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Describes how to check and adjust valve clearance for intake and exhaust valves when the engine is cold.
Details the use of a compression tester to check wear and damage in cylinder liners and piston rings.
Step-by-step instructions for removing the cylinder head from the engine block.
Procedures for dismantling the cylinder head, including valve removal and component inspection.
Procedures for checking, changing valve stem seals, and machining valves and valve seats.
Instructions for removing old valve seat rings and pressing in new ones using specialized tools.
Steps for machining valve seat rings using a valve seat cutter tool and ensuring correct alignment.
Procedure for removing and fitting new bushings in rocker arms using specialized drifts.
Instructions for pressing out old valve guides and pressing in new ones using drive tools.
Checking the cylinder head for cracks and machining the sealing surface and sealing ring grooves.
Steps for assembling cylinder head components, including valve train parts and fitting the cylinder head.
Procedures for fitting the cylinder head to the engine block, including bolt tightening sequences.
Lists and illustrates specialized tools for turbocharger inspection and measurement.
Important notes on cleanliness, oil leakage, foreign bodies, and general care when working on the turbocharger.
Describes causes and consequences of oil leakage in the turbocharger system and potential engine damage.
Explains the damage foreign bodies can cause to turbocharger vanes and the importance of avoiding them.
Discusses the impact of air and exhaust leaks on charge pressure, engine temperature, and wear.
Explains factors affecting charge pressure and notes that low pressure doesn't always mean a faulty turbocharger.
Instructions for cleaning the compressor wheel to resolve low charge pressure issues.
Provides guidance on measuring radial and axial clearances to diagnose potential turbocharger defects.
Detailed steps for measuring the radial clearance of the turbine and compressor wheels using a dial gauge.
Instructions for measuring the axial clearance of the turbocharger shaft using a dial gauge.
Specifies the acceptable radial and axial clearance wear limits for Holset turbochargers.
Troubleshooting steps to identify the cause of turbocharger malfunction, checking various engine systems.
Step-by-step instructions for removing and fitting a new turbocharger, including necessary gasket and filter changes.
Lists and illustrates specialized tools for piston and cylinder liner servicing.
Procedure for removing a tightly fitted loose ring from a cylinder liner using specialized tools.
Steps for removing pistons and connecting rods from the cylinder block, including piston cooling nozzles.
Instructions for removing piston rings using a piston ring compressor tool.
Procedure for removing the gudgeon pin from the piston and connecting rod assembly using a drift.
Methods for checking connecting rods for twist and bend using a specialized connecting rod tester.
Step-by-step guide for assembling pistons and connecting rods, including fitting piston rings and gudgeon pins.
Instructions for marking and extracting cylinder liners from the engine block using a puller.
Procedure for measuring cylinder liner height relative to the cylinder block surface using a dial gauge.
Guidance on adjusting cylinder liner height using shims, including machining if necessary.
Steps for machining cylinder liners to achieve the correct height using a specialized cutter tool.
Instructions for checking, lubricating, and fitting cylinder liners into the engine block, ensuring correct orientation.
Steps for fitting pistons and connecting rods into the cylinder block, including bearing cap installation and tightening.
Lists and illustrates specialized tools for flywheel and flywheel housing assembly and removal.
Procedure for removing the flywheel from the crankshaft using puller bolts.
Instructions for removing and fitting the support bearing in the flywheel using a drift.
Steps for removing a worn ring gear and fitting a new one by heating and mounting.
Procedure for changing the crankshaft seal using specialized assembly tools.
Instructions for removing the flywheel housing, cleaning surfaces, and fitting a new gasket.
Steps for fitting the flywheel housing, tightening bolts in sequence, and fitting a new crankshaft seal.
Procedure for fitting the flywheel onto the crankshaft, using guide pins and tightening bolts to specified torque.
Lists and illustrates specialized tools for timing gear assembly and removal.
Steps for removing the crankshaft seal, including damper, pulley, and hub removal.
Instructions for fitting a new crankshaft seal using assembly tools and degreasing the crankshaft.
Steps for removing components obstructing access to the timing gear cover and removing the cover.
Instructions for fitting the timing gear cover, including cleaning surfaces, gasket, and bolt tightening.
Steps for removing the intermediate gear, including timing gear cover and oil catcher removal.
Instructions for fitting the intermediate gear and thrust bearings, ensuring correct alignment and bolt tightening.
Steps for removing the crankshaft gear, including intermediate gear and oil pump gear removal.
Instructions for fitting the crankshaft gear, including heating, key placement, and intermediate gear fitting.
Steps for removing the camshaft gear, including timing gear cover and intermediate gear removal.
Instructions for fitting the camshaft gear, including heating, key placement, and intermediate gear fitting.
Steps for removing the camshaft, including rocker arms, pushrods, side covers, and intermediate gear.
Instructions for fitting the camshaft, including lubrication, guide flange bolts, and rocker arm fitting.
Procedure for removing and fitting valve tappets and their retaining rings.
Notes on checking camshaft bearings for wear and fitting new bearings with correct oilway alignment.
Method for checking camshaft timing by measuring valve lifting height using dial gauges.
Steps for removing the crankshaft, including main bearing caps, halves, and thrust washers.
Procedure for measuring crankshaft journals for wear and considering regrinding or replacement.
Instructions for fitting the crankshaft, including cleaning oilways, lubricating bearings, and tightening cap bolts.
Diagram and parts list for the oil cooler and instructions for changing seals and the cooling element.
Steps for removing the drive belt, draining coolant, and detaching the oil cooler and coolant pump.
Instructions for dismantling the oil cleaner rotor, cleaning the bowl, and checking components.
Lists and illustrates specialized tools for lifting the engine, including lifting chain and lever block.
Provides general engine specifications such as cylinder configuration, bore, stroke, and firing order.
Lists various compounds used for assembly, including part numbers and applications.
Specifications for cylinder head machining, height, and valve head angle.
Combines intake/exhaust valve clearance, head angle, min dimension, valve seat specs, valve guide specs, rocker arm specs.
Lists tightening torques for cylinder head bolts, injector nuts, rocker arms, and exhaust manifolds.
Wear limits for radial and axial shaft clearance for the turbocharger.
Specifications for cylinder liner shims, height, and maximum permitted height difference.
Piston orientation, rings, and connecting rod markings for correct assembly.
Housing seal, timing gear, camshaft gear, injection pump gear, intermediate gear, PTO gear, camshaft clearances.
Specifications for main bearing races, big-end bearing journals, and thrust bearings.
Specifications for oil pump backlash, oil pressure valve, oil cleaner deposits, and oil filter.
Lists tightening torques for oil pump cover, oil pump to block bolts, and oil cleaner locknut.
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