Table of Contents
-
Group system exploded diagram
4 -
General safety instructions
8 -
Engine identification
16 -
General cleaning instructions
20 -
Section 0 - Engine Disassembly and Assembly - Group 00
21 -
Engine disassembly and assembly - service tools
25 -
Engine disassembly and assembly - general information
29 -
Engine - preparation for cleaning
30 -
Coolant - drainage
31 -
Crankcase breather - removal
32 -
Alternator Belts - Removal
33 -
Alternator - Removal
34 -
Dipstick tube and housing - removal
35 -
Water header covers - removal
36 -
Flywheel - removal
38 -
Flywheel housing - removal
39 -
Rear cover - removal
40 -
Water pump belt - removal
41 -
Air Compressor Coolant Inlet and Outlet Tubes - Removal
42 -
Accessory Drive Pulley - Removal
43 -
Stc external oil plumbing - removal
44 -
Stc oil control valve - removal
45 -
Celect™ sensor harness - removal
47 -
Celect™ ambient air pressure sensor - removal
48 -
Celect™ lubricating oil pressure sensor - removal
49 -
Stc engines
50 -
Accessory Drive - Removal
51 -
Lubricating oil pump - removal
52 -
Celect™ intake air temperature sensor - removal
53 -
Rocker housing covers - removal
54 -
Valve crossheads - removal
55 -
Rocker lever housing - removal
56 -
Fuel crossovers - removal
57 -
Cam Follower Assemblies - Removal
58 -
Accessory Drive Seal - Removal
59 -
Cylinder liners - removal
62 -
Crankshaft - removal
64 -
Cylinder block - removal from the rebuild stand
66 -
Crankshaft - installation
68 -
Cylinder liners - installation
77 -
Rear cover - installation
85 -
Crankshaft seal, rear - installation
86 -
Flywheel housing - installation
87 -
Flywheel - installation
92 -
Cylinder heads - installation
96 -
Camshaft - Installation
98 -
Cam Follower Assemblies - Installation
100 -
Timing tool installation
102 -
Accessory Drive - Installation
109 -
Celect™ engine position sensor (eps) - installation
111 -
Gear cover - installation
112 -
Camshaft Bearing Support - Installation
114 -
Accessory Drive Seal - Installation
116 -
Accessory Drive Pulley - Installation
117 -
Lubricating oil pan - installation
118 -
Injectors - installation
120 -
Push tubes - installation
122 -
Valve crossheads - installation
123 -
Rocker lever shaft assemblies - installation
124 -
Injector and valve adjustment
125 -
Engine brake - installation
135 -
C-brake - alternate method
138 -
Jacobs brake
139 -
Intake manifold - installation
140 -
Celect™ intake air temperature sensor - installation
141 -
Lubricating oil pump signal line - installation
142 -
Fuel tubing - installation
143 -
Air Compressor - Installation
144 -
Celect™ lubricating oil pressure sensor - installation
146 -
Stc oil control valve - installation
149 -
Vibration damper - installation
151 -
Water pump - installation
153 -
Water pump belt - installation and adjustment
154 -
Air Compressor Coolant Inlet and Outlet Tubes - Installation
155 -
Fan hub and fan hub support bracket - installation
156 -
Fan belts - installation and adjustment
157 -
Engine - removal from the rebuild stand
158 -
Piston cooling nozzles - installation
159 -
Water header covers - installation
160 -
Lubricating oil cooler assembly - installation
161 -
Alternator - Installation
162 -
Fan and fan spacer - installation
163 -
Starting motor - installation
164 -
Turbocharger - installation
165 -
Crankcase breather tube - installation
167 -
Engine - covering all openings
168 -
Section 1 - Cylinder Block - Group 01
169 -
Cylinder block - service tools
171 -
Cylinder block - exploded view
174 -
Cylinder block - general information
176 -
Cam bore rear cup plug - removal
177 -
Dowel pin - removal
178 -
Camshaft bushings - removal
179 -
Camshaft bore - cleaning
183 -
Cylinder block - inspection
188 -
Coolant passage - inspection
189 -
Coolant passage - repairing
191 -
Cylinder head capscrew holes - repairing
194 -
Camshaft bushings - installation
198 -
Dowel pin - installation
202 -
Cam bore rear cup plug - installation
204 -
Pistons - cleaning and inspection
209 -
Connecting rod ring dowels - removal
215 -
Alignment - inspection
216 -
Twist - inspection
217 -
Crankshaft - cleaning and inspection
222 -
Main bearings - cleaning
230 -
Thrust bearings - inspection
231 -
Gear cover - cleaning and inspection
237 -
Accessory drive bushing - replacement
239 -
Rear cover - cleaning and inspection
240 -
Magnetic crack inspection
242 -
Cylinder head - service tools
244 -
Cylinder head - exploded view
248 -
Cylinder head - general information
249 -
Grinding the valve seats
259 -
Cylinder head - grinding the valves
271 -
Cylinder head - pressure testing
277 -
Rocker lever housing assembly - service tools
286 -
Rocker lever housing assembly - general information
291 -
Rocker lever bushing - replacement
296 -
Ring and pin dowel - replacement
304 -
Cam follower assembly - service tools
308 -
Cam follower assembly - exploded view
309 -
Cam follower assembly - general information
310 -
Cam follower assembly - rebuild
313 -
Inspection - magnetic crack
319 -
Cam follower socket - replacement
323 -
Fuel pump - general information
327 -
Cleaning - pt fuel pump
328 -
Cleaning - celect™ fuel pump
329 -
Section 6 - Injectors and Fuel Lines - Group 06
334 -
Injector - celect™ - exploded view
337 -
Injectors - pt (type d) step timing control (stc) - general information
338 -
Cleaning - stc
339 -
Inspection - celect
340 -
Stc oil control valve - cleaning
341 -
Lubricating oil system - service tools
344 -
Lubricating oil system - exploded view
345 -
Lubricating oil pump assembly - exploded view
346 -
Lubricating oil system - general information
349 -
Lubricating oil dipstick - calibration
351 -
Testing - oil cooler core
375 -
Testing - oil cooler bypass valve
376 -
Testing - lubricating oil filter bypass valve poppet valve spring
377 -
Installation - oil cooler core
378 -
Installation - lubricating oil filter bypass valve
380 -
Drive units - service tools
406 -
Accessory drive - exploded view
407 -
Drive units - general information
408 -
Accessory drive gear - replacement
414 -
Intake air system - service tools
421 -
Intake air system - exploded view
422 -
Exhaust system - exploded view
429 -
Exhaust system - general information
430 -
Mounting hole threads - inspection
432 -
Air compressor
434 -
Electrical equipment - general information
438 -
Wiring diagrams
439 -
Section 14 - Engine Testing - Group 14
441 -
General information
442 -
Definition of terms on engine performance curve
443 -
General run-in procedures
444 -
General engine test/run-in specifications
446 -
Engine testing - service tools
447 -
Engine dynamometer - install engine
449 -
Fuel pressure
453 -
Electronic hookup - celect™ engines only
454 -
Lubricating oil system priming
458 -
Fuel system priming - pt system
462 -
Fuel system priming - celect™ system
463 -
Dynamometer worksheet
468 -
Chassis dynamometer operation
469 -
Fuel pressure (stc engines only)
472 -
Intake manifold pressure
474 -
Charge air cooler restriction
475 -
Exhaust air restriction
476 -
Lubricating oil pressure
477 -
Engine painting
482 -
Remove the engine from short term storage
485 -
Remove the engine from long term storage
487 -
Mounting adaptations - service tools
493 -
Mounting adaptations - exploded view
494 -
Mounting adaptations - general information
495 -
Flywheel ring gear - replacement
497 -
Front engine support bracket - cleaning and inspection for reuse
504 -
Capscrew markings and torque values
509
