Section 1 Operating Instructions
General Information
Starting Procedure Matrix
Starting Procedure
Cold Weather Operation
Starting Procedure After Extended Shutdown or Oil Change
Operating the Engine
Engine Operating Range
Section 2 Maintenance Guidelines
General Information
Tool Requirements
Maintenance Schedule
Page References for Maintenance Instructions
Page References for Maintenance Instructions - Continued
Page References for Maintenance Instructions - Continued
Maintenance Record Form
Maintenance Record Form - Continued
NOTES
Section 3 Daily Maintenance Procedures
General Information
Oil Level
Coolant Level
Coolant Level - Continued
Drive Belt
Section 4 Maintenance Procedures at 10,000 Kilometers [6,000 Miles], 250 Hours or 3 Months
General Information
Lubricating Oil and Filter Change Interval
Lubricating Oil and Filter
Lubricating Oil and Filter - Continued
90 to 95 mm Filter Wrench
90 to 95 mm Filter Wrench - Continued
90 to 95 mm Filter Wrench - Continued
90 to 95 mm Filter Wrench - Continued
Air Intake System
Charge Air Cooler
Charge Air Cooler - Continued
Section 5 Maintenance Procedures at 19,000 Kilometers [12,000 Miles], 500 Hours or 6 Months
General Information
Fuel Filter
Fuel System
Low Pressure Lines and Fuel Filter(s)
High Pressure Lines
Re-Tighten Line Fittings
NOTES
Section 6 Maintenance Procedures at 38,000 Kilometers [24,000 Miles], 1000 Hours or 1 Year
General Information
Valves
Valves - Continued
Feeler Gauge
Six-Cylinder Engine Adjustment
Six-Cylinder Engine Adjustment - Continued
Drive Belt Tension
Drive Belt
NOTES
Section 7 Maintenance Procedures at 77,000 Kilometers [48,000 Mi.], 2000 Hours or 2 Years
General Information
Cooling System Maintenance
Cooling System Maintenance - Continued
Cooling System Flushing
Cooling System Flushing - Continued
Coolant System Filling
Coolant System Filling - Continued
Vibration Damper (Rubber)
Air Compressor
Air Compressor Discharge Inspection
Air Compressor Discharge Inspection - Continued
Section T Troubleshooting
Section T Troubleshooting - Continued
Troubleshooting Procedures and Techniques
Engine Will Not Crank or Cranks Slowly
Engine Hard to Start or Will Not Start (Exhaust Smoke Present)
Engine Hard to Start or Will Not Start (Exhaust Smoke Present) (Continued)
Engine Cranks But Will Not Start (No Smoke From Exhaust)
Engine Cranks But Will Not Start (No Smoke From Exhaust) (Continued)
Engine Starts But Will Not Keep Running
Engine Will Not Shut Off
Rough Idle, Warm Engine
Engine Surges at Idle
Lubricating Oil Pressure Low
Lubricating oil Pressure Low (Continued)
Lubricating Oil Pressure Too High
Lubricating Oil Loss
Coolant Temperature Above Normal
Coolant Temperature Above Normal (Continued)
Coolant Loss
Coolant Temperature Below Normal
Coolant Contaminated
Lubricating Oil Contaminated
Fuel or Oil Leaking from Exhaust Manifold
Exhaust Smoke Excessive Under Load
Exhaust Smoke Excessive Under Load (Continued)
Engine Will Not Reach Rated Speed When Loaded
Engine Will Not Reach Rated Speed When Loaded (Continued)
Power Output Low
Power Output Low (Continued)
Power Output Low (Continued)
Engine Misfiring
Fuel Knock
Fuel Consumption Excessive
Vibration Excessive
Engine Noises Excessive
Alternator Not Charging or Insufficient Charging
White Smoke Excessive During Cold Start
White Smoke Excessive During Cold Start (Continued)
Section A Adjustment, Replacement and Repair
Section A Adjustment, Replacement and Repair - Continued
Section A Adjustment, Replacement and Repair - Continued
Cooling System Repair Summary
Cooling System Repair
Belt Tensioner - Replacement
Fan Pulley Replacement
Water Pump Replacement
Water Pump Replacement - Continued
Water Pump Replacement - Continued
Water Pump Replacement - Continued
Water Pump Replacement - Continued
Water Pump Replacement - Continued
Thermostat Replacement
Thermostat Replacement - Continued
Thermostat Replacement - Continued
Thermostat Replacement - Continued
Thermostat Replacement - Continued
Thermostat Replacement - Continued
Fuel System Repair Summary
Fuel System Repair - In-Line Pump
Fuel System Repair - In-Line Pump - Continued
Lift Pump Replacement
Lift Pump Replacement - Continued
High Pressure Fuel Lines - Replacement
High Pressure Fuel Lines - Replacement - Continued
Fuel Drain Manifold - Replacement
Fuel Drain Manifold - Replacement - Continued
Injectors - Replacement
Injector Bore Brush
Injector Bore Brush - Continued
Injector Bore Brush - Continued
Fuel Shutoff Solenoid - Replacement
Injection Pump - Replacement
Injection Pump - Removal
Injection Pump - Removal - Continued
75 mm T-Bar Puller
Injection Pump - Installation
Injection Pump - Installation - Continued
Injection Pump - Installation - Continued
Injection Pump - Installation - Continued
Injection Pump - Installation - Continued
22 mm (A Pump), 30 mm (P Pump)
22 mm (A Pump), 30 mm (P Pump) - Continued
10 mm Hex Drive
Injection Pump - Idle Speed Adjustment
Air System Repair Summary
Air System Repair
Intake Manifold Cover and Gasket Replacement
Intake Manifold Cover and Gasket Replacement - Continued
Intake Manifold Cover and Gasket Replacement - Continued
Jacket-Water Aftercooler and Gasket - Replacement
Jacket-Water Aftercooler and Gasket - Replacement - Continued
Jacket-Water Aftercooler and Gasket - Replacement - Continued
Jacket-Water Aftercooler and Gasket - Replacement - Continued
Charge Air Cooler - Leak Check
Intake Manifold Pressure - Check
Intake Manifold Temperature - Check
Turbocharger - Replacement
Turbocharger - Replacement - Continued
Turbocharger - Replacement - Continued
Turbocharger - Replacement - Continued
Turbocharger - Replacement - Continued
Turbocharger - Replacement - Continued
Turbocharger - Replacement - Continued
Turbocharger - Replacement - Continued
Turbocharger - Replacement - Continued
Turbocharger - Replacement - Continued
Exhaust Manifold and Gaskets Replacement
Exhaust Manifold and Gaskets Replacement - Continued
Exhaust Manifold and Gaskets Replacement - Continued
Lubricating System Repair Summary
Lubricating System Repair
Oil Cooler Element and Gasket Replacement
Oil Cooler Element and Gasket Replacement - Continued
Oil Cooler Element and Gasket Replacement - Continued
Oil Cooler Element and Gasket Replacement - Continued
Oil Cooler Element and Gasket Replacement - Continued
Oil Cooler Element and Gasket Replacement - Continued
Electrical System Repair Summary
Electrical System Repair
Alternator - Replacement
Alternator - Replacement - Continued
Alternator - Replacement - Continued
Alternator - Replacement - Continued
NOTES
Section V Specifications and Torque Values
General Specifications (Automotive Engines)
General Specifications (Automotive Engines)
General Specifications (Automotive Engines)
General Specifications (Automotive Engines)
Fuel Recommendations/Specifications
Acceptable Alternate Fuels - Component Wear/Durability
Lubricating Oil Recommendations/Specifications
New Engine Break-In Oils
Recommended Oil Change Intervals
Arctic Operation
Coolant Recommendations/Specifications
Filter Selection
Engine Component Torque Value
Engine Component Torque Value (Continued)
Engine Component Torque Value (Continued)
Sealants
Capscrew Markings and Torque Values
Capscrew Markings and Torque Values - Metric
Capscrew Markings and Torque Values U.S. Customary
Section S Service Assistance
Service Assistance
Problem Solving
General Information
Starting Procedure Matrix
Starting Procedure
Cold Weather Operation
Starting Procedure After Extended Shutdown or Oil Change
Operating the Engine
Engine Operating Range
Section 2 Maintenance Guidelines
General Information
Tool Requirements
Maintenance Schedule
Page References for Maintenance Instructions
Page References for Maintenance Instructions - Continued
Page References for Maintenance Instructions - Continued
Maintenance Record Form
Maintenance Record Form - Continued
NOTES
Section 3 Daily Maintenance Procedures
General Information
Oil Level
Coolant Level
Coolant Level - Continued
Drive Belt
Section 4 Maintenance Procedures at 10,000 Kilometers [6,000 Miles], 250 Hours or 3 Months
General Information
Lubricating Oil and Filter Change Interval
Lubricating Oil and Filter
Lubricating Oil and Filter - Continued
90 to 95 mm Filter Wrench
90 to 95 mm Filter Wrench - Continued
90 to 95 mm Filter Wrench - Continued
90 to 95 mm Filter Wrench - Continued
Air Intake System
Charge Air Cooler
Charge Air Cooler - Continued
Section 5 Maintenance Procedures at 19,000 Kilometers [12,000 Miles], 500 Hours or 6 Months
General Information
Fuel Filter
Fuel System
Low Pressure Lines and Fuel Filter(s)
High Pressure Lines
Re-Tighten Line Fittings
NOTES
Section 6 Maintenance Procedures at 38,000 Kilometers [24,000 Miles], 1000 Hours or 1 Year
General Information
Valves
Valves - Continued
Feeler Gauge
Six-Cylinder Engine Adjustment
Six-Cylinder Engine Adjustment - Continued
Drive Belt Tension
Drive Belt
NOTES
Section 7 Maintenance Procedures at 77,000 Kilometers [48,000 Mi.], 2000 Hours or 2 Years
General Information
Cooling System Maintenance
Cooling System Maintenance - Continued
Cooling System Flushing
Cooling System Flushing - Continued
Coolant System Filling
Coolant System Filling - Continued
Vibration Damper (Rubber)
Air Compressor
Air Compressor Discharge Inspection
Air Compressor Discharge Inspection - Continued
Section T Troubleshooting
Section T Troubleshooting - Continued
Troubleshooting Procedures and Techniques
Engine Will Not Crank or Cranks Slowly
Engine Hard to Start or Will Not Start (Exhaust Smoke Present)
Engine Hard to Start or Will Not Start (Exhaust Smoke Present) (Continued)
Engine Cranks But Will Not Start (No Smoke From Exhaust)
Engine Cranks But Will Not Start (No Smoke From Exhaust) (Continued)
Engine Starts But Will Not Keep Running
Engine Will Not Shut Off
Rough Idle, Warm Engine
Engine Surges at Idle
Lubricating Oil Pressure Low
Lubricating oil Pressure Low (Continued)
Lubricating Oil Pressure Too High
Lubricating Oil Loss
Coolant Temperature Above Normal
Coolant Temperature Above Normal (Continued)
Coolant Loss
Coolant Temperature Below Normal
Coolant Contaminated
Lubricating Oil Contaminated
Fuel or Oil Leaking from Exhaust Manifold
Exhaust Smoke Excessive Under Load
Exhaust Smoke Excessive Under Load (Continued)
Engine Will Not Reach Rated Speed When Loaded
Engine Will Not Reach Rated Speed When Loaded (Continued)
Power Output Low
Power Output Low (Continued)
Power Output Low (Continued)
Engine Misfiring
Fuel Knock
Fuel Consumption Excessive
Vibration Excessive
Engine Noises Excessive
Alternator Not Charging or Insufficient Charging
White Smoke Excessive During Cold Start
White Smoke Excessive During Cold Start (Continued)
Section A Adjustment, Replacement and Repair
Section A Adjustment, Replacement and Repair - Continued
Section A Adjustment, Replacement and Repair - Continued
Cooling System Repair Summary
Cooling System Repair
Belt Tensioner - Replacement
Fan Pulley Replacement
Water Pump Replacement
Water Pump Replacement - Continued
Water Pump Replacement - Continued
Water Pump Replacement - Continued
Water Pump Replacement - Continued
Water Pump Replacement - Continued
Thermostat Replacement
Thermostat Replacement - Continued
Thermostat Replacement - Continued
Thermostat Replacement - Continued
Thermostat Replacement - Continued
Thermostat Replacement - Continued
Fuel System Repair Summary
Fuel System Repair - In-Line Pump
Fuel System Repair - In-Line Pump - Continued
Lift Pump Replacement
Lift Pump Replacement - Continued
High Pressure Fuel Lines - Replacement
High Pressure Fuel Lines - Replacement - Continued
Fuel Drain Manifold - Replacement
Fuel Drain Manifold - Replacement - Continued
Injectors - Replacement
Injector Bore Brush
Injector Bore Brush - Continued
Injector Bore Brush - Continued
Fuel Shutoff Solenoid - Replacement
Injection Pump - Replacement
Injection Pump - Removal
Injection Pump - Removal - Continued
75 mm T-Bar Puller
Injection Pump - Installation
Injection Pump - Installation - Continued
Injection Pump - Installation - Continued
Injection Pump - Installation - Continued
Injection Pump - Installation - Continued
22 mm (A Pump), 30 mm (P Pump)
22 mm (A Pump), 30 mm (P Pump) - Continued
10 mm Hex Drive
Injection Pump - Idle Speed Adjustment
Air System Repair Summary
Air System Repair
Intake Manifold Cover and Gasket Replacement
Intake Manifold Cover and Gasket Replacement - Continued
Intake Manifold Cover and Gasket Replacement - Continued
Jacket-Water Aftercooler and Gasket - Replacement
Jacket-Water Aftercooler and Gasket - Replacement - Continued
Jacket-Water Aftercooler and Gasket - Replacement - Continued
Jacket-Water Aftercooler and Gasket - Replacement - Continued
Charge Air Cooler - Leak Check
Intake Manifold Pressure - Check
Intake Manifold Temperature - Check
Turbocharger - Replacement
Turbocharger - Replacement - Continued
Turbocharger - Replacement - Continued
Turbocharger - Replacement - Continued
Turbocharger - Replacement - Continued
Turbocharger - Replacement - Continued
Turbocharger - Replacement - Continued
Turbocharger - Replacement - Continued
Turbocharger - Replacement - Continued
Turbocharger - Replacement - Continued
Exhaust Manifold and Gaskets Replacement
Exhaust Manifold and Gaskets Replacement - Continued
Exhaust Manifold and Gaskets Replacement - Continued
Lubricating System Repair Summary
Lubricating System Repair
Oil Cooler Element and Gasket Replacement
Oil Cooler Element and Gasket Replacement - Continued
Oil Cooler Element and Gasket Replacement - Continued
Oil Cooler Element and Gasket Replacement - Continued
Oil Cooler Element and Gasket Replacement - Continued
Oil Cooler Element and Gasket Replacement - Continued
Electrical System Repair Summary
Electrical System Repair
Alternator - Replacement
Alternator - Replacement - Continued
Alternator - Replacement - Continued
Alternator - Replacement - Continued
NOTES
Section V Specifications and Torque Values
General Specifications (Automotive Engines)
General Specifications (Automotive Engines)
General Specifications (Automotive Engines)
General Specifications (Automotive Engines)
Fuel Recommendations/Specifications
Acceptable Alternate Fuels - Component Wear/Durability
Lubricating Oil Recommendations/Specifications
New Engine Break-In Oils
Recommended Oil Change Intervals
Arctic Operation
Coolant Recommendations/Specifications
Filter Selection
Engine Component Torque Value
Engine Component Torque Value (Continued)
Engine Component Torque Value (Continued)
Sealants
Capscrew Markings and Torque Values
Capscrew Markings and Torque Values - Metric
Capscrew Markings and Torque Values U.S. Customary
Section S Service Assistance
Service Assistance
Problem Solving
