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tN-1

INTRODUCTION

Page

HOW TO

USE

THIS MANUAL ........

IN-2

IDENTIFICATION

INFORMATION

IN-4

GENERAL

REPAIR INSTRUCTIONS

IN-4

ABBREVIATIONS USED

IN THIS MANUAL

IN.7

r[

Table of Contents

Repair Procedures5
Remove Injection Nozzles6
Identification Information7
General Repair Instructions7
Engine Serial Number7
Table of Contents9
Engine Mechanical9
Description10
B, 3B, 11B and 14B Engines10
Diesel Engine Diagnosis12
Preliminary Checks12
Engine will Not Crank13
Engine Cranks Slowly-Will Not Start13
Engine Cranks Normally but will Not Start14
Rough Idle with Warm Engine16
Engine Suddenly Stops17
Lack of Power17
Excessive Exhaust Smoke18
Excessive Fuel Consumption19
Engine Noise When Warm19
Engine will Not Return to Idle20
Engine will Not Shut off with Key20
Diesel Electrical System Diagnosis21
Engine Does Not Start Cold21
Pre-Heating System (Super Glow Type)21
Fuel Cut Solenoid23
Diesel Electrical System Diagnosis (11B and 14B)24
DIAGNOSIS [11B and 14824
- Inspection Control Section25
- Engine Tune up27
- Cleaning of Air Filter27
- Adjustment of Valve Clearances29
- Inspection and Adjustment of Injection Timing30
- Inspection and Adjustment of Idle and Maximum Speed33
- Compression Check (B and 3B)35
And 14836
- Cylinder Head Components37
- Removal of Cylinder Head39
- Disassembly of Cylinder Head43
- Inspection, Cleaning and Repair of Cylinder Head Components44
- Inspect Valve Springs49
- Inspect Valve Rocker Shaft Assembly50
- Assembly of Cylinder Head52
- Install Valves53
- Installation of Cylinder Head54
- Torque Cylinder Head Bolts54
- Timing Gears and Camshaft Components60
- Removal of Timing Gears and Camshaft61
- Inspection of Timing Gears and Camshaft65
- Inspect Idle Gears66
- Replacement of Camshaft (or Camshaft Timing Gear)67
- Replacement of Crankshaft Front Oil Seal68
- Replacement of Injection Pump Drive Gear Bearing69
- Installation of Timing Gears and Camshaft70
- Displace Valve Lifters73
- Install Crankshaft Pulley73
- Cylinder Block Components75
- Disassembly of Cylinder Block76
- Remove Connecting Rod Caps and Check Oil Clearance77
- Check Crankshaft Thrust Clearance79
- Remove Piston and Connecting Rod Assemblies79
- Remove Crankshaft82
- Remove Valve Lifters82
- Inspection of Cylinder Block83
- Disassembly of Piston and Connecting Rod Assemblies85
- Inspection and Repair of Piston and Connecting Rod Assemblies86
- Inspect Piston Diameter and Oil Clearance87
- Inspect Clearance between Wall of Piston Ring Groove and New Piston Ring88
- Check Piston Pin Fit89
- Inspect Connecting Rods89
- Inspect Piston Ring End Gap89
- Boring of Cylinders93
- Calculate Dimension to Bore Cylinders93
- Inspection and Repair of Crankshaft94
- Inspection and Repair of Camshaft Bearings and Camshaft96
- Inspection of Valve Lifters and Valve Lifter Bores97
- Replacement of Crankshaft Rear Oil Seal98
- Assembly of Piston and Connecting Rod Assemblies99
- Assembly of Cylinder Block101
- Install Main Bearing Caps and Lower Thrust Washers102
- Installation Piston and Connecting Rod Assemblies102
- Install Connecting Rod Caps103
- Torque Connecting Rod Cap Nuts103
- Select Cylinder Head Gasket104
- Fuel System106
- Fuel System Description107
- Injection Pump (VE Type)108
- Fuel Heater System Circuit109
- Inspection of Fuel Heater109
- Removal and Test of Injection Nozzles111
- Injection Pressure Test112
- Disassembly, Cleaning and Test of Injection Nozzle114
- Fuel System Components114
- Sinking Test115
- Assembly of Injection Nozzles116
- Installation of Injection Nozzles116
- Disassembly, Cleaning and Test of Injection Nozzles120
- Removal of Injection Pump123
- Disassembly of Injection Pump127
- Inspection of Injection Pump Components133
- Assembly of Injection Pump136
- Install Roller Ring138
- Install Timer Piston138
- Adjust Plunger Adjusting Shim139
- Shim Selection Chart140
- Install Governor Link141
- Install Pump Plunger141
- Install Distributive Head142
- Install Four Delivery Valve Holders142
- Check Flyweight Holder Thrust Clearance143
- Install Distributive Head Plug143
- Install Governor Shaft and Flyweight Holder Assembly143
- Adjust Protrusion of Governor Shaft144
- Install Fuel Cut Solenoid144
- Install Governor Cover145
- Install Pneumatic Bellows145
- Install Thermo Wax145
- Adjustment of Injection Pump147
- Pre-Test Check and Preparation147
- Pre-Setting of Full Load Injection Volume151
- Pre-Setting of Load Sensing Timer151
- Pre-Setting of Maximum Speed151
- Measure Overflow Volume152
- Measure Pump Inner Pressure152
- Release Cold Starting System for Next Inspections152
- Measure and Adjust Full Load Injection Volume154
- Adjust Maximum Speed155
- Inspect Injection Volume156
- Adjust Load Sensing Timer159
- Adjust Idle Speed160
- Adjust Cold Starting System162
- Adjust Fast Idle162
- Install Spline Shaft163
- Post Adjustment Check163
- Installation of Injection Pump164
- Cooling System166
- Cooling System Description167
- Radiator167
- Radiator Cap168
- Reservoir Tank168
- Thermostat168
- Water Pump168
- Check and Replacement of Engine Coolant169
- Troubleshooting169
- Replace Engine Coolant170
- Removal of Water Pump171
- Inspection of Water Pump Components172
- Installation of Water Pump173
- Removal of Thermostat173
- Inspection of Thermostat174
- Installation of Thermostat174
- Cleaning of Radiator175
- Inspection of Radiator175
- Lubrication System176
- Lubrication System Description177
- Oil Filter178
- Oil Pump178
- Oil Pump Relief Valve178
- Oil Pressure Check179
- Replacement of Engine Oil and Oil Filter180
- Removal of Oil Pump182
- Disassembly of Oil Pump185
- Inspection of Oil Pump186
- Replacement of Drive Spline187
- Assembly of Oil Pump188
- Installation of Oil Pump189
- Oil Cooler and Relief Valve Components192
- Removal of Oil Cooler and Relief Valve193
- Inspection of Oil Cooler and Relief Valve194
- Installation of Oil Cooler and Relief Valve195
- Oil Nozzles and Check Valve Components196
- Removal of Oil Nozzles and Check Valve196
- Inspection of Oil Nozzle and Check Valve197
- Installation of Oil Nozzles and Check Valve197
- Starting System198
- Pre-Heating System Circuit199
- PRE-HEATING SYSTEM IB and PRE-HEATING SYSTEM TROUBLESHOOTING199
  - Pre-Heating System Inspection of Components200
  - Timer Characteristic Diagram200
  - Inspect Glow Plug203
  - Inspect Water Temp. Sensor203
  - Fixed Delay Type System Circuit204
  - Pre-Heating System (11B and 14B) Circuit206
  - Starting System Circuit209
  - Disassembly of Starter210
  - Remove Field Frame and Armature Assembly210
  - Starter Components210
  - Inspection of Starter212
  - Assembly of Starter216
  - Install Field Frame and Armature Assembly217
- Starting System Starter217
  - Performance Test of Starter218
  - Inspection of Starter Relay (BB, BU, BY)219
  - Inspection of Starter Relay (BJ)220
- STARTER RETAY Tbjl220
- Charging System221
- Charging System Precaution222
- Charging System Troubleshooting222
- Charging System Circuit223
- On-Vehicle Inspection225
- Check Charging Circuit with Load228
- Alternator Components229
- Disassembly of Alternator230
- Inspection and Repair of Alternator232
- Assembly of Alternator236
- Service Specifications239
- Engine Mechanical Specifications240
- Torque Specifications246
- Fuel System Specifications246
- Injection Pump Adjustment and Test249
- Cooling System Specifications255
- Lubrication System Specifications255
- Standard Bolt Torque Specifications257
- SST and SSM260
- SST (Special Service Tools)261
- SSM (Special Service Materials)266

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