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158 pages
Manual
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16
Workshop
Manual
, TSD3450E
, Issue 1
147
2800
GE50033
Pressure
gauge
GE50043
Remov
er/instal
ler, va
lve g
uide
GE50044
Sleeve, va
lve guide
VP12712
Lift bracke
t, cylind
er head
Tool number
Descrip
tion
Illust
ration
156
158
Table of Contents
Main Page
Default Chapter
2
Chapters
2
Table of Contents
3
1 General Information
11
Introduction
11
Safety Precautions
12
Viton Seals
14
Environmental Protection
14
Engine Views
15
Engine Identification
16
Engine Lift Equipment
16
2 Specifications
17
Basic Engine Data
17
Rocker Assemblies
18
Valves
19
Valve Guides
20
Valve Springs
20
Valve Seat Inserts
21
Cylinder Head
22
Camshaft and Bearings
22
Pistons and Connecting Rods
23
Crankshaft, Main Bearings and Flywheel
24
Crankshaft Damper
24
Crankcase and Cylinder Liners
25
Lubricating Oil Pump
27
Coolant Pump
28
Recommended Torque Figures
29
Standard Torque Figures for Metric Fasteners
29
Standard Torque Figures for Imperial Fasteners
30
Standard Torque Figures for 'O' Ring Face Seal Fittings and 37 Degree Flared Fittings
31
'O' Ring Face Seal Fittings
32
Torque Figures for Flared and 'O' Ring Fittings
33
45 Degree Flared and 45 Degree Inverted Flare Fittings
34
Tapered Pipe Thread Fittings
34
Torque Figures for Constant Torque Hose Clamps
35
Torque Figures for Standard Hose Clamps of the Worm Drive Band Type
35
3 Cylinder Head Assembly
37
General Information
37
Cooling System
37
Rocker Cover
38
Operation 3-1 to Remove and to Fit
38
Rocker Lever and Rocker Shaft Assemblies
39
Operation 3-3 to Dismantle and to Assemble
40
To Assemble
41
Special Requirements
42
Operation 3-4 How to Check/Adjust the Tappet Clearances
42
Special Tools
42
To Remove
45
Cylinder Head Assembly
45
To Fit
47
Valve Springs
49
Valves
51
Operation 3-7 to Remove and to Fit
51
Cylinder Head
51
Valve Seals
52
To Renew
52
Valve Guides
53
Camshaft
55
How to Set the Backlash for the Camshaft Gear
60
Electronic Injector Units
61
Operation 3-13 to Check and to Adjust
63
Injector Sleeves
64
4 Pistons and Connecting Rod Assemblies
67
General Information
67
Pistons and Connecting Rod Assemblies
68
Operation 4-1 to Remove and to Fit
68
Operation 4-2 to Dismantle and Assemble
70
Piston Cooling Jets
72
Operation 4-3 to Remove and to Fit
72
5 Crankshaft Assembly
73
General Information
73
Crankshaft
74
Operation 5-1 to Remove and to Fit
74
Crankshaft Front Seal and Wear Sleeve
76
Operation 5-2 to Renew
76
Crankshaft Rear Seal and Wear Sleeve
78
Operation 5-3 to Renew
78
Crankshaft Vibration Damper
80
Operation 5-4 to Remove and to Fit
80
6 Gear Case and Drive Assembly
83
General Information
83
Gear Case Cover
84
Timing Gears
85
How to Check the Position of the Timing Gears
88
Gear Case
88
Gear Case
89
7 Crankcase and Cylinder Liners
91
General Information
91
Front Engine Support
92
Operation 7-1 to Remove and to Fit
92
Cylinder Liners
93
Operation 7-2 to Remove and to Fit
93
Operation 7-3 to Check and to Adjust the Protrusion of the Cylinder Liners
94
8 Engine Timing and Electronic Controls
97
General Information
97
Electronic Control Module
98
Operation 8-1 to Remove and to Fit
98
Engine Timing
99
Operation 8-2 to Check
99
9 Aspiration System
101
General Information
101
Exhaust Manifold
102
Turbocharger
103
To Dismantle and to Assemble
104
10 Lubrication System
105
General Information
105
Oil Filter and Oil Filter Header
106
Operation 10-1 to Remove and to Fit
106
Oil Filter Header
108
Operation 10-2 to Dismantle and to Assemble
108
Sump
109
Operation 10-3 to Remove and to Fit
109
Oil Pump
111
Operation 10-4 to Remove and to Fit
111
Operation 10-5 to Dismantle and to Assemble
112
11 Fuel System
113
General Information
113
Fuel Priming Pump
114
Fuel Transfer Pump
115
Operation 11-3 to Test
116
Drive for the Fuel Transfer Pump
117
Fuel Filter Header
118
Low Pressure Fuel System
119
How to Eliminate Air from the Fuel System
119
12 Cooling System
121
General Information
121
To Inspect
122
Leakage Test
123
Coolant Filler Cap
124
Radiator
124
Radiator
125
Fan
126
Fan Drive Assembly
127
Fan Drive Belts
128
To Check and to Adjust the Tension
128
Engine Oil Cooler
130
Thermostats and Thermostat Housing
131
To Test the Thermostats
133
Coolant Temperature Sensor
134
Coolant Pump
135
To Test the Pressure of the Coolant Pump
138
13 Flywheel and Housing
139
General Information
139
Flywheel
140
Operation 13-1 to Remove and to Fit
140
Flywheel Housing
141
Operation 13-2 to Remove and to Fit
141
14 Electrical Equipment
143
General Information
143
Starter Motor
144
Operation 14-1 to Remove and to Fit
144
Alternator
145
Operation 14-2 to Remove and to Fit
145
Operation 14-3 to Check and to Adjust the Tension of the Alternator Belt
146
Operation 14-4 to Renew the Alternator Belt
147
15 Auxiliary Equipment
149
General Information
149
List of Special Tools
151
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