap - Removal............................................ 61
		Piston Assembly - Removal............................................. 59
		Piston Cooling Nozzle - Removal....................................... 62
		Piston Pin - Removal.................................................. 60
		Piston Ring - Removal................................................. 61
		Push Rod - Removal.................................................... 45
		Rocker Lever Assembly - Removal....................................... 45
		Seal, Front Crankshaft - Removal...................................... 52
		Seal, Rear Crankshaft - Removal....................................... 54
		Starting Motor - Removal.............................................. 52
		Tachometer Drive - Removal............................................ 39
		Thermostat and Housing - Removal...................................... 48
		Turbocharger Exhaust Outlet Connection - Removal...................... 42
		Turbocharger Oil Drain Tube - Removal................................. 46
		Turbocharger Oil Supply Hose - Removal................................ 46
		Turbocharger - Removal................................................ 46
		Valve Cover - Removal................................................. 44
		Valve Tappet - Removal................................................ 55
		Vibration Damper - Removal............................................ 51
		Wastegate Actuator Hose - Removal..................................... 42
		Water Pump - Removal.................................................. 51
		Cylinder Block - Removal from Engine Rebuild Stand.................... 65
	Engine Disassembly and Assembly - Service Tools........................... 30
	General Information....................................................... 34
		Disassembly........................................................... 34
		Assembly.............................................................. 34
Cylinder Block - Group 01.....................................................149
	Camshaft Bore Expansion Plug - Installation...............................168
	Camshaft Bushing Bore - Cleaning..........................................170
	Camshaft Bushing - Installation...........................................170
	Camshaft Bushing - Removal................................................169
	Camshaft - Cleaning and Inspection for Reuse..............................197
		Camshaft - Cleaning...................................................197
		Camshaft Gear - Inspection............................................200
		Camshaft - Inspection.................................................197
	Camshaft Gear - Replacement...............................................201
		Camshaft Gear - Cleaning..............................................201
		Camshaft Gear - Inspection............................................201
		Camshaft Gear - Installation..........................................203
		Camshaft Gear - Removal...............................................201
	Connecting Rod Bearings - Cleaning and  Inspection for Reuse .............186
		Connecting Rod Bearings - Cleaning ...................................186
		Connecting Rod Bearings - Inspection .................................186
	Connecting Rod Bushing - Replacement .....................................192
		Inspection ...........................................................196
		Installation .........................................................194
		Machining ............................................................196
		Removal...............................................................192
	Connecting Rods - Bend and Twist  Inspection..............................190
		Connecting Rod Alignment - Inspection ................................191
		Connecting Rod Twist - Inspection ....................................191
		Fixture Calibration ..................................................190
	Connecting Rods - Cleaning and  Inspection for Reuse .....................187
		Connecting Rods - Cleaning ...........................................187
		Connecting Rods - Inspection .........................................188
	Crankshaft - Cleaning and Inspection for Reuse............................176
		Crankshaft - Cleaning.................................................176
		Crankshaft - Inspection...............................................177
	Crankshaft Gear - Replacement.............................................180
		Crankshaft Gear - Inspection .........................................181
		Crankshaft Gear - Installation .......................................182
		Crankshaft Gear -  Removal ...........................................180
		General Information ..................................................180
	Cylinder Block - Cleaning in a Hot Tank...................................162
	Cylinder Block - Cleaning with Solvent....................................159
	Cylinder Block - Disassembly..............................................157
	Cylinder Block - Exploded View............................................154
	Cylinder Block - General Information......................................156
		Camshaft..............................................................156
		Connecting Rods.......................................................156
		Crankshaft............................................................156
		Cylinder Block........................................................156
		Cylinder Liner........................................................156
		Oil Seals.............................................................156
		Pistons...............................................................156
		Vibration Damper......................................................156
	Cylinder Block - Inspection For Reuse.....................................163
	Cylinder Block - Preparation for Cleaning.................................157
	Cylinder Block - Service Tools............................................151
	Cylinder Head Capscrews - Cleaning and Inspection for Reuse  .............211
		Cleaning..............................................................211
		Free Length - Measurement.............................................213
		Inspection............................................................212
	Cylinder Liners - Cleaning and Inspection for Reuse.......................171
		Cylinder Liners - Cleaning............................................171
		Cylinder Liners - Inspection..........................................172
	Dowel Pins (Cylinder Head) - Removal......................................158
	Engine Dataplate - Replacement ...........................................206
		Engine Dataplate - Installation.......................................206
		Engine Dataplate - Removal............................................206
	Engine Lifting Brackets - Cleaning and Inspection for Reuse...............213
	Expansion Plug - Installation.............................................166
		Pipe Plug - Installation..............................................167
	Gear Cover - Cleaning and Inspection for Reuse............................207
		Gear Cover - Cleaning.................................................207
		Gear Cover - Inspection...............................................207
	Gear Housing - Cleaning and Inspection for Reuse..........................204
		Gear Housing - Cleaning...............................................204
		Gear Housing - Inspection.............................................204
	Main Bearing Caps and Capscrews - Cleaning and Inspection for Reuse ......185
		Cleaning .............................................................185
		Inspection ...........................................................186
	Main Bearings -  Cleaning and Inspection  for Reuse.......................183
		General Information ..................................................183
		Main Bearings - Cleaning .............................................184
		Main Bearings - Inspection ...........................................184
		Thrust Bearings - Inspection .........................................185
	Pistons - Cleaning and Inspection for Reuse...............................174
		Piston Rings - Removal................................................174
		Pistons - Cleaning....................................................174
		Pistons - Inspection..................................................175
	Rear Cover - Cleaning and Inspection......................................210
		Cleaning..............................................................210
		Inspection............................................................211
	Vibration Damper - Cleaning and Checking for Reuse........................208
		General Information...................................................208
		Rubber Element Vibration Damper - Inspection..........................208
		Rubber Vibration Damper - Cleaning....................................208
		Viscous Vibration Damper - Cleaning...................................209
		Viscous Vibration Damper - Inspection.................................209
Cylinder Head - Group 02......................................................215
	Cylinder Head Capscrew - Cleaning and Inspection..........................251
		Cleaning..............................................................251
		Inspection............................................................252
	Cylinder Head - Cleaning and Inspection for Reuse ........................223
		Cleaning..............................................................223
		Handling..............................................................223
		Inspection............................................................224
	Cylinder Head - Exploded View.............................................220
	Cylinder Head - General Information.......................................222
	Cylinder Head - Pressure Testing..........................................248
	Cylinder Head - Rebuild...................................................225
		Assembly..............................................................240
		Cleaning..............................................................226
		Disassembly...........................................................225
		Inspection............................................................227
		Valve - Grinding......................................................235
		Valve Guide - Inspection..............................................231
		Valve - Inspection....................................................234
		Valve Seat Insert - Grinding..........................................236
		Valve Seat Insert - Inspection........................................232
		Valve Spring - Inspection.............................................233
		Valve Stem Seal - Inspection..........................................233
	Cylinder Head - Service Tools.............................................216
	Cylinder Head - Vacuum Testing Valve Seating..............................250
	Cylinder Head - Valve Guide Replacement...................................242
		Assembly..............................................................243
		Disassembly...........................................................242
		Inspection............................................................243
	Cylinder Head - Valve Seat Insert Replacement.............................245
		Inspection............................................................247
		Installation..........................................................247
		Removal...............................................................245
	Free Length - Measurement.................................................253
Rocker Levers - Group 03......................................................255
	Crankcase Breather Tube - Cleaning and Inspection for Reuse...............262
		Cleaning and Inspection...............................................262
	Rocker Assembly Oil Manifold - Cleaning . and Inspection for Reuse........261
		Cleaning..............................................................261
		Inspection............................................................261
	Rocker Lever Assembly - Cleaning and Inspection...........................258
		Assembly..............................................................260
		Cleaning..............................................................259
		Disassembly...........................................................258
		Inspection............................................................259
	Rocker Lever Assembly - Exploded View.....................................256
	Rocker Lever Assembly - General Information...............................257
	Valve Cover - Cleaning and Inspection for Reuse...........................262
		Cleaning..............................................................262
		Inspection............................................................262
Valve Tappets and Push Rods - Group 04........................................263
	Push Rods - Reuse Cleaning and Inspection for.............................266
		Cleaning..............................................................266
		Inspection............................................................266
	Valve Tappet Cleaning and Inspection for Reuse............................265
		Cleaning..............................................................265
		Inspection............................................................265
	Valve Tappets and Push Rods - Exploded View...............................264
	Valve Tappets and Push Rods - General Information.........................265
Fuel Systems - Group 05.......................................................269
	Fuel Injection Pump Gaskets and Seals - Replacement.......................279
	Fuel System - General Information.........................................270
		Derivative Fuel Injection Pump - Data Tag Information.................271
		Fuel Injection Pump...................................................270
		Fuel Injection Pump - Data Tag Information............................270
		Fuel Injection Pump - Data Tag Location...............................270
		Fuel Shutoff Solenoid - Wiring Requirements...........................271
		Governor - Data Tag Information.......................................271
	Fuel Transfer Pump - Exploded View........................................272
	Fuel Transfer Pump - Rebuild .............................................273
		Cleaning..............................................................273
		Assembly..............................................................273
	RQVK Governor Fuel Shutoff Solenoid - Adjustment..........................277
	RSV Governor Fuel Shutoff Solenoid - Orientation and Adjustment...........274
		Fuel Shutoff Solenoid - Adjustment....................................276
		Fuel Shutoff Solenoid - Orientation...................................274
	Shutdown Lever or Spring - Replacement....................................278
Injectors and Fuel Lines - Group 06...........................................281
	Fuel Drain Manifold - Inspection..........................................296
	Fuel Lines, High Pressure - Cleaning and Inspection for Reuse.............294
		Fuel Lines - Cleaning and Inspection..................................295
		General Information...................................................294
	Fuel Lines, Low Pressure - Cleaning and Inspection for Reuse..............296
	Injector - Chatter Testing................................................294
	Injector - Spray Testing..................................................293
	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 and Fuel Lines - Service Tools..................................282
	Injectors - Cleaning and Inspection for Reuse.............................288
		General Information...................................................288
		Injector - Assembly...................................................292
		Injector - Cleaning and Inspection....................................290
		Injector - Disassembly................................................288
Lubricating Oil System - Group 07.............................................299
	Lubricating Oil Dipstick - Calibration....................................311
	Lubricating Oil Pan - Cleaning and Inspection for Reuse...................303
		Cleaning..............................................................303
		Inspection............................................................303
	Lubricating Oil Pump - Cleaning and Inspection for Reuse..................312
		Cleaning..............................................................313
		Disassembly...........................................................312
		Inspection............................................................313
	Lubricating Oil System - Exploded View....................................302
	Lubricating Oil System - General Information..............................301
		Dipstick..............................................................301
		Lubricating Oil Cooler and Filter Head................................301
		Lubricating Oil Pump..................................................301
		Oil Filter Head.......................................................301
		Oil Pan...............................................................301
		Oil Pressure Regulator................................................301
		Oil Temperature Thermostat............................................301
	Lubricating Oil System - Service Tools....................................300
	Lubricating Oil Temperature Thermostat - Cleaning and Inspection..........310
		Cleaning..............................................................310
		Inspection............................................................310
	Oil Cooler Cover - Disassembly and Assembly...............................308
		Assembly..............................................................309
		Cleaning..............................................................308
		Disassembly...........................................................308
	Oil Cooler Element - Cleaning and Inspection for Reuse....................304
		Cleaning..............................................................304
		Inspection............................................................304
		Pressure Test.........................................................304
	Oil Filter Bypass Valve - Replacement.....................................307
	Oil Pressure Regulating Valve - Cleaning and Inspection...................305
		Assembly..............................................................306
		Cleaning..............................................................306
		Disassembly...........................................................305
		Inspection............................................................306
Cooling System - Group 08.....................................................317
	Belt Tensioner Inspection.................................................326
	Coolant Filter Shutoff Valve - Cleaning and Inspection for Reuse..........326
		Assembly..............................................................327
		Cleaning..............................................................327
		Disassembly...........................................................326
	Cooling System Components - Exploded View.................................319
	Cooling System - General Information......................................320
		Belt Tensioner........................................................320
		Cooling Fans..........................................................320
		Fan Hub...............................................................320
		Pressure Caps.........................................................320
		Thermostats...........................................................320
		Water Pump............................................................320
	Cooling System - Service Tools............................................318
	Fan Hub - Cleaning and Inspection for Reuse...............................323
		Cleaning..............................................................323
		Inspection............................................................324
	Fan Hub - Rebuild.........................................................324
		Assembly..............................................................325
		Disassembly...........................................................324
	Thermostat Housing Cleaning and Inspection Reuse..........................322
		Cleaning..............................................................322
		Inspection............................................................322
	Thermostat - Inspection...................................................322
	Water Outlet Connection - Cleaning and Inspection for Reuse...............323
	Water Pump Assembly - Cleaning and Inspection for Reuse...................321
		Cleaning..............................................................321
		Inspection............................................................321
Drive Units - Group 09........................................................329
	Accessory Drive Adapter - Cleaning and Inspection for Reuse...............333
		Cleaning..............................................................333
		Inspection............................................................333
	Accessory Drive Adapter - Exploded View...................................331
	Accessory Drive Adapter - Rebuild ........................................333
		Assembly..............................................................334
		Disassembly...........................................................333
	Accessory Drive - General Information.....................................332
		Accessory Drive Adapter...............................................332
	Drive Units - Service Tools...............................................330
Air Intake System - Group 10..................................................337
	Aftercooler Assembly - Cleaning and Inspection for Reuse..................343
		Inspection............................................................344
	Aftercooler Assembly - Rebuild............................................344
	Air Crossover Tube - Cleaning and Inspection for Reuse....................345
		Cleaning..............................................................345
		Inspection............................................................345
	Air Intake System - Exploded View.........................................339
	Air Intake System - General Information...................................340
	Air Intake System - Service Tools.........................................338
	Air Transfer Pipe - Cleaning and Inspection for Reuse.....................345
		Cleaning..............................................................345
		Inspection............................................................345
	Intake Manifold Cover - Cleaning and Inspection for Reuse.................343
		Inspection............................................................343
	Turbocharger - Cleaning and Inspection for Reuse..........................341
		Inspection............................................................341
Exhaust System - Group 11.....................................................347
	Exhaust Manifold - Cleaning and Inspection for Reuse......................350
		Cleaning..............................................................350
		Inspection............................................................350
	Exhaust Manifold - Exploded View..........................................348
	Exhaust Manifold Outlet Connection - Cleaning and Inspection for Reuse....352
		Cleaning..............................................................352
		Inspection............................................................352
	Exhaust Manifold Turbocharger Mounting Stud - Replacement.................351
		Inspection............................................................351
		Installation..........................................................351
		Removal...............................................................351
	Exhaust System - General Information......................................349
		Exhaust Manifold......................................................349
Air Equipment - Group 12......................................................353
Electrical Equipment - Group 13...............................................355
Engine Testing - Group 14.....................................................357
	Blowby Measurement........................................................363
	Engine Dynamometer Test - Engine Run-In...................................373
	Engine Dynamometer Test - Installation of the Engine......................365
	Engine Dynamometer Test - Performance Checking............................377
	Engine Painting ..........................................................382
	Engine Run-In Procedure - "In-Chassis"....................................380
	Engine Run-In - General Procedures........................................364
	Engine Storage - Long Term................................................385
		Engine Removal from Long Term Storage.................................388
	Engine Storage - Short Term...............................................383
		Engine Removal From Short Term Storage................................385
	Engine Testing - Component Identification and Diagrams....................359
	Engine Testing - General Information......................................361
		Engine Dynamometer Run-in.............................................361
		In-Chassis Run-In.....................................................361
	Engine Testing - General Specifications...................................362
	Engine Testing - Service Tools............................................358
	Fuel Injection Pump - Idle Speed Adjustment...............................381
		RSV Governor..........................................................381
		RQV and RQVK Governor.................................................382
	General Engine Test Procedure - In Chassis................................379
Instruments and Controls - Group 15...........................................393
Mounting Adaptations - Group 16...............................................395
	Engine Support Bracket, Front - Cleaning and Inspection for Reuse.........403
		Cleaning..............................................................403
		Inspection............................................................403
	Flexplate Assembly - Cleaning and Inspection for Reuse....................400
	Flywheel - Cleaning and Inspection for Reuse..............................399
		Cleaning..............................................................399
		Inspection............................................................399
	Flywheel Housing - Assembly (Wet Clutch Application)......................402
	Flywheel Housing - Cleaning and Inspection for Reuse......................401
		Cleaning..............................................................401
		Inspection............................................................401
	Flywheel Ring Gear - Replacement..........................................400
		Installation..........................................................400
		Removal...............................................................400
	Mounting Adaptations - Exploded View......................................397
	Mounting Adaptations - General Information................................398
		Flywheel and Ring Gear................................................398
		Flywheel Housing......................................................398
	Mounting Adaptations - Service Tools......................................396
Section V - Specifications and Torque Values - Group 18.......................405
	Air Compressor Inspection Specifications..................................441
	Air Compressor Torque Values..............................................441
	Capscrew Markings and Torque Values.......................................449
		Capscrew Markings and Torque Values - Metric..........................450
		Capscrew Markings and Torque Values - U.S. Customary..................450
	Component Specifications and Torque Values................................407
		Cylinder Block - Rebuild Specifications...............................419
		Cylinder Block - Torque Values........................................425
		Cylinder Head - Rebuild Specifications................................426
		Engine Assembly - Specifications......................................407
		Engine Assembly - Torque Values.......................................409
	Cooling System Specifications.............................................437
		Air Intake System Specifications......................................439
		Air Intake System Torque Values.......................................439
		Cooling System Torque Values..........................................438
	Drive Belt Tension........................................................445
	Electrical System Specifications..........................................442
	Electrical System Torque Values...........................................442
	Engine Components - General Information...................................406
	Engine Testing - Test Specifications......................................443
	Exhaust System Specifications.............................................441
	Exhaust System Torque Values..............................................441
	Fuel Systems - Rebuild Specifications.....................................429
		Fuel Injection Pump Sealing Washer....................................431
		Fuel Shutoff Solenoid Adjustment......................................431
		Fuel System Specifications............................................429
		Fuel System Torque Values.............................................431
	Lubricating Oil System Specifications.....................................434
	Lubricating Oil System Torque Values......................................435
	Mounting Adaptations Specifications.......................................443
		Flywheel Housing (Wet Application)....................................443
		Flywheel Ring Gear Installation.......................................444
	Mounting Adaptations - Torque Values......................................444
	Newton-Meter to Foot-Pound Conversion Chart...............................448
	Pipe Plug Torque Values...................................................451
	Rocker Lever Assembly - Rebuild Specifications............................429
	Tap-Drill - U.S. Customary & Metric.......................................452
	Valve Tappet - Rebuild Specifications.....................................429
	Weight and Measures - Conversion Factors..................................447
Section L - Service Literature................................................453
Index.........................................................................457

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⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
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