WORKHORSE CUSTOM CHASSIS
Service Manual
W SeriesWCC
SECTION
6.2
PAGE
2
Engine Mechanical
W Series Chassis
TOC
© 2006 WorkhorseCustom Chassis — All Rights Reserved
TABLE OF CONTENTS
8.1L (L18) ENGINE .............................................................4
Fastener Tightening Specifi cations L18 (8.1L) Engine ...4
Engine Mechanical Specifi cations L18 (8.1L) Engine .....8
Diagnostic Starting Point - Engine Mechanical —
(8.1l/ L18 Engine) ........................................................14
Base Engine Misfi re with Abnormal Valve Train Noise .18
Base Engine Misfi re with Coolant Consumption ...........19
Base Engine Misfi re with Excessive Oil Consumption ..19
Engine Noise on Start-Up, but Only Lasting a Few
Seconds ......................................................................20
Upper Engine Noise, Regardless of Engine Speed ......21
Lower Engine Noise, Regardless of Engine Speed ......23
Engine Noise Under Load .............................................25
Engine Will Not Crank - Crankshaft Will Not Rotate .....26
Coolant in Combustion Chamber ..................................27
Coolant in Engine Oil ....................................................28
Engine Compression Test .............................................29
Cylinder Leakage Test ..................................................30
Oil Consumption Diagnosis ...........................................32
Oil Pressure Diagnosis and Testing ..............................33
Oil Leak Diagnosis ........................................................34
Drive Belt Chirping, Squeal, and Whine Diagnosis .......37
Diagnostic Aids .............................................................42
Drive Belt Falls Off and Excessive Wear Diagnosis ......46
Base Engine Misfi re with Abnormal Valve Train
Noise ............................................................................50
Crankcase Ventilation System Description L18 (8.1L)
Engine .........................................................................51
Drive Belt System Description ......................................53
Drive Belt Chirping, Squeal, and Whine Diagnosis .......54
Drive Belt Rumbling and Vibration Diagnosis ...............59
Drive Belt Falls Off and Excessive Wear Diagnosis ......60
Drive Belt Tensioner Diagnosis .....................................64
Engine Component Description (LQ4/LR4) ..................64
Lubrication Description .................................................67
Separating Parts ...........................................................68
Replacing Engine Gaskets ............................................69
Use of Room Temperature Vulcanizing (RTV) and
Anaerobic Sealer .........................................................71
4.8L/6.0 (LR4/LQ4) ENGINES ..........................................75
Fastener Tightening Specifi cations
(LR4/LQ4 VIN V/U) .....................................................75
Engine Mechanical Specifi cations (LR4 VIN V) ............80
Engine Mechanical Specifi cations (LQ4 VIN U) ............84
Engine Identifi cation ......................................................89
Diagnostic Starting Point - Engine Mechanical
(LR4 VIN V & LQ4 VIN U) ...........................................89
Base Engine Misfi re without Internal Engine Noises ....92
Base Engine Misfi re with Abnormal Internal Lower
Engine Noises .............................................................95
Base Engine Misfi re with Abnormal Valve Train
Noise ............................................................................96
Base Engine Misfi re with Coolant Consumption ...........97
Base Engine Misfi re with Excessive Oil Consumption ..97
Engine Noise on Start-Up, but Only Lasting a Few
Seconds ......................................................................98
Upper Engine Noise, Regardless of Engine Speed ......99
Lower Engine Noise, Regardless of Engine Speed ....101
Engine Noise Under Load ...........................................102
Engine Will Not Crank - Crankshaft Will Not Rotate ...103
Coolant in Combustion Chamber ................................105
Coolant in Engine Oil ..................................................106
Engine Compression Test ...........................................107
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