CHAPTER 4 ENGINE MAINTENANCE INTRODUCTIONDefinition of TermsIllustrationsGeneral Safety InstructionsGeneral Safety Instructions Important Safety NoticeCHAPTER 5 MAINTENANCE PROCEDURESEngine Data plateFuel Pump Data plate (Nameplate)External Engine ComponentsExternal Engine Components - CONTEngine SpecificationsIntake Air, Exhaust and FuelSection 2. Troubleshooting LogicTroubleshooting LogicEngine Will Not Crank Or Cranks SlowlyEngine Cranks But Will Not Start No Smoke From ExhaustEngine Cranks But Will Not Start No Smoke From Exhaust (Continued)Engine Hard To Start Or Will Not Start Smoke From ExhaustEngine Hard To Start Or Will Not Start Smoke From Exhaust (Continued)Engine Starts But Will Not Keep RunningSurging (Speed Change)Rough Idle (Irregularly Firing Or Engine Shaking)Rough Idle (Irregularly Firing Or Engine Shaking) (Continued)Engine Runs Rough Or MisfiringEngine Runs Rough Or Misfiring (Continued)Engine RPM Will Not Reach Rated SpeedEngine RPM Will Not Reach Rated Speed (Continued)Low PowerLow Power (Continued) - TM-10-3950-672-24-20032Low Power (Continued) - TM-10-3950-672-24-20033Low Power (Continued) - TM-10-3950-672-24-20034Excessive Exhaust SmokeCoolant Temperature Above NormalCoolant Temperature Above Normal (Continued) - TM-10-3950-672-24-20037Coolant Temperature Above Normal (Continued) - TM-10-3950-672-24-20038Coolant Temperature Below NormalCoolant LossCoolant Loss (Continued)Lubricating Oil Pressure LowLubricating Oil Pressure Low (Continued)Lubricating Oil Pressure Too HighLube Oil LossLube Oil Loss (Continued)Contaminated CoolantContaminated Lube OilFuel Or Oil Leaking From Exhaust ManifoldCompression KnocksExcessive Fuel ConsumptionEngine Will Not Shut OffExcessive VibrationExcessive Vibration (Continued)Excessive Engine NoisesAlternator Not Charging Or Insufficient ChargingSection 3. Coolant SystemCoolant SystemCoolant System Malfunctions DiagnosisCoolant System Malfunctions Diagnosis - CONT - TM-10-3950-672-24-20060Coolant System Malfunctions Diagnosis - CONT - TM-10-3950-672-24-20061Coolant System Malfunctions Diagnosis - CONT - TM-10-3950-672-24-20062Coolant System Malfunctions Diagnosis - CONT - TM-10-3950-672-24-20063Coolant System Malfunctions Diagnosis - CONT - TM-10-3950-672-24-20064Coolant System Malfunctions Diagnosis - CONT - TM-10-3950-672-24-20065Coolant System Malfunctions Diagnosis - CONT - TM-10-3950-672-24-20066Cooling System Replacement ProceduresFan Hub - ReplacementWater Pump - ReplacementThermostat - ReplacementThermostat - InspectionThermostat - Inspection - CONTCup Plugs Replacement - TM-10-3950-672-24-20073Section 4. Fuel SystemFuel System Components And FlowFuel System SpecificationFuel System Malfunction DiagnosisAir In the Fuel SystemFuel Water Separator/Filter UnitInjection Pump - TM-10-3950-672-24-20080Fuel Control Lever Travel and AdjustmentManual Shut Down LeversElectrical Shut Off ValvesDelivery Valves (Back Leakage Valves On Lucas CAV Pumps)Injection Pump TimingInjection Pump Timing - CONTHigh Pressure Fuel LinesInjectors - TM-10-3950-672-24-20088Injectors - TM-10-3950-672-24-20089Fuel Drain ManifoldFuel System Replacement ProceduresLow Pressure Lines and Fuel Filter - Venting 10mmHigh Pressure Lines - Venting 17mm24mm, Flat Blade ScrewdriverLow Pressure Fuel Line - Replacement 14mm and 17mmLift Pump - ReplacementHigh Pressure Lines - Replacement - TM-10-3950-672-24-20097High Pressure Lines - Replacement - TM-10-3950-672-24-20098High Pressure Lines - Replacement - CONTFuel Drain Manifold - ReplacementInjection Pump Supply Line - ReplacementInjection Pump Supply Line - Replacement - CONTInjector - ReplacementInjector Bore BrushElectric Fuel Shut Off Valve - Replacement - TM-10-3950-672-24-20105Electric Fuel Shut Off Valve - Replacement - TM-10-3950-672-24-20106Lucas CAV DPA Back Leakage Valve and Sealing Washer - Replacement - TM-10-3950-672-24-20107Lucas CAV DPA Back Leakage Valve and Sealing Washer - Replacement - TM-10-3950-672-24-20108External Pump Leaks - RepairRemoving the PumpRemoving the Pump - CONTInstalling the PumpInstalling the Pump - CONT - TM-10-3950-672-24-20113Installing the Pump - CONT - TM-10-3950-672-24-20114Installing the Pump - CONT - TM-10-3950-672-24-20115Installing the Pump - CONT - TM-10-3950-672-24-20116Injection Pump Timing CheckInjection Pump RelatingSection 5. Air SystemDamage From Non-Filtered AirAir System Replacement ProceduresExhaust Manifold and/or Gasket - ReplacementIntake Air RestrictionSection 6. Lubricating SystemLubricating Oil Pump - TM-10-3950-672-24-20125Oil CoolersOil Filter Bypass ValveLubrication System - TM-10-3950-672-24-20128Diagnosing Lubricating SystemOil Filter - TM-10-3950-672-24-20130Incorrect Oil PumpFuel Diluted OilFuel Diluted Oil - CONT - TM-10-3950-672-24-20133Fuel Diluted Oil - CONT - TM-10-3950-672-24-20134Oil LeaksLubricating System ReplacementPressure Regulator Valve - InspectionOil Cooler Element and/or Gasket - ReplacementBe sure to remove the shipping plugs from the element.Oil Pan, Suction Tube and/or Gaskets ReplacementOil Pump ReplacementRemove the Lubricating Oil PumpRemove the Lubricating Oil Pump - cont - TM-10-3950-672-24-20143Remove the Lubricating Oil Pump - CONT - TM-10-3950-672-24-20144Installing the Lubricating Oil PumpGear Cover InstallationInstall the cap screws but do not tighten at this time.1/2 inch Square DriveCup Plugs Replacement - TM-10-3950-672-24-20149To Install the Cup PlugsSection 7. Electrical SystemPrestolite Model 8AR2201L AlternatorInjection Pump Fuel Shutoff ValveElectrical System - TM-10-3950-672-24-20154Diagnosing Electrical MalfunctionsEngine Does Not CrankEngine Cranking Speed Too SlowAlternatorNormal Indicator Lamp OperationAbnormal Charging System OperationFuel Shutoff Valve - CheckOil Pressure Switch - CheckEngine Electrical System Replacement Procedures - TM-10-3950-672-24-20163Engine Electrical System Replacement Procedures - TM-10-3950-672-24-20164Electric Fuel Shut Off Valve - Replacement - TM-10-3950-672-24-20165Temperature Sensor ReplacementSection 8. Base Engine ComponentsSection 8. Base Engine Components - continuedOperation and DescriptionCylinder Head and Valve TrainFront Crankshaft SealCamshaft, Tappets and Push RodsCamshaft, Tappets and Push Rods - cont - TM-10-3950-672-24-20173Camshaft, Tappets and Push Rods - cont - TM-10-3950-672-24-20174Crankshaft and Main Bearings - TM-10-3950-672-24-20175Cylinder Block - TM-10-3950-672-24-20176Oil PanAir and Fuel Systems CheckCompression CheckHead Gasket SealingValve Seal WearInjector ProtrusionFront Gear Housing and Gear TrainFront Gear Housing and Gear Train - cont - TM-10-3950-672-24-20184Front Gear Housing and Gear Train - cont - TM-10-3950-672-24-20185Front Gear Housing and Gear Train - cont - TM-10-3950-672-24-20186Crankshaft and Main Bearings - TM-10-3950-672-24-20187Cylinder Block - TM-10-3950-672-24-20188Flywheel Housing Concentricity CheckRecord the indicator reading.Flywheel Housing Face Alignment CheckDetermine the Total Indicator Reading (TIR).Base Engine Components SpecificationsBase Engine Components Specifications - contPistonsConnecting Rod - TM-10-3950-672-24-20196Cylinder BoreRemove the valve covers.Remove the rocker levers.Measure the rocker lever bore.'30607.doc' by LOGSA - Page 1 of 388Measure the shaft diameter.Check the push rods for roundness and straightness.Rocker Lever Assembly InstallationValve Clearance Adjustment - TM-10-3950-672-24-20205Step BCamshaft and Tappet - ReplacementCamshaft InspectionCamshaft Bushing inspectionCamshaft Bushing inspection - contTappet RemovalFlashlightTappet stem specificationsTappet InstallationCamshaft InstallationCamshaft Installation - CONTTiming Pin Assembly or Gasket - ReplacementGear Housing or Gasket - ReplacementTiming Pin - InstallationTiming Pin - Installation - CONT - TM-10-3950-672-24-20220Timing Pin - Installation - CONT - TM-10-3950-672-24-20221T-25 TorkscrewFlywheel Ring Gear and Rear Seal - ReplacementBrass Drift PinRear Seal - InstallationFlywheel - InstallationIn-Chassis OverhaulCylinder Head RemovalMain Bearing Preliminary InspectionPiston and Rod RemovalCylinder Bores - De-GlazeCylinder Bores - De-Glaze - cont - TM-10-3950-672-24-20232Cylinder Bores - De-Glaze - cont - TM-10-3950-672-24-20233Cylinder Bores - De-Glaze - cont - TM-10-3950-672-24-20234Main Bearing ReplacementMain Bearing Replacement - cont - TM-10-3950-672-24-20236Main Bearing Replacement - cont - TM-10-3950-672-24-20237Flat Blade ScrewdriverPiston and Rod - DisassemblyPiston, Pin and Connecting Rod - CleanPiston, Pin and Rod - InspectionPiston, Pin and Rod - Inspection - contPiston to Connecting Rod InstallationInstall the second retaining ring.Piston Rings InstallationPiston Rings Installation - cont75 to 125mm Ring Compressor75 to 125mm Ring Compressor - cont12mm Socket. Torque WrenchInstall the suction tube and oil pan.Adjust the valve clearance.Observe the Following Check List During Final AssemblyObserve the Following Check List During Final Assembly - cont - TM-10-3950-672-24-20253Observe the Following Check List During Final Assembly - cont - TM-10-3950-672-24-20254Cylinder Head Clean and InspectCylinder Head Clean and Inspect - cont - TM-10-3950-672-24-20256Cylinder Head Clean and Inspect - cont - TM-10-3950-672-24-20257Valves GrindValve Seats GrindValve Seats Grind - contValve DepthValve Seat Width LimitCheck the valve spring tension.Check the valve spring tension - contCup Plug ReplacementCup Plug Driver Part No. 3900965Section 9. Engine Disassembly and AssemblyEngine Disassembly continuedEngine Assembly - TM-10-3950-672-24-20269Engine Assembly - continuedSection 10. Fuel Injector PumpInjection Pump - Service ToolsBack Leakage Valve Replacement/ InspectionShutdown Solenoid Replacement mm Protective Sleeve Part No. 3376930Bleed Screws/Sealing Washers ReplacementFuel Inlet Fitting/Sealing Washer ReplacementControl Lever ReplacementShutdown Lever/Spring ReplacementAutomatic Timing Advance DisassemblyAutomatic Timing Advance Disassembly - contTiming Advance Components InspectionTiming Advance AssemblyTiming Advance Assembly - cont mm Protective Sleeve Part No. 3376931Section 11. Cylinder Block Disassembly and AssemblyCylinder Block - Precheck Before DisassemblyPunch, VisegripsUniversal Bushing Installation Tool - TM-10-3950-672-24-20289Cleaning Brush Kit, 3823614Brush, 400 Grit Sandpaper, Diesel FuelWarning: Use protective measures to prevent personal injury.Warning: Use protective measures to prevent personal injury. - contInspect the bore after 10 strokes.Cylinder Block - InspectionCylinder Block AssemblyPipe Plug Torque ValuesDriver Part No. 3823524 (Coolant Passages)Large Drift, HammerUniversal Bushing Installation Tool - TM-10-3950-672-24-20300Cylinder Block - StoringCrankshaft - InspectionDetermining Main Bearing Clearance2 lb Steel Hammer, Gear Splitter Part No. 3823585Camshaft - CleaningPitting Reuse CriteriaEdge Deterioration (Breakdown) CriteriaEdge Deterioration (Breakdown) Criteria - cont - TM-10-3950-672-24-20308Edge Deterioration (Breakdown) Criteria - cont - TM-10-3950-672-24-20309Camshaft Gear - ReplacementWear protective gloves to prevent personal injury.Gear Housing and Timing Pin Assembly - InspectionFlywheel Housing InspectionFlywheel Housing AssemblyFront Support - Cleaning and InspectionSection 12. Engine Replacement and TestingSection 12. Engine Replacement and Testing Engine InstallationEngine Only Coolant CapacityOperating Conditions for Run-In and TestBlowby LimitsEngine Run-In and Test in the ChassisSection 13. Engine TestingEngine Testing - Service ToolsEngine Testing - Service Tools - contEngine Testing - Engine Side ViewsEngine Testing - Engine Side Views - contEngine Testing - General InformationEngine Dynamometer Test - Installation of the Engine (14-01)Engine Dynamometer Test - Installation of the Engine (14-01) - cont - TM-10-3950-672-24-20330Engine Dynamometer Test - Installation of the Engine (14-01) - cont - TM-10-3950-672-24-20331Engine Dynamometer Test - Installation of the Engine (14-01) - cont - TM-10-3950-672-24-20332Engine Dynamometer Test - Installation of the Engine (14-01) - cont - TM-10-3950-672-24-20333Engine Dynamometer Test - Installation of the Engine (14-01) - cont - TM-10-3950-672-24-20334Engine Dynamometer Test Engine Run-In (14-02)Engine Dynamometer Test Engine Run-In (14-02) - cont - TM-10-3950-672-24-20336Engine Dynamometer Test Engine Run-In (14-02) - cont - TM-10-3950-672-24-20337Engine Dynamometer Test Engine Run-In (14-02) - cont - TM-10-3950-672-24-20338Engine Dynamometer Test Engine Run-In (14-02) - cont - TM-10-3950-672-24-20339Engine Dynamometer Test Performance CheckingEngine Dynamometer Test Performance Checking - contGeneral Engine Test Procedures (Chassis Dynamometer) (14-05) General Engine Test Procedures (Chassis Dynamometer) (14-05) - CONTEngine Run-In Procedure "In Chassis" Highway Vehicles)Engine Painting (14-08)Engine Storage Short Term (14-09)Engine Storage Short Term (14-09) - CONTRemoving the Engine from Short-Term storageEngine Storage - Long Term (14-10)Engine Storage - Long Term (14-10) - CONTRemoving the Engine from Long-Term Storage - TM-10-3950-672-24-20351Removing the Engine from Long-Term Storage - TM-10-3950-672-24-20352Removing the Engine from Long-Term Storage - CONT - TM-10-3950-672-24-20353Removing the Engine from Long-Term Storage - CONT - TM-10-3950-672-24-20354Section 14. SpecificationsTools Required to Repair the B Series EngineEngine Disassembly - Group 0 SpecificationsEngine Assembly - Group 0 SpecificationsEngine Assembly - Group 0 Specifications - CONT - TM-10-3950-672-24-20359Engine Assembly - Group 0 Specifications - CONT - TM-10-3950-672-24-20360Engine Assembly - Group 0 Specifications - CONT - TM-10-3950-672-24-20361Engine Assembly - Group 0 Specifications - CONT - TM-10-3950-672-24-20362Camshaft - TM-10-3950-672-24-20363Vibration Damper - TM-10-3950-672-24-20364Vibration Damper - TM-10-3950-672-24-20365Vibration Damper - TM-10-3950-672-24-20366Vibration Damper - TM-10-3950-672-24-20367Vibration Damper - CONT - TM-10-3950-672-24-20368Vibration Damper - CONT - TM-10-3950-672-24-20369Vibration Damper - CONT - TM-10-3950-672-24-20370Vibration Damper - CONT - TM-10-3950-672-24-20371Capscrew Markings and Torque Values - MetricPipe: Plugs, Fittings, and AdaptersEngine Component Torque Value - TM-10-3950-672-24-20374Engine Component Torque Value - TM-10-3950-672-24-20375Engine Component Torque Value - TM-10-3950-672-24-20376B Series SealantsTM-10-3950-672-24-2 Warehouse Crane 10 000 lb. Capacity M469 Wheeled Diesel Powered Manual