John Deere Series 300, 3179, 4239, 6359, 4276, 6414 Diesel Engines Component Technical Manual (CTM4)
Complete service repair manual with Electrical Wiring Diagrams for John Deere Series 300, 3179, 4239, 6359, 4276, 6414 Diesel Engines, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
John Deere Series 300, 3179, 4239, 6359, 4276, 6414 Diesel Engines workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 547 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CTM4 (28OCT95) - John Deere Series 300, 3179, 4239, 6359, 4276, 6414 Diesel Engines Component Technical Manual.pdf
CTM4 - John Deere Series 300 (3179, 4239, 6359, 4276, and 6414) Diesel Engines Component Technical Manual (CTM).pdf
MAIN SECTIONS
Introduction...2
FOREWORD...2
JOHN DEERE DEALERS...3
ABOUT THIS MANUAL...4
3179D ENGINE IDENTIFICATION...5
4276D ENGINE IDENTIFICATION...5
6359A ENGINE IDENTIFICATION...6
6359T ENGINE IDENTIFICATION...6
Contents...7
Group 00Safety...7
Group 01General Information...7
Group 02Fuels, Lubricants, and Coolant...7
Group 03Engine Mounting...7
Group 04Engine Rebuild Guide...7
Group 05Cylinder Head and Valves...7
Group 10Cylinder Block, Liners, Pistons, and Rods...8
Group 15Crankshaft, Main Bearings, and Flywheel...8
Group 16Camshaft, Balancer Shafts, and Timing Gear Train...9
Group 20Lubrication System...10
Group 25Cooling System...10
Group 30Air Intake and Exhaust System...10
Group 35Fuel System...11
Group 100Engine Tune-Up and Break-In...12
Group 105Engine System Operation and Tests...12
Group 110Air Intake System Operation and Tests...12
Group 115Fuel System Operation and Tests...12
Group 199Dealer Fabricated Tools...13
Safety ...15
HANDLE FLUIDS SAFELYAVOID FIRES...15
PREVENT BATTERY EXPLOSIONS...15
PREPARE FOR EMERGENCIES...15
PREVENT ACID BURNS...16
AVOID HIGH-PRESSURE FLUIDS...17
WEAR PROTECTIVE CLOTHING...17
SERVICE MACHINES SAFELY...18
WORK IN VENTILATED AREA...18
ILLUMINATE WORK AREA SAFELY...18
REMOVE PAINT BEFORE WELDING OR HEATING...19
AVOID HEATING NEAR PRESSURIZED FLUID LINES...19
USE PROPER LIFTING EQUIPMENT...19
WORK IN CLEAN AREA...20
PRACTICE SAFE MAINTENANCE...20
USE PROPER TOOLS...21
DISPOSE OF WASTE PROPERLY...21
LIVE WITH SAFETY...22
General Information ...23
UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES...23
METRIC BOLT AND CAP SCREW TORQUE VALUES...24
ENGINE MODEL DESIGNATION...25
ENGINE SERIAL NUMBER PLATE INFORMATION...27
ENGINE APPLICATION CHART*...29
ENGINE APPLICATION CHARTCONTINUED...30
ENGINE APPLICATION CHARTCONTINUED...31
ENGINE APPLICATION CHARTCONTINUED...32
ENGINE APPLICATION CHARTCONTINUED...33
ENGINE APPLICATION CHARTCONTINUED...34
ENGINE APPLICATION CHARTCONTINUED...35
Fuels, Lubricants, and Coolant ...37
DIESEL FUEL...37
LUBRICITY OF DIESEL FUELS...37
ENGINE BREAK-IN OIL...38
DIESEL ENGINE OIL...39
OILSCAN AND COOLSCAN...40
ALTERNATIVE AND SYNTHETIC LUBRICANTS...40
GREASE...41
ENGINE COOLANT REQUIREMENTS...42
ENGINE COOLANT REQUIREMENTSCONTINUED...43
RECOMMENDED ENGINE COOLANT...44
ENGINE COOLANT SPECIFICATIONS...45
ENGINE COOLANT SPECIFICATIONSCONTINUED...46
REPLENISHING SUPPLEMENTAL COOLANT ADDITIVES (SCAS) BETWEEN COOLANT CHANGES...47
OPERATING IN TROPICAL CONDITIONS...48
FLUSH AND SERVICE COOLING SYSTEM...49
DISPOSING OF COOLANT...50
Engine Mounting ...51
ENGINE REPAIR STAND...51
SAFETY PRECAUTIONS...52
INSTALL 300 SERIES ADAPTERS ON REPAIR STAND...53
ENGINE LIFTING PROCEDURE...53
CLEAN ENGINE...54
DISCONNECT TURBOCHARGER OIL INLET LINE...54
MOUNT ENGINE ON REPAIR STAND...55
ENGINE MOUNTED ON REPAIR STAND...56
Engine Rebuild Guide ...57
ENGINE DISASSEMBLY SEQUENCE...57
SEALANT APPLICATION GUIDELINES...58
SEALANT APPLICATION GUIDELINESCONTINUED...59
ENGINE ASSEMBLY SEQUENCE...60
Cylinder Head and Valves ...61
SPECIAL OR ESSENTIAL TOOLS...61
CYLINDER HEAD AND VALVES SPECIFICATIONS...65
CYLINDER HEAD AND VALVES SPECIFICATIONSCONTINUED...66
CYLINDER HEAD AND VALVES SPECIFICATIONSCONTINUED...67
CYLINDER HEAD AND VALVES SPECIFICATIONSCONTINUED...68
CYLINDER HEAD AND VALVES SPECIFICATIONSCONTINUED...69
CHECK AND ADJUST VALVE CLEARANCE...70
MEASURE VALVE LIFT...74
REMOVE CYLINDER HEAD...76
DISASSEMBLE AND INSPECT ROCKER ARM SHAFT ASSEMBLY...79
ASSEMBLE ROCKER ARMS ON SHAFT...81
CLEAN AND INSPECT PUSH RODS...81
MAKE PRELIMINARY VALVE CHECKS...82
CHECK VALVE RECESS IN CYLINDER HEAD...83
REMOVE VALVE ASSEMBLY...83
INSPECT AND MEASURE VALVE SPRINGS...84
INSPECT VALVE ROTATORS AND WEAR CAPS...84
CLEAN VALVES...85
INSPECT AND MEASURE VALVES...85
GRIND VALVES...86
INSPECT AND CLEAN CYLINDER HEAD...87
CHECK CYLINDER HEAD FLATNESS...87
MEASURE CYLINDER HEAD THICKNESS...88
CLEAN INJECTION NOZZLE BORES...88
CLEAN VALVE GUIDES...89
MEASURE VALVE GUIDES...89
KNURL VALVE GUIDES...90
CLEAN AND INSPECT VALVE SEATS...90
GRIND VALVE SEATS...91
REMOVE VALVE SEAT INSERTS...93
MEASURE VALVE SEAT BORE IN CYLINDER HEAD...94
INSTALL VALVE SEAT INSERTS...95
INSTALL VALVES...95
VALVE STEM SEALSGENERAL INFORMATION...96
INSTALL VALVE STEM O-RING SEALS...96
INSTALL VALVE STEM TOWER SEALS...97
INSPECT AND CLEAN VENTILATOR OUTLET HOSE...98
INSPECT AND CLEAN EXHAUST MANIFOLD...99
CLEAN AND INSPECT TOP DECK OF CYLINDER BLOCK...99
MEASURE CYLINDER LINER STANDOUT (HEIGHT ABOVE BLOCK)...100
CLEAN AND INSPECT CYLINDER HEAD CAP SCREWS...100
INSTALL CYLINDER HEAD...101
INSTALL CYLINDER HEAD CAP SCREWS...102
TORQUE-TURN METHOD FOR PROPER TORQUE...105
INSTALL ROCKER ARM ASSEMBLY...105
INSTALL ROCKER ARM COVER...107
COMPLETE FINAL ASSEMBLY...108
PERFORM ENGINE BREAK-IN...109
Cylinder Block, Liners, Pistons, and Rods ...111
SPECIAL OR ESSENTIAL TOOLS...111
OTHER MATERIAL...113
CYLINDER BLOCK, LINERS, PISTONS AND RODS SPECIFICATIONS...114
CYLINDER BLOCK, LINERS, PISTONS AND RODS SPECIFICATIONSCONTINUED...115
CYLINDER BLOCK, LINERS, PISTONS AND RODS SPECIFICATIONSCONTINUED...116
CYLINDER BLOCK, LINERS, PISTONS AND RODS SPECIFICATIONSCONTINUED...117
CYLINDER BLOCK, LINERS, PISTONS AND RODS SPECIFICATIONSCONTINUED...117
REMOVE PISTONS AND CONNECTING RODS...118
REMOVE CYLINDER LINERS...121
COMPLETE DISASSEMBLY OF CYLINDER BLOCK (IF REQUIRED)...123
PRELIMINARY LINER, PISTON AND ROD CHECKS...124
DISASSEMBLE PISTON AND ROD ASSEMBLY...125
CLEAN PISTONS...126
VISUALLY INSPECT PISTONS...127
INSTALL PISTON PIN...128
CLEAN CYLINDER LINERS...129
VISUALLY INSPECT CYLINDER LINERS...129
CHECK PISTON RING GROOVE WEAR...130
MEASURE PISTON SKIRT...131
DETERMINE PISTON-TO-LINER CLEARANCE...132
DEGLAZE CYLINDER LINERS...133
REPLACE PISTON AND LINER SETS...134
DETERMINE PISTON TYPE...135
MEASURE PISTON PROTRUSION...136
INSPECT AND MEASURE CONNECTING ROD BEARINGS...137
INSPECT ROD AND CAP...139
INSPECT PISTON PINS AND BUSHINGS...140
REMOVE PISTON PIN BUSHING...141
CLEAN AND INSPECT CONNECTING ROD PIN BORE...142
INSTALL PISTON PIN BUSHING IN CONNECTING ROD...142
INSPECT AND CLEAN CYLINDER BLOCK...143
CLEAN CYLINDER LINER O-RING BORE...144
MEASURE CYLINDER BLOCK MAIN BEARING BORE...144
MEASURE CAMSHAFT FOLLOWER BORE...145
MEASURE CAMSHAFT BEARING BORE...145
MEASURE BALANCER SHAFT BORE4-CYLINDER ENGINES...146
MEASURE CYLINDER BLOCK TOP DECK FLATNESS...147
INSPECT PISTON COOLING ORIFICES...148
MEASURE LINER FLANGE THICKNESS AND BLOCK COUNTERBORE DEPTH...148
RECHECK CYLINDER LINER STANDOUT (HEIGHT ABOVE BLOCK)...149
INSTALL STEEL BALL IN OIL PASSAGE OF SERVICE CYLINDER BLOCK...151
INSTALL CYLINDER LINER O-RINGS AND PACKINGS...152
INSTALL CYLINDER LINER...153
ASSEMBLE PISTON AND CONNECTING ROD...154
INSTALL PISTON RINGS...155
INSTALL PISTON AND CONNECTING ROD ASSEMBLY...156
CHECK ENGINE ROTATION FOR EXCESSIVE TIGHTNESS...158
MEASURE PISTON PROTRUSION...159
COMPLETE FINAL ASSEMBLY...159
Crankshaft, Main Bearings, and Flywheel ...161
SPECIAL OR ESSENTIAL TOOLS...161
CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL SPECIFICATIONS...165
CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL SPECIFICATIONSCONTINUED...166
CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL SPECIFICATIONSCONTINUED...167
CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL SPECIFICATIONSCONTINUED...167
OTHER MATERIAL...168
CRANKSHAFT AND MAIN BEARING FAILURE ANALYSIS...169
INSPECT VIBRATION DAMPER (6-CYLINDER ENGINE)...170
REMOVE PULLEY OR VIBRATION DAMPER PULLEY...171
INSTALL PULLEY OR VIBRATION DAMPER PULLEY...172
CHECKING VIBRATION DAMPER OR PULLEY (ENGINE WITH FRONT PTO)...173
REMOVING VIBRATION DAMPER OR PULLEY (ENGINE WITH FRONT PTO)...174
INSTALL VIBRATION DAMPER OR PULLEY (ENGINE WITH FRONT PTO)...175
REPLACE FRONT CRANKSHAFT OIL SEAL (WITHOUT REMOVING TIMING GEAR COVER)...176
CHECK CRANKSHAFT END PLAY...179
INSPECT FLYWHEEL...180
CHECK FLYWHEEL HOUSING FACE RUNOUT...180
CHECK FLYWHEEL FACE FLATNESS...181
REMOVE FLYWHEEL...181
REPLACE FLYWHEEL RING GEAR...182
INSTALL FLYWHEEL...183
CRANKSHAFT REAR OIL SEAL AND WEAR SLEEVE GENERAL INFORMATION...184
REMOVE TWO-PIECE CRANKSHAFT REAR OIL SEAL AND WEAR SLEEVE (WITHOUT REMOVING FLYWHEEL HOUSING)...184
REMOVE UNITIZED (NON-SEPARABLE) CRANKSHAFT REAR OIL SEAL AND WEAR SLEEVE...187
INSTALL CRANKSHAFT REAR OIL SEAL AND WEAR SLEEVE...188
REMOVE FLYWHEEL HOUSING...190
REMOVE CRANKSHAFT MAIN BEARINGS...190
CHECK MAIN BEARING CLEARANCE...191
REMOVE AND INSTALL CRANKSHAFT GEAR (CRANKSHAFT INSTALLED IN ENGINE)...192
REMOVE CRANKSHAFT...193
REMOVE CRANKSHAFT REAR WEAR SLEEVE (CRANKSHAFT REMOVED FROM ENGINE)...194
INSPECT CRANKSHAFT...195
MEASURE ASSEMBLED ID OF BEARINGS AND OD OF CRANKSHAFT JOURNAL...196
MEASURE MAIN THRUST JOURNAL WIDTH AND THRUST BEARING WIDTH...197
CRANKSHAFT GRINDING GUIDELINES...198
CRANKSHAFT GRINDING GUIDELINESCONTINUED...199
CRANKSHAFT GRINDING SPECIFICATIONS...200
MEASURE ASSEMBLED ID OF MAIN BEARING CAPS...200
INSPECT PISTON COOLING ORIFICES...202
INSTALL MAIN AND THRUST BEARING INSERTS IN BLOCK...203
INSTALL CRANKSHAFT...204
INSTALL FLYWHEEL HOUSING...206
COMPLETE FINAL ASSEMBLY...208
Camshaft, Balancer Shafts, and Timing Gear Train ...209
SPECIAL OR ESSENTIAL TOOLS...209
OTHER MATERIALS...211
CAMSHAFT, BALANCER SHAFTS, AND TIMING GEAR TRAIN SPECIFICATIONS...212
CAMSHAFT, BALANCER SHAFTS, AND TIMING GEAR TRAIN SPECIFICATIONSCONTINUED...213
CAMSHAFT, BALANCER SHAFTS, AND TIMING GEAR TRAIN SPECIFICATIONSCONTINUED...214
CAMSHAFT, BALANCER SHAFTS, AND TIMING GEAR TRAIN SPECIFICATIONSCONTINUED...215
CAMSHAFT, BALANCER SHAFTS, AND TIMING GEAR TRAIN SPECIFICATIONSCONTINUED...216
CAMSHAFT, BALANCER SHAFTS, AND TIMING GEAR TRAIN SPECIFICATIONSCONTINUED...217
AUXILIARY GEAR DRIVE SPECIFICATIONS...218
MEASURE VALVE LIFT...219
REMOVE TIMING GEAR COVER...221
REMOVE AUXILIARY DRIVE GEARS (ENGINES WITH AUXILIARY GEAR DRIVE OPTION)...222
MEASURE CAMSHAFT END PLAY...222
MEASURE BALANCER SHAFT END PLAY4-CYLINDER ENGINES...223
MEASURE TIMING GEAR BACKLASH...224
MEASURE IDLER GEAR END PLAY...225
REMOVE CAMSHAFT...225
VISUALLY INSPECT CAMSHAFT...226
MEASURE CAMSHAFT THRUST PLATE CLEARANCE...227
INSPECT AND MEASURE CAMSHAFT BEARING BORE ID AND JOURNAL OD...227
MEASURE CAMSHAFT LOBE HEIGHT...228
REMOVE AND INSTALL CAMSHAFT GEAR...228
INSPECT CAMSHAFT FOLLOWERS...229
REPLACE TACHOMETER DRIVE GEAR...230
REMOVE BALANCER SHAFTSIF EQUIPPED (4-CYLINDER ENGINES)...231
INSPECT AND MEASURE BALANCER SHAFT BUSHINGS AND JOURNALS...232
REMOVE AND INSTALL BALANCER SHAFT BUSHINGS IN BLOCK (4-CYLINDER, IF EQUIPPED)...233
INSTALL OVERSIZE BALANCER SHAFT BUSHINGS IN CYLINDER BLOCK 4239 ENGINES...234
INSPECT BALANCER SHAFT GEARS AND THRUST PLATES...235
REMOVE AND INSTALL BALANCER SHAFT GEARS...236
REMOVE BALANCER SHAFT...237
REMOVE CYLINDER BLOCK FRONT PLATE...237
MEASURE IDLER GEAR BUSHING AND SHAFT...239
REMOVE AND INSTALL IDLER GEAR BUSHINGS...239
REMOVE LOWER AND UPPER IDLER SHAFTS...240
CLEAN AND INSPECT FRONT PLATE...241
REPLACE ENGINE FRONT PLATE...242
TRANSFER FUEL INJECTION PUMP TIMING MARK ONTO REPLACEMENT FRONT PLATE...243
INSTALL IDLER SHAFT SPRING PINS...243
INSTALL UPPER IDLER SHAFT IN FRONT PLATE...244
INSTALL LOWER IDLER SHAFT IN FRONT PLATE...244
INSTALL ENGINE FRONT PLATE...246
INSTALL AND TIME BALANCER SHAFTSIF EQUIPPED (4-CYLINDER ENGINES)...247
INSTALL AND TIME CAMSHAFT AND FUEL INJECTION PUMP...250
CLEAN AND INSPECT TIMING GEAR COVER...252
INSTALL BALL BEARINGS AND DOWELS (ENGINES WITH CRANKSHAFT-DRIVEN AUXILIARY GEAR DRIVE OPTION)...252
INSTALL DRIVE GEAR (ENGINES WITH CRANKSHAFT-DRIVEN AUXILIARY GEAR DRIVE OPTION)...253
INSTALL TIMING GEAR COVER...254
INSTALL CRANKSHAFT FRONT OIL SEAL...257
INSTALL IDLER GEAR AND OUTPUT GEAR (ENGINES WITH AUXILIARY GEAR DRIVE OPTION)...258
COMPLETE FINAL ASSEMBLY...259
Lubrication System ...261
SPECIAL OR ESSENTIAL TOOLS...261
OTHER MATERIAL...262
LUBRICATION SYSTEM SPECIFICATIONS...263
LUBRICATION SYSTEM SPECIFICATIONSCONTINUED...264
LUBRICATION SYSTEM SPECIFICATIONSCONTINUED...265
ENGINE CRANKCASE OIL FILL QUANTITIES...266
ENGINE CRANKCASE OIL FILL QUANTITIESCONTINUED...267
ENGINE CRANKCASE OIL FILL QUANTITIESCONTINUED...268
ENGINE CRANKCASE OIL FILL QUANTITIESCONTINUED...269
ENGINE CRANKCASE OIL FILL QUANTITIESCONTINUED...270
ENGINE CRANKCASE OIL FILL QUANTITIESCONTINUED...271
ENGINE CRANKCASE OIL FILL QUANTITIESCONTINUED...272
ENGINE CRANKCASE OIL FILL QUANTITIESCONTINUED...273
IDENTIFY OIL COOLER TYPE3179, 4239, 6359 ENGINES...274
REMOVE, INSPECT, AND INSTALL STANDARD-FLOW OIL COOLER (3179, 4239, 6359 ENGINES)...274
REMOVE AND INSTALL HIGH-FLOW OIL COOLER (6359 ENGINES)...275
REMOVE DISTRIBUTOR BASEHIGH-FLOW OIL COOLER (6359)...276
INSPECT AND REPAIR DISTRIBUTOR BASEHIGH-FLOW OIL COOLER (6359)...276
INSTALL DISTRIBUTOR BASEHIGH-FLOW OIL COOLER (6359)...277
REMOVE OIL COOLER (4276, 6414 ENGINES)...277
REPAIR OIL COOLER (4276, 6414 ENGINES)...277
INSTALL OIL COOLER (4276, 6414 ENGINES)...278
REMOVE AND INSPECT OIL BYPASS VALVE (3179, 4239, 6359 ENGINES)...279
MEASURE OIL BYPASS VALVE LENGTH AND CYLINDER BLOCK BORE...280
INSTALL OIL BYPASS VALVE (3179, 4239, 6359 ENGINES)...280
REMOVE AND INSTALL OIL COOLER/FILTER BYPASS VALVE (4276, 6414 ENGINES)...281
REMOVE AND INSTALL OIL PRESSURE REGULATING VALVE AND SEAT (3179, 4239, 6359 ENGINES)...281
REMOVE, INSPECT, AND INSTALL OIL PRESSURE REGULATING VALVE (4276, 6414 ENGINES)...282
REPAIR OIL PRESSURE REGULATING VALVE (4276, 6414 ENGINES)...283
REMOVE OIL FILTER ADAPTER (3179, 4239, 6359 ENGINES)...284
INSTALL OIL FILTER ADAPTER (3179, 4239, 6359 ENGINES)...285
REMOVE, INSTALL, AND ADJUST DIPSTICK TUBE...286
GENERAL OIL PUMP INFORMATION...286
REPLACE OIL PUMP PICK-UP TUBE ASSEMBLY...287
REMOVE STANDARD CAPACITY OIL PUMP...287
INSPECT AND MEASURE CLEARANCES (STANDARD CAPACITY OIL PUMP)...288
COMPLETE STANDARD CAPACITY OIL PUMP DISASSEMBLY...289
ASSEMBLE STANDARD CAPACITY OIL PUMP...290
INSTALL STANDARD CAPACITY OIL PUMP...291
REMOVE HIGH CAPACITY OIL PUMP...293
INSPECT AND MEASURE CLEARANCES (HIGH CAPACITY OIL PUMP)...294
COMPLETE HIGH CAPACITY OIL PUMP DISASSEMBLY...295
ASSEMBLE HIGH CAPACITY OIL PUMP...296
INSTALL HIGH CAPACITY OIL PUMP...296
INSTALL OIL PAN...298
Cooling System ...301
SPECIAL OR ESSENTIAL TOOLS...301
SERVICE EQUIPMENT AND TOOLS...301
OTHER MATERIAL...302
COOLING SYSTEM SPECIFICATIONS...303
COOLING SYSTEM SPECIFICATIONSCONTINUED...304
COOLING SYSTEM SPECIFICATIONSCONTINUED...305
COOLING SYSTEM SPECIFICATIONSCONTINUED...306
COOLING SYSTEM SPECIFICATIONSCONTINUED...307
COOLING SYSTEM SPECIFICATIONSCONTINUED...308
COOLING SYSTEM SPECIFICATIONSCONTINUED...309
REMOVE, TEST, AND INSTALL THERMOSTATS...310
REMOVE AND INSTALL THERMOSTAT HOUSING/WATER MANIFOLD...311
GENERAL WATER PUMP INFORMATION...313
REMOVE LOW FLOW (STANDARD DUTY) WATER PUMP...314
DISASSEMBLE LOW FLOW (STANDARD DUTY) WATER PUMP...315
INSPECT AND CLEAN LOW FLOW (STANDARD DUTY) WATER PUMP PARTS...317
ASSEMBLE LOW FLOW (STANDARD DUTY) WATER PUMP...318
INSTALL LOW FLOW (STANDARD DUTY) WATER PUMP...321
REMOVE HIGH FLOW (HEAVY-DUTY) WATER PUMP...322
DISASSEMBLE HIGH FLOW (HEAVY-DUTY) WATER PUMP...322
INSPECT AND CLEAN HIGH FLOW (HEAVY-DUTY) WATER PUMP PARTS...326
ASSEMBLE HIGH FLOW (HEAVY-DUTY) WATER PUMP...327
CHECKING WATER PUMP CAP SCREW PROTRUSION...331
INSTALL HIGH FLOW (HEAVY-DUTY) WATER PUMP...333
INSPECT AND INSTALL FAN BLADE ASSEMBLY...334
REMOVE COOLANT HEATERIF EQUIPPED...334
INSTALL COOLANT HEATERIF EQUIPPED...335
Air Intake and Exhaust System ...337
AIR INTAKE AND EXHAUST SYSTEM SPECIFICATIONS...337
AIR INTAKE AND EXHAUST SYSTEM SPECIFICATIONSCONTINUED...338
EXTENDING TURBOCHARGER LIFE...339
REMOVE TURBOCHARGER4239T AND 6359T & A ENGINES (AIRESEARCH/GARRETT AND K.K.K.*)...341
TURBOCHARGER FAILURE ANALYSIS...343
TURBOCHARGER SEVEN-STEP INSPECTION...345
PERFORM RADIAL BEARING CLEARANCE TESTK.K.K...349
PERFORM AXIAL BEARING END PLAY BEARING TESTK.K.K...350
PERFORM RADIAL BEARING CLEARANCE TESTAIRESEARCH/GARRETT...350
PERFORM AXIAL BEARING END PLAY TESTAIRESEARCH/GARRETT...351
REPAIR TURBOCHARGER...352
DISASSEMBLE AND INSPECT TURBOCHARGER...353
REPLACE CENTER HOUSING AND ROTATING ASSEMBLY...354
PRELUBE TURBOCHARGER...355
INSTALL K.K.K. AND AIRESEARCH/GARRETT TURBOCHARGER...355
TURBOCHARGER BREAK-IN...357
REMOVE, INSPECT, AND INSTALL INTAKE MANIFOLD (D AND T ENGINES)...358
REMOVE CROSS-OVER TUBE ASSEMBLYIF EQUIPPED...359
INSPECT AND REPAIR CROSS-OVER TUBE ASSEMBLYIF EQUIPPED...359
INSTALL CROSS-OVER TUBE ASSEMBLYIF EQUIPPED...360
REMOVE AFTERCOOLER AND INTAKE MANIFOLD (6359A)...361
INSPECT AND REPAIR AFTERCOOLER (6359A)...362
INSPECT AND REPAIR INTAKE MANIFOLD (6359A)...362
INSTALL INTAKE MANIFOLD AND AFTERCOOLER (6359A)...363
REMOVE, INSPECT AND INSTALL EXHAUST MANIFOLD...364
Fuel System ...365
SPECIAL OR ESSENTIAL TOOLS...365
FUEL SYSTEM SPECIFICATIONS...369
FUEL SYSTEM SPECIFICATIONSCONTINUED...370
FUEL SYSTEM SPECIFICATIONSCONTINUED...371
FUEL SYSTEM SPECIFICATIONSCONTINUED...372
RELIEVE FUEL SYSTEM PRESSURE...372
REPLACE FUEL FILTER...373
REMOVE FUEL SUPPLY PUMP...374
BENCH TEST FUEL SUPPLY PUMP...375
REPAIR SOFABEX AND AC FUEL SUPPLY PUMPS...377
REPAIR CORONA FUEL SUPPLY PUMP...377
INSTALL FUEL SUPPLY PUMP...379
FUEL INJECTION PUMP TIMING...379
FUEL INJECTION PUMPGENERAL INFORMATION...380
REMOVE ROTO DIESEL/LUCAS CAV FUEL INJECTION PUMP...381
REPAIR ROTO DIESEL/LUCAS CAV FUEL INJECTION PUMP...384
INSTALL ROTO DIESEL/LUCAS CAV FUEL INJECTION PUMP...385
TIMING ROTO DIESEL/LUCAS CAV INJECTION PUMP WHEN NEW SERVICE FRONT PLATE HAS BEEN INSTALLED...388
REMOVE STANADYNE INJECTION PUMPMODEL JDB AND DB2 WITH NON-RETAINED DRIVE SHAFT...391
REMOVE STANADYNE MODEL JDB AND DB2 INJECTION PUMP WITH NON-RETAINED DRIVE SHAFT FROM ENGINE...392
REPAIR STANADYNE MODEL JDB AND DB2 FUEL INJECTION PUMP WITH NON-RETAINED DRIVE SHAFT...394
INSTALL NON-RETAINED DRIVE SHAFT IN STANADYNE MODEL JDB AND DB2 INJECTION PUMP (IF REMOVED FROM ENGINE)...394
INSTALL STANADYNE MODEL JDB AND DB2 INJECTION PUMP WITH NON-RETAINED DRIVE SHAFT...395
REMOVE STANADYNE MODEL DB2 (WITH RETAINED DRIVE SHAFT) AND DB4 INJECTION PUMP...398
INSPECT INJECTION PUMP DRIVE GEAR I.D. AND SHAFT O.D...402
REPAIR STANADYNE FUEL INJECTION PUMP...402
INSTALL STANADYNE MODEL DB2 (WITH RETAINED DRIVE SHAFT) AND DB4 INJECTION PUMP...403
REMOVE STANADYNE MODEL DM4 FUEL INJECTION PUMP...406
REPAIR STANADYNE FUEL INJECTION PUMP...407
INSTALL STANADYNE MODEL DM4 FUEL INJECTION PUMP...408
REPLACE ENGINE FRONT PLATE...410
TRANSFER FUEL INJECTION PUMP TIMING MARK ONTO REPLACEMENT FRONT PLATE...411
ANEROID REPLACEMENT...412
ANEROID FIELD ADJUSTMENT...412
ANEROID WORKSHOP ADJUSTMENT...413
REMOVE FUEL INJECTION NOZZLES...414
CLEAN FUEL INJECTION NOZZLE BORE...415
CLEAN INJECTION NOZZLES...416
DIAGNOSE INJECTION NOZZLE MALFUNCTION...417
DIAGNOSE INJECTION NOZZLE MALFUNCTIONCONTINUED...418
TEST INJECTION NOZZLES...419
DISASSEMBLE INJECTION NOZZLES...422
INSPECT AND CLEAN NOZZLE BODY...423
INSPECT AND CLEAN VALVE AND VALVE SEAT...424
INSPECT VALVE ADJUSTING MECHANISM...426
ASSEMBLE INJECTION NOZZLES...427
ADJUST FUEL INJECTION NOZZLES...427
INSTALL SEALS ON INJECTION NOZZLE...430
INSTALL INJECTION NOZZLES...430
REPAIR LEAK-OFF LINE ASSEMBLY...431
Engine Tune-Up and Break-In ...433
SPECIAL OR ESSENTIAL TOOLS...433
EFFECTS OF ALTITUDE AND TEMPERATURE ON ENGINE PERFORMANCE...433
PRELIMINARY ENGINE TESTING...434
GENERAL TUNE-UP RECOMMENDATIONS...435
DYNAMOMETER TEST...436
DYNAMOMETER TEST SPECIFICATIONSSARAN BUILT ENGINES...437
DYNAMOMETER TEST SPECIFICATIONSSARAN BUILT ENGINESCONTINUED...438
DYNAMOMETER TEST SPECIFICATIONSDUBUQUE BUILT ENGINES...439
DYNAMOMETER TEST SPECIFICATIONSDUBUQUE BUILT ENGINESCONTINUED...440
ENGINE BREAK-IN GUIDELINES...441
PERFORM ENGINE BREAK-IN...442
CHECK CRANKCASE VENTILATION SYSTEM...443
CHECK AIR INTAKE SYSTEM...443
CHECK EXHAUST SYSTEM...443
CHECK AND SERVICE COOLING SYSTEM...444
CHECK ELECTRICAL SYSTEM...445
Engine System Operation and Tests ...447
SPECIAL OR ESSENTIAL TOOLS...447
ENGINE TEST SPECIFICATIONS...449
ENGINESECTIONAL VIEW...450
GENERAL ENGINE DESCRIPTION...451
HOW THE LUBRICATION SYSTEM WORKS (4239 ENGINE WITH TURBOCHARGER SHOWN)...452
HOW THE LUBRICATION SYSTEM WORKSCONTINUED...453
OIL COOLER OPERATION4276 AND 6414 ENGINES...454
HOW THE COOLING SYSTEM WORKSENGINES WITH STANDARD-FLOW OIL COOLER...455
HOW THE COOLING SYSTEM WORKSENGINES WITH HIGH-FLOW OIL COOLER...456
HOW THE CRANKSHAFT GEAR-DRIVEN AUXILIARY DRIVE WORKS...457
HEAD GASKET JOINT CONSTRUCTION AND OPERATION...459
DIAGNOSING HEAD GASKET JOINT FAILURES...460
HEAD GASKET INSPECTION AND REPAIR SEQUENCE...463
DIAGNOSING ENGINE MALFUNCTIONS...465
DIAGNOSING ENGINE MALFUNCTIONSCONTINUED...466
DIAGNOSING ENGINE MALFUNCTIONSCONTINUED...467
TEST ENGINE COMPRESSION PRESSURE...468
CHECK ENGINE OIL PRESSURE...469
MEASURE ENGINE CRANKCASE PRESSURE (BLOW-BY)...470
PRESSURE TEST COOLING SYSTEM AND RADIATOR CAP...471
INSPECT THERMOSTAT AND TEST OPENING TEMPERATURE...472
Air Intake System Operation and Tests ...473
SPECIAL OR ESSENTIAL TOOLS...473
AIR INTAKE AND EXHAUST SYSTEM TEST SPECIFICATIONS...474
DIAGNOSING AIR INTAKE MALFUNCTIONS...475
HOW THE AIR INTAKE AND EXHAUST SYSTEM WORKS...476
AIR CLEANER OPERATION...477
DIAGNOSING TURBOCHARGER MALFUNCTIONS...478
HOW THE TURBOCHARGER IS LUBRICATED...479
TURBOCHARGER OPERATION...479
HOW THE AFTERCOOLER WORKS...480
CHECK INTAKE MANIFOLD PRESSURE (TURBO BOOST)...481
AIR FILTER RESTRICTION INDICATOR SWITCH TEST...482
Fuel System Operation and Tests ...483
SPECIAL OR ESSENTIAL TOOLS...483
FUEL SYSTEM TEST SPECIFICATIONS...485
FUEL SYSTEM TEST SPECIFICATIONSCONTINUED...485
SARAN FUEL INJECTION PUMP SPECIFICATIONS*...486
SARAN FUEL INJECTION PUMP SPECIFICATIONSCONTINUED*...487
SARAN FUEL INJECTION PUMP SPECIFICATIONSCONTINUED*...488
DUBUQUE FUEL INJECTION PUMP SPECIFICATIONS*...489
DUBUQUE FUEL INJECTION PUMP SPECIFICATIONS*CONTINUED...490
FUEL INJECTION PUMP TIMING...491
CHECK AND ADJUST INJECTION PUMP DYNAMIC TIMING USING JT07158 TIME TRAC KIT...491
CHECK ROTO DIESEL/LUCAS CAV INJECTION PUMP STATIC TIMING...499
CHECK STANADYNE DB2 PUMP STATIC TIMING...502
CHECK STANADYNE JDB INJECTION PUMP STATIC TIMING...503
CHECK STANADYNE DM4 INJECTION PUMP STATIC TIMING...504
FUEL SYSTEM OPERATION...506
DIAGNOSE FUEL SYSTEM MALFUNCTIONS...507
DIAGNOSE FUEL SYSTEM MALFUNCTIONSCONTINUED...508
DIAGNOSE FUEL SYSTEM MALFUNCTIONSCONTINUED...509
DIAGNOSE FUEL SYSTEM MALFUNCTIONSCONTINUED...510
FUEL SUPPLY PUMP OPERATIONIF EQUIPPED...511
DIAGNOSE SUPPLY PUMP MALFUNCTION...512
MEASURE FUEL SUPPLY PUMP PRESSUREIF EQUIPPED...513
RECTANGULAR FINAL FUEL FILTER OPERATION...514
BLEED THE FUEL SYSTEM...515
ROTO DIESEL/LUCAS CAV FUEL INJECTION PUMP OPERATION...518
STANADYNE DM4 FUEL INJECTION PUMP OPERATION...520
STANADYNE DB2/DB4 FUEL INJECTION PUMP OPERATION...522
DIAGNOSE FUEL INJECTION PUMP MALFUNCTIONS...524
CHECK AND ADJUST ENGINE SPEEDS ON LUCAS CAV PUMP...525
ADJUST VARIABLE SPEED ON GENERATOR SET ENGINES (LUCAS CAV PUMPS ONLY)...526
CHECK AND ADJUST ENGINE SPEEDS ON STANADYNE PUMP...527
ADJUST VARIABLE SPEED ON GENERATOR SET ENGINESSTANADYNE INJECTION PUMPS ONLY...528
CHANGING GEN SET ENGINE RATED SPEED FROM 1800 RPM TO 1500 RPMSTANADYNE INJECTION PUMPS ONLY...529
FUEL INJECTION NOZZLESGENERAL INFORMATION AND OPERATION...531
DIAGNOSE MALFUNCTIONFUEL INJECTION NOZZLE...532
TEST FUEL INJECTION NOZZLES (ENGINE RUNNING)...533
FUEL DRAIN BACK TEST PROCEDURE...533
Dealer Fabricated Tools ...535
HOW TO MAKE TOOLS...535
DFRG2INJECTION PUMP FRONT PLATE TIMING MARK TRANSFER TOOL...535
DFRG3CYLINDER LINER HOLDING FIXTURE...536
Index...0
A...53
Adapters, 300 series ...53
Install ...53
Aftercooler ...362
6359A, inspect and repair ...362
Aftercooler (6359A) ...362
Inspect and repair ...362
Aftercooler (6359A), intake manifold ...363
Install ...363
Aftercooler and intake manifold (6359A)...361
Remove ...361
Air cleaner ...477
Operation ...477
Air cleaner operation ...477
Air intake and exhaust system ...474
Test specifications ...474
Air intake system ...443
Check ...443
Diagnostics ...475
General information ...476
Inspect ...443
Altitude compensation ...433
Aneroid ...412
Field adjustment ...412
Replacement ...412
Workshop adjustment ...413
Auxiliary drive ...252
Bearings ...252
Dowels ...252
Drive gear ...253
Gears, remove ...222
General description ...457
Idler gear ...258
Output gear ...258
Axial bearing end play test ...351
AiResearch/Garrett, perform ...351
Axial bearing end play testK.K.K. ...350
Perform ...350
B...232
Balancer shaft ...232
Bushings, inspect ...232
Bushings, measure ...232
Gears, install ...236
Gears, remove ...236
Install ...247
Install and time ...247
Journals, inspect and measure ...232
Remove ...231
Remove ...237
Time ...247
Balancer shaft bore ...146
Measure ...146
Balancer shaft bushings ...233
Remove and install ...233
Balancer shaft end play ...223
Measure ...223
Balancer shaft gears ...236
Remove and install ...236
Balancer shaft gears and thrust plate ...235
Inspect ...235
Bearing ...203
Main, install ...203
Bearings ...252
Auxiliary gear drive ...252
Failure analysis ...169
Main thrust, clearance ...197
Bearings, crankshaft ...190
Main, remove ...190
Block, cylinder ...143
Clean ...143
Inspect ...143
Liner O-ring bore, clean ...144
Top deck, clean and inspect ...99
Blow-by, crankcase, measure ...470
Break-In Engine Oil ...38
Break-in, engine ...441
Guidelines ...441
Bushings ...232
Balancer shaft, inspect ...232
Balancer shaft, measure ...232
Idler gear, install ...239
Idler gear, remove ...239
Inspect ...140
C...227
Camshaft ...227
End play ...227
Followers, inspect ...229
Gear, install ...228
Gear, remove ...228
Inspect ...226
Remove ...225
Thrust plate, clearance ...227
Camshaft and fuel injection pump ...250
Install and time ...250
Camshaft bearing bore ...145
Measure ...145
Camshaft bearing bore ID ...227
Inspect and measure ...227
Camshaft end play ...222
Measure ...222
Camshaft follower ...145
Bore, measure ...145
Camshaft follower bore ...145
Measure ...145
Camshaft journal OD ...227
Inspect and measure ...227
Camshaft lobe height ...228
Measure ...228
Cap screw protrusion, water pump ...331
Check ...331
Composite material timing gear cover ...256
Installation ...256
Connecting rod ...154
Assemble ...154
Cap, inspect ...139
Inspect ...139
Remove ...118
Connecting rod bearings ...137
Inspect and measure ...137
Connecting rod pin bore ...142
Clean and inspect ...142
Connecting rods ...124
Failure analysis ...124
Preliminary checks ...124
Coolant ...335
Heater, install ...335
Heater, remove ...334
Tropical ...48
Coolant, engine ...47
Additives ...47
Disposal ...50
Products ...44
Requirements ...42
Specifications ...45
Cooling system ...444
Check ...444
Flush and service ...49
General description ...455
General description ...456
Pressure test ...471
Service ...444
Corona fuel supply pump ...377
Repair ...377
Counterbore depth ...148
Measure ...148
Crankcase ...470
Blow-by, measure ...470
Crankcase ventilation system ...443
Check ...443
Crankshaft ...197
End play ...197
End play, check ...179
Front oil seal, install ...257
Grinding guidelines ...198
Grinding guidelines ...199
Inspect ...195
Install ...204
Pulley, install ...172
Pulley, remove ...171
Rear oil seal, general information ...184
Rear oil seal, two-piece, install ...188
Rear oil seal, two-piece, remove ...184
Rear oil seal, unitized, install ...188
Rear oil seal, unitized, remove ...187
Rear wear sleeve, remove ...194
Remove ...193
Thrust bearing, clearance ...197
5/6-piece thrust bearing inst. ...203
Crankshaft end play ...179
Check ...179
Crankshaft gear ...192
Remove and install ...192
Crankshaft main bearings ...190
Remove ...190
Cross-over tube assembly ...359
Inspect and repair ...359
Install ...360
Remove ...359
Cylinder block ...143
Clean ...143
Inspect ...143
Inspect and clean ...143
Liner O-ring bore, clean ...144
Measure main bearing bore ...144
Top deck, clean and inspect ...99
Cylinder block bore ...280
Measure ...280
Cylinder block front plate ...237
Remove ...237
Cylinder block top deck ...147
Measure flatness ...147
Cylinder head ...100
Cap screws, clean and inspect ...100
Cap screws, TORQUE-TURN method ...105
Check valve recess ...83
Clean valves ...85
Injection nozzle bores ...88
Inspect and clean ...87
Inspect rotators and wear caps ...84
Install ...101
Make preliminary valve checks ...82
Measure thickness ...88
Push rods, clean and inspect ...81
Remove ...76
Cylinder head cap screws ...100
Clean and inspect ...100
Cylinder head gasket ...460
Failure diagnostics ...460
Joint construction ...459
Joint operation ...459
Cylinder head, valve seat bore ...94
Measure ...94
Cylinder liner ...129
Clean ...129
Deglaze ...133
Inspect ...129
Install ...153
O-ring bore, clean ...144
O-rings ...152
Packings ...152
Recheck standout ...149
Cylinder liner O-rings and packings ...152
Install ...152
Cylinder liner standout ...100
Measure ...100
Cylinder liners ...124
Failure analysis ...124
Preliminary checks ...124
Remove ...121
D...170
Damper, vibration ...170
Inspect ...170
Install ...172
Remove ...171
Diagnostics ...465
Engine ...465
Head gasket failure ...460
Diesel Engine Oil ...39
Diesel fuel ...37
Diesel fuel, lubricity ...37
Dipstick tube ...286
Adjust ...286
Install ...286
Remove ...286
Dynamometer test ...436
Procedure ...436
Dynamometer test specifications-Saran ...437
Dynamometer test specificationsDubuque ...439
E...445
Electrical system ...445
Check ...445
Service ...445
Elevations ...433
Compensation guideline ...433
Engine ...29
Application chart ...29
Assembly sequence ...60
Blow-by, measure ...470
Break-in guidelines ...441
Check for excessive tightness ...158
Cleaning ...54
Crankcase oil fill quantities ...266
Diagnostics ...465
Disassembly sequence ...57
Dynamometer test ...436
General description ...451
Lifting procedure ...53
Model designation ...25
Mount on repair stand ...55
Mounted on repair stand ...56
Preliminary testing ...434
Repair stand ...51
Sectional view ...450
Sectional view ...450
Serial number plate ...27
Speeds, Gen set, change ...529
Test specifications ...449
Engine break-in ...109
Perform ...109
Perform ...442
Engine compression pressure ...468
Test ...468
Engine coolant ...47
Additives ...47
Disposal ...50
Products ...44
Requirements ...42
Specifications ...45
Engine front plate ...246
Install ...246
Replace ...242
Replace ...410
Engine oil ...38
Break-In ...38
Diesel ...39
Engine speeds on Lucas CAV pump ...525
Check and adjust ...525
Engine speeds on Stanadyne pump ...527
Check and adjust ...527
Exhaust manifold ...99
Clean and inspect ...99
Remove, inspect and install ...364
Exhaust system ...443
Check ...443
General information ...476
Inspect ...443
Exhaust system, air intake and ...474
Test specifications ...474
F...535
Fabricated tools ...535
Failure analysis ...460
Head gasket ...460
Fan blade assembly ...334
Inspect ...334
Inspect and install ...334
Install ...334
Filter, fuel ...373
Replace ...373
Final assembly ...208
Complete ...208
Final fuel filter, rectangular ...514
Operation ...514
Flywheel ...181
Face flatness ...181
Inspect ...180
Remove ...181
Ring gear, replace ...182
Flywheel housing ...180
Face runout ...180
Install ...206
Remove ...190
Followers, camshaft ...229
Inspect ...229
Front plate ...241
Clean ...241
Clean and inspect ...241
Inspect ...241
Remove ...237
Timing mark, transfer ...243
Timing mark, transfer ...411
Front plate, engine ...410
Replace ...410
Fuel ...373
Filter, replace ...373
Fuel drain back test ...533
Fuel filter ...373
Replace ...373
Fuel filter, final ...514
Operation ...514
Fuel injection nozzle ...532
Diagnose malfunctions ...532
General information ...531
General operation ...531
Fuel injection nozzle bore ...415
Clean ...415
Fuel injection nozzles ...427
Adjustment ...427
Diagnosis ...417
Disassembly ...422
Remove ...414
Test, engine running ...533
Fuel injection pump ...412
Aneroid field adjustment ...412
Aneroid workshop adjustment ...413
Diagnose malfunctions ...524
Information ...380
Install ...385
Install, Stanadyne DM4 ...408
Operation ...518
Remove ...381
Remove, Stanadyne DM4 ...406
Repair ...384
Repair, Stanadyne ...402
Repair, Stanadyne ...407
Timing ...379
Timing ...491
Fuel injection pump, Stanadyne DB2/DB4 ...522
Operation ...522
Fuel injection pump, Stanadyne DM4 ...520
Operation ...520
Fuel injection pumpDubuque ...489
Specifications ...489
Fuel injection pumpSaran ...486
Specifications ...486
Fuel supply pump ...375
Bench test ...375
Install ...379
Operation ...511
Operation ...511
Remove ...374
Fuel supply pump pressure ...513
Measure ...513
Fuel system ...515
Bleed ...515
Diagnose malfunctions ...507
Fuel drain back test ...533
Operation ...506
Test specifications ...485
Fuel, diesel
Fuel, diesel, lubricity
G...258
Gear ...258
Auxiliary drive, idler gear ...258
Auxiliary drive, output gear ...258
Auxiliary drive, remove ...222
Balancer shaft, install ...236
Balancer shaft, remove ...236
Camshaft, remove and install ...228
Idler, bushings, install ...239
Idler, bushings, remove ...239
Tachometer drive, replace ...230
Gear drive, auxiliary ...252
Bearings ...252
Dowels ...252
Drive gear ...253
General description ...457
Gear, crankshaft ...192
Remove and install ...192
Gen set engine speeds ...529
Change, from 18001500 RPM ...529
General information ...313
Water pump ...313
Generator set engines ...528
Adjust variable speed ...528
Generator set variable speed ...526
Adjust ...526
Grease ...41
Extreme pressure and multipurpose ...41
H...100
Head, cylinder ...100
Cap screws, clean and inspect ...100
Cap screws, TORQUE-TURN method ...105
Gasket failure diagnostics ...460
Gasket joint construction ...459
Gasket joint operation ...459
Injection nozzle bores ...88
Inspect and clean ...87
Inspect rotators and wear caps ...84
Make preliminary valve checks ...82
Push rods, clean and inspect ...81
Heater, coolant ...335
Install ...335
Remove ...334
High flow (heavy-duty) water pump ...327
Assemble ...327
Disassemble ...322
Inspect and clean parts ...326
Install ...333
Remove ...322
Housing, flywheel ...180
Face runout ...180
How the aftercooler works ...480
I...239
Idler gear ...239
Bushings, install ...239
Bushings, remove ...239
Idler gear bushing and shaft ...239
Remove ...239
Idler gear bushings ...239
Remove and install ...239
Idler gear end play ...225
Measure ...225
Idler shaft spring pins ...243
Install ...243
Idler shaft, lower ...244
Install in front plate ...244
Idler shafts, lower and upper ...240
Remove ...240
Inch torque values ...23
Injection nozzle ...427
Adjustment ...427
Clean ...416
Disassemble ...422
Disassembly ...422
Install ...430
Remove ...414
Test ...419
Test ...419
Injection nozzle bores ...88
Clean ...88
Injection nozzle seal ...430
Install ...430
Injection nozzles ...427
Assemble ...427
Diagnosis ...417
Test, engine running ...533
Injection pump ...491
Dynamic timing ...491
Timing ...388
Injection pump static timing ...499
Check ...499
Inserts in block, main bearing ...203
Install ...203
Intake manifold ...358
Remove, inspect, and install ...358
6359A, inspect and repair ...362
Intake manifold ("D" and "T" engines) ...358
Remove, inspect, and install ...358
Intake manifold (6359A) ...362
Inspect and repair ...362
Intake manifold (6359A), aftercooler ...361
Remove ...361
Intake manifold and aftercooler ...363
6359A, install ...363
Intake manifold and aftercooler (6359A)...363
Install ...363
Intake manifold pressure (turbo boost) ...481
Check ...481
Intake, air system ...443
Inspect ...443
J...232
Journals, balancer shaft ...232
Inspect and measure ...232
L...431
Leak-off line assembly ...431
Repair ...431
Liner flange thickness ...148
Measure ...148
Liner, cylinder ...129
Clean ...129
Deglaze ...133
Inspect ...129
Install ...153
O-rings ...152
Packings ...152
Liners, cylinder ...124
Failure analysis ...124
Preliminary checks ...124
Low flow (standard duty) water pump ...318
Assemble ...318
Disassemble ...315
Inspect and clean parts ...317
Install ...321
Remove ...314
Lubricant ...40
Alternative ...40
Synthetic ...40
Lubrication system ...452
General description ...452
Lucas CAV pump, engine speeds ...525
Check and adjust ...525
M...200
Main Bearing Cap ID ...200
Measure ...200
Main bearing inserts in block ...203
Install ...203
Main thrust bearing ...197
Clearance ...197
Make preliminary valve checks ...82
Manifold, exhaust ...99
Clean and inspect ...99
Remove, inspect and install ...364
Manifold, intake ...358
Remove, inspect, and install ...358
Mechanical tachometer ...230
Drive gear, replace ...230
Metric torque values ...24
N...423
Nozzle body ...423
Inspect and clean ...423
Inspect and clean ...423
Nozzle valve ...424
Inspect and clean ...424
Nozzle valve seat ...424
Inspect and clean ...424
Nozzle, injection ...416
Clean ...416
Nozzles, fuel injection ...417
Diagnosis ...417
Test, engine running ...533
O...280
Oil bypass valve (3179, 4239, 6359) ...280
Install ...280
Remove and inspect ...279
Oil bypass valve length ...280
Measure ...280
Oil cooler ...454
Operation ...454
Oil cooler (4276, 6414 engines) ...278
Install ...278
Remove ...277
Repair ...277
Oil cooler/filter bypass valve ...281
Remove and install ...281
Oil cooler, distributor basehigh-flow ...276
Inspect and repair ...276
Install ...277
Remove ...276
Oil cooler, high-flow (6359 engines) ...275
Remove and install ...275
Oil cooler, standard-flow ...274
Remove, inspect and install ...274
Oil cooler3719, 4139 and 6359 engines ...274
Identification ...274
Oil filter adapter (3179, 4239, 6359) ...285
Install ...285
Remove ...284
Oil pan ...298
Install ...298
Oil pressure regulating valve ...282
Remove, inspect, and install ...282
Repair ...283
Oil pressure regulating valve and seat ...281
Remove and install ...281
Oil pump ...290
Assemble ...290
General information ...286
High capacity, assemble ...296
High capacity, clearances ...294
High capacity, disassemble ...295
High capacity, inspect ...294
High capacity, install ...296
Standard capacity, clearances ...288
Standard capacity, disassemble ...289
Standard capacity, install ...291
Standard capacity, remove ...287
Oil pump pick-up tube ...287
Replacement (on standard oil pump) ...287
Oil pump, high capacity ...293
Remove ...293
Oil pump, standard capacity ...289
Disassemble ...289
Install ...291
Oil seal, crankshaft rear ...184
General information ...184
Two-piece, install ...188
Two-piece, remove ...184
Unitized, install ...188
Oil seal, front crankshaft ...257
Install ...257
Replace ...176
Oil seal, rear crankshaft ...187
Unitized, remove ...187
Orifices, piston cooling ...202
Inspect ...202
Oversize balancer shaft bushings ...234
Install ...234
P...135
Piston ...135
Determine type ...135
Measure protrusion ...136
Measure skirt ...131
Piston and connecting rod assembly ...156
Install ...156
Piston and liner sets ...134
Replace ...134
Piston and rod assembly ...125
Disassemble ...125
Piston cooling orifices ...148
Inspect ...148
Inspect ...202
Piston pin ...128
Install ...128
Install ...154
Piston pin bearing ...142
Install in connecting rod ...142
Piston pin bushing ...141
Remove ...141
Piston pins ...140
Inspect ...140
Piston pins and bushings ...140
Inspect ...140
Piston protrusion ...159
Measure ...159
Piston ring groove wear ...130
Check ...130
Piston rings ...155
Install ...155
Pistons ...154
Assemble ...154
Clean ...126
Failure analysis ...124
Preliminary checks ...124
Remove ...118
Visually inspect ...127
Pistons and connecting rods ...118
Remove ...118
Plate, front ...241
Clean ...241
Inspect ...241
Remove ...237
Pulley ...172
Install ...172
Install ...175
Remove ...171
Pulley for front PTO ...173
Inspection ...173
Removal ...174
Pump, Corona fuel supply ...377
Repair ...377
Pump, fuel injection ...380
Information ...380
Timing ...379
Timing ...491
Pump, fuel supply ...375
Bench test ...375
Install ...379
Remove ...374
Pump, oil ...296
High capacity, assemble ...296
High capacity, clearances ...294
High capacity, disassemble ...295
High capacity, inspect ...294
High capacity, install ...296
Standard capacity, clearances ...288
Standard capacity, disassemble ...289
Standard capacity, install ...291
Standard capacity, remove ...287
Pump, water ...313
General information ...313
Pumps, Sofabex and AC fuel supply ...377
Repair ...377
Push rods ...81
Clean and inspect ...81
R...350
Radial bearing clearance test ...350
AiResearch/Garrett, perform ...350
Radial bearing clearance testK.K.K. ...349
Perform ...349
Radiator cap ...471
Pressure test ...471
Rectangular final fuel filter ...514
Operation ...514
Ring gear, flywheel, replace ...182
Rings, piston ...155
Install ...155
Rocker arm assembly ...105
Install ...105
Rocker arm cover ...107
Install ...107
Rocker arms ...81
Assemble on shaft ...81
Rod and cap ...139
Inspect ...139
Rods, connecting ...124
Failure analysis ...124
Preliminary checks ...124
Roto diesel/Lucas CAV fuel inj. pump ...518
Operation ...518
Roto diesel/Lucas CAV injection pump ...499
Static timing, check ...499
S...257
Seal, crankshaft front oil ...257
Install ...257
Seal, crankshaft rear oil ...184
General information ...184
Two-piece, install ...188
Two-piece, remove ...184
Unitized, install ...188
Unitized, remove ...187
Seal, injection nozzle ...430
Install ...430
Seals, valve stem ...96
General information ...96
Shaft ...247
Balancer, install ...247
Balancer, remove ...231
Balancer, time ...247
Sofabex and AC fuel supply pumps ...377
Repair ...377
Specifications ...45
Coolant ...45
Engine test ...449
Fuel system ...485
Stanadyne DB2 and DB4 injection pump ...403
Install ...403
Remove ...398
Stanadyne DB2 injection pump ...503
Static timing, check ...503
Stanadyne DB2 pump static timing ...502
Check ...502
Stanadyne DB2/DB4 fuel injection pump ...522
Operation ...522
Stanadyne DM4 fuel injection pump ...520
Operation ...520
Stanadyne DM4 inj. pump static timing ...504
Check ...504
Stanadyne JDB & DB2 fuel injection pump...394
Repair ...394
Stanadyne JDB and DB2 injection pump ...391
Remove ...391
Remove ...392
Stanadyne pump, engine speed ...527
Check and adjust ...527
Static timing, injection pump ...503
Check ...503
Static timing, Stanadyne DB2 pump ...502
Check ...502
Static timing, Stanadyne DM4 inj. pump ...504
Check ...504
Steel ball ...151
Install in oil passage ...151
Supply pump ...512
Diagnose malfunction ...512
Synthetic Lubricants ...40
T...230
Tachometer drive gear ...230
Replace ...230
Temperature compensation ...433
Thermostat ...310
Install ...310
Remove ...310
Remove, test, and install ...310
Test ...310
Thermostat housing/water manifold ...311
Remove and install ...311
Thermostats ...472
Inspect and test ...472
Thrust plate ...227
Camshaft, clearance ...227
Timing gear backlash ...224
Measure ...224
Timing gear cover ...252
Clean and inspect ...252
Remove ...221
Timing mark ...243
Transfer ...243
Transfer ...411
Torque values ...23
Inch ...23
Metric ...24
TORQUE-TURN method ...105
Cylinder head cap screws ...105
Tube ...286
Dipstick, adjust ...286
Dipstick, install ...286
Dipstick, remove ...286
Tune-up ...435
General recommendations ...435
Preliminary engine testing ...434
Turbocharger ...355
AiResearch/Garrett, install ...355
Break-in ...357
Center housing, replace ...354
Diagnostics ...478
Disassemble and inspect ...353
Extending life ...339
Failure analysis ...343
Lubrication ...479
Operation ...479
Prelube ...355
Repair ...352
Seven-step inspection ...345
Turbocharger oil inlet line ...54
Disconnect ...54
Turbocharger, AiResearch/Garrett ...355
Install ...355
Turbocharger4239T, 6359T, & A engines ...341
Remove ...341
V...84
Valve ...84
Springs, inspect ...84
Springs, measure ...84
Valve adjusting mechanism ...426
Inspect ...426
Valve and valve seat ...424
Inspect and clean ...424
Valve assembly ...83
Remove ...83
Valve clearance ...70
Check and adjust ...70
Valve guide ...90
Knurl ...90
Valve lift ...74
Measure ...74
Measure ...219
Valve seat inserts ...95
Install ...95
Remove ...93
Valve seats ...91
Grind ...91
Valve stem ...96
Install o-ring seals ...96
Valve stem o-ring seals ...96
Install ...96
Valve stem seals ...96
General information ...96
Valve stem tower seals ...97
Install ...97
Valve, cylinder head ...82
Make preliminary checks ...82
Valve, rotators ...84
Inspect ...84
Valves ...85
Clean ...85
Install ...95
Make preliminary checks ...82
Variable speed, adjust
Vibration damper ...170
Inspect ...170
Install ...172
Install ...175
Remove ...171
Vibration damper pulley ...172
Install ...172
Remove ...171
W...313
Water pump ...313
General information ...313
Water pump cap screw protrusion ...331
Check ...331
Water pump, high flow (heavy-duty) ...327
Assemble ...327
Disassemble ...322
Inspect and clean parts ...326
Install ...333
Remove ...322
Water pump, low flow (standard duty) ...318
Assemble ...318
Disassemble ...315
Inspect and clean parts ...317
Install ...321
Remove ...314
Wear caps ...84
Inspect ...84
Wear sleeve, rear crankshaft ...194
Remove ...194
...
