John Deere Series 300, 3179, 4239, 6359, 4276, 6414 Diesel Engines Component Technical Manual (CTM4)

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Price: US$ 45.00

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
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