Overhaul Manual
TK482 and TK486 TK 50136-2-OM (Rev. 2, 02/06)
Copyright © 1998 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in U.S.A.
This manual is published for informational purposes only and the information so provided should not be considered as all-inclusive or covering all contingencies. If further information is required, Thermo King Corporation should be consulted. Sale of product shown in this manual is subject to Thermo King’s terms and conditions including, but not limited to, the Thermo King Ki ng Limited Express Warranty. Warranty. Such terms and conditions are available upon request. Thermo King’s warranty will not apply to any equipment which has been “so repaired or altered alter ed outside the manufacturer’s plants as, in the manufacturer’s judgment, to effect its stability.” stability.” No warranties, express or implied, including warranties of fitness for a particular purpose or merchantability, or warranties arising from course of dealing or usage of trade, are made regarding the information, recommendations, and descriptions contained herein. Manufacturer Manufacturer is not responsible and will wil l not be held liable in contract or in tort (including negligence) for any special, indirect or consequential damages, including injury or damage caused to vehicles, contents or persons, by reason of the installation of any Thermo King product or its mechanical failure.
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Table of Contents List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TK482 & TK486 Diesel Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Tier 1 and Earlier - TK482, TK482E, TK486, TK486E, and TK486EH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Tier 2 - TK486V, TK486VB, and TK486VH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Exhaust Gas Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 TK482, TK482E, TK486, TK486E, and TK486EH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 TK486V, TK486VB, and TK486VH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Inspection and Reconditioning Recondit ioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Wrist Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Timing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Valve Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Valve Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Push Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Oil Pump for Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Oil Pump for Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Crankcase Breather System Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Crankcase Breather System Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Checking Crankcase Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Assembly Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Bleeding Air from the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Injection Pump Timing Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Attaching Injection Pump Gear to Flange on Tier 1 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Injection Pump Timing Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Injection Pump Removal and Installation (All Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 105 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Trochoid Feed Pump Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Trochoid Feed Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Trochoid Feed Pump O-Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Cold Start Device Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Checking Cold Start Device Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Cold Start Device Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
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Table of Contents Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Fuel Return Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Fuel Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Fuel Transfer Pump Operation Operatio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Fuel System Operation and Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Normal Fuel System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Static Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Static Air Leaks Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Solution for Static Air Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 FAQ (Frequently Asked Questions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Using Clear Fuel Lines To Diagnose Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122 . 122 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Battery Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Cold Weather Battery Recommendation for Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 TK482/TK486 Starters Not Interchangeable with di2.2/se2.2 Starters . . . . . . . . . . . . . . . . . . . . . . . . . . . .124 . 124 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Major Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Fuel Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Fuel Solenoid Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Run In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Dynamometer Run In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Run In Procedure without Dynamometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137 . 137 Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Compression Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Compression Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Special Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Checking Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Gear Case Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Engine History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Engine History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Released . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Front Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Rear Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Flywheel Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 EPA Tier 1 Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Oil Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 ELC Compatible Water Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 EMI 3000 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Screw-In Oil Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 EPA Tier 2 Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Engine History Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Engine Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 History of Engine Related Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153 . 153 Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Fuel Solenoid Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Alternator Mounting Brackets for Model 30 Trailer Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
4
List of Figures Figure 1: Valve Guide Removal Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Figure 2: Valve Guide Installation Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Figure 3: Valve Stem Seal Installation Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Figure 4: Connect Connecting ing Rod Bushing Bushing Removal Removal and Installation Installation Tool Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Figure 5: Camshaft Bearing Removal Tool To ol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Figure 6: Front View of Early Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Figure 7: Front View of Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Figure 8: 8: Remove Remove Fuel Injectio Injection n Lines Tier Tier 1 and Earlier Earlier Engines Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Figure 9: 9: Remove Remove Fuel Injection Injection Lines Tier Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Figure 10: 10: Remove Remove Fuel Injectio Injection n Nozzles Nozzles Tier 1 and Earlier Earlier Engines Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Figure 11: 11: Remove Fuel Fuel Injection Injection Nozzles Nozzles Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Figure 12: Remove Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Figure 13: 13: Disconnect Disconnect Coolant Coolant Hoses Hoses on Tier 2 Engines Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Figure 14: Remove Valve Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Figure 15: Remove Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Figure 16: Remove Valve Stem Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Figure 17: Remove Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Figure 18: Remove Oil Filter and Oil Filter Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Figure 19: Remove Oil Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Figure 20: Remove Fuel Transfer Tran sfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Figure 21: Remove Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Figure 22: 22: Remove Remove Gear Case Case Cover and Sound Shield Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Figure 23: Check Timing Gear Lash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Figure 24: 24: Remove Remove Fuel Injection Injection Pump Pump Gear Nut Nut and Lock Washer Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Figure 25: Use Puller Puller to Remove Remove Fuel Fuel Injection Injection Pump Gear Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Figure 26: 26: Single-Pie Single-Piece ce Fuel Injection Injection Pump Gear Gear Early Early Engines Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Figure 27: 27: Three-Piece Three-Piece Fuel Fuel Injection Injection Pump Gear Tier Tier 1 Engine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Figure 28: 28: Three-Piece Three-Piece Fuel Fuel Injection Injection Pump Gear Gear Tier 2 Engine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Figure 29: Tier 1 and Earlier Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Figure 30: 30: Typical Tier Tier 1 and Earlier Earlier Index Index Mark Alignment Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Figure 31: Tier 2 Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Figure 32: Typical Tier 2 Index Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Figure 33: 33: Remove Remove Fuel Injection Injection Pump Pump Tier 1 and Earlier Earlier Engines Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Figure 34: 34: Remove Fuel Fuel Injection Injection Pump Tier Tier 2 Engines Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Figure 35: 35: Remove Remove Oil Pump Pump Tier 1 and Earlier Earlier Engines Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Figure 36: Remove Idler Gear and Idler Gear Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Figure 37: Remove Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Figure 38: Remove Bellhousing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Figure 39: Rear Seal Removal Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Figure 40: Remove Rear Seal Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Figure 41: Remove Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Figure 42: Remove Oil Pump Intake Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Figure 43: Remove Camshaft Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Figure 44: Remove Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Figure 45: Remove Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Figure 46: Remove Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Figure 47: Remove Piston and Rod Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Figure 48: Remove Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Figure 49: Measuring Cylinder Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Figure 50: Cylinder Measuring Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Figure 51: Pressing Tool Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Figure 52: Cylinder Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Figure 53: Cylinder Sleeve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Figure 54: Measuring Front Fron t Camshaft Bearing Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Figure 55: Main Bearing Cap Marks Ma rks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Figure 56: Measuring Main Bearing Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Figure 57: Checking Main Bearing Bore Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Figure 58: Measuring Main Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5
List of Figures Figure 59: Measuring Rod Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Figure 60: Measuring Crankshaft Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Figure 61: Crankshaft Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Figure 62: Piston Measuring Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Figure 63: Measuring Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Figure 64: Checking Ring Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Figure 65: Measuring Wrist Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Figure 66: Measuring Rod Bearing or Bearing Bear ing Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Figure 67: Measuring Connecting Rod Twist and Parallelism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 . 48 Figure 68: Measuring Wrist Pin Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Figure 69: Measuring Idler Gear Gea r Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Figure 70: Measuring Idler Gear Ge ar Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Figure 71: Measuring Camshaft Journals Jour nals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Figure 72: Measuring Cam Lobes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Figure 73: Measuring Camshaft Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Figure 74: Checking Thrust Plate Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 Figure 75: Checking Cylinder Head Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Figure 76: Cylinder Head Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Figure 77: Removing or Installing Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Figure 78: Valve Guide Projection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Figure 79: Valve Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Figure 80: Measuring Valve Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Figure 81: Measuring Valve Stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Figure 82: Valve Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Figure 83: Intake Valve Seat Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Figure 84: Exhaust Valve Seat Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Figure 85: Measuring Valve Seat Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Figure 86: 86: Dimensions Dimensions for Replacem Replacement ent Valve Valve Seat Bores Tier Tier 1 and Earlier Earlier Engines Engines . . . . . . . . . . . . . . . . . . . 55 Figure 87: 87: Dimensions Dimensions for Replacement Replacement Valve Seat Bores Tier Tier 2 Engines Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 Figure 88: Measuring Valve Spring Free Fre e Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Figure 89: Checking Valve Spring Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Figure 90: Valve Spring Measurements Measuremen ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Figure 91: Installing Valve Stem Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Figure 92: Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Figure 93: Lapping Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Figure 94: Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Figure 95: Measuring Rocker Arm Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Figure 96: Measuring Rocker Arm Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 Figure 97: Checking Bend in Push Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Figure 98: Tappet Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Figure 99: Measuring Tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Figure 100: 100: Oil Pump Assembly Assembly Tier 1 and Earlier Earlier Engines Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 . 61 Figure 101: Checking Checking Clearan Clearance ce Between Between Oil Pump Body and and Outer Rotor Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . .61 Figure 102: Checking Clearance Between Inner Rotor and Outer Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Figure 103: Checking Clearance Between Rotor Plate and Rotors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 . 62 Figure 104: Mark on Outer Outer Rotor Faces Faces Oil Pump Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 Figure 105: Oil Pump Located in Gear Case Cover on Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Figure 106: Oil Pump Components Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Figure 107: 107: Measure Inner Inner Rotor to Cranksh Crankshaft aft Gear Boss Clearance Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Figure 108: Oil Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Figure 109: Water Water Pump Pump and Thermostat Thermostat Assembli Assemblies es Tier Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . 64 Figure 110: Water Water Pump and Thermostat Thermostat Assembly Assembly Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Figure 111: Crankcase Crankcase Breather Breather Tier Tier 1 and Earlier Earlier Engines Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Figure 112: Crankcase Breather Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Figure 113: Magnehelic Gauge Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Figure 114: Measuring Crankcase Pressure Pre ssure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Figure 115: Install Camshaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Figure 116: Install Upper Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Figure 117: Install Upper Thrust Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Figure 118: Install Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 6
List of Figures Figure 119: Install Lower Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Figure 120: Install Lower Thrust Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Figure 121: Main Bearing Cap Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Figure 122: Install Main Bearing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Figure 123: Check Plastigauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Figure 124: Check End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Figure 125: Assemble Piston and Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Figure 126: 126: Ring Placemen Placementt Tier 1 and Earlier Earlier Engines Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Figure 127: 127: Ring Placemen Placementt Tier 2 Engines Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Figure 128: Check Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Figure 129: Mark on Ring Faces Face s Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Figure 130: Oil Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Figure 131: Ring Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Figure 132: Install Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Figure 133: Install Rod Cap and Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Figure 134: Check Plastigauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Figure 135: Front of Engine Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Figure 136: Install Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Figure 137: Install Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Figure 138: Install Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Figure 139: Install Camshaft Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Figure 140: 140: Install Install Oil Pump Tier Tier 1 and Earlier Earlier Engines Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Figure 141: 141: Install Install Fuel Fuel Injection Injection Pump Pump Tier 1 and Earlier Earlier Engines Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Figure 142: 142: Install Install Fuel Fuel Injection Injection Pump Pump Tier 2 Engines Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Figure 143: Tier 1 and Earlier Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Figure 144: 144: Typical Typical Tier 1 and Earlier Earlier Index Index Mark Alignment Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Figure 145: Tier 2 Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Figure 146: Typical Tier 2 Index Ind ex Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Figure 147: Install Fuel Injection Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Figure 148: Install Idler Gear and Idler Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Figure 149: Align Timing Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Figure 150: Install Cylinder Head and Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Figure 151: Cylinder Head Bolt Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Figure 152: Install Valve Stem Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Figure 153: Install Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Figure 154: Adjust Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Figure 155: Install Oil Filter Head and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Figure 156: Install Valve Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Figure 157: Install Oil Pump Intake Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Figure 158: Install Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Figure 159: Install Rear Seal Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Figure 160: Install Rear Seal with Tool P/N 204-952 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Figure 161: Install Bellhousing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Figure 162: Install Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Figure 163: Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Figure 164: Align Flat Sides of Crankshaft Gear with Flat Sides of Inner Rotor in Timing Gear Cover . . . . . . . 84 Figure 165: 165: Install Install Gear Case Cover Cover and Sound Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Figure 166: Install Front Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Figure 167: Dowel Pin Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Figure 168: Install Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Figure 169: Install Oil Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Figure 170: Install Fuel Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Figure 171: Install Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Figure 172: 172: Connect Connect Coolant Coolant Hoses Hoses on Tier 2 Engines Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Figure 173: 173: Install Install Fuel Fuel Injection Injection Nozzles Nozzles Tier Tier 1 and Earlier Earlier Engines Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Figure 174: 174: Install Install Fuel Injection Injection Nozzles Nozzles Tier Tier 2 Engines Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Figure 175: 175: Install Install Fuel Fuel Injection Injection Lines Lines Tier 1 and Earlier Earlier Engines Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Figure 176: 176: Install Install Fuel Injection Injection Lines Lines Tier 2 Engines Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Figure 177: 177: Fuel Injection Injection Line Connections Connections on Tier 2 Engines Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Figure 178: Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 7
List of Figures Figure 179: Typical Fuel System for Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Figure 180: Typical Fuel System for Tier Tie r 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Figure 181: Tier 1 and Earlier Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Figure 182: Tier 2 Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Figure 183: Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Figure 184: Top Dead Center One and Four . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97 Figure 185: 185: Fuel Solenoid Solenoid Connector Connector Pin Identificati Identification on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Figure 186: Timing Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Figure 187: Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Figure 188: Correct Timing Mark Alignment for TK482 and TK486 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 . 99 Figure 189: Correct Timing Mark Alignment for TK482E and TK468E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 . 99 Figure 190: Correct Correct Timing Timing Mark Mark Alignment Alignment for TK486EH TK486EH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 . 99 Figure 191: Three-Piece Fuel Injection Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Figure 192: Timing Mark on Injection Pump Gear with Transfer Pump Cam Installed . . . . . . . . . . . . . . . . . . .100 . 100 Figure 193: Timing Mark on Injection Pump Gear without Transfer T ransfer Pump Cam Installed . . . . . . . . . . . . . . . . . 100 Figure 194: Flange and Injection Pump Gear Alignment with Transfer Pump Cam Installed . . . . . . . . . . . . . .101 Figure 195: Flange and Injection Pump Gear Alignment without without Transfer Pump Cam Installed Installed . . . . . . . . . . .101 . 101 Figure 196: Timing Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Figure 197: Tier 2 Index Mark Location Loca tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Figure 198: Tier 2 Index Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 . 102 Figure 199: Marking Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Figure 200: Place Place Injectio Injection n Angle Angle Sticker Sticker on Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Figure 201: Injection Angle Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Figure 202: Removing Injection Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Figure 203: Injection Angle Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Figure 204: Injection Angle Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Figure 205: Injection Pump Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Figure 206: Examples of Injection Pump Index Mark Alignment with Injection Angle Sticker . . . . . . . . . . . . . .104 .10 4 Figure 207: Timing Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Figure 208: Align Flat Sides of Crankshaft Gear with Flat Sides of Inner Rotor in Timing Gear Cover . . . . . . 104 Figure 209: Tier 1 and Earlier Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Figure 210: 210: Typical Typical Tier 1 and Earlier Earlier Index Index Mark Alignment Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Figure 211: Tier 2 Index Mark Location Loca tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Figure 212: Typical Tier 2 Index Mark Mar k Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Figure 213: Injection Pump Gear Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Figure 214: Trochoid Feed Pump Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Figure 215: Trochoid Feed Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Figure 216: Trochoid Feed Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Figure 217: Trochoid Feed Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Figure 218: Trochoid Feed Pump Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109 . 109 Figure 219: Cold Start Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Figure 220: Remove Engine Coolant Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Figure 221: Remove Cold Start Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Figure 222: Clean Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Figure 223: Testing Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Figure 224: Acceptable Spray Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Figure 225: Unacceptable Spray Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 . 111 Figure 226: Injection Nozzle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Figure 227: Testing Nozzle Valve and Seat Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Figure 228: Fuel Return Line Replacement Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Figure 229: Fuel Return Line Replacement Replaceme nt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Figure 230: Outlet Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Figure 231: Inlet and Delivery Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Figure 232: Pressure Controlled Delivery Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Figure 233: Fuel Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Figure 234: Fuel System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Figure 235: Fuel Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Figure 236: Tier 1 and Earlier Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Figure 237: Tier 2 Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Figure 238: Tier 1 and Earlier Starter Star ter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 8
List of Figures Figure 239: Tier 2 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Figure 240: TK482/TK TK482/TK486 486 Starter Starter (Tier (Tier 1 and Earlier Earlier Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Figure 241: di2.2/se2.2 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Figure 242: De-energized Starter Star ter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Figure 243: Energized Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Figure 244: Starter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Figure 245: Check Brush Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Figure 246: Measure Brushes Brushe s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Figure 247: Check Field Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Figure 248: Check Stator Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Figure 249: Check Armature Distortion Distortio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Figure 250: Clean Up Commutator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Figure 251: Check Commutator Undercut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Figure 252: Check Armature Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Figure 253: Check Shunt Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Figure 254: Check Series Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Figure 255: Check Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Figure 256: Install Shift Lever and Spring Spr ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Figure 257: No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Figure 258: Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Figure 259: 259: Fuel Solenoid Solenoid Connector Connector Pin Identificatio Identification n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Figure 260: Fuel Solenoid Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Figure 261: Fuel Solenoid Timer Time r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Figure 262: 262: Simplified Simplified Schematic Schematic Diagram Diagram of Fuel Solenoid Solenoid System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Figure 263: 263: Main Wire Wire Harness Connect Connector or Pin Identificatio Identification n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Figure 264: 264: Fuel Solenoid Solenoid Connector Connector Pin Identificatio Identification n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Figure 265: Relay Socket Terminal Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Figure 266: Top Dead Center One and Four . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Figure 267: Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Figure 268: Adjusting Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Figure 269: Early Engine Shown Others Similar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Figure 270: Remove Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Figure 271: 271: Remove Remove Sound Shield Shield and and Gear Case Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Figure 272: Oil Pump Located in Gear Case Cover on Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Figure 273: 273: Remove Remove Oil Pump Pump Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Figure 274: 274: Check Check Intake Intake Pipe Gasket Gasket Tier Tier 1 and Earlier Earlier Engines Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Figure 275: Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Figure 276: Align Flat Sides of Crankshaft Gear with Flat Sides of Inner Rotor in Timing Gear Cover . . . . . . 143 Figure 277: Dowel Pin Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Figure 278: Install Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Figure 279: Front Pulley and Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Figure 280: Front Pulley and Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Figure 281: Water Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Figure 282: Oil Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Figure 283: 283: Retrofitting Retrofitting Low Mount ELC Compatible Compatible Water Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Figure 284: Oil Filter Heads and Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Figure 285: Oil Level Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Figure 286: Tier 1 (and Earlier) Earlier ) Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Figure 287: Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Figure 288: Typical Serial Number Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Figure 289: 289: Serial Number Number Nameplat Nameplate e Location Location Tier 1 and Earlier Earlier Engines Engines . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Figure 290: 290: Serial Number Number Nameplat Nameplate e Location Location Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Figure 291: Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Figure 292: Early Early Style Style Fuel Solenoid Solenoid Timer Timer P/N 41-1533 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Figure 293: 293: Late Style Style Fuel Fuel Solenoid Solenoid Timer P/N 41-2191 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Figure 294: 294: Alternator Alternator Mountin Mounting g Brackets Brackets for High Mount Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Figure 295: Early Style Alternator Mounting Brackets for Low Mount Water Pump . . . . . . . . . . . . . . . . . . . . . 154 Figure 296: Late Style Alternator Mounting Brackets for Low Mount Water Pump . . . . . . . . . . . . . . . . . . . . . . 154
9
List of Figures
10
TK482 & TK486 Diesel Engine Specifications This manual contains information about the TK482 and TK486 engine families.
The TK482 TK482 engi engine ne fami family ly inclu includes des the TK482 TK482 and and TK48 TK482E. 2E.
•
The TK486 TK486 engine engine family family include includess the TK486, TK486, TK486 TK486E, E, TK486EH TK486EH,, TK486V TK486V,, TK486VB, TK486VB, and and TK486VH.
•
The TK482 TK482 and TK486 TK486 were made before before the requiremen requirementt to comply comply with EPA EPA regulation regulations. s.
•
The TK482E, TK482E, TK486E TK486E,, and and TK486EH TK486EH comply comply with with EPA EPA Tier Tier 1 regulation regulations. s.
•
The TK486V TK486V,, TK486VB TK486VB (used (used in bus applic application ations), s), and TK486 TK486VH VH comply comply with any any EPA EPA Tier Tier 2 regulations.
•
Tier Tier 1 and earlier earlier engine enginess (TK482, (TK482, TK486, TK486, TK482 TK482E, E, TK486E, TK486E, and and TK486EH TK486EH)) use an an in-line in-line injection injection pump.
•
Tier Tier 2 engines engines (TK486V (TK486V,, TK486VB, TK486VB, and TK486 TK486VH) VH) use a mono-plu mono-plunger nger and and distributor distributor injection injection pump.
See “Engine Model Model Identification” Identification” on page 152 for 152 for information about identifying the engine models. See “Engine “Engine History” History” on page 147 more 147 more information about the engine models and changes. NOTE: The number 1 cylinder is on the flywheel (rear) end of of the engine.
Tier 1 and Earlier TK482, TK482E, TK486, TK486E, and TK486EH Except where noted, the specifications for these engines are the same. General Type
Four Stroke Cycle Water Cooled
Number of Cylinders
4
Cylinder Arrangement
In-line Vertical, Number 1 on Flywheel End
Bore TK482, and TK482E
3.23 in. (82.0 mm)
TK486, TK486 486E, and TK486EH
3.39 in. (86.0 mm)
Stroke
3.54 in. (90.0 mm)
Displacement TK482, and TK482E
116 cu. in. (1.90 liters)
TK48 TK486, 6, TK48 TK486E 6E,, and and TK48 TK486E 6EH H
128 128 cu. cu. in. in. (2.0 (2.09 9 lite liters rs))
Power Rating TK482, and TK482E
30.3 hp (22.6 kW) @ 2200 rpm
TK486, and TK486E
33.9 hp (25.3 kW) @ 2200 rpm
TK486EH
35.0 hp (26.1 kW) @ 2600 rpm
Compression Ratio
18.0 to 1
Direction of Rotation
Counterclockwise (Viewed from Flywheel)
Firing Order
1-3-4-2 (Number 1 on Flywheel End)
Fuel Injection Timing TK482 and TK486
12 ± 1 Degrees BTDC
TK482E and TK486E
10 ± 1 Degrees BTDC
TK486EH
11 ± 1 Degrees BTDC
Nozzle Injection Pressure
2,800-3,000 psi (19,600-20,600 kPa)
11
TK482 & TK486 Diesel Engine Specifications
Tier 1 and Earlier TK482, TK482E, TK486, TK486E, and TK486EH (Continued) General (Continued) Oil Pressure
18.5 psi (127 kPa) Minimum @ 230 F (110 C) & 1600 rpm 45-57 psi (310-390 kPa) @ 230 F (110 C) & 2200 rpm
Engine Coolant Thermostat
180 F (82 C)
Valve Clearance (Static @ 70 F [21 C]) Intake
0.006-0.010 in. (0.15-0.25 mm)
Exhaust
0.006-0.010 in. (0.15-0.25 mm)
Valve Train
Standard Dimensions
Wear Limit
Free Length
1.75 in. (44.5 mm)
1 . 6 7 i n. ( 42 . 5 m m )
Inclination (Top to Bottom from Vertical)
0-0.04 in. (0-1.1 mm)
0.04 in. (1.1 mm)
Intake
0.3154-0.3159 in. (8.010-8.025 mm)
0.3189 in. (8.100 mm)
Exhaust
0.3156-0.3161 in. (8.015-8.030 mm)
0.3189 in. (8.100 mm)
Intake
0.3132-0.3140 in. (7.955-7.975 mm)
0.3110 in. (7.900 mm)
Exhaust
0.3132-0.3138 in. (7.955-7.970 mm)
0.3110 in. (7.900 mm)
Intake
0.0014-0.0028 in. (0.035-0.070 mm)
0.0079 in. (0.200 mm)
Exhaust
0.0018-0.0030 in. (0.045-0.075 mm)
0.0079 in. (0.200 mm)
Intake
0.0490-0.0569 in. (1.244-1.444 mm)
0.020 in. (0.50 mm)
Exhaust
0.0531-0.0610 in. (1.350-1.550 mm)
0.020 in. (0.50 mm)
Intake
0.0120-0.0199 in. (0.306-0.506 mm)
0.039 in. (1.00 mm)
Exhaust
0.0118-0.0197 in. (0.300-0.500 mm)
0.039 in. (1.00 mm)
Valve Spring
Valve Guide Inside Diameter
Valve Stem Outside Diameter
Valve Stem to Valve Guide Clearance
Valve Margin Mar gin
Valve Depth (Cylinder Head Deck to Valve)
Valve Guide Projection (Above Valve Spring Seat in Cylinder Head) Intake
0.591 in. (15.00 mm)
Exhaust
0.591 in. (15.00 mm)
Valve Angle Intake
30 Degrees
Exhaust
45 Degrees
Valve Seat Angle Intake
30 Degrees
Exhaust
45 Degrees
Valve Seat Width Intake
0.042-0.049 in. (1.07-1.24 mm)
0.069 in. (1.74 mm)
Exhaust
0.049-0.057 in. (1.24-1.45 mm)
0.076 in. (1.94 mm)
Rock Ro cker er Arm Arm Bush Bushin ing g Insi Inside de Dia Diame meter ter
0.629 0.62999-0.6 0.630 307 7 in. in. (16.0 (16.000 00-1 -16.0 6.020 20 mm) mm)
0.63 0.6335 35 in. in. (16.0 (16.090 90 mm) mm)
Rock Ro cker er Arm Arm Shaf Shaftt O Out utsi side de Diam Diamet eter er
0.628 0.6 286-0 6-0.6 .6293 293 in. in. ((15. 15.96 966-1 6-15. 5.98 984 4 mm) mm)
0.62 0.6280 80 in. in. ((15 15.9 .950 50 mm mm))
12
TK482 & TK486 Diesel Engine Specifications
Tier 1 and Earlier TK482, TK482E, TK486, TK486E, and TK486EH (Continued) (Continu ed) Valve Train (Continued)
Standard Dimensions
Wear Limit
Rocker Arm Bushing to Rocker Arm Shaft Clearance
0.00 0.0006 06-0 -0.0 .002 021 1 in. in. (0.0 (0.016 16-0 -0.0 .054 54 mm) mm)
0.00 0.0055 55 in. in. (0. (0.14 140 0 mm) mm)
Tappet O Ou utside Di Diameter
0.4715-0.4720 in in. ((1 11.975-11.990 mm mm)
0.4697 in in. ((1 11.930 mm mm)
Tappet Bo Bore In Inside Di Diameter
0.4724-0.4731 in in. (1 (12.000-12.018 mm mm)
0.4744 in in. (1 (12.050 mm mm)
Tappe appett To Tappe appett Bore Bore Clea Cleara ranc nce e
0.00 0.0004 04-0 -0.0 .001 017 7 in. in. (0.0 (0.010 10-0 -0.0 .043 43 mm mm))
0.00 0.0047 47 in. in. (0.1 (0.120 20 mm mm))
Push Rod Bend
0-0.001 in. (0-0.03 mm)
0.001 in. (0.03 mm)
1.5211-1.5262 in. (38.635-38.765 mm)
1.5118 in. (38.400 mm)
Timing Gear End
1.7687-1.7697 in. (44.925-44.950 mm)
1.7657 in. (44.850 mm)
Middle
1.7681-1.7691 in. (44.910-44.935 mm)
1.7657 in. (44.850 mm)
Flywheel End
1.7687-1.7697 in. (44.925-44.950 mm)
1.7657 in. (44.850 mm)
Timin iming g Gea Gearr End End Bear Bearin ing g Ins Inser ertt
1.77 1.7713 13-1 -1.7 .773 738 8 in. in. (44. (44.99 9900-45 45.0 .055 55 mm mm))
1.77 1.7756 56 in. in. (45 (45.1 .100 00 mm mm))
Middle Be Bearing (N (No In Insert)
1.7717-1.7726 in in. (4 (45.000-45.025 mm mm)
1.7756 in in. (4 (45.100 mm mm)
Flyw Flywhe heel el End End Bea Beari ring ng (No (No Ins Insert ert))
1.771 1.7 717-1 7-1.7 .7726 726 in. in. ((45. 45.000 000-4 -45.0 5.025 25 mm mm))
1.775 1.7756 6 in. in. (45.1 (45.100 00 mm mm))
Timing Gear End
0.0016-0.0051 in. (0.040-0.130 mm)
0.0079 in. (0.200 mm)
Middle
0.0026-0.0045 in. (0.065-0.115 mm)
0.0079 in. (0.200 mm)
Flywheel End
0.0020-0.0039 in. (0.050-0.100 mm)
0.0079 in. (0.200 mm)
Camshaft Deflection
0.001 in. (0.02 mm)
0.002 in. (0.05 mm)
Camshaft End Play
0.002-0.010 in. (0.05-0.25 mm)
0.016 in. (0.40 mm)
Camshaft Cam Lobe Height Camshaft Journal Outside Diameter
Camshaft Bearing Inside Diameter
Camshaft Camshaft Journal to Camshaft Bearing Bearing Clearance
Piston, Piston Rings, and Wrist Pin Piston Outside Diameter Measuring Point (From Bottom of Piston Perpendicular to Wrist Pin)
0.95 in. (24.0 mm)
Piston Outside Diameter TK482 and TK482E Standard
3.2260-3.2272 in. (81.940-81.970 mm)
3.2244 in. (81.900 mm)
1st Oversi Oversize ze 0.01 0.010 0 in. in. (0.25 (0.25 mm) mm)
3.2358-3 3.23 58-3.237 .2370 0 in. in. (82.190(82.190-82.2 82.220 20 mm)
3.2343 3.2 343 in. (82.150 (82.150 mm)
2nd Overs Oversize ize 0.0 0.020 20 in. in. (0.50 (0.50 mm) mm)
3.24573.24 57-3.24 3.2469 69 in. in. (82.44 (82.440-8 0-82.47 2.470 0 mm) mm)
3.2441 3.2 441 in. in. (82.4 (82.400 00 mm) mm)
Standard
3.3835-3.3846 in. (85.940-85.970 mm)
3.3819 in. (85.900 mm)
1st Oversi Oversize ze 0.01 0.010 0 in. in. (0.25 (0.25 mm) mm)
3.3933-3 3.39 33-3.394 .3945 5 in. in. (86.190(86.190-86.2 86.220 20 mm)
3.3917 3.3 917 in. (86.150 (86.150 mm)
2nd Overs Oversize ize 0.0 0.020 20 in. in. (0.50 (0.50 mm) mm)
3.40313.40 31-3.40 3.4043 43 in. in. (86.44 (86.440-8 0-86.47 6.470 0 mm) mm)
3.4016 3.4 016 in. in. (86.4 (86.400 00 mm) mm)
TK486, TK486E, and TK486EH
Pist Piston on to Cyli Cylind nder er Wall all Clea Cleara ranc nce e
0.00 0.0012 12-0 -0.0 .003 035 5 in. in. (0.0 (0.030 30-0 -0.0 .090 90 mm mm))
Piston Top Clearance (Between Top of Piston at TDC and Combustion Chamber with Cylinder Head Installed)
0.026-0.033 in. (0.65-0.83 mm)
13
TK482 & TK486 Diesel Engine Specifications
Tier 1 and Earlier TK482, TK482E, TK486, TK486E, and TK486EH (Continued) Piston, Piston Rings, and Wrist Pin (Continued)
Standard Dimensions
Wear Limit
Piston Ring Groove Width Top Ring Groove
0.0813-0.0819 in. (2.065-2.080 mm)
Middle Ring Groove
0.0801-0.0807 in. (2.035-2.050 mm)
Bottom Ring Groove
0.1581-0.1587 in. (4.015-4.030 mm)
Piston Ring Width Top Ring
0.0776-0.0783 in. (1.970-1.990 mm)
Middle Ring TK482 and TK482E
0.0776-0.0783 in. (1.970-1.990 mm)
TK48 TK486, 6, TK4 TK486 86E, E, and and TK4 TK486E 86EH H
0.07 0.076868-0. 0.07 0776 76 in. in. (1. (1.95 950-1 0-1.9 .970 70 mm) mm)
Bottom Ring
0.1563-0.1571 in. (3.970-3.990 mm)
Piston Ring to Ring Groove Clearance Top
0.0030-0.0043 in. (0.075-0.110 mm)
0.0098 in. (0.250 mm)
TK482 and TK482E
0.0018-0.0031 in. (0.045-0.080 mm)
0.0098 in. (0.250 mm)
TK48 TK486, 6, TK48 TK486E 6E,, and and TK48 TK486E 6EH H
0.00 0.0026 26-0 -0.0 .003 039 9 in. in. (0.0 (0.065 65-0 -0.1 .100 00 mm mm))
0.00 0.0098 98 in. in. (0.2 (0.250 50 mm mm))
0.0010-0.0024 in. (0.025-0.060 mm)
0.0079 in. (0.200 mm)
Top Ring
0.008-0.016 in. (0.20-0.40 mm)
0.059 in. (1.50 mm)
Middle Ring
0.008-0.016 in. (0.20-0.40 mm)
0.059 in. (1.50 mm)
Bottom Ring
0.008-0.016 in. (0.20-0.40 mm)
0.059 in. (1.50 mm)
Piston Piston Wrist Wrist Pin Bore Bore Insi Inside de Diamete Diameterr
1.02361.0 236-1.0 1.0240 240 in. (26.000(26.000-26. 26.009 009 mm)
1.0244 1.0 244 in. (26.020 (26.020 mm)
Wrist Pin Outside Diameter
1.0231-1.0236 in. (25.987-26.000 mm)
1.0197 in. (25.900 mm)
Wrist Pin to Piston Wrist Pin Bore Clearance
0-0.0009 in. (0-0.022 mm)
0.0047 in. (0.120 mm)
Wrist rist Pin Pin Bus Bushi hing ng Insi Inside de Diam Diamet eter er
1.02 1.0246 46-1 -1.0 .025 251 1 in. in. (26. (26.02 0255-26 26.0 .038 38 mm mm))
1.02 1.0276 76 in. in. (26 (26.1 .100 00 mm mm))
Wrist Pin Outside Diameter
1.0231-1.0236 in. (25.987-26.000 mm)
1.0197 in. (25.900 mm)
Wrist Pin to Wrist Pin Bushing Clearance
0.00 0.0010 10-0 -0.0 .002 020 0 in. in. (0.0 (0.025 25-0 -0.0 .051 51 mm) mm)
0.00 0.0079 79 in. in. (0. (0.20 200 0 mm) mm)
Larg Large eE End nd Bore Bore (Wit (Witho hout ut Bear Bearin ing) g)
2.00 2.0079 79-2 -2.0 .008 083 3 in. in. (51. (51.00 0000-51 51.0 .010 10 mm mm))
Rod Bearing Clearance
0.0015-0.0029 in. (0.038-0.074 mm)
0.0063 in. (0.160 mm)
Side Clearance (Crank to Rod)
0.008-0.016 in. (0.20-0.40 mm)
0.022 in. (0.55 mm)
Twist per 4 in. (100 mm)
0.001 in. (0.03 mm)
0.003 in. (0.08 mm)
Parallelism per 4 in. (100 mm)
0.001 in. (0.03 mm)
0.003 in. (0.08 mm)
Standard
1.9666-1.9670 in. (49.952-49.962 mm)
1.9650 in. (49.910 mm)
Undersize
1.9568-1.9572 in. (49.702-49.712 mm)
1.9551 in. (49.660 mm)
Standard
1.9685-1.9693 in. (50.000-50.020 mm)
1.9709 in. (50.060 mm)
Undersize
1.9587-1.9594 in. (49.750-49.770 mm)
1.9610 in. (49.810 mm)
0.0015-0.0027 in. (0.038-0.068 mm)
0.0059 in. (0.150 mm)
Middle
Bottom Piston Ring End Gap
Connecting Rod
Crankshaft and Crankshaft Bearings Main Journal Outside Diameter
Main Bearing Inside Diameter
Main Bearing Clearance
14
TK482 & TK486 Diesel Engine Specifications
Tier 1 and Earlier TK482, TK482E, TK486, TK486E, and TK486EH (Continued) (Continu ed) Crankshaft and Crankshaft Bearings (Continued) Main Bearing Bore Inside Diameter (Without Bearing)
Standard Dimensions
Wear Limit
2.1260-2.1267 in. (54.000-54.019 mm)
Rod Journal Outside Diameter Standard
1.8879-1.8883 in. (47.952-47.962 mm)
1.8862 in. (47.910 mm)
Undersize
1.8780-1.8784 in. (47.702-47.712 mm)
1.8764 in. (47.660 mm)
Standard
1.8898-1.8908 in. (48.000-48.026 mm)
1.8925 in. (48.070 mm)
Undersize
1.8799-1.8809 in. (47.750-47.776 mm)
1.8827 in. (47.820 mm)
Rod Bearing Clearance
0.0015-0.0029 in. (0.038-0.074 mm)
0.0063 in. (0.160 mm)
End Play
0.0035-0.0107 in. (0.090-0.271 mm)
0.0130 in. (0.330 mm)
Rod Bearing Inside Diameter
Deflection
0.0008 in. (0.020 mm)
Cylinder Block Cylinder Inside Diameter TK482 and TK482E Standard
3.2283-3.2295 in. (82.000-82.030 mm)
3.2362 in. (82.200 mm)
1st Oversize
3.2382-3.2394 in. (82.250 -82.280 mm) 3.2461 in. (82.450 mm)
2nd Oversize
3.2480-3.2492 in. (82.500-82.530 mm)
3.2559 in. (82.700 mm)
Standard
3.3858-3.3870 in. (86.000-86.030 mm)
3.3937 in. (86.200 mm)
1st Oversize
3.3957-3.3969 in. (86.250-86.280 mm)
3.4035 in. (86.450 mm)
2nd Oversize
3.4055-3.4067 in. (86.500-86.530 mm)
3.4134 in. (86.700 mm)
Cylinder Roundness
0-0.0004 in. (0-0.010 mm)
0.0012 in. (0.030 mm)
Cylinder Taper (Cylindricity)
0-0.0004 in. (0-0.010 mm)
0.0012 in. (0.030 mm)
TK486, TK486E, and TK486EH
Deck Distortion
0.002 in. (0.05 mm)
Cylinder Head Distortion
0-0.002 in. (0-0.05 mm)
0.006 in. (0.15 mm)
Crankshaft aft Gear to Idler Gear
0.00 .0028-0.0 0.0059 in. (0.070-0. -0.150 mm)
0.0079 079 in. (0.200 200 mm)
Cran Cranks ksha hafft Gea Gearr to to Oil Oil Pump Pump Gear Gear
0.00 0.0028 28-0 -0.0 .005 059 9 in. in. (0.0 (0.070 70-0 -0.1 .150 50 mm mm))
0.00 0.0079 79 in. in. (0. (0.20 200 0 mm) mm)
Idler Gear to Camshaft Gear
0.0028-0.0059 in. (0.070-0.150 mm)
0.0079 in. (0.200 mm)
Idler Gear to Fuel Injection Pump Gear
0.00 0.0028 28-0 -0.0 .005 059 9 in. in. (0.0 (0.070 70-0 -0.1 .150 50 mm) mm)
0.00 0.0079 79 in. in. (0. (0.20 200 0 mm) mm)
Idle Idlerr Gear Gear Bus Bushi hing ng Ins Insid ide e Diam Diamet eter er
1.81 1.8110 10-1 -1.8 .812 120 0 in. in. (46. (46.00 0000-46 46.0 .025 25 mm) mm)
1.81 1.8142 42 in. in. (46 (46.0 .080 80 mm) mm)
Idle Idlerr Gea Gearr Sha Shaft ft Outs Outsid ide e Dia Diame mete terr
1.80 1.8091 91-1 -1.8 .810 100 0 in. in. (45. (45.95 9500-45 45.9 .975 75 mm mm))
1.80 1.8083 83 in. in. (45 (45.9 .930 30 mm mm))
Idler Gear Shaft to Idler Gear Bushing Clearance
0.00 0.0010 10-0 -0.0 .003 030 0 in. in. (0.0 (0.025 25-0 -0.0 .075 75 mm) mm)
0.00 0.0059 59 in. in. (0. (0.15 150 0 mm) mm)
Timing Gears Timing Gear Lash
15
TK482 & TK486 Diesel Engine Specifications
Tier 1 and Earlier TK482, TK482E, TK486, TK486E, and TK486EH (Continued) Oil Pump Type
Trochoid
Oute Outerr Rot Rotor or to Pum Pump p Bod Body y Cle Clear aran ance ce
0.00 0.0039 39-0 -0.0 .006 063 3 in. in. (0. (0.10 1000-0. 0.16 160 0 mm) mm)
Inner Rotor Tip to Outer Rotor Lobe Clearance
0.00 0.0098 98 in. in. (0.2 (0.250 50 mm) mm) 0.0059 in. (0.150 mm)
Rotor Plate to Rotor Clearance
0.0012-0.0035 in. (0.030-0.090 mm)
0.0059 in. (0.150 mm)
Rotor Shaft to Rotor Shaft Bore Clearance
0.00 0.0005 05-0 -0.0 .001 017 7 in. in. (0.0 (0.013 13-0 -0.0 .043 43 mm) mm)
0.00 0.0079 79 in. in. (0. (0.20 200 0 mm) mm)
Pressure C Co ontrol Va Valve Se Setting
36-50 ps psi (2 (245-343 kP kPa)
Starter
Standard Dimensions
Wear Limit
No Load Test Voltage
11 volts
Current
Maximum of 140 amps @ 11 volts
Speed
Minimum of 3900 rpm @ 11 volts
Loaded Properties Voltage
8.76 volts
Current
300 amps
Commutator Outside Diameter
16
1.44 in. (36.5 mm)
1.40 in. (35.5 mm)
Tier 2 - TK486V, TK486VB, and TK486VH Except where noted, the specifications for these engines are the same. General Type
Four Stroke Cycle Water Cooled
Number of Cylinders
4
Cylinder Arrangement
In-line Vertical, Number 1 on Flywheel End
Bore
3.39 in. (86.0 mm)
Stroke
3.54 in. (90.0 mm)
Displacement
128 cu. in. (2.09 liters)
Power Rating TK486V and TK486VB
33.9 hp (25.3 kW) @ 2200 rpm
TK486VH
35.0 hp (26.1 kW) @ 2600 rpm
Compression Ratio
19.1 to 1
Direction of Rotation
Counterclockwise (Viewed from Flywheel)
Firing Order
1-3-4-2 (Number 1 on Flywheel End)
Fuel Injection Timing
See “Injection Pump Timing Timing Tier 2 Engines” on page 102 102..
Nozzle Injection Pressure
3,100-3,300 psi (21,600-22,600 kPa)
Oil Pressure
18.5 psi (127 kPa) Minimum @ 230 F (110 C) & 1600 rpm 45-57 psi (310-390 kPa) @ 230 F (110 C) & 2200 rpm
Engine Coolant Thermostat
160 F (71 C)
Valve Clearance (Static ( Static @ 70 F [21 C]) Intake
0.006-0.010 in. (0.15-0.25 mm)
Exhaust
0.006-0.010 in. (0.15-0.25 mm)
Valve Train
Standard Dimensions
Wear Limit
Free Length
1.65 in. (42.0 mm)
1.63 in. (41.5 mm)
Inclination (Top to Bottom from Vertical)
0-0.04 in. (0-1.4 mm)
0.06 in. (1.4 mm)
Intake
0.3154-0.3159 in. (8.010-8.025 mm)
0.3189 in. (8.100 mm)
Exhaust
0.3156-0.3161 in. (8.015-8.030 mm)
0.3189 in. (8.100 mm)
Intake
0.3132-0.3140 in. (7.955-7.975 mm)
0.3110 in. (7.900 mm)
Exhaust
0.3132-0.3138 in. (7.955-7.970 mm)
0.3110 in. (7.900 mm)
Intake
0.0014-0.0028 in. (0.035-0.070 mm)
0.0071 in. (0.180 mm)
Exhaust
0.0018-0.0030 in. (0.045-0.075 mm)
0.0071 in. (0.180 mm)
Intake
0.053 in. (1.34 mm)
0.020 in. (0.50 mm)
Exhaust
0.057 in. (1.45 mm)
0.020 in. (0.50 mm)
Valve Spring
Valve Guide Inside Diameter
Valve Stem Outside Diameter
Valve Stem to Valve Guide Clearance
Valve Margin
17
TK482 & TK486 Diesel Engine Specifications
Tier 2 - TK486V, TK486V, TK486VB, and TK486VH (Continued) (Conti nued) Valve Train (Continued)
Standard Dimensions
Wear Limit
Intake
0.012-0.020 in. (0.30-0.50 mm)
0.031 in. (0.80 mm)
Exhaust
0.012-0.020 in. (0.30-0.50 mm)
0.031 in. (0.80 mm)
Valve Depth (Cylinder Head Deck to Valve)
Valve Guide Projection (Above Valve Spring Seat in Cylinder Head) Intake
0.579-0.591 in. (14.70-15.00 mm)
Exhaust
0.579-0.591 in. (14.70-15.00 mm)
Valve Angle Intake
30 Degrees
Exhaust
45 Degrees
Valve Seat Angle Intake
30 Degrees
Exhaust
45 Degrees
Valve Seat Width Intake
0.042-0.049 in. (1.07-1.24 mm)
0.069 in. (1.74 mm)
Exhaust
0.049-0.057 in. (1.24-1.45 mm)
0.076 in. (1.94 mm)
Rock Ro cker er Arm Arm Bush Bushin ing g Insi Inside de Dia Diame meter ter
0.629 0.62999-0. 0.630 6307 7 in. in. (16.0 (16.00000-16. 16.02 020 0 mm) mm)
0.63 0.6327 27 in. in. (16.0 (16.070 70 mm) mm)
Rock Ro cker er Arm Arm Shaf Shaftt O Out utsi side de Diam Diamet eter er
0.628 0.6 286-0 6-0.6 .6293 293 in. in. ((15. 15.96 966-1 6-15. 5.98 984 4 mm) mm)
0.62 0.6276 76 in. in. ((15 15.9 .940 40 mm mm))
Rocker Arm Bushing to Rocker Arm Shaft Clearance
0.00 0.0006 06-0 -0.0 .002 021 1 in. in. (0.0 (0.016 16-0 -0.0 .054 54 mm) mm)
0.00 0.0051 51 in. in. (0. (0.13 130 0 mm) mm)
Tappet O Ou utside Di Diameter
0.4715-0.4720 in in. ((1 11.975-11.990 mm mm)
0.4707 in in. ((1 11.955 mm mm)
Tappet Bo Bore In Inside Di Diameter
0.4724-0.4734 in in. (1 (12.000-12.025 mm mm)
0.4742 in in. (1 (12.045 mm mm)
Tappe appett To Tappe appett Bore Bore Clea Cleara ranc nce e
0.00 0.0004 04-0 -0.0 .002 020 0 in. in. (0.0 (0.010 10-0 -0.0 .050 50 mm mm))
0.00 0.0035 35 in. (0.0 (0.090 90 mm mm))
Push Rod Bend
0-0.001 in. (0-0.03 mm)
0.001 in. (0.03 mm)
Camshaft
Standard Dimensions
Wear Limit
Cam Lobe Height
1.5197-1.5276 in. (38.600-38.800 mm)
1.5098 in. (38.350 mm)
Timing Gear End
1.7687-1.7697 in. (44.925-44.950 mm)
1.7673 in. (44.890 mm)
Middle
1.7681-1.7691 in. (44.910-44.935 mm)
1.7667 in. (44.875 mm)
Flywheel End
1.7687-1.7697 in. (44.925-44.950 mm)
1.7673 in. (44.890 mm)
Timin iming g Gea Gearr End End Bear Bearin ing g Ins Inser ertt
1.77 1.7713 13-1 -1.7 .773 738 8 in. in. (44. (44.99 9900-45 45.0 .055 55 mm mm))
1.77 1.7768 68 in. in. (45 (45.1 .130 30 mm mm))
Middle Be Bearing (N (No In Insert)
1.7717-1.7726 in in. (4 (45.000-45.025 mm mm)
1.7756 in in. (4 (45.100 mm mm)
Flyw Flywhe heel el End End Bea Beari ring ng (No (No Ins Inser ert) t)
1.771 1.7 717-1 7-1.7 .772 726 6 in. in. (45.0 (45.00000-45 45.0 .025 25 mm mm))
1.775 1.7756 6 in. in. (45. (45.100 100 mm mm))
Timing Gear End
0.0016-0.0051 in. (0.040-0.130 mm)
0.0094 in. (0.240 mm)
Middle
0.0026-0.0045 in. (0.065-0.115 mm)
0.0089 in. (0.225 mm)
Flywheel End
0.0020-0.0039 in. (0.050-0.100 mm)
0.0082 in. (0.210 mm)
Camshaft Deflection
0.001 in. (0.02 mm)
0.002 in. (0.05 mm)
Camshaft End Play
0.002-0.008 in. (0.05-0.20 mm)
0.012 in. (0.30 mm)
Camshaft Journal Outside Diameter
Camshaft Bearing Inside Diameter
Camshaft Camshaft Journal to Camshaft Camshaft Bearing Clearance
18
TK482 & TK486 Diesel Engine Specifications
Tier 2 - TK486V, TK486V, TK486VB, and TK486VH (Continued) (Conti nued) Piston, Piston Rings, and Wrist Pin
Standard Dimensions
Piston Outside Diameter Measuring Point (From Bottom of Piston Perpendicular to Wrist Pin)
0.95 in. (24.0 mm)
Wear Limit
Piston Outside Diameter Standard
3.3835-3.3846 in. (85.940-85.970 mm)
3.3817 in. (85.895 mm)
1st 1st Over Oversi size ze 0.0 0.010 10 in. in. (0. (0.25 25 mm) mm)
3.39 3.3935 35-3 -3.3 .394 941 1 in. in. (86. (86.19 1955-86 86.2 .210 10 mm) mm)
3.39 3.3917 17 in. in. (86 (86.1 .150 50 mm) mm)
2nd 2nd Ove Overs rsiz ize e 0.0 0.020 20 in. in. (0. (0.50 50 mm mm))
3.403 3.40333-3. 3.403 4039 9 in. in. (86.4 (86.445 45-86 -86.4 .460 60 mm mm))
3.401 3.4 016 6 in. in. (86. (86.400 400 mm mm))
Piston to Cylinder Wall Clearance Standard
0.0018-0.0030 in. (0.045-0.075 mm)
1st 1st Over Oversi size ze 0.01 0.010 0 in. in. (0.25 (0.25 mm)
0.001 0.00166-0.0 0.003 033 3 in. in. (0.04 (0.040-0 0-0.0 .085 85 mm mm))
2nd 2nd Ove Overs rsiz ize e 0.0 0.020 20 in. in. (0.50 (0.50 mm mm))
0.00 0.001616-0. 0.003 0033 3 in. in. (0.0 (0.04040-0. 0.08 085 5 mm) mm)
Piston Top Clearance (Between Top of Piston at TDC and Combustion Chamber with Cylinder Head Installed)
0.0262-0.0306 in. (0.666-0.778 mm)
Piston Ring Groove Width Top Ring Groove
0.0813-0.0819 in. (2.065-2.080 mm)
Middle Ring Groove
0.0801-0.0807 in. (2.035-2.050 mm)
Bottom Ring Groove
0.1581-0.1587 in. (4.015-4.030 mm)
Piston Ring Width Top Ring
0.0776-0.0783 in. (1.970-1.990 mm)
0.0768 in. (1.950 mm)
Midd Middle le Ring Ring
0.07 0.076868-0. 0.077 0776 6 in. in. (1.9 (1.95050-1. 1.97 970 0 mm mm))
0.076 0.0 760 0 in. in. (1.9 (1.930 30 mm mm))
Bottom Ring
0.1563-0.1571 in. (3.970-3.990 mm)
0.1555 in. (3.950 mm)
Top
0.0030-0.0043 in. (0.075-0.110 mm)
0.0098 in. (0.250 mm)
Middle
0.0026-0.0039 in. (0.065-0.100 mm)
0.0098 in. (0.250 mm)
Bottom
0.0010-0.0024 in. (0.025-0.060 mm)
0.0079 in. (0.200 mm)
Top Ring
0.008-0.016 in. (0.20-0.40 mm)
0.019 in. (0.49 mm)
Middle Ring
0.012-0.020 in. (0.30-0.50 mm)
0.023 in. (0.59 mm)
Bottom Ring
0.008-0.016 in. (0.20-0.40 mm)
0.019 in. (0.49 mm)
Piston Piston Wrist Wrist Pin Bore Bore Insi Inside de Diamet Diameter er
1.02361.02 36-1.02 1.0240 40 in. (26.000(26.000-26. 26.009 009 mm)
1.0252 1.0 252 in. (26.039 (26.039 mm)
Wrist Pi Pin Ou Outside D Diiameter
1.0234-1.0236 in in. (2 (25.995-26.000 mm mm)
1.0222 in in. (2 (25.965 mm mm)
Wrist Pin to Piston Wrist Pin Bore Clearance
0-0.0006 in. (0-0.014 mm)
0.0029 in. (0.074 mm)
Connecting Rod
Standard Dimensions
Wear Limit
Wris Wristt Pin Pin Bush Bushin ing g Ins Insid ide e Dia Diame mete terr
1.02 1.0246 46-1 -1.0 .025 251 1 in. in. (26. (26.02 0255-26 26.0 .038 38 mm mm))
1.02 1.0263 63 in. in. (26 (26.0 .068 68 mm mm))
Wrist Pi Pin Ou Outside D Diiameter
1.0234-1.0236 in in. (2 (25.995-26.000 mm mm)
1.0223 in in. (2 (25.967 mm mm)
Wrist Pin to Wrist Pin Bushing Clearance
0.00 0.0010 10-0 -0.0 .001 017 7 in. in. (0.0 (0.025 25-0 -0.0 .043 43 mm) mm)
0.00 0.0040 40 in. in. (0. (0.10 101 1 mm) mm)
Larg Large eE End nd Bore Bore (Wit (Witho hout ut Bear Bearin ing) g)
2.00 2.0079 79-2 -2.0 .008 083 3 in. in. (51. (51.00 0000-51 51.0 .010 10 mm mm))
Rod Bearing Clearance
0.0015-0.0029 in. (0.038-0.074 mm)
0.0059 in. (0.150 mm)
Side Clearance (Crank to Rod)
0.008-0.016 in. (0.20-0.40 mm)
0.022 in. (0.55 mm)
Twist per 4 in. (100 mm)
0.001 in. (0.03 mm)
0.003 in. (0.08 mm)
Parallelism per 4 in. (100 mm)
0.001 in. (0.03 mm)
0.003 in. (0.08 mm)
Piston Ring to Ring Groove Clearance
Piston Ring End Gap
19
TK482 & TK486 Diesel Engine Specifications
Tier 2 - TK486V, TK486V, TK486VB, and TK486VH (Continued) (Conti nued) Crankshaft and Crankshaft Bearings Standard Dimensions
Wear Limit
Main Journal Outside Diameter Standard
1.9666-1.9670 in. (49.952-49.962 mm)
1.9646 in. (49.902 mm)
Undersize
1.9568-1.9572 in. (49.702-49.712 mm)
1.9548 in. (49.652 mm)
Standard
1.9685-1.9693 in. (50.000-50.020 mm)
1.9705 in. (50.052 mm)
Undersize
1.9587-1.9594 in. (49.750-49.770 mm)
1.9607 in. (49.802 mm)
Main Bearing Clearance
0.0015-0.0027 in. (0.038-0.068 mm)
0.0059 in. (0.150 mm)
Main Bearing Bore Inside Diameter (Without Bearing)
2.1260-2.1267 in. (54.000-54.019 mm)
Main Bearing Inside Diameter
Rod Journal Outside Diameter Standard
1.8879-1.8883 in. (47.952-47.962 mm)
1.8859 in. (47.902 mm)
Undersize
1.8780-1.8784 in. (47.702-47.712 mm)
1.8761 in. (47.652 mm)
Standard
1.8898-1.8908 in. (48.000-48.026 mm)
1.8918 in. (48.052 mm)
Undersize
1.8799-1.8809 in. (47.750-47.776 mm)
1.8820 in. (47.802 mm)
Rod Bearing Clearance
0.0015-0.0029 in. (0.038-0.074 mm)
0.0059 in. (0.150 mm)
End Play
0.0051-0.0091 in. (0.130-0.230 mm)
0.0110 in. (0.280 mm)
Rod Bearing Inside Diameter
Deflection
0.0008 in. (0.020 mm)
Cylinder Block Cylinder Inside Diameter Standard
3.3858-3.3870 in. (86.000-86.030 mm)
3.3937 in. (86.200 mm)
1st Oversize
3.3957-3.3969 in. (86.250-86.280 mm)
3.4035 in. (86.450 mm)
2nd Oversize
3.4055-3.4067 in. (86.500-86.530 mm)
3.4134 in. (86.700 mm)
Cylinder Roundness
0-0.0004 in. (0-0.010 mm)
0.0012 in. (0.030 mm)
Cylinder Taper (Cylindricity)
0-0.0004 in. (0-0.010 mm)
0.0012 in. (0.030 mm)
Deck Distortion
0.002 in. (0.05 mm)
Cylinder Head
Standard Dimensions
Wear Limit
Distortion
0-0.002 in. (0-0.05 mm)
0.006 in. (0.15 mm)
Crank ankshaft Gear to Idler Gear
0.002 0028-0.0059 059 in. (0. (0.070-0. -0.150 mm)
0.006 0067 in. (0.170 mm)
Idler Gear to Camshaft Gear
0.0028-0.0059 in. (0.070-0.150 mm)
0.0067 in. (0.170 mm)
Idler Gear to Fuel Injection Pump Gear
0.00 0.0028 28-0 -0.0 .005 059 9 in. in. (0.0 (0.070 70-0 -0.1 .150 50 mm) mm)
0.00 0.0067 67 in. in. (0. (0.17 170 0 mm) mm)
Idle Idlerr Gear Gear Bus Bushi hing ng Ins Insid ide e Diam Diamet eter er
1.81 1.8110 10-1 -1.8 .812 120 0 in. in. (46. (46.00 0000-46 46.0 .025 25 mm) mm)
1.81 1.8140 40 in. in. (46 (46.0 .075 75 mm) mm)
Idle Idlerr Gea Gearr Sha Shaft ft Outs Outsid ide e Dia Diame mete terr
1.80 1.8091 91-1 -1.8 .810 100 0 in. in. (45. (45.95 9500-45 45.9 .975 75 mm mm))
1.80 1.8071 71 in. in. (45 (45.9 .900 00 mm mm))
Idler Gear Shaft to Idler Gear Bushing Clearance
0.00 0.0010 10-0 -0.0 .003 030 0 in. in. (0.0 (0.025 25-0 -0.0 .075 75 mm) mm)
0.00 0.0069 69 in. in. (0. (0.17 175 5 mm) mm)
Timing Gears Timing Gear Lash
20
TK482 & TK486 Diesel Engine Specifications
Tier 2 - TK486V, TK486V, TK486VB, and TK486VH (Continued) (Conti nued) Oil Pump Type
Trochoid
Outer Rotor to Gear Case Cover Clearance
0.004 0.00477-0.0 0.008 083 3 in. in. (0.12 (0.120-0 0-0.2 .210 10 mm mm))
0.01 0.0118 18 in. in. (0. (0.30 300 0 mm)
Oil Pump Cover to Outer Rotor Clearance
0.00 0.0008 08-0 -0.0 .002 028 8 in. in. (0.0 (0.020 20-0 -0.0 .070 70 mm) mm)
0.00 0.0047 47 in. in. (0. (0.12 120 0 mm) mm)
Inner Rotor Inside Diameter
2.1043-2.1083 in. (53.450-53.550 mm)
Crankshaft Gear Boss Outside Diameter
2.0886-2.0925 in. (53.050-53.150 mm)
Inner Rotor to Crankshaft Gear Boss Clearance
0.01 0.0118 18-0 -0.0 .019 197 7 in. in. (0.3 (0.300 00-0 -0.5 .500 00 mm) mm)
Inner Rotor Wi Width Ac Across Fl Flat
1.9665-1.9705 in in. (49.950-50.050 mm)
Crankshaft Gear Boss Width Across Flat
1.9468-1.9587 in. (49.450-49.750 mm)
Inner Rotor to Crankshaft Gear Boss Clearance Between Flats
0.00 0.0079 79-0 -0.0 .023 236 6 in. in. (0.2 (0.200 00-0 -0.6 .600 00 mm) mm)
Pressure C Co ontrol Va Valve Se Setting
43-57 ps psi (2 (294-392 kP kPa)
0.02 0.0236 36 in. in. (0. (0.60 600 0 mm) mm)
0.02 0.0276 76 in. in. (0. (0.70 700 0 mm) mm)
Starter No Load Test Voltage
11 volts
Current
Maximum of 130 amps @ 11 volts
Speed
Minimum of 3900 rpm @ 11 volts
Loaded Properties Voltage
8.5 volts
Current
400 amps
Commutator Outside Diameter
1.44 in. (36.5 mm)
1.40 in. (35.5 mm)
21
TK482 & TK486 Diesel Engine Specifications
Exhaust Gas Specifications The following specifications are provided to help design a system to remove exhaust gas from a shop or garage. Exhaust Gas Temperature at Muffler Outlet 1 4 5 0 r pm
340 F (171 C)
2 2 0 0 r pm
450 F (232 C)
2 6 0 0 r pm
450 F (232 C)
Exhaust Gas Flow Rate
22
1 4 50 r p m
49 cubic feet/minute (1.4 cubic meters/minute)
2 2 00 r pm
106 cubic feet/minute (3.0 cubic meters/minute)
2 6 00 r pm
124 cubic feet/minute (3.5 cubic meters/minute)
Torque Values
Torque Values TK482, TK482E, TK486, TK486E, and TK486EH Dia. x Pitch (mm)
N•m
ft-lb
kgm
Connecting Rod Bolt
9x1.0
44.1-53.9
32.5-39.8
4.5-5.5
Crankshaft Pulley Bolt
14x1.5
112.8-122.6
83.2-90.4
11.5-12.5
Cylinder Head Mtg. Bolt
10x1.25
85.3-91.2
62.9-67.3
8.7-9.3
Flywheel Mtg. Bolt
10x1.25
83.4-88.3
61.5-65.1
8.5-9.0
Fuel Injection Line Nut
12x1.5
29.4-34.3
21.7-25.3
3.0-3.5
Fuel Injection Nozzle Mtg. Nut
6x1.0
6.9-8.8
5.1-6.5
0.7-0.9
39.2-44.1
28.9-32.5
4.0-4.5
Description
Fuel Injection Nozzle Nut Fuel Injection Pump Gear Mtg. Nut
12x1.75
58.8-68.6
43.4-50.6
6.0-7.0
Main Bearing Bolt
12x1.5
96.1-100.0
70.9-73.8
9.8-10.2
Rocker Arm Support Mtg. Bolt
8x1.25
22.6-28.4
16.6-21.0
2.3-2.9
Standard 6 mm Bolt and Nut
6x1.0
9.8-11.8
7.2-8.7
1.0-1.2
Standard 8 mm Bolt and Nut
8x1.25
22.6-28.4
16.6-21.0
2.3-2.9
Standard 10 mm Bolt and Nut
10x1.5
44.1-53.9
32.5-39.8
4.5-5.5
Standard 12 mm Bolt and Nut
12x1.75
78.5-98.1
57.9-72.3
8.0-10.0
NOTE: For standard bolts in aluminum parts use 80% of the specified torque.
TK486V, TK486VB, and TK486VH Dia. x Pitch (mm)
N•m
ft-lb
kgm
Connecting Rod Bolt
9x1.0
44.1-49.0
32.5-36.2
4.5-5.0
Crankshaft Pulley Bolt
14x1.5
112.8-122.6
83.2-90.4
11.5-12.5
Cylinder Head Mtg. Bolt
10x1.25
85.3-91.2
62.9-67.3
8.7-9.3
Flywheel Mtg. Bolt
10x1.25
83.4-88.3
61.5-65.1
8.5-9.0
Fuel Injection Line Nut
12x1.5
29.4-34.3
21.7-25.3
3.0-3.5
Fuel Injection Nozzle Mtg. Bolt
8x1.25
24.4-28.4
18.0-21.0
2.5-2.9
39.2-44.1
28.9-32.5
4.0-4.5
Description
Fuel Injection Nozzle Nut Fuel Injection Pump Gear Mtg. Nut
14x1.5
78.5-88.3
57.9-65.1
8.0-9.0
Main Bearing Bolt
12x1.5
93.2-98.1
68.7-72.4
9.5-10.0
5.4-8.4
3.9-6.2
0.6-0.9
Oil Pump Cover Mtg. Screw Rocker Arm Support Mtg. Bolt
8x1.25
22.6-28.4
16.6-21.0
2.3-2.9
Standard 6 mm Bolt and Nut
6x1.0
9.8-11.8
7.2-8.7
1.0-1.2
Standard 8 mm Bolt and Nut
8x1.25
22.6-28.4
16.6-21.0
2.3-2.9
Standard 10 mm Bolt and Nut
10x1.5
44.1-53.9
32.5-39.8
4.5-5.5
Standard 12 mm Bolt and Nut
12x1.75
78.5-98.1
57.9-72.3
8.0-10.0
NOTE: For standard bolts in aluminum parts use 80% of the specified torque.
23
Special Tools
Special Tools The following special tools for all versions of TK482/486 engines are available from the Thermo King Service Parts Department. Refer to the Tool Catalog (TK 5955). Description
Part Number
Fuel Injection Nozzle Puller
204-902
Rear Seal Installation Tool
204-952
Rear Seal Remover
2 04 - 99 4
Injection Pump Remover
204-1011
Compression Compression Test Test Adapter Adapter (For use with Compressi Compression on Tester Tester 204-542) 204-542) 204-1056 Inje Inject ctio ion n Pum Pump p Plu Plung nger er Sprin pring g Too Tooll (T (Tier ier 1 and and Ear Earli lier er Engi Engine nes) s)
204204-10 1083 83
Front Seal Installation Tool
204-1138
The following drawings show dimensions for special tools that are to be made a locally. The tools are for all versions of TK482/486 engines.
L1. L1.
0.79 0.79 in. in. (20 (20.0 .0 mm mm))
L2. L2.
2.95 2.95 in. in. (75 (75.0 .0 mm
d1. d1.
0.30 0.30 in. in. (7. (7.5 5 mm) mm)
d2. d2.
0.43 0.43 in. in. (11. (11.0 0 mm mm))
Figure 1: Valve Guide Removal Removal Tool Tool
L1. L1.
0.59 0.59 in. (15. (15.0 0 mm) mm)
L2. L2.
2.56 2.56 in. (65. (65.0 0 mm) mm)
d1. d1.
0.55 0.55 in. (14. (14.0 0 mm) mm)
d2. d2.
0.79 0.79 in. (20. (20.0 0 mm) mm)
Figure 2: Valve Guide Installation Tool
24
Special Tools
L1. L1.
0.79 0.79 in. in. (20 (20.0 .0 mm mm))
L2. L2.
3.94 3.94 in. in. (10 (100. 0.0 0 mm mm))
d1. d1.
1.02 1.02 in. in. (26 (26.0 .0 mm mm))
d2. d2.
1.14 1.14 in. in. (29 (29.0 .0 mm mm))
Figure 4: Connecting Connecting Rod Bushing Bushing Removal Removal and Install Installati ation on Tool
L1. L1.
0.74 0.74 in. (18. (18.8 8 mm) mm)
L2. L2.
2.56 2.56 in. (65. (65.0 0 mm) mm)
L3. L3.
0.16 0.16 in. (4.0 (4.0 mm mm))
L1. L1.
0.71 0.71 in. in. (18 (18.0 .0 mm mm))
d1. d1.
0.64 0.64 in. (16. (16.2 2 mm) mm)
L2. L2.
2.76 2.76 in. in. (70 (70.0 .0 mm mm))
d2. d2.
0.87 0.87 in. (22. (22.0 0 mm) mm)
d1. d1.
1.77 1.77 in. in. (45 (45.0 .0 mm mm))
d3. d3.
0.53 0.53 in. (13. (13.5 5 mm) mm)
d2. d2.
1.89 1.89 in. in. (48 (48.0 .0 mm mm))
Figure 3: Valve Stem Seal Installation Installation Tool
Figure 5: Camshaft Camshaft Bearing Removal Tool Tool
25
Special Tools
26
Engine Disassembly NOTE: Most of the illustrations in this manual show the early engine engine with the in-line fuel injection pump and the high mount water pump. The other engines are similar and significant differences are are noted.
Before disassembling the engine, drain the engine oil and coolant, disconnect the battery cables, and remove the engine from the unit.
2
3 4
1
1
16
5 6 7
15
8 14 9
13
AGA01
12 11
10
1.
Lift Bracket
9.
Oil Pan
2.
Fuel Injection Line
10 .
Fuel Transfer Pump
3.
Valve Cover
11.
Oil Level Switch
4.
Crankcase Breather Hose
12 .
Dipstick
5.
Water Pump
13 .
Oil Filter
6. 7. 8.
In-Line Fuel Injection Pump Gear Case Cover Crankshaft Pulley
14. 15 . 16 .
Oil Line Starter Intake Manifold
Figure 6: Front View View of Early Engine Engine
27
Engine Disassembly
2
3
4
1
1
17
5
16
6
15 7 14 8 13 12 11 10
9
1.
Lift Bracket
1 0.
Oil Level Switch
2.
Fuel Injection Line
11.
Dipstick
3.
Crankcase Breather Hose
12 .
Oil Filter
4.
Valve Cover
13 .
Trochoid Feed Pump
5.
Water Pump
14. Mono-Plunger and Distributor Fuel Injection Pump
6. 7.
Gear Case Cover Crankshaft Pulley
15 . 1 6.
Cold Start Device Starter
8.
Oil Pan
17. 17.
Int Intake ake Man Manif ifol old d
9.
Fuel Transfer Pump Figure 7: Front View View of Tier 2 Engine Engine
28
Engine Disassembly
While disassembling the engine, note things such as the position of dowel pins and O-rings, and the existing timing marks and bearing cap marks. Identical components in the valve train and the crankshaft assembly should be kept in order or marked. This prevents mixing up these components and allows the components to be placed in their original positions when the engine is assembled.
2
1
1. Remov Removee the the exhaus exhaustt mani manifol fold. d. 2. Remov Removee the cran crankc kcase ase brea breathe therr hose. hose. NOTE: The crankcase breather hose hose on Tier 1 and earlier engines is not interchangeable with the crankcase breather hose on the Tier 2 engine. See “Crankcase Breather System Tier 1 and Earlier Earlier Engines” on page 65 and 65 and “Crankcase Breather System Tier 2 Engine” on page 66 for for more information. 3. Remove Remove the the fuel fuel injection injection lines. Cover Cover all the injection lines, fuel lines, and fittings with plastic covers or tape. The smallest amount of dirt can damage the fuel system.
1.
Fuel Injection Lines
2.
Fuel Re Return Li Lines
Figure 9: Remove Fuel Injectio Injection n Lines Tier Tier 2 Engi Engine nes s
4. Remove Remove the fuel return lines. lines. Do not reuse the fuel return lines if they are old style lines. See “Fuel Return Line Replacement” on page 113.
1
5. Remove Remove the intake intake manifol manifold. d. 2
6. Remove Remove the the lift lift bracke brackets ts from from the cyli cylinde nderr head.
AGA02
1.
Fuel Injection Lines
2.
Fuel Re Return Li Lines
Figure 8: Remove Fuel Fuel Injection Injection Lines Tier Tier 1 and and Earli Earlier er Engi Engine nes s
29
Engine Disassembly
7. Remove Remove the the fuel injec injectio tion n nozzle nozzle mount mounting ing nuts and retainers from Tier 1 and earlier engines. Remove the fuel injection nozzle mounting bolts and retainers from Tier 2 engines.
8. Remove Remove the the fuel fuel injec injectio tion n nozzle nozzles. s. Use Use injection nozzle puller P/N 204-902 if necessary. 9. Remo Remove ve the the wat water er pump pump.. 1
1 2 3 4
2
1.
Retainer
2.
Fue Fuel In Injection Noz Nozz zle
3.
Nozzle Protector
4.
Nozzle Gasket
Figure 10: Remove Fuel Fuel Injection Nozzles Nozzles Tier Tier 1 and and Earl Earlier ier Engi Engines nes
1
1.
High Moun ount Wate ater Pump
2.
Low Mo Mount Wa Water Pu Pump
Figure 12: 12: Remove Water Water Pump Pump
NOTE: Tier Tier 2 engines have have two coolant hoses that go from from the water pump to a the cold start device device on the fuel injection pump. Disconnect the hoses hoses from the water water pump before removing it.
2
1
3 4 1
1.
Coolant Hoses
Figure 13: Disconnect Disconnect Coolant Hoses Hoses on Tier Tier 2 Engi Engine nes s
1.
Retainer
2.
Fue Fuel In Injection Noz Nozz zle
3.
Nozzle Protector
4.
Nozzle Gasket
Figure 11: 11: Remove Fuel Injection Injection Nozzles Nozzles Tier Tier 2 Engi Engine nes s
30
Engine Disassembly
10. Remove the valve cover by by removing the three special cap nuts. Inspect the O-rings O-r ings under these cap nuts and replace the O-rings, if necessary, during assembly.
12. Remove the valve stem stem caps and keep keep them in order.
NOTE: The valve cover cover on Tier 1 and earlier engines is not interchangeable with the valve cover on the Tier Tier 2 engine. See See “Crankcase Breather System Tier 1 and Earlier Engines” on page 65 and 65 and “Crankcase Breather System Tier Tier 2 Engine” Engine” on page page 66 for for more information. AGA07
Figure 16: Remove Valve Valve Stem Caps Caps
13. Remove the push push rods and keep them in order if they will be reused. 14. Break each cylinder head bolt bolt loose 1/4 to 1/2 turn in a crisscross pattern starting at the ends. Then remove the cylinder head bolts. 15. Remove the cylinder head from the cylinder cylinder block.
AGA05
Figure 14: Remove Valve Valve Cover Cover
11. Remove the rocker arm assembly assembly by removing the bolts that mount the rocker arm supports. Alternately loosen each bolt one turn at a time to evenly release the spring pressure on the rocker arm assembly.
AGA08
Figure 17: 17: Remove Cylinder Cylinder Head Head
AGA06
Figure 15: Remove Rocker Rocker Arm Assembly Assembly
31
Engine Disassembly
16. Remove the oil filter and the oil filter head.
18. Remove the fuel transfer pump from the gear case cover.
AGA09 AGA11
Figure 18: Remove Oil Filter Filter and Oil Filter Filter Head
17. Remove the oil line that goes goes from the cylinder block to the fuel injection pump and the gear case cover. NOTE: On later model engines engines the oil line stops at the fuel injection pump and and does not not go to the gear case case cover. cover. The hole in the gear case cover cover is plugged with with a screw (P/N 55-5768). Tier Tier 2 engines engines do not have the hole hole in the gear gear case case cover cover and do not use the plug screw. screw.
Figure 20: Remove Fuel Transfer Transfer Pump Pump
19. Remove the front crankshaft bolt. 20. The end of the crankshaft crankshaft is tapered. Remove the crankshaft pulley by using a suitable puller. Check the pulley for a crack in the area near the dowel pin (see Figure 167 on page 85). 85). A cracked pulley can leak oil and should be replaced.
AGA12
Figure 21: Remove Crankshaf Crankshaftt Pulley AGA10
Figure 19: 19: Remove Oil Oil Line
32
Engine Disassembly
21. Remove the gear gear case cover and sound shield. NOTE: On Tier Tier 2 engines the oil pump is located in the gear case cover. cover. The inner rotor of the oil pump fits around the crankshaft gear gear.. See “Oil Pump for Tier 2 Engines” on page page 62.
23. Note the timing marks on the timing gears. The timing marks must be aligned when the engine is assembled. 24. Remove the fuel injection pump gear nut and and lock washer.
AGA13
Figure 22: 22: Remove Gear Gear Case Cover Cover and Sound Sound Shie Shield ld
22. Check the timing gear lash. lash. If the gear lash is within specifications (refer to Specifications), the gears can probably be reused. If the gear lash is excessive, some or all of the gears must be replaced to meet the specifications.
Figure 24: Remove Fuel Injection Injection Pump Pump Gear Nut and Lock Lock Washer Washer
25. The fuel injection pump shaft is tapered. The fuel injection pump gear must be removed to remove the fuel injection pump. Remove the fuel injection pump gear by using a suitable puller. NOTE: See “Injection Pump Removal and Installation (All Engines)” Engines)” on page 105 for 105 for information about removing the injection pump without removing the crankshaft crankshaft pulley and gear case cover. cover.
AGA14
Figure 23: Check Timing Timing Gear Lash Lash
Figure 25: 25: Use Puller Puller to Remove Remove Fuel Injecti Injection on Pump Pump Gear Gear
33
Engine Disassembly
NOTE: Early engines (before Tier Tier 1) use a single-piece fuel injection pump gear (see Figure 26 ). Tier 1 engines use a three-piece fuel injection pump gear assembly (see Figure (see Figure 27 ). Do not loosen or remove the four bolts bolts that fasten the injection pump pump gear to the flange because that changes the timing. See See “Attaching Injection Pump Gear to Flange on Tier 1 Engines” on page page 100 if 100 if the injection pump gear is detached from the flange. Tier 2 engines use a three-piece fuel injection pump gear assembly (see Figure (see Figure 28 on page 35 ). Do not loosen or remove the four bolts bolts that that fasten the injection injection pump gear to the flange because because that changes the timing. That will cause the engine engine to violate EPA, EPA, CARB, or other emission emission control regulations and require require recertification.
2 3 4 5 6
7 1.
Fuel In Injection Pu Pump
2.
Key
3.
Flange
4.
Injection Pu Pump Ge Gear
5.
Transfer Pump Cam
6.
Nutt ((In Nu Inje ject ctio ion n Pum Pump p Gea Gear) r)
7.
Do No Nott Rem Remov ove e Gea Gearr Fro From m Fl Flange ange
Figure 27: Three-Piece Three-Piece Fuel Fuel Injection Injection Pump Pump Gear Tier 1 Engine
1
2 3 4
1.
Fuel In Injection Pu Pump
2.
Key
3.
Injection Pu Pump Ge Gear
4.
Nutt ((In Nu Injjecti ection on Pump Pump Gear Gear))
Figure 26: Single-Piece Single-Piece Fuel Injection Injection Pump Gear Early Early Engines Engines
34
1
Engine Disassembly
1
2 3 4
1 5
1. 6
Index Marks
Figure 29: Tier 1 and Earlier Earlier Index Mark Location Location
7 1.
Fuel In Injection Pu Pump
2.
Key
3.
Flange
4.
Injection Pu Pump Ge Gear
5.
Transfer Pump Cam
6.
Nut (Inj (Injec ecti tion on Pum ump p Gea Gear) r)
7.
Do Not Not Re Remo mov ve Gea Gearr Fro From m Fla Flang nge e
Figure 28: Three-Piece Three-Piece Fuel Fuel Injection Injection Pump Pump Gear Tier 2 Engine
26. Note the alignment alignment of the index index marks on on the injection pump and the gear case. On On Tier 1 and earlier engines, the index mark on the injection pump is usually aligned with the center (long) index mark on the gear case. On Tier 2 engines, the index mark on the injection i njection pump is usually aligned with the single index mark on the gear case. If not, mark it so the injection pump can be returned to the same position when it is reinstalled.
1
2
1.
Inde Index x Mar Mark k on on Inj Injec ecti tion on Pum ump p
2.
Cent Ce nter er Inde Index x Mar Mark k on on Gea Gearr Cas Case e
Figure 30: Typical Tier 1 and Earlier Index Index Ma Mark rk Align Alignmen mentt
1 1.
Index Marks
Figure 31: Tier 2 Index Index Mark Location Location
35
Engine Disassembly
28. Remove the oil pump from Tier 1 and earlier engines. On Tier 2 engines the oil pump is located in the gear case cover. NOTE: See “Checking Oil Pump” on page 141 for 141 for information about check and changing the oil pump without pulling the engine from the unit.
1
2
1.
Inde Index x Mar Mark k on on Inj Injec ecti tion on Pum ump p
2.
Index Mark ark on Gear ear Case
Figure 32: Typical Tier 2 Index Mark Alignment Alignment
27. Remove the fuel injection pump from the gear case.
AGA17
Figure 35: 35: Remove Oil Pump Pump Tier Tier 1 and and Earl Earlie ierr Engi Engine nes s
29. Remove the two bolts from the idler gear shaft. 30. Remove the idler gear and and the idler gear gear shaft from the cylinder block.
AGA16
Figure 33: Remove Fuel Fuel Injection Injection Pump Tier Tier 1 and and Earl Earlier ier Engi Engines nes
AGA18
Figure 36: Remove Idler Idler Gear and Idler Gear Shaft Shaft
Figure 34: Remove Fuel Fuel Injection Injection Pump Tier Tier 2 Engi Engine nes s
36
Engine Disassembly
31. Remove Remove the flywheel flywheel..
housing and the rubber portion of the seal. The metal ring can then be removed by carefully cutting it with a chisel. NOTE: Any scratches, scratches, nicks or damaged damaged areas of the crankshaft crankshaft must be cleaned cleaned up or the new metal metal ring may not seal seal to the crankshaft. a. Remov Removee the the two hex head head screw screwss and and the removable part of the tool from the t he seal removal tool.
1
AGA19
Figure 37: Remove Flywheel Flywheel
32. Remove Remove the bellhousing bellhousing.. 2
3 4 5
8
AGA20
Figure 38: 38: Remove Bellhous Bellhousing ing
33. Some early engines engines use a radial rear seal. seal. No special tools are needed to remove the radial rear seal. It is removed with the t he rear seal housing (see step step 34). 34). The radial rear seal can be replaced with an axial rear seal if the rear seal housing is also replaced. Use the rear seal removal tool P/N 204-994 to remove the axial rear seal. If the seal has been previously replaced using Loctite or a similar sealant on the metal ring, the possibility exists that the removal tool will straighten the lip on the metal ring instead of removing the seal assembly. assembly. If this occurs, remove the rear seal
7
6
1.
Crankshaft
2.
Outer Lip on on Me Metal Ri Ring
3.
Lip Lip on Tool ool (Fi (Fits ts Behi Behind nd Lip Lip on Met Metal al Ring Ring))
4.
Stati ationar onary y Par Partt of of T Too ooll
5.
Removal Bolt
6.
Coun Co unter tersu sunk nk Scre Screw w (Mu (Must st Be Kept Kept Tigh Tight) t)
7.
Hex Head Screw
8.
Removable Pa Part of To Tool Figure 39: Rear Seal Removal Removal Tool Tool
b. Press Press the the station stationary ary part part of of the tool tool past past and behind the outer lip on the metal ring of the seal. c. While While holdi holding ng the the stati stationa onary ry side side of of the tool engaged on the lip, press the removable part of the tool in and behind the outer lip on the other side of the metal ring.
37
Engine Disassembly
d. Reinst Reinstall all the the hex head head screw screwss that secu secure re the removable part of the tool. At this point the removable part will not be flat against the top of the tool, but will be close enough to get the hex head screws started.
36. Remove the upper part of the oil pan. 37. Remove the oil pump intake pipe.
e. Carefu Carefully lly tight tighten en the the hex hex head head scre screws ws while holding the tool behind the lip on the metal ring. As the t he screws are tightened the tool will pull together and firmly grip the lip. f. With the the tool tool firmly firmly locked locked behind behind the lip, tighten the removal bolt. The entire seal assembly will be pulled out. 34. Remove the rear seal housing. housing. Use the slots slots on the sides to pry it off if necessary. necessary.
Figure 42: Remove Oil Pump Pump Intake Intake Pipe
38. Remove the mounting bolts from the camshaft thrust plate by turning the camshaft gear to access the bolts through the holes in the gear.
AGA21
Figure 40: Remove Rear Rear Seal Housing Housing
35. Make sure the the oil has been drained and remove the lower part of the oil pan. The lower part of the oil pan must be removed to access some of the mounting bolts for the upper part of the oil pan.
AGA24
Figure 43: Remove Camshaft Camshaft Mounting Mounting Bolts
AGA22
Figure 41: Remove Oil Pan Pan
38
Engine Disassembly
39. Carefully remove the camshaft camshaft to avoid avoid scratching or marring the camshaft bearings. The engine must be upside down to prevent the tappets from interfering with the removal of the camshaft.
41. Remove the gear case. Also remove the two O-rings from the oil passages between the gear case and the cylinder block on Tier 1 and earlier engines.
NOTE: Removal of the camshaft gear from the camshaft can can damage the gear gear and camshaft. Therefore, Therefore, it is not recommended. recommended.
AGA27
Figure 46: Remove Gear Case Case
42. Remove the ring ridge from the top of each cylinder, if necessary. AGA25
Figure 44: 44: Remove Camshaf Camshaftt
40. Remove the tappets (valve lifters) with a valve valve lapping tool or a magnet. Keep the tappets in order so they will be placed in the same position when assembled.
43. Mark the connecting connecting rod caps, caps, connecting connecting rods, pistons, and main bearing caps so they can be placed in the same position when assembled. The main bearing caps are marked as shown in Figure 55 on page 44. 44 . 44. Remove the connecting rod caps. caps. 45. Carefully remove the the piston and connecting rod assemblies through the top of the cylinders to avoid scratching or marring the cylinder walls.
AGA28 AGA26
Figure 45: Remove Tappet Tappets s
Figure 47: Remove Piston Piston and Rod Assemblies Assemblies
39
Engine Disassembly
46. Remove the main bearing caps. NOTE: The rear rear main bearing bearing cap (flywheel (flywheel end) has a thrust bearing on each side. Make sure to remove these two thrust bearings. bearings. 47. Carefully remove the crankshaft crankshaft from the block. NOTE: The upper rear rear main bearing bearing (flywheel end) has a thrust bearing on each side. Make sure to remove these two thrust bearings.
AGA29
Figure 48: 48: Remove Crankshaft Crankshaft
40
Inspection and Reconditioning NOTE: Refer to the Specifications Specifications Chapter for specific dimensions that are not given in this this chapter. chapter.
1
This chapter covers the cleaning, inspection, overhaul, and assembly of individual engine components. After disassembling the engine, check the components and discard unusable parts such as gaskets, O-rings, burned valves, and broken rings. Check the items that may need machine shop work first so this work can be completed by the time the rest of the engine is ready to assemble.
Cylinder Block 1. Inspect Inspect the the cylinde cylinderr block block for for cracks, cracks, damage, damage, and distortion. Use a straight edge and a feeler gauge to check the cylinder block deck for distortion. Check all four sides, both diagonals, and the center lines of the cylinder block deck. If there is more than 0.002 in. (0.05 mm) distortion, resurface the cylinder cylinder block. Do not remove more than 0.002 in. (0.05 mm) from the surface of the t he cylinder block. 2. Check Check each each cylind cylinder er for for out of round, round, taper, taper, pocketing, or any other damage that would require boring the cylinders. Use a dial bore gauge or a snap gauge to measure the cylinders. Measure each cylinder both parallel and perpendicular to the crankshaft, at the top, the middle, and the bottom of the cylinder bore. The cylinder out of roundness and taper should not exceed 0.0012 in. (0.030 mm). If the cylinders are in good condition, deglaze the cylinders with a glaze breaker. breaker. 3. If the cyli cylinde nders rs must must be bore bored, d, deter determin minee which oversize pistons should be used. Pistons are available in 0.010 and 0.020 in. (0.25 and 0.50 mm) oversizes.
AGA31
1.
Dial Bo Bore Ga Gauge
Figure 49: Measuring Measuring Cylinder Diameter Diameter
AGA32
1.
Top
2.
Middle
3.
Bottom
4.
Perpe erpend ndic icul ular ar to to Cran Cranks ksha hafft
5.
Paral rallel to Cr Crankshaft aft
Figure 50: Cylinder Cylinder Measuring Positions Positions
41
Inspection and Reconditioning
NOTE: If the 0.020 in. (0.50 mm) oversize is not large enough to clean up the cylinders, cylinders, cylinder sleeves and standard standard pistons must be installed. Cylinder sleeves are available from the Service Parts Parts Department.
b. Press the cylinder cylinder sleeves sleeves into into the cylinder cylinder block using a hydraulic press and a pressing tool.
Use P/N 11-9036 for all TK482 engines.
The pressing tool can be fabricated using the dimensions in the preceding illustration.
Use P/N 11-8919 for all TK486 engines.
•
Plan Planes es A and and B mus mustt be be par paral alle lel. l.
Use the following procedure to install cylinder sleeves: sleeves:
•
Plan Planes es A and and B mus mustt be be per perpe pend ndic icul ular ar to the center line of the tool.
a. Bore Bore and hone hone the cyli cylinde nderr block block to acce accept pt the cylinder sleeves. The recommended interference fit for the cylinder sleeves is 0.0024 to 0.0047 in. (0.060 to 0.120 mm).
•
Relie Relieve ve area area C slig slight htly ly as show shown n to to prevent interference with the sleeve.
•
Beve Bevell all all the the edge edgess sli sligh ghtl tly y.
Measure each cylinder sleeve and subtract 0.0035 in. (0.090 mm). Bore and hone each cylinder to match this dimension. The final surface finish should have an RA (Roughness Average) less than 248 micro inches (6.3 microns).
c. Use a hydr hydraul aulic ic press press to to press press the the cylind cylinder er sleeves into the block. Place the pressing tool in the top end of the cylinder sleeve. The bottom end of a cylinder sleeve has a slightly smaller outside diameter than the rest of the sleeve.
AGA33
1.
1.575 in in. ((4 40.00 mm mm)
2.
TK48 TK482 2 — 3.81 3.819 9 in. in. (97. (97.00 00 mm mm)) TK486 — 3.976 in. (101.00 mm)
3.
0.591 in in. ((1 15.00 mm mm)
4.
TK482 TK482 — 3.17 3.1777-3. 3.18 181 1 in. in. (80.7 (80.700-80 80.80 .80 mm mm)) TK486 — 3.335-3.33.9 in. (84.70-84.80 mm)
1.
Top
5.
P l an e B
2.
Bottom
6.
P l an e A
7.
Area Area C - Re Reli liev eve e thi this s are area a as as sho shown wn.. Figure 51: Pressing Pressing Tool Tool Dimensions
42
AGA34
Figure 52: Cylinder Cylinder Sleeve Sleeve
Inspection and Reconditioning
Spray oil on the outside of the cylinder sleeve or on the inside of the cylinder bore in the block. Place the cylinder sleeve in the block and press the sleeve into place. The pressing load should be 2200 to 4400 lb. (1000 to 2000 kg). The top of the cylinder sleeve must be flush with the top of the block. The cylinder sleeve cannot protrude above the top of the block at all.
AGA35
1.
Cylinder Bl Block
2.
Cylinder Sleeve
3.
The The cyl cylin inde derr sle sleev eve e mus mustt be be flu flush sh..
4.
The The cyl cylin inde derr slee sleeve ve cann cannot ot pro protr trud ude e above the block.
Figure 53: Cylinder Cylinder Sleeve Installation Installation
d. Bore Bore and and hone hone each each cyli cylinde nderr sleeve sleeve to to obtain the correct piston clearance. 4. Measure Measure each piston. piston. Bore Bore and hone each cylinder to obtain the correct piston to cylinder wall clearance (see Specifications). CAUTION: The pistons will vary slightly in diameter. Therefore, each piston must be measured and each cylinder cylinder must be bored and honed honed to match each piston.
5. Measure Measure the front camshaft camshaft bearing bearing insert insert.. If the front camshaft bearing insert is larger than 1.7756 in. (45.100 mm) on Tier 1 and earlier engines, 1.7768 in. (45.130 mm) on Tier 2 engines, or has a damaged surface, remove the bearing insert with a bearing driver. If the block will be boiled out, remove the bearing insert and all the core plugs. NOTE: The middle and rear camshaft camshaft bearings do not have have bearing inserts. inserts.
AGA36
Figure 54: Measuring Measuring Front Camshaft Bearing Bearing Insert
6. This This engine engine does does not not have have middl middlee and rear rear camshaft bearing inserts. The bearing surfaces for middle and rear camshaft bearings are machined into the block. Measure the middle and rear camshaft bearings. If the middle or rear camshaft bearings are larger than 1.7756 in. (45.100 mm), or if the surfaces have been damaged significantly, replace the block. Minor damage to the middle and rear camshaft bearings can be cleaned up with a brake cylinder hone. The middle and rear r ear camshaft bearings should also be lightly honed after the block has been boiled out.
The final surface finish in the cylinders should have an RA (Roughness Average) of 10 to 35 micro inches inches (0.25 to 0.90 microns).
43
Inspection and Reconditioning
7. Install Install the the main main bearin bearing g caps caps in their their prope properr positions. The cast arrows are labeled FW and should point to the rear (flywheel end) of the engine. The main bearing cap that is machined for the thrust bearing goes to the rear end of the engine. The main bearing caps with numbers stamped on them go to the middle of the engine with the main bearing cap marked number one closest to the rear of the engine. The main bearing cap with no number goes to the front end of the engine. Torque the main bearing cap bolts to 70.9 to 73.8 ft-lb (96.1 to 100.0 N•m) on Tier Tier 1 and earlier engines, or 68.7 to 72.4 ft-lb (93.2 to 98.1 N•m) on Tier Tier 2 engines.
9. Check Check the the main main bearin bearing g bore bore alignme alignment nt with with a straight edge and a 0.0015 in. (0.038 mm) feeler gauge. Lay the straight edge in main bearing bores of the block and place the feeler gauge between the straight edge and each main bearing bore. There should be some drag on the feeler gauge at each main bearing bore. If there is no drag on the feeler gauge at any main bearing bore, the block must be align bored.
1
AGA37
Front Pulley End 1.
Rear Flywheel End Rear Main Beari aring Cap
Figure 55: 55: Main Bearing Bearing Cap Marks Marks
8. Measur Measuree the main main beari bearing ng bore boress both both vertically and horizontally. The standard dimension is 2.1260 to 2.1267 in. (54.000 to 54.019 mm). If the main bearing bores are more than 0.001 in. (0.25 mm) out of round, the block must be align bored.
AGA39
Figure 57: Checking Checking Main Bearing Bore Alignment Alignment
10. Measure each each tappet bore bore in the block. block. If any of the tappet bores are larger than 0.4744 in. (12.050 mm) on Tier 1 and earlier engines, or 0.4742 in. (12.045 mm) on Tier 2 engines, the block must be replaced. Small scratches or nicks should be cleaned up with a brake cylinder hone. The tappet bores should also be lightly honed after the block has been boiled out. 11. Check or replace replace all of the the core plugs. plugs.
AGA38
Figure 56: Measuring Measuring Main Bearing Bearing Bore
44
Inspection and Reconditioning
Crankshaft 1. Check Check the crankshaft crankshaft for cracks cracks and check check the main journals, rod journals, and the oil seal surface for excessive wear or damage. Check to see that the oil passages are not clogged or dirty. 2. Measu Measure re the main main jour journal nals. s. If any any of the the main main journals are smaller than 1.9650 in. (49.910 mm) on Tier Tier 1 and earlier engines, 1.9646 in. (49.902 mm) on Tier Tier 2 engines, or tapered or out of round more than 0.0010 in. (0.025 mm), the main journals must be ground undersize.
3. Measur Measuree the rod rod journa journals. ls. If If any of of the rod rod journals are smaller than 1.8862 in. (47.910 mm) on Tier Tier 1 and earlier earlier engines, 1.8859 in. (47.902 (47.902 mm) on Tier Tier 2 engines, engines, or tapered or out of round more than 0.0010 in. (0.025 mm), the rod journals must be ground undersize. Only the 0.010 in. (0.25 mm) undersize rod bearings are available. The wear limit for the outside diameter of undersized rod journals is 1.8764 in. (47.660 mm) on Tier 1 and earlier engines, or 1.8761 in. (47.652 (47.652 mm) on Tier Tier 2 engines.
Only the 0.010 in. (0.25 mm) undersize main bearings are available. The wear limit for the outside diameter of undersized main journals is 1.9551 in. (49.660 mm) on Tier 1 and earlier engines, or 1.9548 in. (49.652 mm) on Tier Tier 2 engines.
AGA41
Figure 59: 59: Measuring Measuring Rod Journal Journal
AGA40
Figure 58: 58: Measuring Measuring Main Journal Journal
NOTE: The most accurate accurate method of determining the outside outside diameter of the undersized main journals is to install the main bearing caps caps with the undersized undersized bearing inserts inserts in place. Properly Properly torque the main bearing caps caps to the block and measure the inside diameter of the main bearings. Subtracting the suggested oil clearance of 0.0015 to 0.0027 in. (0.038 to 0.068 mm) from the inside diameter diameter of the main bearings results results in the correct correct outside diameter for the undersized undersized main journals. journals.
NOTE: The most accurate accurate method of determining the outside outside diameter of the undersized rod journals is to install the rod caps with the undersized undersized bearing inserts inserts in place. Properly torque the rod caps caps to the rods and measure measure the inside diameter diameter of the rod bearings. Subtracting the suggested suggested oil clearance of 0.0015 0.0015 to 0.0029 in. (0.038 (0.038 to 0.074 mm) from the inside diameter of the rod bearings results results in the correct correct outside diameter for the undersized undersized rod journals. journals. 4. Measure Measure the crankshaft crankshaft deflection deflection by placing placing the front and rear main journals in a set of “V” blocks, or place the crankshaft in the block resting on only the old front and rear upper main bearing inserts. Set a dial indicator on the middle main journal and rotate the crankshaft one full turn. The crankshaft deflection equals one half of the largest difference in readings on the dial indicator. indicator. If the crankshaft deflection is greater than 0.0008 in. (0.020 mm) the crankshaft crankshaft must be replaced.
45
Inspection and Reconditioning
NOTE: A radial rear rear seal can be replaced replaced with an axial rear seal if the t he rear seal housing is also replaced. replaced. See step See step 56 on on page 82 .
Pistons
AGA352
1. Remove Remove and and disca discard rd the the old pist piston on rings rings..
1.
Dial In Indicator
2.
“V” block
Figure 60: Measuring Measuring Crankshaft Crankshaft Deflection
AGA353
1.
Differenc ence in in Re Readings
2.
Deflection
Figure 61: Crankshaft Crankshaft Deflection Deflection
5. Inspect Inspect the the cranksh crankshaft aft timing timing gear for chippe chipped d or worn teeth and for any cracks on or between the teeth. To remove the gear use a standard gear puller. Install the gear by pressing it onto the crankshaft. Apply a sealant to the inside of the gear to prevent oil leaks. NOTE: Removal of the crankshaft crankshaft timing gear from the crankshaft crankshaft can damage damage the gear. gear. Therefore, it is not not recommended except when necessary.
2. Remove Remove the the wrist wrist pin pin circl circlips ips and and push push the the wrist pin out of the piston. If it is difficult to push the wrist pin out of the piston, heat the piston in hot water that is at 120 to 140 F (49 to 60 C). NOTE: Do not clamp a connecting rod in a vise with steel jaws. Instead, use a vise that has soft jaws, or or use soft jaw covers. Clamping a connecting rod in the steel jaws of a vise will put small nicks nicks in the connecting rod. These These nicks raise the stress on the connecting rod and can cause cause the connecting rod to break while the engine engine is running. 3. Remove Remove the the carbo carbon n from from the top top of the the piston piston but do not scratch the piston. Clean the piston and inspect it for damage. Replace the piston if it has any cracks, or if the top of the piston is significantly burned or damaged. 4. Measure Measure the outside outside diameter diameter of each each piston. piston. This measurement should be taken perpendicular to the wrist pin 0.95 in. (24.0 mm) above the bottom of the piston skirt. If the piston is smaller than the wear limit (see Specifications), replace the piston.
6. Check Check the the area area on the the end of of the cran cranks kshaf haftt from which the metal seal ring for the axial rear seal was removed. Any scratches, nicks, or damage to this area of the crankshaft must be cleaned up, or the new metal seal ring may not seal to the crankshaft. Remove the metal seal ring for the rear seal if it has not yet been removed. The metal seal ring can be removed by carefully cutting it with a sharp chisel.
AGA44
1.
0.95 in in. ((2 24. 0 m mm m)
Figure 62: Piston Measuring Measuring Point Point
46
Inspection and Reconditioning
7. Measur Measuree the insid insidee diamet diameter er of the the wrist wrist pin bore. If the inside diameter of the wrist pin bore is larger than 1.0244 in. (26.020 mm) on Tier 1 and earlier engines, or 1.0252 in. (26.039 mm) on Tier 2 engines, replace the piston. AGA45
Figure 63: 63: Measuring Measuring Piston Piston
5. Clean Clean the the ring ring groves groves with a ring ring groove groove cleaner. cleaner. Be careful to t o avoid scraping any metal off the piston. If a ring groove cleaner is not available, break a used ring ri ng and sharpen the end. This can be used to clean the ring grooves.
Wrist Pins The wrist pin and the connecting rod bushing carry a large load concentrated in a small area. Therefore a precise fit is critical. If I f possible, a qualified machine shop should fit new wrist pins to new connecting rod bushings when an engine is overhauled. 1. Measure Measure the the outsid outsidee diamete diameterr of the wrist wrist pins pins with a micrometer. If a wrist pin is smaller than 1.0197 in. (25.900 mm) on Tier 1 and earlier engines, or 1.0222 in. (25.965 mm) on Tier 2 engines, replace the wrist pin.
NOTE: Tier 2 engines have have a steel insert in the top ring groove groove for added endurance. endurance. 6. Use a new new set of of piston piston ring ringss and and a feele feelerr gauge to check the clearance between the rings and the ring grooves. If the clearance between a new ring and its respective ring groove is greater greater than 0.0098 0.0098 in. (0.250 (0.250 mm) for the top and middle rings or 0.0079 in. (0.200 mm) for the bottom ring, the t he piston must be replaced. NOTE: The top ring on on Tier 2 engines is a keystone ring so so the clearance cannot be measured.
AGA46
AGA47
Figure 65: 65: Measuring Measuring Wrist Pin Pin
2. If a micrometer micrometer with this this degree degree of accura accuracy cy is not available, the fit between the wrist pin and the connecting rod bushing can be checked by oiling the wrist pin and inserting it into the connecting rod bushing. The fit should be snug and it should take a slight push to move the wrist pin through the connecting rod bushing, but the wrist pin should rotate freely.
Figure 64: Checking Checking Ring Clearance Clearance
47
Inspection and Reconditioning
Connecting Rods The procedures used to recondition a connecting rod, which include honing the connecting rod bearing bore, straightening the connecting rod, and replacing the connecting rod bushing, require various pieces of expensive equipment. If this equipment is not available, most machine shops can recondition serviceable connecting rods to meet standard specifications. 1. If possib possible, le, bead bead blast the connectin connecting g rods rods with glass beads. Bead blasting does an exceptional job of cleaning the rods, and it also relieves stress by removing minor surface damage that tends to increase stress. NOTE: Bead blasting the connecting rods is highly recommended. recommended. Most machine shops shops offer this service service and the price price is usually quite reasonable. 2. Check Check each each conne connecti cting ng rod rod bearing bearing by by installing the connecting rod cap with the original bearing inserts in place and torquing the rod cap bolts to 32.5 to 39.8 ft-lb (44.1 to 53.9 N•m) on Tier 1 and earlier engines, or 32.5 to 36.2 ft-lb (44.1 to 49.0 N•m) on Tier Tier 2 engines.
AGA48
Figure 66: Measuring Measuring Rod Bearing or Bearing Bearing Bore
6. Use a conn connect ecting ing rod rod alignme alignment nt fixture fixture to to check each rod for twist and parallelism. The wear limit for both twist and parallelism is 0.003 in. per 4 in. (0.08 mm per 100 mm). If the twist or parallelism exceeds the wear limit, straighten or replace the rod.
3. Measure Measure the inside inside diamete diameterr of the connectin connecting g rod bearings. If any of the connecting rod bearings are larger than the wear limit (see Specifications), or show significant damage, replace the entire set of connecting rod bearing inserts. 4. Check Check each each conne connecting cting rod bearing bearing bore bore by installing the rod caps with the rod bearing inserts removed and properly torquing the rod cap bolts to 32.5 to 39.8 ft-lb (44.1 to 53.9 N•m) on Tier Tier 1 and earlier engines, or 32.5 to 36.2 ft-lb (44.1 to 49.0 N•m) on Tier Tier 2 engines. 5. Measure Measure each connecting connecting rod bearing bearing bore both parallel and perpendicular to the rod. The standard dimension is 2.0079 to 2.0083 in. i n. (51.000 to 51.010 mm). If the rod bearing bore is more than 0.001 in. (0.25 mm) out of round the rod must be reconditioned or replaced.
48
AGA49
1.
4 in. (100 mm)
2.
Parallelism
3.
Twist
Figure 67: Measuring Measuring Connecting Rod Twist Twist and Paralle Parallelis lism m
Inspection and Reconditioning
7. Measur Measuree the insi inside de diame diameter ter of of the wrist wrist pin pin bushings. If the wrist pin bushings are larger than 1.0276 in. (26.100 mm) on Tier 1 and earlier engines, 1.0263 in. (26.068 mm) on Tier 2 engines, or show significant damage, replace the wrist pin bushings.
NOTE: The crankshaft crankshaft gear uses uses a press fit. Use a hydraulic press to remove and install the crankshaft gear gear.. Removing the crankshaft gear gear can damage it. Therefore, it is not recommended except when necessary. The camshaft gear uses a very secure press fit. It cannot be removed removed without damaging the camshaft and the camshaft gear gear. Therefore, the camshaft gear and camshaft must be replaced as an assembly. assembly. 2. Measure Measure the inside inside diamete diameterr of the idler gear bushing. If the idler gear bushing is larger than 1.8142 in. (46.080 mm) on Tier 1 and earlier engines, 1.8140 in. (46.075 mm) on Tier 2 engines, or is significantly damaged, replace the idler gear bushing. To To replace the bushing, press the old bushing out of the idler gear and press the new bushing into the idler gear.
AGA50
Figure 68: Measuring Measuring Wrist Pin Bushing Bushing
8. To replace replace a wrist wrist pin bushing, bushing, press the old old bushing out of the connecting rod. Press the new bushing into the rod and make sure to align the oil hole in the bushing with the oil hole in the top of the rod. The bushing is pre-finished.
Timing Gears 1. Inspec Inspectt the timi timing ng gears gears for for chipp chipped ed or or excessively worn teeth, and for any cracks on or between the teeth. The gear lash should have been checked during the disassembly of the engine. If not, check the gear lash during the assembly of the engine.
AGA51
Figure 69: Measuring Measuring Idler Gear Bushing Bushing
3. Measure Measure the outside outside diame diameter ter of of the idler gear shaft. If the idler gear shaft is smaller than 1.8083 in. (45.930 (45.930 mm) on Tier Tier 1 and earlier engines, 1.8071 in. (49.090 mm) on Tier 2 engines, or is significantly damaged, replace the idler gear shaft.
AGA52
Figure 70: Measuring Measuring Idler Gear Shaft Shaft
49
Inspection and Reconditioning
Camshaft NOTE: The camshaft camshaft gear cannot cannot be removed without damaging the camshaft and the camshaft gear. gear. Therefore, Therefore, the camshaft camshaft gear and and camshaft must be be replaced as an assembly. assembly. 1. Check Check the the camshaf camshaftt journals journals,, the the cam cam lobes, lobes, the thrust plate, and the camshaft gear for wear or damage.
4. Measure Measure the camshaft camshaft deflection deflection by placing placing the front and rear camshaft journals in a set of “V” blocks. Set a dial indicator on the middle camshaft journal and rotate the camshaft one full turn. The camshaft deflection equals one half of the largest difference in readings on the dial indicator. If the camshaft deflection exceeds 0.002 in. (0.05 mm), the camshaft assembly must be replaced.
2. Measur Measuree the camsh camshaft aft journ journals als.. If any of the the camshaft journals are smaller than the wear limit (see Specifications) or significantly damaged, replace the camshaft assembly.
Figure 73: Measuring Measuring Camshaft Deflection Deflection
Figure 71: Measuring Measuring Camshaft Camshaft Journals
3. Measur Measuree the cam lobe lobes. s. If any any of of the cam cam lobes are smaller than 1.5118 in. (38.400 mm) on Tier 1 and earlier engines, 1.5098 in. (38.350 mm) on Tier 2 engines, or significantly damaged, replace the camshaft assembly.
5. Check Check the the thrust thrust plate plate clearance clearance (end play) by placing a feeler gauge between the thrust plate and the camshaft journal (or camshaft gear). If the clearance exceeds the 0.016 in. (0.40 mm) on Tier 1 and earlier engines, or 0.012 in. (0.30 mm) on Tier 2 engines, replace the camshaft assembly.
AGA56
Figure 74: Checking Checking Thrust Plate Plate Clearance
Figure 72: 72: Measuring Measuring Cam Lobes Lobes
50
Inspection and Reconditioning
Cylinder Head
1
NOTE: The cylinder head on Tier Tier 1 and earlier earlier engines is not interchangeable with the cylinder head on the Tier Tier 2 engine.
2 3 4
8
1. Clean all the the carbon carbon and any other deposits deposits from the cylinder head with a gasket scraper or a wire brush. Visually Visually inspect the cylinder head for cracks and check the sealing surfaces for damage.
5 6
2. Use a straig straight ht edge edge and and a feel feeler er gauge gauge to check the cylinder head deck for distortion. Check all four sides, both diagonals, and the center lines of the cylinder head deck. Resurface or replace the head if the distortion exceeds 0.006 in. (0.15 mm).
AGA58
NOTE: When resurfacing resurfacing the cylinder head, head, remove only enough enough material to make it flat. Do not remove more than 0.008 in. (0.20 (0.20 mm). mm).
AGA57
Figure 75: Checking Checking Cylinder Head Distortion Distortion
7
1.
Valve Stem Cap
2.
Valve Keeper
3.
Valve alve Sprin pring g Re Rettaine ainerr
4.
Valve Spring
5.
Valve Stem Seal
6.
Valve Guide
7.
Valve
8.
Driv Drive e Val Valve ve Gui Guide des s in this this Dire Direct ctio ion n
Figure 76: Cylinder Cylinder Head Components Components
Disassembly 1. Use a valve valve spring spring compres compressor sor to remove remove the valve keepers. 2. Remov Removee the keep keepers ers,, the valve valve spri spring ng retainers, the valve springs, and the valves. Mark each valve or keep them in order so they can be returned to their original positions when assembled. 3. Remov Removee the valv valvee stem stem seals seals and and boil boil out the the head if possible.
51
Inspection and Reconditioning
Valve Guides Gui des 1. Remove Remove the the carbon carbon from the valve guides guides with with a valve guide carbon beater. 2. Measur Measuree the insi inside de diame diameter ter of the the valve valve guides with a small hole gauge or a graduated set of tapered pilots. If the valve guides are larger than 0.3189 in. (8.100 mm), replace the valve guides. NOTE: If the engine has been in use for some time and has accumulated many hours of running time, it is advisable to replace replace the valve guides because they usually show significant wear after numerous hours hours of service. Because Because the valve seat seat grinding procedure is centered by a pilot placed placed in the valve guide, new straight valve guides allow the valve seats to be ground accurately accurately.. 3. Remove Remove the the valve valve guid guides es by usin using g a valve valve guide removal tool (see Figure 1 on page 24) 24 ) and a press or a hammer to drive the valve guides out through the combustion chamber.
4. Instal Installl the new new valve valve guid guides es using using a valv valvee guide installation tool (see Figure 2 on page 24) 24) and a press or a hammer. hammer. Drive the valve guide into the top of the cylinder head until the valve guide projection (the distance between the top of the valve guide and the top of the valve spring seat) is 0.591 in. (15.00 mm) on Tier Tier 1 and earlier engines, or 0.579 to 0.591 0.591 in. (14.70 to 15.00 mm) on Tier Tier 2 engines.
AGA60
1.
Valve alve Guid Guide e Proje roject ctiion
Figure 78: Valve Guide Projection Projection
5. After installation installation,, ream ream the the new new valve valve guides. guides. Use a 0.3155 in. (8.010 mm) ream for the intake valve guides. Use a 0.3155 in. i n. (8.015 mm) ream for the exhaust valve guides.
Valve Depth D epth The valve depth is the distance between the cylinder head deck and the valve.
AGA59
1.
Valve Guide Tool
2.
Cylinder Head
3.
Valve Guide AGA61
Figure 77: Removing or Installing Installing Valve Valve Guides 1.
Cylinder Head Deck
2.
Valve Depth
3.
Valve
Figure 79: 79: Valve Valve Depth Depth
52
Inspection and Reconditioning
The valve depth is a critical dimension for most diesel engines. Grinding the valve or the valve seat increases the valve depth. As the valve depth increases, the volume of the combustion chamber also increases and the compression ratio decreases. Decreasing the compression ratio can cause hard starting or poor performance. Therefore it is very important to check the valve depth of each valve before and after grinding the valve, and before and after grinding the valve seat. If the valve depth is near the wear limit before grinding the valve or valve seat, the valve, the valve seat or both may need replacement. If the valve depth exceeds the wear limit after grinding the valve or the valve seat, the valve, the valve seat or both must be replaced. To check the valve depth, install the valves in in their respective valve seats and measure the valve depth of each with a depth gauge or a caliper. The wear limit for both the intake and exhaust valve depth is 0.039 in. (1.00 mm) on Tier 1 and earlier engines, or 0.031 0.031 in. (0.80 mm) on Tier Tier 2 engines.
AGA63
Figure 81: Measuring Measuring Valve Valve Stem
3. The valv valves es can can be ground ground to clea clean n up any any wear or minor damage on the valve faces. Grind the valves until all signs of wear or damage are removed. Grind the valve faces to the following angles: Intake
30 degrees
Exha Exhaus ustt 45 deg degre rees es 4. After After grindin grinding g the valve valves, s, check check the the valve valve margin. Replace any valve with a valve margin that is less than 0.020 in. (0.50 mm).
AGA64 AGA62
Figure 80: Measuring Measuring Valve Valve Depth
Valves 1. Clean and inspect inspect the the valves valves.. Replace Replace valves valves that are cracked, bent, or have valve faces that are significantly damaged. 2. Measu Measure re the outs outside ide diam diamete eterr of the valv valvee stems. If the valve stem is smaller than t han 0.3110 0.3110 in. (7.900 mm), replace the valve. valve.
1.
0.02 0.020 0 in. in. (0.5 (0.50 0 mm) mm) Mini Minimu mum m Figure 82: 82: Valve Valve Margin Margin
NOTE: Valves Valves with a valve margin that is not even after being ground are slightly bent. These valves should be replaced if the valve margin is less than 0.020 in. (0.50 mm) at the narrowest point. 5. After grinding grinding the the valves valves,, install install the the valves valves in their respective valve seats and check the t he valve depth of each. Replace any valve that has a valve depth over the wear limit.
53
Inspection and Reconditioning
Valve Seats 1. Inspect Inspect the the valve valve seats seats for for any any major major damag damagee that would require valve seat replacement. 2. Grind each valve seat to remove remove any sign of wear or minor damage. Valve seats that show no wear or damage should also be ground lightly to clean up any slight imperfections. Grind the valve seats to the following angles: Intake
3. After grinding grinding the valve valve seats seats,, install install the valves in their respective valve seats and check the valve depth of each. Replace any valve that has been ground and now has a valve depth over the wear limit. Replace any valve seat that has a new valve installed and still has a valve depth over the wear limit. limi t. 4. Check Check the the width width of the the valv valvee seats seats with with a caliper.
30 degrees
Exha Exhaus ustt 45 deg degre rees es
AGA65
AGA67
Figure 85: Measuring Measuring Valve Valve Seat Width 1.
Valve Seat Width
Figure 83: Intake Intake Valve Valve Seat Angles
5. Use Prus Prussia sian n Blue Blue or a simila similarr dye to chec check k the alignment of the each valve seat and valve face. The valve seat should contact the middle of the valve face. 6. Use 15 and and 70 70 degree degree grinding grinding stone stoness to size and align the valve seats to meet the width specifications (see Specifications), and alignment recommendation above.
AGA66
1.
Valve Seat Width
Figure 84: Exhaust Valve Valve Seat Angles Angles
54
Inspection and Reconditioning
Valve Seat Replacement The original cylinder head is not equipped with removable valve seats. The cylinder head must be machined to accept replacement valve seats. Replacement valve seats are available from the Service Parts Department. The following illustrations show the dimensions for replacement valve seat bores. 1. After After machi machinin ning g the head, head, chill chill each each replacement valve seat and install it with a valve seat installation tool. 2. Grind the new valve seats seats after after instal installation lation..
AGA68
1.
Beve Bevell 0.0 0.016 16 to to 0.0 0.031 31 in. in. (0. (0.4 4 to to 0. 0.8 8m mm) m)
2.
Depth 0.321 to 0.329 in. (8.15 to 8.35 mm)
3.
Exhaust Diameter 1.2402 to 1.2408 in. (31.500 to 31.516 mm)
4.
Intake Diameter 1.4567 to 1.4573 in. (37.000 to 37.016 mm)
1.
Beve Bevell 0.01 0.016 6 to to 0.03 0.031 1 in. in. (0. (0.4 4 to to 0.8 0.8 mm) mm)
2.
Depth 0.321 to 0.329 in. (8.15 to 8.35 mm)
3.
Exhaust Diameter 1.2402 to 1.2408 in. (31.500 to 31.516 mm)
4.
Intake Diameter 1.4961 to 1.4967 in. (38.000 to 38.016 mm)
5.
Exha Exhaus ustt Bev Bevel el Angl Angle e 30 30 to to 45 45 Deg Degre rees es
6.
Exhaust Bevel Outside Diameter 1.311 to 1.319 in. (33.3 to 33.5 mm) m m)
7.
Intake Bevel Outside Diameter 1.642 to 1.650 in. (41.7 to 41.9)
8.
Inta Intake ke Beve Bevell Ang Angle le 45 to 60 De Degr gree ees s
Figure 87: Dimensions Dimensions for Replacement Replacement Valv alve e Seat Seat Bores Bores Tier 2 Engines Engines
Figure 86: Dimensions Dimensions for Replacement Replacement Valve Valve Seat Bores Tier 1 and Earlier Earlier Engines Engines
55
Inspection and Reconditioning
Valve Springs 1. Clean and inspect inspect the valve springs. springs. Replace Replace valve springs that are cracked, or significantly scratched or damaged. 2. Measure Measure the free length length of of the valve valve springs springs with a caliper. Replace any valve springs that are shorter than 1.67 in. (42.5 mm) on on Tier 1 and earlier engines, engines, or 1.63 in. (41.5 mm) on Tier 2 engines. AGA71
1.
Inclination
2.
Free Length
Figure 90: Valve Valve Spring Measurements Measurements
4. Inspect Inspect the the valve valve stem stem caps, caps, the valve valve spring spring retainers, and the valve keepers. Replace any of these components that show significant wear or damage.
Cylinder Head Assembly AGA69
Figure 88: Measuring Measuring Valve Valve Spring Free Length
3. Check Check the inclination inclination of the the valve valve springs springs with with a square. Replace any valve springs with inclinations larger than 0.04 in. (1.1 mm) on Tier 1 and earlier engines, or 0.06 in. (1.4 mm) on Tier 2 engines.
Assemble the cylinder head after all the components have been reconditioned or replaced. Thoroughly clean the cylinder head and all the components before assembly. 1. Lightl Lightly y oil the the valve valve stem stem seals seals and and place place them on the valve guides. The intake and exhaust valve stem seals are different from each other. The exhaust valve stem seals are marked with yellow paint. Make sure to put the intake and exhaust valve stem seals on the matching valve guides. NOTE: New valve stem stem seals should always always be used when assembling the cylinder cylinder head. 1 2
AGA70
Figure 89: Checking Checking Valve Spring Spring Inclination AGA72
1.
Valve Stem Seal
2.
Valve Guide
Figure 91: Installing Installing Valve Valve Stem Seals
56
Inspection and Reconditioning
2. Oil the the valve valve stem stem and and place place the valve valvess in their respective valve seats. Oiling the valve stems prevents them from seizing to the new valve stem seals. 3. Install Install the valve springs. springs. The end of a valve spring that has less pitch (this end is wound tighter and may have some paint on it) should be placed on the cylinder head.
c. Lift Lift the valve valve off off the the valve valve seat seat,, rotate rotate the the valve about a quarter of a turn, and drop the valve back onto the valve seat. Spin the valve against the valve seat again for a short time. Repeat this several times. 1
1 AGA74
2
1.
AGA52
Valve Lappi pping Tool
Figure 93: 93: Lapping Valves Valves AGA73
1.
Top—More Pitch
2.
Bott Bottom om—L —Les ess s Pit Pitch ch—P —Pla lace ce On Cyli Cylind nder er He Head ad Figure 92: 92: Valve Spring Spring
4. Place the valve spring spring retaine retainers rs in the valve springs and compress the valve springs with a valve spring compressor. 5. Install Install the valve keepers keepers and remove remove the the valve valve spring compressor. 6. After installing installing the valves, valves, place place the cylinder cylinder head on the intake side and fill the exhaust ports with diesel fuel. Check to see if any diesel fuel is leaking l eaking past the exhaust valves. Turn the cylinder head over and check the intake valves in the same way. Minor seeping is acceptable, but any valves that leak significantly must be removed and lapped. l apped.
d. Remov Removee the valve valve and and wipe wipe the the lappi lapping ng compound off the valve seat and the valve face. The valve seat should appear smooth and be an even gray color. The valve face should show a smooth, even gray ring where it contacts the valve seat. Repeat the lapping procedure if either the valve seat or the valve face does not appear smooth and even. 7. Recheck Recheck the valves valves for for leaks leaks after they have been lapped.
a. To lap a valve valve plac placee a small small amou amount nt of medium grit valve lapping compound on the valve face. b. Place Place the the valve valve in the the valve valve seat seat and and use a valve lapping tool to spin the valve against the valve seat for a short time.
57
Inspection and Reconditioning
Rocker Arm Assembly
2. Remove Remove the the rocker rocker arm arm suppor supports, ts, the the rocker rocker arms, and the springs from the rocker arm shaft. Keep these parts in order to make sure they will be assembled correctly.
1. Remove Remove the stud studss from from the rock rocker er arm arm supports on both ends of the rocker arm shaft and from the rocker arm support in the center of the rocker arm shaft.
3. Clean Clean and and inspec inspectt all the componen components ts of of the rocker arm assembly. Replace any parts that show significant wear or damage.
1
2 3
8
7
6
5
4 AGA75
1.
Rocker Arm Shaft
5.
Spring
2.
Locknut
6.
Rocker Arm
3.
Valve Ad Adjustment Sc Screw
7.
Rocker Ar Arm Su Support
4.
Stud
8.
Intake (Front) Side
Figure 94: 94: Rocker Arm Arm Assembly Assembly
58
Inspection and Reconditioning
4. Measu Measure re the outs outside ide diam diamete eterr of the rocke rockerr arm shaft at the pivot point of each rocker arm. Replace the rocker arm shaft if it is smaller than 0.6280 in. (15.950 mm) on Tier 1 and earlier engines, or 0.6276 in. (15.940 mm) on Tier 2 engines, at any of the rocker arm pivot points.
6. Loosen Loosen the the lockn locknut ut and and remove remove the the valve valve adjustment screw from each rocker arm. Inspect each valve adjustment screw and replace any that show significant wear or damage. Place the valve adjustment screws back in the rocker arms but do not tighten the locknuts. 7. Reasse Reassembl mblee the rocke rockerr arm assem assembly bly and and make sure the parts are in the correct order. order. See Figure 94 on page 58 and 58 and note the following items: a. The rocker rocker arm shaft shaft is symme symmetric trical. al.
AGA76
Figure 95: Measuring Measuring Rocker Arm Shaft Shaft
5. Measure Measure the inside inside diamete diameterr of each rocker rocker arm bushing. If a rocker arm bushing is larger than 0.6335 in. (16.090 mm) on Tier 1 and earlier engines, 0.6327 in. (16.070 mm) on Tier 2 engines, or shows significant damage, replace the rocker arm.
AGA77
b. The inta intake ke and and exhaus exhaustt rocker rocker arms arms are are identical. The valve adjustment screws go to the push rod (back) side. c. The three three middl middlee rocker rocker arm arm suppo supports rts are are identical. They go on the rocker arm shaft with the long mounting bolts to the intake (front) side. d. The center center rock rocker er arm arm suppor supportt and both both end rocker arm supports are fastened to the rocker arm shaft with studs. The studs go through the tops of the rocker arm supports into holes in the rocker arm shaft. e. The two rocke rockerr arm suppor supports ts on on the the ends ends of the rocker arm shaft are identical. Each has an oil passage in its bottom. This oil passage carries oil from the cylinder head to the rocker arm shaft. The oil passage must go to the push rod (back) side and align with the oil passage in the cylinder head.
Figure 96: Measuring Measuring Rocker Arm Bushing Bushing
59
Inspection and Reconditioning
Push Rods 1. Clean and inspect inspect the the push push rods. rods. Repla Replace ce any any push rods that show significant wear or damage. 2. Place Place each each push push rod rod on a compl complete etely ly flat flat surface and use a feeler gauge to check how much the push rod is bent. Replace any push rod that is bent more than 0.001 in. (0.03 mm).
AGA79
1
2
1.
Abnormal Wear
2.
Normal Wear
Figure 98: 98: Tappet Wear Wear
2. Measure Measure the outside outside diameter diameter of of each each tappe tappet. t. Replace any tappets that are smaller than 0.4697 in. (11.930 (11.930 mm) on Tier 1 and earlier engines, or 0.4707 0.4707 in. (11.955 (11.955 mm) on Tier 2 engines.
AGA78
Figure 97: Checking Bend Bend in Push Rods Rods
Tappets 1. Clean and inspect inspect the the tappet tappets. s. Normal Normally ly the the tappets rotate while the engine is running. This causes normal wear to appear as concentric rings on the surface of the tappet that contacts the cam lobe. A tappet that does not rotate shows an abnormal wear pattern straight across its contact surface. Replace any tappet that shows an abnormal wear pattern, significant wear, or significant damage.
60
AGA80
Figure 99: Measuring Measuring Tappet Tappet
Inspection and Reconditioning
Oil Pump Oil Pump for Tier 1 and Earlier Engines 1. Remov Removee the rotor rotor plate plate and and inspe inspect ct the the oil pump. If the rotor plate, the inner rotor, the outer rotor, or the oil pump body show significant wear, scratches, or damage, replace the oil pump. 1 AGA82
2 3
Figure 101: Checking Checking Clearance Between Between Oil Pump Pump Body and Outer Outer Rotor Rotor
4
8 7 6
AGA81
5 1.
Rotor Plate
2.
Outer Rotor
3.
Rotor Shaft
4.
Oil Pres Pressu sure re Contr ontrol ol Valve alve
5.
Gear
6.
Pump Body
7.
Inner Rotor
8.
Rotor Shaft Bore
Figure 100: 100: Oil Pump Pump Assembly Assembly Tier Tier 1 and and Earl Earlie ierr Engi Engine nes s
2. Use a fee feeler ler gauge gauge to to check check the the cleara clearance nce between the oil pump body and the outer rotor. If the clearance between the oil pump body and the outer rotor exceeds 0.0098 in. (0.250 (0.250 mm), replace replace the oil oil pump.
AGA83
Figure 102: Checking Checking Clearance Between Between Inner Rotor and and Outer Rotor
4. Check Check the the clearan clearance ce betwee between n the the rotor rotor plate plate and both rotors. Place a straight edge across the oil pump body and insert a feeler f eeler gauge between the straight edge and the rotors. If I f the clearance between the rotor plate and either rotor exceeds 0.0059 in. (0.150 mm), replace the oil pump.
3. Use a fee feeler ler gauge gauge to to check check the the cleara clearance nce between the inner rotor and the outer rotor r otor.. Place the feeler gauge between the tip of a vane on the inner rotor and the high point of a lobe on the outer rotor. rotor. If the clearance between the inner rotor and the outer rotor exceeds 0.0059 in. (0.150 mm), replace the oil pump.
61
Inspection and Reconditioning
Oil Pump for Tier 2 Engines On Tier 2 engines the oil pump is located in the gear case cover. The inner rotor of the t he oil pump fits around the boss on the crankshaft gear. NOTE: Replace the oil pump pump as an assembly assembly when replacing the oil pump. Make sure the mark on the side of of the outer rotor faces faces the oil pump cover when installing the oil pump. pump. Torque Torque the oil pump cover mounting screws to 3.9 3.9 to 6.2 ft-lb (5.4 (5.4 to 8.4 N•m). N•m). AGA84
Figure 103: Checking Checking Clearance Between Between Rotor Plate and Rotors Rotors
5. Measure Measure the outsid outsidee diamet diameter er of of the rotor shaft shaft and the inside diameter of the rotor shaft bore in the rotor plate. Subtract the diameter of rotor shaft from the diameter of the rotor shaft bore to obtain the rotor shaft clearance. If the rotor shaft clearance exceeds 0.0079 in. (0.200 (0.200 mm), replace replace the oil pump. pump.
1
6. Hold Hold the oil pump pump body body in in one one hand hand and and the the oil pump gear in the other hand. Wiggle the gear to check the clearance between the rotor shaft and the oil pump body. The wear limit is 0.0079 in. (0.200 mm). If the clearance exceeds this, replace the oil pump.
1.
Mark on Outer Rotor
Figure 104: 104: Mark on Outer Outer Rotor Face Faces s Oil Oil Pump Pump Cove Coverr 1
7. Press on the the oil pressure pressure control control valve valve piston piston from the cylinder block side of the oil pump. Check to make sure that the piston moves smoothly and is returned by the spring. If not, replace the oil pump.
2
5
3 4
1.
Crankshaft Gear
4.
Inner Rotor
2.
Oil Pump Cover
5.
Gear Case Cover
3.
Outer Rotor
Figure 105: Oil Pump Located Located in Gear Case Cover Cover on Tier 2 Engines
62
Inspection and Reconditioning
1. Remov Removee the oil oil pump pump cover cover and and inspec inspectt the oil oil pump components. If the oil pump cover, the inner rotor, or the outer rotor show significant wear, scratches, scratches, or damage, replace the oil pump.
1 2
2 3
1
4
4
1.
Oil Pres Pressu sure re Contr ontrol ol Valve alve
2.
Oil Pump Cover
3.
Outer Rotor
4.
Inner Rotor
Figure 106: Oil Pump Components Components Tier Tier 2 Engines
2. Place the outer outer rotor in the the gear gear case case cover cover.. Use a feeler gauge to t o check the clearance between the outer rotor and the gear case cover. cover. If the clearance between the outer rotor and the gear case cover exceeds 0.0118 in. (0.300 mm), replace the oil pump. 3. Check Check the the cleara clearance nce betw between een the the oil oil pump pump cover and the outer rotor. Place a straight edge across the gear case cover where the oil pump cover mounts. Insert a feeler f eeler gauge between the straight edge and the outer rotor. If the clearance between the oil pump cover and the outer rotor exceeds 0.0047 in. (0.120 mm), replace the oil pump. 4. Measure Measure the the inside inside diameter diameter of of the inner rotor and the outside diameter of the crankshaft gear boss. Subtract the inside diameter of inner rotor from the outside diameter of the crankshaft gear boss to obtain the inner rotor to crankshaft gear boss clearance. If the inner rotor to crankshaft gear boss clearance exceeds 0.0236 in. (0.600 mm), replace the oil pump.
1.
Cranks nkshaft Gear Boss
2.
Widt Width h Acr Acros oss s Fla Flats ts of Inne Innerr Rot Rotor or
3.
Insi Inside de Diam Diamet eter er of Inne Innerr Ro Roto torr
4.
Flat Flat of Cran Cranks ksha hafft Gea Gearr Bos Boss s
3
Figure 107: 107: Measure Inner Inner Rotor Rotor to Cranksh Cra nkshaf aftt Gear Gear Boss Boss Cle Clearan arance ce
5. Measure Measure the the width width across across the flats of the the inner inner rotor and the width across the flats of the crankshaft gear boss. Subtract the width across the flats of the inner rotor from the width across the flats of the crankshaft gear boss to obtain the inner rotor to crankshaft gear boss clearance between flats. If the inner rotor to crankshaft gear boss clearance between flats exceeds exceeds 0.0276 0.0276 in. (0.700 (0.700 mm), replace the oil pump. 6. Check Check the oil pressu pressure re contro controll valve valve to make make sure that the piston moves smoothly and is returned by the spring. If not, replace the oil pump.
1 2 3
4
1.
Cap
2.
Spring
3.
Piston
4.
Oil Pump Cover
Figure 108: Oil Pressure Control Control Valve Valve
63
Inspection and Reconditioning
Water Pump 1. Check Check the the weep weep hole hole on on the the bottom bottom of of the water pump for any signs of leaking coolant. If coolant is leaking out of the weep hole, the mechanical seal is leaking and the water pump must be replaced.
2. Check Check the the water water pump pump beari bearing. ng. If If the water water pump shaft does not rotate smoothly, smoothly, or if it i t is loose or wobbly, replace the water pump.
1
NOTE: Check the cooling cooling system to make sure it is clean. A dirty dirty cooling system can can cause water pump pump leaks. 3 2
1
1
2
3
1.
Ther hermostat 16 160 F (71 C)
2.
Tier 2 Water Pump
3.
Cool Co olant ant Line Line Con Conne nect ctio ions ns for for Col Cold d Sta Start rt Dev Devic ice e
Figure 110: 110: Water Water Pump and Thermostat Thermostat Assembly Tier Tier 2 Engi Engine ne AGA85
1.
Ther hermostat 180 F (82 C) C)
2.
High igh Moun ount Water Pum ump p
3.
Low Mo Mount Wa Water Pu Pump
Figure 109: Water Water Pump and Thermostat Thermostat Asse As sembl mblie ies s Tier Tier 1 and Earli Earlier er Engi Engines nes
NOTE: Do not use the 180 F (82 C) thermostat thermostat in the Tier 2 engine.
64
NOTE: The water pump pump for the Tier Tier 2 engine can be used on on Tier 1 engines if the coolant coolant line connections for the cold start start device are plugged securely. securely.
Inspection and Reconditioning
Manifolds 1. Inspect Inspect the the manifold manifoldss for cracks, cracks, damage, damage, or a build up of carbon. 2. Use a straig straight ht edge edge and and a feel feeler er gauge gauge to check the manifolds for distortion. Resurface or replace the manifold if it is distorted more than 0.006 in. (0.15 mm).
Crankcase Breather System Tier 1 and Earlier Engines The crankcase breather system ducts crankcase gases formed in the crankcase directly to the air intake. Harmful vapors that would otherwise collect in the crankcase and contaminate the oil, or escape to the outside, are drawn back into the engine and burned.
The following items can effect the crankcase pressure readings. Crankcase Pressure Effect
Typical Cause
Increase
Piston Rings Stuck or Worn
Increase
Breather Hose or Restrictor Plugged with Dirt or Ice
Decre ecreas ase e
Air Air Cle Clean aner er Dirt Dirty y or or Plu Plugg gged ed
NOTE: The breather breather hose must be routed so it slopes down from the crankcase breather to the intake manifold. This prevents condensation condensation from collecting in the breather breather hose. The The condensation can can plug the breather hose if it collects and freezes freezes in the hose. hose. The insulation prevents freezing. freezing. It must be in place and undamaged.
The crankcase breather is located on top of the valve cover. A breather hose connects the crankcase breather to the intake manifold. A restrictor is placed in the breather hose to limit the flow of gases from the crankcase to the intake and keep the crankcase pressure from getting too low. Normal crankcase pressures with a new air cleaner are 5 to 10 in. (127 to 254 mm) H 2O of vacuum at 1450 rpm and 7 to 11 in. (178 to 279 279 mm) mm) H2O of vacuum at 2200 rpm. The vacuum will increase as the air cleaner gets dirty and becomes more restrictive. Inspect the crankcase breather and the breather hose to make sure they are not plugged or damaged. Inspect the insulation to make sure it is in place and undamaged. The insulation is used to prevent freezing in cold weather. See “Checking Crankcase Pressure” on on page 67 to 67 to check the crankcase pressure. If your readings are significantly more positive than 5 to 11 in. (127 to 279 mm) H2O of vacuum, you may have excess blowby past the rings. A compression check should be performed to confirm this.
2
1
5
3
4
1.
Insulation (Covers breather hose to prevent freezing.)
2.
Restrictor
3.
Crankcase Br Breather
4.
Air Re Rest stri rict ctio ion n Ind Indic icat ator or
5.
Intake Manifold Figure 111 111:: Crankcase Crankcase Breather Tier Tier 1 and and Earl Earlie ierr Engi Engine nes s
65
Inspection and Reconditioning
Crankcase Breather System Tier 2 Engine The crankcase breather system on the Tier 2 engine is similar to the system on the Tier 1 and earlier engines. Gases formed in the crankcase are directed to the intake manifold. Harmful vapors that would otherwise collect in the crankcase and contaminate the oil, or escape to the outside, are drawn back into the engine and burned. The crankcase breather is located in the valve cover. cover. A restrictor is molded into the fitting for the breather hose on the intake manifold. The restrictor limits the flow of gases from the crankcase to the intake manifold and keeps the crankcase pressure from getting too low. A breather hose connects the crankcase breather to the intake manifold. 3 2
1
4
Normal crankcase pressures with a new air cleaner are 2 to 12 in. (50 to 300 mm) H 2O of vacuum. The vacuum will increase as the air cleaner gets dirty and becomes more restrictive. Check the air restriction indicator before checking the crankcase pressure. Replace the air cleaner if if the reading on the air restriction indicator exceeds 20 in. (508 (508 mm) H2O of vacuum. A dirty air cleaner may cause oil carry over and lead to high oil consumption. Inspect the crankcase breather and the breather hose to make sure they are not plugged or damaged. Inspect the insulation to make sure it is in place and undamaged. The insulation is used to prevent freezing in cold weather. See “Checking Crankcase Crankcase Pressure” on on page 67 to 67 to check the crankcase pressure. If your readings are significantly more positive than 2 to 12 in. (50 to 300 mm) H2O of vacuum, you may have excess blowby past the rings. A compression check should be performed to confirm this. The following items can effect the crankcase pressure readings.
8
7
6
1.
Breather Hose
5.
Baffle Breather
2.
Insulation
6.
Baffle Plate
3.
Breather Cover
7.
Intake Manifold
4.
O-Ring
8.
Restrictor Location
Figure 112: 112: Crankcase Crankcase Breather Tier 2 Engine
66
Crankcase Pressure Effect
Typical Cause
Increas ease
Piston Rings ngs Stuc tuck or Worn
Increase
Breather Hose or Restrictor Plugged with Dirt or Ice
Decr De crea ease se
Air Air Cle Clean aner er Dirty irty or Plug Plugge ged d
5
Inspection and Reconditioning
Checking Crankcase Pressure 1. An adapte adapterr to check check crankca crankcase se pressu pressure re can can be made from a TK482/486 dipstick (P/N 11-8667) 11-8667) and a fitting (P/N 55-2857). 2. Cut the the dipst dipstick ick off off of of the cap and and cut cut a section out of the tab on top of the cap. Make the section cut out of the tab t ab wide enough to install the fitting (P/N 55-2857). 3. Drill a 11/32 11/32 in. in. (8.7 (8.7 mm) hole in the cap. Tap the hole with an 1/8 in. NPT tap and install the fitting.
1
4. This adapter adapter provides provides a conve convenient nient hook-up hook-up for the Magnehelic gauge to monitor crankcase pressure. 1
2
3
4
2 1.
Adapter
2.
Magnehelic Ga Gauge
Figure 114: 114: Measuring Measuring Crankcase Pressure
1.
Fitting
2.
Cut Se Section tion Out of of T Ta ab
3.
Dipstick Cap
4.
Cut Dipstick Off
Figure 113: 113: Magnehelic Magnehelic Gauge Adapter
5. To use the adapte adapter, r, remov removee the oil dipstic dipstick k and replace it with the adapter. Connect Connect the low pressure side of the Magnehelic gauge (10 in. [254 mm] minimum) to the adapter and observe the readings on high and low speed.
67
Inspection and Reconditioning
68
Engine Assembly Assembly Precautions NOTE: Refer to the Specifications Specifications chapter for specifications not given given in this chapter. chapter. After the components of the engine have been repaired, reconditioned, or replaced, the engine can be assembled. It is very important to keep the engine as clean as possible while it is being assembled, because because dirt is one of the major factors that contributes to the failure of rebuilt engines. To avoid problems, take these precautions: 1. Do not not assem assemble ble the engine engine in an area area where any type of grinding is done. 2. Keep your workbench workbench,, tools, tools, and hands hands clean. clean. 3. Keep sub-assem sub-assemblies blies covered covered until they are needed. 4. If the the engin enginee must must be left, left, even even for for a shor shortt period of time, cover the engine until you return. 5. Make sure to follow follow the the seque sequence nce of assemb assembly ly exactly. exactly. If certain parts are not installed in the correct order, the engine may require some disassembly to install these parts properly.
AGA86
Figure 115: 115: Install Install Camshaft Camshaft Bearing
3. Place Place the the new uppe upperr main main bearin bearing g insert insertss in the cylinder block. The upper main bearing inserts are identical and have oil holes and oil groves in them. Make sure the holes in the bearing inserts line up with the holes in the main bearing bores. CAUTION: The lower main bearing inserts are plain and do not have oil holes and grooves. grooves. If they are placed placed in the cylinder block, oil oil will not flow to the crankshaft crankshaft bearings. The crankshaft crankshaft will be damaged and and the engine may seize. seize.
6. Check Check all all the assembly assembly tolerances tolerances such as bearing clearance, end play, and gear lash carefully. carefully. Neglecting these tolerances can cause serious reliability problems in a rebuilt engine.
Assembly Procedure 1. Install Install the the front front camsh camshaft aft bearin bearing g insert insert using using a bearing driver. Make sure the oil holes in the bearing insert line up with the oil holes in the front camshaft bearing bore. The camshaft bearing insert is pre-finished. 2. Instal Installl new oil gall gallery ery and and core core plug plugs. s. AGA87
Figure 116: 116: Install Install Upper Main Bearings Bearings
69
Engine Assembly
4. Place the upper upper thrust thrust bearings bearings in positio position n in the cylinder block on each side of the upper rear main bearing. The grooves on the thrust bearings should face away from the upper rear main bearing. Use a little grease to help hold them in place.
6. Place Place the the new lowe lowerr main main bearin bearing g insert insertss in the main bearing caps. The lower main bearing inserts are plain and identical.
1
AGA90
Figure 119: 119: Install Install Lower Main Bearings Bearings
AGA88
1.
Groo Groove ves s Fac Face e Awa Away y Fro From mM Mai ain n Bea Beari ring ng
7. Place Place the the lower lower thrust thrust bearings bearings in positio position n on each side of the rear main bearing cap. The lower thrust bearings each have a tab on the bottom. The grooves on the thrust bearings should face away from the rear main bearing cap.
Figure 117: 117: Install Install Upper Thrust Bearings Bearings
5. Carefully Carefully lay lay the the cranks crankshaft haft in the the upper upper main bearing inserts.
1
AGA91
1.
Groo Groove ves s Fac Face e Awa Away y Fro From mM Mai ain n Bea Beari ring ng
Figure 120: Install Install Lower Thrust Thrust Bearings
AGA89
Figure 118: 118: Install Install Crankshaft Crankshaft
70
Engine Assembly
8. Place Place a piec piecee of plasti plastigau gauge ge on eac each h main main bearing journal and install the main bearing caps in their proper positions. The cast arrows on the main bearing caps are labeled FW and should point to the rear (flywheel end) of the engine. The main bearing cap with the thrust bearings goes to the rear end of the engine. The main bearing caps with numbers stamped on them go to the middle of the engine with the main bearing cap marked number one closest to the rear main bearing. The main bearing cap with no number goes to the front end of the engine.
10. Remove the main bearing bearing caps and check the plastigauge to determine the clearance of each main bearing. The recommended main bearing clearance is 0.0015 to 0.0027 in. (0.038 to 0.068 mm).
1 AGA354
Figure 123: 123: Check Plastigau Plastigauge ge
AGA37
Front Pulley End 1.
Rear Flywheel End Rear ear Main Bearing Cap
Figure 121: Main Bearing Bearing Cap Placement Placement
9. Instal Installl and torq torque ue the the main main bearin bearing g bolts bolts to 70.9 to 73.8 73.8 ft-lb (96.1 to 100.0 100.0 N•m) on Tier 1 and earlier engines, or 68.7 to 72.4 ft-lb (93.2 to 98.1 N•m) on Tier Tier 2 engines, in two or three equal increments.
11. Lubricate the main bearings, the main journals, and the thrust thrust bearings with engine assembly compound or engine oil. Install the main bearing caps and torque the bolts. Check to make sure the crankshaft rotates freely. freely. 12. Use a dial indicator to check check the crankshaft crankshaft end play. play. The wear limit l imit is 0.0130 in. i n. (0.330 mm) on Tier Tier 1 and earlier engines, or 0.0110 in. (0.280 mm) on Tier 2 engines. If the end play is larger than the wear limit, the thrust bearings must be replaced.
AGA94
Figure 124: 124: Check End Play Play
AGA92
Figure 122: Install Install Main Bearing Bolts Bolts
71
Engine Assembly
13. Install each piston on its respective connecting rod by heating the piston in hot water and then pressing the wrist pin into the piston and through the rod bushing. Install the circlips. The swirl chamber on the top of the piston must be positioned so it is on the identification mark side of the connecting rod.
1 AGA96
1.
Barrel Face Ring
2.
Tapered Face Ring
3.
Oil Ri Ring with Ex Expander
Figure 126: 126: Ring Placement Placement Tier Tier 1 and and Earl Earlie ierr Engi Engine nes s
2
AGA95
1.
Swirl Chamber
2.
Identificati ation Marks
Figure 125: 125: Assemble Assemble Piston and Rod Rod
14. Each piston has three piston rings. a. The top ring ring for for Tier Tier 1 and and earl earlier ier engi engines nes is a barrel faced compression ring. The top ring for Tier 2 engines is a keystone compression ring. b. The midd middle le ring ring is compr compress ession ion ring ring with with a tapered face. c. The bottom bottom ring ring is an oil oil ring ring with a separate internal expander. expander.
72
1.
Keystone Ring
2.
Tapered Face Ring
3.
Oil Ri Ring with Ex Expander
Figure Figure 127: 127: Ring Ring Placem Placement ent Tier Tier 2 Engine Engines s
Engine Assembly
15. Before installing the the piston rings, check the end gap of each ring. Place a ring in its respective cylinder. cylinder. Level the ring in the cylinder with a piston and check the end gap with a feeler gauge. The recommended end gap is 0.008 to 0.016 in. (0.20 to 0.40 mm), except for the middle ring in Tier 2 engines, which is 0.012 to 0.020 in. (0.30 to 0.50 mm). If the end gap is not correct, check to make sure that the cylinder bore is the correct size and that the ring is the correct size.
1 2
AGA99
1.
Oil Ring End Gap
2.
Expander Joint
Figure 130: Oil Ring Install Installation ation
c. Place Place the the comp compres ressio sion n ring ring with with the the tapered face in the middle ring groove.
AGA97
Figure 128: 128: Check Ring Ring End Gap Gap
16. Place the piston piston rings on their respective pistons in the proper order. order. Use a ring spreader to install the rings, but do not spread the rings more than necessary. The manufacturer’s mark near the end gap of each ring should always face the top of the piston.
d. On Tier Tier 1 and and earlie earlierr engine engines, s, place place the the barrel faced compression ring in the top ring groove. On Tier 2 engines, place the keystone compression ring in the top ring groove. 17. Place the connecting connecting rod bearing bearing inserts in the connecting rods and the rod caps. 18. Stagger the end gaps of the piston rings on each piston so the end gaps are at 120 degree intervals. Make sure that the end gap for the top ring is not above either end of the wrist pin.
AGA98
Figure 129: 129: Mark on Ring Ring Faces Faces Up
a. Place Place the the oil ring ring expa expande nderr in the the bottom bottom ring groove. b. Place Place the the oil oil ring ring in in the the botto bottom m ring ring groove over the expander. expander. Position the end gap of the oil ring 180 degrees from the joint in the expander. expander.
AGA100
1.
Top Ring End Gap
2.
Oil Ring End Gap
3.
Middle Ring End Gap
Figure 131: Ring Alignment Alignment
73
Engine Assembly
19. Oil each cylinder, cylinder, piston, piston, piston ring, wrist pin, and rod bushing, with engine oil. 20. Use a ring compressor to install each piston piston assembly. assembly. The swirl chamber on top of the piston and the identification marks on the connecting rod should face toward the intake side of the engine, away from the camshaft bearings. 1
2 AGA103
Figure 133: Install Install Rod Cap and Bolts Bolts
3
23. Remove the rod cap cap and check the the plastigauge to determine the clearance of each connecting rod bearing. The recommended rod bearing clearance is 0.0015 to 0.0029 in. (0.038 to 0.074 mm).
AGA102 AGA93
1.
Swirl Chamber
2.
Identi ntification Mark
3.
Camshaft Bearing
Figure 132: 132: Install Install Piston Piston
21. Place a piece piece of plastigauge plastigauge on each each rod journal. Install each rod cap correctly by matching the identification marks with those on the connecting rod. 22. Install and torque the connecting rod bolts to 32.5 to 39.8 ft-lb (44.1 to 53.9 N•m) on Tier 1 and earlier engines, or 32.5 to 36.2 ft-lb (44.1 to 49.0 N•m) on Tier Tier 2 engines, in two or three equal increments.
74
Figure 134: 134: Check Plastigaug Plastigauge e
24. Lubricate the rod journal and the rod bearings of each connecting rod with engine assembly compound or engine oil. Install the rod caps and torque the bolts. 25. After installing each piston assembly, assembly, turn the crankshaft over several times. Check to see that the bearings move freely and that the pistons and rings slide through the cylinders easily.
Engine Assembly
26. Use a feeler gauge gauge to check check the side clearance clearance between the crankshaft and each connecting rod. The standard dimension is 0.008 to 0.016 0.016 in. (0.20 (0.20 to 0.40 mm). mm).
30. Lubricate the tappets tappets with engine engine assembly compound or engine oil. Insert each tappet into its respective tappet bore.
27. Place new O-rings (Tier 1 and earlier engines only) on the front of the engine block and make sure the dowel pins are in place. NOTE: Tier 2 engines do not not use these O-rings.
1
2
1 AGA105
1.
Dowel Pins
2.
O-Ri O-Ring ngs s (Ti (Tier er 1 and and Earl Earlie ierr Eng Engine ines s Onl Only) y)
AGA26
Figure 137: Install Install Tappets Tappets
31. Lubricate the camshaft camshaft bearing, journals, and lobes with engine assembly compound or engine oil. 32. Carefully install the camshaft camshaft to avoid avoid damaging the camshaft bearing.
Figure 135: 135: Front of Engine Engine Block Block
28. Place a thin layer of silicone sealant on the back sealing surface of the gear case. 29. Install the gear gear case. Make sure to align the dowel pins and tighten the mounting bolts.
AGA25
Figure 138: 138: Install Install Camshaft Camshaft
AGA484
Figure 136: 136: Install Install Gear Case Case
75
Engine Assembly
33. Install and tighten the camshaft thrust plate mounting bolts.
35. Install the fuel injection pump, align the index marks (as they were when the fuel injection pump was removed, see step step 26 on pag pagee 35), 35), and tighten the mounting nuts. NOTE: The The injection timing will be correct correct if the original injection pump is being reinstalled and the index marks are aligned as they were when when the fuel injection pump pump was removed. If not, see “Injection Pump Timing Tier 1 and Earlier Engines” on page 97 or or “Injection Pump Timing Tier 2 Engines” on page page 102 .
AGA24
Figure 139: Install Install Camshaft Mounting Mounting Bolts
34. On Tier Tier 1 and earlier earlier engines, install the oil pump with a new gasket and tighten the mounting bolts. On Tier 2 engines the oil pump is located in the gear case cover and is installed with the gear case cover. AGA107
Figure 141: Install Install Fuel Injection Injection Pump Tier Tier 1 and Earli Earlier er Engin Engines es
AGA106
Figure 140: 140: Install Install Oil Pump Pump Tier Tier 1 and and Earl Earlie ierr Engi Engine nes s
76
Figure 142: Install Install Fuel Injection Injection Pump Tier Tier 2 Engi Engine nes s
Engine Assembly
1 1.
1
Index Marks
Figure 143: Tier 1 and Earlier Earlier Index Mark Location Location
2
1.
Inde Index x Mar Mark k on on Inj Injec ecti tion on Pum ump p
2.
Index Mark on on Gear Case
Figure 146: Typical Tier Tier 2 Index Mark Alignment
36. Install the fuel injection injection pump gear, gear, lock lock washer, washer, and mounting nut. Make sure the key is aligned properly. Torque the mounting nut to 43.4 to 50.6 ft-lb (58.8 to 68.6 N•m) on Tier 1 and earlier engines, or 57.9 to 65.1 65.1 ft-lb (78.5 to 88.3 N•m) on Tier Tier 2 engines. engines.
1
2
1.
Inde Index x Mar Mark k on on Inj Injec ecti tion on Pump Pump
2.
Cente enterr Ind Index ex Ma Mark rk on Gear Gear Case ase
Figure 144: Typical Tier Tier 1 and Earlier Index Index Mark Mark Alig Alignme nment nt AGA108
Figure 147: Install Install Fuel Injection Injection Pump Gear
1 1.
Index Marks
Figure 145: 145: Tier 2 Index Index Mark Location Location
77
Engine Assembly
37. Install the idler gear gear and the idler shaft and align the timing marks. The A mark on the idler gear should line up with the A mark on the crankshaft gear. The B mark on the idler gear should line up with the B mark on the injection pump gear. gear. The C mark on the idler gear should line up with the C mark on the camshaft gear.
38. Install and tighten the idler shaft mounting bolts. 39. Use a dial dial indicator to check check the gear gear lash between the timing gears, if it has not been checked already. 40. Make sure the dowel pins are in place in the top of the block. 41. Place a new head head gasket on the block. Align the head gasket with the dowel pins and make sure the engine model inscription is facing up. 42. Place the cylinder cylinder head on on top of the block and the head gasket. Make sure to align the head with the dowel pins.
AGA109
Figure 148: Install Install Idler Gear and Idler Shaft Shaft
3
1 2
AGA111
5 4 AGA110
1.
Fuel Inj Inje ection Pu Pump Ge Gear
2.
Idler Gear
3.
Camshaft Gear
4.
Crankshaft Gear
5.
Oil Oil Pum Pump p Gea Gearr (No (Nott on on Tie Tierr 2 Eng Engin ines es)) Figure 149: 149: Align Timing Timing Marks Marks
78
Figure 150: Install Install Cylinder Head Head and Gasket
Engine Assembly
43. Install the cylinder head head bolts. Torque Torque the cylinder head bolts to 62.9 to 67.3 ft-lb (85.3 to 91.2 N•m) in two or three equal increments using the sequence shown in the following illustration.
AGA112
Figure 151: Cylinder Cylinder Head Bolt Torque Sequence Sequence
44. Place the valve stem caps on the valve stems. AGA113
Figure 153: Install Install Rocker Arm Assembly Assembly
48. Torque the rocker rocker arm mounting bolts to 16.6 to 21.0 ft-lb (22.6 (22.6 to 28.4 28.4 N•m).
AGA07
49. Adjust both the intake and the exhaust valves. valves. See “Valve Clearance Adjustment” on page page 137 137.
Figure 152: Install Install Valve Valve Stem Caps
45. Install the push rods in their respective respective openings. Make sure the push rods are seated properly in the tappets. Lubricate the socket in the top end of each push rod with engine oil. 46. Place the rocker rocker arm assembly assembly in position. position. Make sure all the valve adjustment screws are loose and have been backed out a few turns. 47. Install the rocker arm mounting bolts. bolts. Alternately turn each bolt one turn at a time to evenly apply the valve spring pressure to the rocker arm assembly. assembly. Make sure the valve adjustment screws all seat properly in the sockets on the ends of the push rods while the rocker arm assembly is being tightened.
AGA114
Figure 154: 154: Adjust Valves Valves
79
Engine Assembly
50. Install the oil filter head head and the oil filter. filter. NOTE: The EMI 3000 oil filter started at serial number A08750 A08750 on TK482 engines and serial number L32014 on TK486E/EH TK486E/EH engines. Earlier engines can be retrofitted with EMI 3000 Oil Filter Kit P/N 90-336. See “EMI 3000 3000 Oil Filter” on page page 149 for 149 for more information.
b. Cap off off any any other other open open oil oil system system fittin fittings gs such as the fitting for the oil line to the fuel injection pump and gear case cover. c. Press Pressuriz urizee the tank tank to 60 psi (413 (413 kPa) kPa) and open the outlet line to the engine. d. The tank tank will will fill fill the oil oil filter filter first first and and will will then pressurize the whole lubrication system. The oil pressure control valve may release some oil into the bottom end. e. Check Check each each main main beari bearing ng and and rod bear bearing ing.. Oil should drip from each bearing at a fairly good rate, but there should be no large streams of oil from any of the bearings. f. Check Check the the idle idlerr gear gear shaf shaftt and and the the front front camshaft bearing on Tier 1 and earlier engines. Oil should drip from each at a fairly good rate, but there should be no large streams of oil from either.
AGA115
Figure 155: Install Install Oil Filter Head and Oil Filter Filter
51. Pressure check check the engine’s engine’s lubrication system, if possible. A pressure check can point out problem areas in the lubrication system, and it eliminates the possibility that any of the engine components are dry when the engine is first started. NOTE: On Tier Tier 2 engines the gear case cover must be installed for the pressure pressure check because because the oil pump is located located in the gear case cover cover.. See steps 64 through 64 through 72 starting on starting on page 84 to 84 to install the gear case cover. cover. a. Fill Fill the pres pressur suree tank tank with with engin enginee oil and and attach the outlet line to the engine at the fitting for an oil pressure gauge or oil pressure switch.
80
g. Check Check the the rocker rocker arm assem assembly bly.. Oil flows flows to the rocker arm assembly through internal oil passages in the cylinder block, the cylinder head, the two end rocker arm supports, and the rocker arm shaft. Oil should drip from each rocker arm bushing and from the hole in each rocker arm at a fairly good rate, but there should be no large streams of oil from any of the t he rocker arms or bushings. h. Turn Turn the engi engine ne over over sever several al times times and and check the components again. i.
Lack Lack of of oil oil or a low low flow flow rat ratee at at any any of these components indicates there is a restriction in an oil gallery or passage leading to the component. Excessive oil flow at any of the components indicates that the oil clearance is too large, the wrong part has been used, or a component is damaged or missing.
Engine Assembly
52. Install the valve cover with a new gasket and put new O-rings on the special cap nuts.
54. Install Install the oil oil pan. a. Place Place a thin thin layer layer of seal sealant ant on the the top top sealing surface of the upper part of the oil pan. b. Place Place the the uppe upperr part part of the oil pan pan in in position on the bottom of the block. c. Instal Installl the moun mountin ting g bolts bolts for for the uppe upperr part of the oil pan. Make sure the rear end of the block and the upper part of the oil pan are flush before tightening the mounting bolts. d. Place Place a thin thin layer layer of of sealan sealantt on the sea sealing ling surface of the lower part of the oil pan. e. Place Place the lower lower part part of the the oil oil pan pan in in position on the upper part of the oil pan.
AGA116
Figure 156: Install Install Valve Valve Cover
53. Install the oil pump pump intake pipe. pipe. Tier Tier 1 and earlier engines use a gasket between the oil pump intake pipe and the block. Tier 2 engines use an O-ring between the oil pump intake pipe and the block. Make sure the gasket or O-ring is installed properly because a missing gasket or O-ring will cause low oil pressure.
1
f. Instal Installl and and tighte tighten n the the mount mounting ing bolts bolts for for the lower part of oil pan.
2
1.
Gask Gasket et on Tier ier 1 and and Ear Earli lier er Engi Engine nes s
2.
O-Ring on on Ti Tier 2 En Engines
Figure 157: Install Install Oil Pump Intake Intake Pipe
AGA118
Figure 158: 158: Install Install Oil Pan Pan
81
Engine Assembly
55. Check to make make sure the dowel pins are are in position in the rear of the block. There are two for the rear seal housing and two for the bellhousing. 56. Make sure the old rear rear seal has been been removed from the rear seal housing. If not, remove it. NOTE: Some early early engines use use a radial rear rear seal. Later engines use use an axial rear rear seal. No special tools are needed to remove remove or install the radial rear seal. seal. Install the radial radial rear seal by pressing pressing it into the rear rear seal housing. housing. Coat the lip of the t he radial rear seal with engine oil before installing the rear seal housing. The radial radial rear rear seal seal can can be replaced with an axial rear seal if the rear seal housing is also replaced. replaced. The axial rear rear seal requires special special tools for removal and and installation (see step (see step 60 ). 57. Place a thin layer of sealant sealant on the sealing surface of the rear seal housing. 58. Place the rear rear seal housing housing in position and make sure to align the dowel pins.
60. Install the axial axial rear seal using installation tool P/N 204-952 and and the following procedure. procedure. CAUTION: Do not attempt to install this seal without using the installation installation tool. Driving the seal in by by hand will crush the rubber lip into the metal metal ring and cause cause the seal to burn up up when the engine is run. NOTE: If necessary, necessary, the inside diameter of the metal seal seal ring can be lightly coated with Loctite 620 or silicone silicone gasket sealant. sealant. The original seal ring was was installed without sealant, but the use of sealant offers some insurance against leaks if the crankshaft has some surface damage. However However, sealant will make future removal removal of the metal ring more difficult. If necessary, necessary, a light coat of silicone sealer may also also be applied to the outside outside diameter of the seal. seal. a. If neces necessar sary y, remove remove the the old old metal metal ring ring (see step step 33 on pag pagee 37) 37) and any imperfections from the surface of the crankshaft that contacts the metal ring of the seal. Check your work by placing the installation tool cup over the end of the crankshaft to check the fit. The cup must fit smoothly over the crankshaft or it will bind when installing the seal. NOTE: The cups for some of the early installation tools were slightly undersized. If you have trouble fitting the cup over the end end of the crankshaft, crankshaft, have a a machine shop remove 0.005 in. (0.13 mm) from the inside diameter of the cup.
AGA119
Figure 159: Install Install Rear Seal Housing Housing
59. Install and tighten the mounting bolts bolts for the rear seal housing. NOTE: The bolts at at the bottom of the rear seal housing screw screw into the oil pan and and are longer than the other bolts that fasten the rear seal housing housing to the block.
82
b. Attach Attach the the install installati ation on tool tool mandrel mandrel to the the crankshaft using three flywheel bolts as shown in Figure 160 on page 83 83.. If a point of the hex on a bolt is facing directly out it may extend past the mandrel. Grind down the points as required. c. Place Place the the seal seal over over the the instal installat lation ion tool tool mandrel with the metal face of the t he seal toward the engine.
Engine Assembly
d. Place Place the the tool tool cup cup over over the mand mandrel rel and and against the seal. Align the cutout on the cup away from the bolts on the mandrel as shown. This allows you to see when the cup has completely bottomed on the mandrel.
62. Install and tighten the mounting bolts for the bellhousing. NOTE: The bolts at at the bottom of the bellhousing screw into the oil pan and are are longer than the other bolts that fasten the bellhousing to the block. block.
4 3 2 1 AGA120
5 1.
Nut
2.
Cup
3.
Seal
4.
Mandrel
5.
Check Chec k Cu Cuto tout ut To Be Be Sure Sure Mandrel Contacts Cup
Figure 160: Install Rear Seal with Tool Tool P/N 204-952
AGA121
Figure 161: Install Install Bellhousing Bellhousing
63. Install the flywheel flywheel and align align it with the dowel pin in the end of the crankshaft. Torque Torque the flywheel mounting bolts to 61.5 to 65.1 ft-lb (83.4 to 88.3 N•m).
e. Carefu Carefully lly tight tighten en the the install installati ation on tool tool nut. This pulls the cup over the mandrel and presses the seal into place. When the nut stops turning, check the cutout on the cup to be sure it is completely bottomed on the mandrel. The seal is now installed to the proper depth. f. Remo Remove ve the the ins insta talla llatio tion n tool tool.. NOTE: If there are any imperfections imperfections on the crankshaft crankshaft the cup may jam and and be difficult to remove. Tapping Tapping alternately on each side will assist assist in removing a jammed cup. This problem problem can be eliminated by testing the fit of the cup on the crankshaft crankshaft before installing the seal.
AGA122
Figure 162: 162: Install Install Flywheel Flywheel
61. Place the bellhousing bellhousing in position on the rear of the block and make sure to align the dowel pins.
83
Engine Assembly
64. Check to make make sure the dowel pins are are in position in the gear case (see Figure 163). 163).
1
65. Replace the front seal seal by pressing the old old seal out and pressing a new seal into the gear case cover. cover. The front seal can also be installed to the proper depth after the gear case cover has been installed using the front seal installation tool P/N 204-1138 (see step step 73). 73).
2 4
7
6
66. If the front seal has been installed, coat the lip of the front seal with engine oil. 67. Place new O-rings (Tier (Tier 2 engines only) only) in the gear case. NOTE: Tier Tier 1 and earlier engines do not use these O-rings because because of the different different oil pump configuration. 1
5
3
1.
Crankshaft Gear
2.
Oil Pump Cover
3.
Outer Rotor
4.
Inner Rotor
5.
Timing Gear Cover
6.
Flat Si Sides on on In Inner ner Ro Rotor
7.
Flat Flat Side Side on Cran Cranks ksha hafft Gea Gearr
Figure 164: Align Flat Sides of Crankshaft Crankshaft Gear with Flat Sides of Inner Rotor in Timing Gear Cover
1
70. Install and tighten the gear case case cover mounting bolts that are covered by the sound shield. 71. If the sponge on the back of the sound sound shield is damaged, replace it before installing the sound shield.
2 1.
Dowel Pins
2.
O-Ri O-Ring ngs s (Tie (Tierr 2 Engi Engine nes s Only Only))
72. Place the sound sound shield in position and and install and tighten the mounting bolts.
Figure 163: Gear Case
68. Place a thin layer of sealant sealant on the sealing surface of the gear case cover. 69. Place the gear gear case cover in position and make sure to align the dowel pins. NOTE: The oil pump is located in the timing gear cover cover on on Tier Tier 2 engines. The inner rotor of the oil pump fits around around the crankshaft crankshaft gear. gear. Make sure that that the flat sides of the inner rotor are aligned with the flat sides on the crankshaft crankshaft gear when installing installing the timing gear cover. cover.
84
AGA123
Figure 165: Install Install Gear Case Cover Cover and Sound Sound Shie Shield ld
Engine Assembly
73. Use the front seal installation tool P/N 204-1138 204-1138 to install the front seal (if not yet installed). a. Place Place a thin thin layer layer of of sealan sealantt on the the outsid outsidee diameter or the front seal. b. Place the front seal in the the gear gear case case cover cover and press it in slightly so it i t stays in place. c. Place Place the the front front seal seal insta installa llatio tion n tool tool over over the end of the crankshaft and against the seal. d. Place Place the the mounti mounting ng bolt bolt and and washer washer for for the the crankshaft pulley through the front seal installation tool and into the crankshaft.
74. Install the crankshaft crankshaft pulley and and align it with the dowel pin in the crankshaft gear. Torque the mounting bolt to 83.2 to 90.4 ft-lb f t-lb (112.8 to 122.6 N•m). NOTE: Make sure to align align the dowel pin with the mating hole in the crankshaft pulley. If not, the pulley will not pull pull down on the tapered end of the crankshaft crankshaft and will be loose. The pulley can also crack where it contacts the the dowel pin. This can can cause the front seal to leak oil. Check Check the pulley for cracks if the front seal seal leaks. Replace Replace the dowel pin if it is damaged. damaged. 1
e. Tight Tighten en the the bolt bolt unti untill the the front front seal seal installation tool stops against the end of the crankshaft. This installs the front seal to the proper depth.
2
f. Remove Remove the bolt bolt and and the front front seal seal installation tool. g. Coat Coat the lip lip of the the front front seal seal with with engi engine ne oil.
1.
Dowel Pin
2.
Mati Ma ting ng Ho Hole le in Cran Cranks ksha haft ft Pull Pulley ey Figure 167: 167: Dowel Pin Pin Alignment Alignment
1
2
1.
Front Seal
2.
Front Front Sea Seall Inst Instal alla lati tion on Too Tooll P/N P/N 204204-1 1138 138 Figure 166: 166: Install Install Front Seal Seal
AGA124
Figure 168: Install Install Crankshaft Crankshaft Pulley
85
Engine Assembly
75. Install the oil line that goes from the cylinder block to the fuel injection pump and the gear case cover.
77. Install the water pump with a new O-ring, a new thermostat, and new gaskets.
NOTE: On later model engines engines the oil line stops at the fuel injection pump and and does not not go to the gear case case cover. cover. The hole in the gear case cover cover is plugged with with a screw (P/N 55-5768). Tier Tier 2 engines engines do not have the hole hole in the gear gear case case cover cover and do not use the plug screw. screw.
1
2
1.
High Moun ount Wate ater Pump
2.
Low Mo Mount Wa Water Pu Pump
Figure 171: Install Install Water Water Pump
AGA125
Figure 169: 169: Install Install Oil Line Line
NOTE: Tier Tier 2 engines have have two coolant hoses that go from from the water pump to a the cold start device device on the fuel injection pump. Connect the hoses to the water pump and the fuel injection pump pump after installing the water pump.
76. Install the fuel transfer transfer pump in the gear case case cover.
1
1
1.
Coolant Hoses
Figure 172: Connect Connect Coolant Hoses Hoses on Tier ier 2 Engi Engine nes s
AGA126
Figure 170: Install Install Fuel Transfer Transfer Pump
86
Engine Assembly
78. Place a nozzle nozzle gasket and a nozzle protector protector in each opening for the fuel injection nozzles. Install the nozzle gasket first, then install the nozzle protector. The nozzle protector is shaped like a cup, and the bottom of the cup should face down.
1
79. Install the fuel injection nozzles. 80. Install the fuel injection injection nozzle retainers and mounting nuts or bolts. Torque the mounting nuts to 5.1 to 6.5 ft-lb (6.9 to 8.8 N•m) on Tier 1 and earlier engines. engines. Torque Torque the mounting bolts to 18.0 to 21.0 ft-lb (24.4 to 28.4 N•m) N•m) on Tier 2 engines. engines. 81. Install Install the lift brackets. brackets. 82. Install the intake manifold with a new gasket.
2
83. Install Install the fuel return lines. lines. See “Fuel Return Line Replacement” Replacement” on page 113.
3 4
84. Install Install the fuel injection injection lines. Figure 177 on page 88 shows 88 shows the injection line connections for Tier 2 engines. 1 1.
Retainer
2.
Fuel uel Inje njection No Nozzle
3.
Nozzle Protector
4.
Nozzle Gasket
2
Figure 173: Install Install Fuel Injection Injection Nozzles Tier Tier 1 and and Earli Earlier er Engi Engine nes s
1
2 3 4 AGA02
1.
Fuel Injection Lines
2
Fuel Return Lines
Figure 175: Install Install Fuel Injection Injection Lines Tier Tier 1 and Earl Earlier ier Engi Engines nes
1.
Retainer
2.
Fuel uel Inje njection No Nozzle
3.
Nozzle Protector
4.
Nozzle Gasket
Figure 174: Install Install Fuel Injection Injection Nozzles Tier Tier 2 Engi Engine nes s
87
Engine Assembly
85. Install the crankcase crankcase breather breather hose. Clean Clean the restrictor in the crankcase breather hose on Tier 1 and earlier engines to make sure it is not blocked.
2
1
86. Install the exhaust manifold manifold with a new gasket. 87. Install Install the starter starter.
1.
Fuel Injection Lines
2.
Fuel Re Return Li Lines
Figure 176: Install Install Fuel Injection Injection Lines Tier Tier 2 Engi Engine nes s
1
3
4
2
1.
For For IInj njec ecti tion on Line Line to Nu Numbe mberr One One Cyli Cylind nder er
2.
For For Inj Injec ecti tion on Line Line to Nu Numb mber er Two Cyli Cylinde nderr
3.
For For Inj Injec ecti tion on Line Line to Nu Numbe mberr Thre Three e Cyl Cylind inder er
4.
For For Inj Injec ecti tion on Line Line to Nu Numb mber er Four Four Cyl Cylin inde derr Figure 177: Fuel Injection Injection Line Connections Connections on Tier ier 2 Engi Engine nes s
88
Lubrication System The TK482 and TK486 engine families use a pressure lubrication system. A trochoid type oil pump circulates the oil through the system to lubricate the engine components. The oil pump contains a pressure control valve that limits the oil pressure to 45 to 57 psi (310 to 390 kPa). On Tier Tier 1 and earlier earlier engines the oil pump is driven by the crankshaft gear, and is attached to the lower part of the t he gear case.
On Tier 2 engines the oil pump is driven by the the boss on the crankshaft gear, and is located in the gear case cover. The oil is picked up by a screened inlet near the bottom of the oil pan. The inlet is positioned far enough from the bottom of the pan to avoid picking up any of the residue that tends to settle on the bottom of the pan. The oil then passes through the intake pipe to the oil pump.
AGA129
1.
Oil Pan
11.
Fuel Transfer Pump
2.
Oil Inlet Pipe (Strainer)
12 .
Camshaft Bearing
3.
Oil Pump
13.
Valve Rocker Arm Shaft
4.
Pressure Control Valve
14 .
Valve Rocker Arm
5.
Bypass Valve
15 .
Tappet and Cam Faces
6.
Bypass Oil Filter
16 .
Crankshaft Journals—Main Bearings
7.
Full Flow Oil Filter
17 .
Crank Pins—Rod Bearings
8.
Cylinde nder Bo Body and and Main Oi Oil Ga Gallery
18.
Fue Fuel In Injection Pump Ge Gear
9.
Idler Gear Shaft
19.
Fuel Injection Pump
10. 10.
Timing ming Gea Gearr Face Faces s Figure 178: 178: Lubrication Lubrication System System
89
Lubrication System
The oil pump forces a large volume of high pressure oil through an oil gallery to the t he dual element (full flow/bypass) oil filter. Dirt and other particles are trapped in the filter element as the oil passes through the oil filter. If the filter element becomes clogged, a bypass valve built in the oil filter head allows the oil to bypass the filter element. This keeps the engine components from being starved for oil if the filter element is clogged. After passing through the oil filter, the oil enters the main oil gallery. Oil passages connected to the main oil gallery supply oil to the idler gear shaft, the camshaft bearings, and the main bearings. An external oil line is connected to the main oil gallery and the fuel injection pump. On early Tier 1 and earlier engines engines the external oil oil line also connects to the gear case cover. The external oil line supplies oil to the fuel injection pump. On early Tier Tier 1 and earlier earlier engines the external oil line also supplies oil to the fuel injection pump gear. Oil from the idler gear shaft lubricates the idler gear bushing, the idler gear, the other timing gears, and the fuel transfer pump before returning to the oil pan. On early early Tier 1 and earlier engines oil is also delivered to the fuel injection pump gear, the timing gears, and the fuel transfer pump through the external oil line connected to the top of the gear case cover. Some of the oil supplied to the main bearings flows through passages in the crankshaft to the connecting rod bearings. This oil is thrown around the bottom end of the engine as it flows out of the bearings while the crankshaft rotates. Some of this oil lubricates the cylinder walls. Some of this oil lands in the holes on the top of the connecting rods and lubricates the wrist pins and the connecting rod bushings. The oil eventually returns to the oil pan.
90
Some of the oil supplied to the t he camshaft bearings flows through passages in the cylinder block, the cylinder head, and the rocker arm supports to the rocker arm shaft. The rocker arm shaft supplies oil to the rocker arm bushings and the rocker arms. Some oil squirts out of holes in the rocker arms to lubricate the valve stem caps and the valve stems. The oil that is pumped up to the rocker arm assembly flows back down through the push rod openings and lubricates the tappets and the cam lobes as it returns to the oil pan. The oil that flows to the fuel injection pump returns to the oil pan after lubricating the injection pump components. Oil pressure is affected by oil temperature, oil viscosity, viscosity, and engine speed. Low oil pressure can usually be traced to the lack of oil, diluted oil, a faulty oil pressure control valve, loose connections in the lubrication system, or worn bearings. Low oil pressure is not normally caused by a faulty oil pump. Use the flow chart on the following page to help diagnose low oil pressure.
Lubrication System
Low Oil Pressure Flow Chart Oil Pressure Low
Check Oil Level
Oil Level Low
Oil Level OK or High
Add Oil Check Oil Pressure
Oil May Be Diluted Change Oil and Filter Check Oil Pressure
Oil Pressure OK
Oil Pressure Low
Oil Pressure OK
Install Known Good Oil Pressure Gauge Check Oil Pressure
Oil Pressure OK
Oil Pressure Low
Remove Oil Pump (Access the oil pump by removing the crankshaft pulley, the sound shield and the gear case cover. See “Checking “Checking Oil Pump” Pump” on page page 141 141.) .) Check Oil Pump Tolerances Check Oil Pressure Control Valve for Broken Spring or Sticking Piston
Reinstall Oil Pump Check Oil Pressure
Oil Pressure OK
Oil Pressure Low
Pull Engine Remove Oil Pan Check Inlet Screen, Intake Pipe, and Intake Pipe Gasket or O-Ring Pressure Check Engine for Internal Leaks
91
Lubrication System
92
Fuel System Description The major components of the fuel system are: •
Fuel Tank
•
Inle Inlett Strai traine nerr (Pre (Prefi filt lter er))
•
Priming Pump
•
Fuel Transfer fer Pump
•
Fuel Fuel Fil Filte ter/ r/W Water ater Sep Separ arat ator or
•
Fuel In Injection ion Pump
•
Troch rochoi oid d Feed Feed Pum Pump p (Tie (Tierr 2 Eng Engin inee Only Only))
•
Injec jection No Nozzles.
The priming pump is used to manually draw fuel from the tank up to the fuel transfer pump if the unit should run out of fuel.
The most common cause of problems in the fuel system is contamination. The fuel must be clean and the fuel tank must be kept free of contaminants. The fuel filter/water separator must be changed regularly. The prefilter should be cleaned when the fuel filter is changed. Any time the fuel system is opened, all possible precautions must be taken to keep dirt from entering the system. All fuel lines must be capped when disconnected. The work should be done in a relatively clean area and the work should be completed in the shortest time possible. Thermo King recommends that any major injection pump or nozzle repairs be done by a qualified diesel injection service shop. The investment in equipment and facilities to t o service these components is quite high. Therefore, this equipment is not found in most repair shops.
The fuel is drawn from the fuel tank through the prefilter by the fuel transfer tr ansfer pump. The fuel transfer pump forces the fuel through the fuel filter/water separator to the injection pump. The injection pump forces the fuel, at a very high pressure, through the injection nozzles. The injection nozzles atomize the fuel as it is injected directly into the combustion chambers.
The following procedures can be performed under field conditions:
Tier 1 and earlier engines use an in-line injection pump. Tier 2 engines use a mono-plunger and distributor injection pump. Injection pump leakage, injection nozzle overflow, overflow, and excess fuel from f rom the fuel filter assembly return to the fuel tank through the return lines. The injection pump and the fuel transfer pump are relatively trouble free and if properly maintained will usually not require major service or repair between engine overhauls.
•
Blee Bleedi ding ng air air from from the the fuel fuel sys syste tem m
•
Main Mainten tenan ance ce of of the the fuel fuel tan tank k and and fuel fuel filt filter er system
•
Prim Primin ing g pum pump p rep repai airr or or rep repla lace ceme ment nt
•
Fuel Fuel tra trans nsfe ferr pump pump rep repai airr or rep repla lace ceme ment nt
•
Inje Inject ctio ion n lin linee repl replac acem emen entt
•
Engi Engine ne spee speed d adju adjust stme ment ntss
•
Inje Injecction tion pump ump timi timin ng
•
Inject Injection ion nozzle nozzle testin testing, g, adjust adjustmen ment, t, and minor repair
•
Troch rochoi oid d feed feed pum pump p repl replac acem emen entt (Tie (Tierr 2 engine only).
93
Fuel System
2
1
3
4 5
8 7
6
1.
Relief Reli ef Val Valve ve (Ke (Keep eps s air air from from ent enter erin ing g fuel fuel system when engine is not running.)
5.
Fuel Transfer Pump
2.
Filter Head
6.
Inlet Strainer (Prefilter)
3.
In-line Injection Pump
7.
Priming Pump
4.
Bleed Screw
8.
Fuel Filter/Water Separator
Figure 179: Typical Fuel System for Tier 1 and Earlier Engines
94
Fuel System
1
2
3
4
8
5
6
7
1.
Relief Reli ef Val Valve ve (Kee (Keeps ps air air from from enter enterin ing g fue fuell system when engine is not running.)
5.
Trochoid Feed Pump
2.
Filter Head
6.
Fuel Transfer Pump
3.
Bleed Screw
7.
Priming Pump
4.
Mono Mo no-p -plu lung nger er and and Dis Distr trib ibut utor or Inje Inject ctio ion n Pum Pump p
8.
Fuel Fuel Filt Filter er/W /Wat ater er Sep Separat arator or
Figure 180: Typical Fuel System System for Tier 2 Engines
95
Fuel System
Bleeding Air from the Fuel System
1
Air usually gets into the fuel system when the engine runs out of fuel or if repairs are made to the fuel system. NOTE: Be sure to keep keep the vent in the fuel tank open. If the vent vent becomes clogged, clogged, a partial vacuum develops in the fuel tank. This increases the chance that air will enter the fuel system. system. Use the following procedure to bleed air out of the fuel system. 1. Loosen Loosen the the bleed bleed screw screw on the the Tier Tier 1 injection injection pump about two turns. Loosen the bleed screw on the Tier 2 injection pump about one turn. 1
2 1.
Bleed Screw
2.
Priming Pump
Figure 182: 182: Tier 2 Injection Injection Pump Pump
2. Unscre Unscrew w the primi priming ng pump pump hand handle le and and manually prime the fuel system until air bubbles are no longer visible in the fuel coming out of the bleed screw. 3. Tighten ighten the the air bleed bleed scre screw w and scre screw w the priming pump handle back in. 4. Loosen Loosen the injection injection lines at the injection injection nozzles. 5. Crank Crank the engine engine over over with with the the starter starter until fuel appears at all of the injection i njection nozzles. 2
1.
Bleed Screw
2.
Priming Pump
Figure 181: Tier 1 and Earlier Earlier Injection Pump Pump
96
6. Tighten ighten the inject injection ion lines. lines. 7. Start Start the engine engine and and observe observe the engine engine run for for a few minutes. If the engine fails to t o start, or starts but stops in a few minutes, repeat the procedure.
Fuel System
Injection Pump Timing Tier 1 and Earlier Engines This timing procedure requires fuel pressure at the injection pump inlet. This can be accomplished by pumping the priming pump by hand, or by using an electric fuel pump to supply fuel to t o the fuel pump inlet. 1. If the engine engine is in the the unit, unit, make make sure sure the the unit unit is turned off. 2. Remov Removee the roun round d cover cover (plug (plug)) from from the timing mark access hole on the front of the bell housing. The index marks on either side of this hole and the timing marks on the flywheel are used to check the injection pump timing.
1
3. Remove Remove the the injectio injection n line line for for the the number number one cylinder from the delivery valve on the injection pump and from the injection nozzle. NOTE: The number one cylinder is the cylinder at the flywheel flywheel end of the engine. NOTE: Do not remove remove the delivery valve valve spring to check the timing. OM636 and C201 C201 engines must have the delivery valve spring removed for injection injection pump timing. TK482 and TK486 engines engines DO NOT! 4. Remove Remove the rocke rockerr arm arm cove coverr. 5. Place Place the the engine engine at at top dead dead cent center er of the the compression stroke for the number one cylinder. cylinder. Refer to steps a through d. a. Rotate Rotate the the engin enginee in the the normal normal dire directi ction on of rotation (clockwise viewed from the water pump end) until the 1-4 timing t iming mark on the flywheel lines up with the index mark in the timing mark access hole. 1
2
AEA701
2 AGA01
1.
Numb Nu mber er One One Cyl Cylin inde derr Inj Injec ecti tion on Line Line
2.
Timing Mar Mark k Ac Access ess Ho Hole Figure 183: 183: Component Component Location Location
CAUTION: Loosen all of the injection lines at the injection nozzles to prevent the possibility of the engine firing while it is being rotated.
1.
Index Mark
2.
Top De Dead ad Ce Cent nter er Ma Mark rk for for 1 and and 4
Figure 184: Top Dead Center One and Four
b. Check Check the the rocker rocker arms arms on on the numb number er one one cylinder to see if they are loose. l oose. c. If the the rocke rockerr arms arms are loose loose the the engin enginee is at at top dead center of the compression stroke for the number one cylinder. d. If the rocker rocker arms arms are are tight tight the engi engine ne is at at top dead center of the exhaust stroke for the number one cylinder. Rotate the engine 360 degrees to place the engine at top dead center of the compression stroke for the number one cylinder.
97
Fuel System
6. Discon Disconnec nectt the 8S 8S wire wire from from the starte starterr solenoid to prevent the engine from cranking when the unit is turned On. 7. Energize Energize the fuel fuel solen solenoid. oid. If the engine engine is in the unit, turn the unit On. Use the Service Test Test Mode to energize the fuel solenoid if the unit has a microprocessor. If the engine is not in i n the unit, use jumper wires to energize the fuel solenoid at the three pin connector. connector. Place a jumper between the black wire (CH - pin C) and ground (–). Place a jumper between the red wire (8D - pin A) and 12 Vdc (+). Momentarily place a jumper between the white wire (8DP - pin B) and 12 Vdc (+).
Tier 1 engines (TK482E, TK486E, and TK486EH) have an additional injection timing mark at 10 degrees BTDC. The 10 degree BTDC timing mark is a horizontal line stamped on the flywheel approximately 1.0 in. (25 mm) before the top dead center center mark. The TK482E and TK486E are timed at 10 degrees BTDC (see Figure 189 on page 99 99). ). The TK486EH is timed at 11 degrees BTDC (see Figure 190 on page 99 99). ). 1
2
CAUTION: Do not leave the jumper on the white wire (8PD (8PD - pin B) for more more than a few seconds or or the fuel solenoid will be damaged.
3
1.
Index Mark
2.
12 De Degr gree ee BTDC BTDC Timin iming g Mar Mark k
3.
10 Deg Degre ree e BTD BTDC C Tim Timin ing g Mark Mark (Tier 1 Engines Only)
AEA633
Figure 186: Timing Mark Mark Alignment Alignment 1.
Red (8D)
2.
White (8DP)
3.
Black (CH)
Figure 185: Fuel Solenoid Solenoid Connecto Connectorr Pin Identif Identificat ication ion
9. Pump Pump the primi priming ng pump pump by hand hand a few few times times,, or energize the electric fuel pump if an electric fuel pump is being used. 10. Use a clean clean towel to wipe the fuel from the top end of the delivery valve holder.
8. Rotate Rotate the engine engine backwa backwards rds (counterclockwise viewed from the water pump end) until the injection timing mark or marks are positioned in the bottom of the timing mark access hole (see Figure 186). 186).
1
Early engines (TK482 and TK486) have one injection timing mark at 12 degrees BTDC (before top dead center). The 12 degree BTDC timing mark is a horizontal line l ine stamped on the flywheel approximately 1.2 in. (30 mm) before the top dead center mark. The TK482 and TK486 are timed at 12 degrees BTDC (see Figure 188 on page 99 99). ).
AEA759
1.
Delivery Va Valve Ho Holder
Figure 187: Injection Injection Pump Pump
98
Fuel System
11. Slowly turn the engine in the normal direction direction of rotation until you see the fuel rise in the end of the delivery valve holder. holder. Stop as soon as you see the fuel rise slowly.
c. On TK48 TK486EH 6EH engine enginess the the index index mark mark should align with the midpoint between the two timing marks on the flywheel. f lywheel.
12. Check position position of the timing marks.
1
2
a. On TK482 TK482 and TK486 TK486 engine enginess the the injection timing mark on the flywheel should be aligned with the index mark on the side of the timing mark access hole. 3 1
2
1.
Index Mark
2.
12 De Degr gree ee BTDC BTDC Timing ming Ma Mark rk
3.
10 De Degr gree ee BTDC BTDC Timing ming Ma Mark rk
Figure 190: Correct Timing Mark Alignment Alignment for TK486 TK486EH EH AEA703
1.
Index Mark
2.
Injection Ma Mark
13. Repeat Repeat steps steps 8 through 12 to 12 to recheck the timing.
Figure 188: Correct Timing Timing Mark Alignment Alignment for TK482 TK482 and TK486 TK486
b. On TK48 TK482E 2E and and TK468E TK468E engi engines nes the 10 10 degree BTDC timing mark on the flywheel should be aligned with the index mark on the side of the timing mark access hole. 1
14. If the timing is off by more than 1 degree degree (0.1 in. [2.5 mm]), loosen the mounting nuts on the studs that fasten the injection pump to the engine and rotate the injection pump to change the timing. a. Pull Pull the top of the the injec injectio tion n pump pump away away from the engine to advance the timing. b. Push Push the top top of the inje injecti ction on pump pump towar toward d the engine to retard the timing.
2
15. Tighten the injection pump mounting nuts and and recheck the timing. Repeat steps 8 through 15 until the timing is correct. 3
1.
Index Mark
2.
12 Degre egree e BTDC BTDC Timin iming g Mar Mark k
3.
10 Degre egree e BTDC BTDC Timin iming g Mar Mark k
16. Install the cover cover in the timing mark access hole, install the injection line for the t he number one cylinder, tighten the other injection lines, li nes, and reconnect the 8S wire to the starter solenoid when finished with the procedure.
Figure 189: Correct Timing Timing Mark Alignment Alignment for TK482E and TK468E TK468E
99
Fuel System
Attaching Injection Pump Gear to Flange on Tier 1 Engines Tier 1 engines have a three-piece injection pump gear. gear. The injection pump gear should not be removed from the flange because that changes the timing. However, if the injection pump gear was removed from the flange, use the following procedure to assemble them correctly.
1. Find Find the timin timing g mark mark on the the inject injection ion pump pump gear. gear. The timing mark is the letter “B” stamped between two teeth near the edge of the gear. gear. It is also marked with a dab of white paint. Remove the transfer pump cam if you are not sure where the timing mark is. i s.
2
1
3 4
1. 5
1
Dab of White Paint
Figure 192: Timing Mark Mark on Injection Pump Pump Gear with Transfer Pump Cam Installed 6
7 1.
Fuel In Injection Pu Pump
2.
Key
3.
Flange
4.
Injection Pu Pump Ge Gear
5.
Transfer Pump Cam
6.
Nutt (Inj Nu (Injec ecti tion on Pump Pump Gear Gear Asse Assemb mbly ly))
7.
Do No Nott Rem Remov ove e Gea Gearr Fro From m Fla Flang nge e
Figure 191: Three-Piece Three-Piece Fuel Fuel Injection Injection Pump Pump Gear
1 1.
Letter “B”
Figure 193: Timing Mark Mark on Injection Pump Pump Gear without Transfer Pump Cam Installed
100
Fuel System
2. Place the injection injection pump gear on the the flange flange so the timing mark on the injection pump gear is approximately 180 degrees from the keyway in the flange. 3. Center Center the slots in the flange flange in the large large holes in the injection pump gear. The slotted adjustment is used to enable the factory to adjust the timing more rapidly during assembly. assembly. If the flange and gear are disassembled, the slot is centered in the hole and the injection pump must be flow timed.
4. Instal Installl the injec injection tion pump pump gear gear mount mounting ing screws and torque them to 25 ft-lb (34 ( 34 N•m). 5. Instal Installl the tran transfe sferr pump pump cam cam if it was was removed. 6. Install Install the the injectio injection n pump pump gear assembly assembly on the fuel injection pump. Torque Torque the mounting nut to 43.4 to 50.6 ft-lb ft-l b (58.8 to 68.6 N•m). The timing marks on the timing gears must be aligned as shown below with the Number 1 Cylinder at TDC (Top (Top Dead Center) of the compression stroke. It helps to install the idler gear last when aligning the timing marks.
2
3
1 2
1
5 4
3 1.
Keyway in Flange
2.
Slot Slot in in Flan Flange ge Cen Cente tere red d in Ho Hole le in in Gear Gear**
3.
Dab of White Paint
AGA110
Figure 194: Flange and Injection Injection Pump Gear Gear Alignment with Transfer Pump Cam Installed
2
1.
Fuel Inj Injec ecttion Pu Pump Ge Gear
2.
Idler Gear
3.
Camshaft Gear
4.
Crankshaft Gear
5.
Oil Pump Gear Figure 196: 196: Timing Mark Mark Alignment Alignment
7. Flow Flow time time the the fuel fuel injec injection tion pump. pump. See “Injection Pump Timing Tier 1 and Earlier Engines” on page 97.
1
3 1.
Keyway in Flange
2.
Slot Slot in in Flan Flange ge Cen Cente tere red d in Ho Hole le in in Gear Gear**
3.
Letter “B”
Figure 195: Flange and Injection Injection Pump Gear Alignment without Transfer Pump Cam Installed
101
Fuel System
Injection Pump Timing Tier 2 Engines Use this timing procedure when installing a new injection pump on a Tier 2 engine. It is not necessary to use this timing procedure when removing and reinstalling the original injection pump. In that case, align the index marks on the injection pump and the gear case as they were before removing the injection pump. 1. Before Before removin removing g the the old old injectio injection n pump, pump, note the alignment of the index marks on the injection pump and the gear case. The index mark on the injection pump is usually aligned with the index mark on the gear case. If not, make a mark on gear case in line with the index mark on the injection pump (see Figure 199). 199).
2 1 3
1.
Inde Index x Mar Mark k on on Inj Injec ecti tion on Pump Pump
2.
Exis Existi ting ng Inde Index x Mar Mark k on Gear Gear Ca Case se
3.
Make Ma ke Ne New w Mar Mark k on on Gea Gearr Cas Case e If If Nee Neede ded d Figure 199: 199: Marking Gear Gear Case Case
2. Clean Clean the the area area with brake brake clea cleaner ner or or something similar. Place an injection angle sticker on the gear case so the center line on the sticker is aligned with the index mark on the injection pump. An injection angle sticker is provided with the new injection pump.
1 1 1.
2
1.
Inde Index x Mar Mark k on on Inj Injec ecti tion on Pump Pump
2.
Inje Inject ctio ion n Angl Angle e Stick ticker er
Index Marks
Figure 200: 200: Place Injection Injection Angl Angle e Stick ticker er on Gear Gear Ca Case se
Figure 197: 197: Tier 2 Index Index Mark Location Location
0.5 Degrees
1 2 3
1
2
1.
Inde Index x Mar Mark k on on Inj Injec ecti tion on Pum ump p
2.
Index Mark on Gear ear Case
Figure 198: Tier 2 Index Index Mark Alignment Alignment
102
1.
–1.0 Degrees Mark
2.
Cente enterr Lin Line e (0 (0 Deg Degre rees es Ma Mark rk))
3.
+ 1. 0 D De egrees Ma Mark
Figure 201: Injection Injection Angle Sticker Sticker
Fuel System
3. Remov Removee the old old injec injectio tion n pump. pump. Use Use the injection pump gear tool P/N 204-1011 to remove the injection pump gear without removing the timing gear cover (see “Injection Pump Removal and Installation (All Engines)” Engines)” on on page 105). 105). NOTE: Remove the injection injection pump gear by by removing the nut nut and lock washer that secure the injection injection pump gear assembly assembly to the injection pump shaft. The injection injection pump gear assembly assembly is made of three pieces; pieces; the flange, the gear, gear, and the transfer transfer pump cam. Do not loosen or remove the four bolts bolts that fasten the gear to the flange because because that changes the timing. timing.
1
1.
Injec njecti tio on Angl ngle Mark
Figure 203: Injection Injection Angle Mark Location Location
1 1 2
1
1
1 1.
1.
Do Not Not Loo Loose sen n or Re Remo move ve The These se Fou Fourr Bolt Bolts s
2.
Remo Re move ve Nut and and Loc Lock k Was Washe herr Figure 202: Removing Removing Injection Injection Pump Gear
4. Record Record the the injectio injection n angle angle marked marked on the old injection pump (see the following photographs). The injection angle mark is located on the side of the pump facing the engine. The injection angle mark on the pump does not use a decimal point. Add a decimal point before the last digit of the injection angle mark to get the injection angle. The injection angle mark in the following photographs is 67. That equals an injection angle of 6.7 degrees.
Injec njecti tio on Angl ngle Mark
Figure 204: 204: Injection Injection Angle Mark Mark
NOTE: If you cannot cannot read the injection angle angle mark, contact contact Yanmar Yanmar (e-mail both Koichi Koichi Sawada at koichi_sawada@yanmar
[email protected] .co.jp and Hisashi Hamada at hisashi_hamada@yanmar
[email protected]) .co.jp) with the injection pump serial number or the engine serial number number and they will provide provide the injection angle. The injection pump serial number is located on the bottom of the sticker on the injection pump.
1
Examples Injection An Angle Ma Mark
Injection An Angle
67
6.7 Degrees
85
8.5 Degrees 1.
Inje Inject ctio ion n Pum Pump p Ser Seriial Nu Numb mber er
Figure 205: Injection Injection Pump Serial Number Location Location
103
Fuel System
5. Record Record the the injectio injection n angle angle marked marked on the the side side of the new injection pump.
3
1 2
6. Calculate Calculate the injection injection angle differenc differencee by by subtracting the injection angle of the old injection pump from the injection angle of the new injection pump. Examples Injection Angle of New Injection Pump (Degrees)
8.5
6.1
– Injection Angle of Old – 6.7 Injection Pump (Degrees)
– 6.7
= Injection Injection Angle Differen Difference ce = +1 + 1.8 (Degrees)
= –0 – 0.6
7. Instal Installl the new new injec injectio tion n pump pump on the the gear gear case and position it so the index mark on the injection pump is aligned with the t he mark equal to the injection angle difference on the injection angle sticker (see the following examples). Tighten the injection pump mounting nuts when the index mark is aligned as necessary with the injection angle sticker. sticker.
4 1.
Fuel Fuel Inje Inject ctio ion n Pum ump p Gear Gear
2.
Idler Gear
3.
Camshaft Gear
4.
Crankshaft Gear
Figure 207: Timing Mark Mark Alignment Alignment
NOTE: The oil pump is located in the timing gear cover on Tier 2 engines. The inner inner rotor of the oil pump fits around around the crankshaft crankshaft gear. gear. Make sure that the flat sides of the inner rotor are aligned with the flat sides sides on the crankshaft crankshaft gear when installing installing the timing gear cover cover..
1
1
2
5
3 4 7 2 6 1.
Inje Inject ctio ion n Pum Pump p Ind Index ex Mark Mark at at –0. –0.6 6 Deg Degree rees s
2.
Injec Injecti tion on Pump Pump Inde Index x Mar Mark k at at +1. +1.8 8 Deg Degree rees s
Figure 206: Examples Examples of Injection Pump Pump Index Mark Alignment Alignment with Injection Injection Angle Sticker Sticker
1.
Crankshaft Gear
8. Install Install the injection injection pump gear, gear, lock lock washer washer,, and nut. Torque Torque the nut to 58 to 65 ft-lb (78 ( 78 to 88 N•m).
2.
Oil Pump Cover
3.
Outer Rotor
4.
Inner Rotor
NOTE: If the timing gear cover was removed removed to remove the injection injection pump gear, gear, make sure the the timing marks on the timing gears gears are aligned aligned as shown below. It helps to install the idler gear last last when aligning the timing marks.
5.
Timing Gear Cover
6.
Flat Si Sides on on In Inner ner Ro Rotor
7.
Flat Flat Side Side on Cran Cranks ksha hafft Gea Gearr
104
Figure 208: Align Flat Sides of Crankshaft Crankshaft Gear with Flat Sides of Inner Rotor in Timing Gear Cover
Fuel System
Injection Pump Removal and Installation (All Engines) Removal The injection pump gear will not fit through the gear housing when removing the injection pump, the gear must be removed from the pump. Using tool P/N 204-1011, it will not be necessary to remove the belts, fuel transfer pump, crankshaft pulley, or gear case cover. See Figure 213 on page 106. 106. 1. Note Note the alig alignme nment nt of the the index index marks marks on on the injection pump and the gear case. On the Tier 1 engine, the index mark mark on the injection injection pump is usually aligned with the center (long) index mark on the gear case. On the Tier 2 engine, the index mark on the injection pump is usually aligned with the single index mark on the gear case. If not, mark it so the injection pump can be returned to the same position when it is reinstalled.
2
1 1.
Inde Index x Mar Mark k on on Inj Injec ecti tion on Pum ump p
2.
Cent Ce nter er Inde Index x Mar Mark k on on Gea Gearr Cas Case e
Figure 210: Typical Tier Tier 1 and Earlier Index Index Ma Mark rk Align Alignmen mentt
1 1.
Index Marks
Figure 211: 211: Tier 2 Index Mark Location Location 1 1.
Index Marks
Figure 209: Tier 1 and Earlier Earlier Index Mark Location Location
1
2
1.
Inde Index x Mar Mark k on on Inj Injec ecti tion on Pum ump p
2.
Index Mark on on Gear Case
Figure 212: Typical Tier Tier 2 Index Mark Alignment
105
Fuel System
2. Remove Remove the the starte starterr for cleara clearanc nce, e, remove remove throttle linkage, fuel lines, harness and mounting hardware from the injection pump.
5. Align the threaded threaded holes in the the injectio injection n pump pump gear with the two holes in the tool plate by rotating the engine crankshaft. Attach the gear to the tool plate with the screws provided with the tool plate.
3. Remove Remove the the cover cover plat platee from from the gear gear case case cover. cover. Remove the nut and lock washer which secure the gear to the injection pump shaft. Use a shop rag to prevent the lock washer or nut from falling into the gear case.
6. Thread Thread the the long long screw screw supplied supplied with the tool plate into the small end of the t he adapter, adapter, also supplied with the tool plate. Insert the adapter into the tool plate and rotate it to provide a solid position to force the injection pump shaft from the gear. Caution should be taken to align the screw over the center of the injection pump shaft.
NOTE: On Tier Tier 1 and Tier Tier 2 engines the injection pump gear assembly is made of three pieces; the flange, the gear, gear, and the transfer pump pump cam. Do not loosen or remove the four bolts that fasten fasten the gear to the flange because that that changes the timing.
7. Remove Remove the the screw screw and adapter adapter leavi leaving ng the the tool tool plate in place. This holds the gear in proper tooth alignment until the injection pump is reinstalled.
4. Use the hard hardwar waree from from the cove coverr plate plate to attach the tool plate (with the t he marked side pointing up and out) to the gear case cover. cover.
1
3
4
2
5
6
9
8
1.
Tier 1 and Earlier Injection Pump
6.
Adapter
2.
Tier 2 Injection Pump
7.
Tool Long Screw
3.
Gear Case
8.
Tool Short Screw
4.
Cover Plate
9.
Tool Plate
5.
Cover Plate Bolt Figure 213: Injection Injection Pump Gear Tool Tool
106
7
Fuel System
Installation 1
1. Positio Position n the inje injecti ction on pump pump shaft shaft into into the injection pump gear, rotating the shaft to mate the key with the keyway in the gear. Take care to make sure the key mates with the keyway. 2. Secure Secure the the injec injectio tion n pump pump to the gear gear case case with previously removed hardware. Make sure to align the index marks on the injection pump and the gear case like they were in step tep 1 of “Removal” “Removal” on on page 105. 105. NOTE: If a different injection injection pump is being installed, see the appropriate injection pump timing procedure to set the timing. 3. Remov Removee hardwa hardware re holdin holding g the gear gear to the the tool plate, then remove the tool plate. 4. Secure Secure the the gear gear to the the injecti injection on pump pump shaft shaft with the lock washer and nut. Use a shop rag, as before, to prevent the lock washer or nut from falling into the gear case. Torque the nut to 43 to 51 ft-lb ft-l b (59 to 69 N•m) on the Tier 1 or earlier engines, or 58 to 65 ft-lb (78 to 88 N•m) on the Tier Tier 2 engines. engines. 5. Fasten Fasten cove coverr plate plate to gear gear cas casee cover cover and and reinstall all components removed previously to facilitate injection pump removal.
Trochoid Feed Pump Tier 2 Engines The Tier 2 engine has a trochoid feed pump on the fuel injection pump. The trochoid feed pump supplies fuel to the injection pump at a pressure of 65 to 87 psi (450 to 600 kPa). Check the outlet pressure of the trochoid feed pump by removing the plug and attaching a pressure gauge to the port shown below. below. The plug has M12x1.25 threads. You will have to t o make an adaptor to t o attach a pressure gauge. Replace the trochoid feed pump if the outlet pressure is below 59 psi (410 kPa) or above 94 psi (650 kPa).
2
1.
Troch Trochoid oid Feed Pump Pump Outl Outlet et Pressu Pressure re Port Port
2.
Troch rochoi oid d Fee Feed d Pum Pump p
Figure 214: Trochoid Trochoid Feed Pump Pump Location
If the seal in the trochoid feed pump fails, it could allow some fuel to leak into the engine oil. A faulty injection nozzle or fuel transfer pump can also dilute the engine oil with fuel. Replace the trochoid feed pump if the engine oil is being diluted with fuel and a faulty injection nozzle or fuel transfer pump is not the cause. See “Trochoid Feed Pump Replacement” on page 107. If oil leaks from between the trochoid feed pump and the injection pump, replace the O-rings between the trochoid feed pump and the injection pump. If fuel leaks from the trochoid t rochoid feed pump, replace all the O-rings. See “Trochoid Feed Pump O-Ring Replacement” on page 108.
Trochoid Feed Pump Replacement 1. Remove Remove the the four four hex hex head head screws screws that that attach attach the trochoid feed pump to the injection pump. Do not remove the two Allen head screws.
1
2
1
1.
Alle Allen n Head Head Scr Screw ews s (Do (Do Not Not Remov Remove) e)
2.
Hex He Head Screw rews
Figure 215: Trochoid Trochoid Feed Pump Pump Removal
107
Fuel System
2. Remove Remove the troc trochoi hoid d feed feed pump pump from from the the injection pump. NOTE: The gear on on the trochoid feed pump is lubricated with engine oil. Some engine oil might leak out of the injection pump when the trochoid feed pump pump is removed. The trochoid feed pump pump does not need to be timed when it is installed.Clean the area on the injection pump from which the trochoid feed pump was removed. removed.
Trochoid Feed Pump O-Ring Replacement 1. Remove Remove the the two two Allen Allen head head screws screws that attach attach the trochoid feed pump cover to the trochoid feed pump body. It is not necessary to remove the Allen head screws if you are not replacing the O-ring between the trochoid feed pump cover and the trochoid feed pump body. 2. Remove Remove the the four four hex head head screw screwss that that attach attach the trochoid feed pump to the injection pump.
3. Place Place new new O-rings O-rings on on the new new troch trochoid oid feed feed pump and make sure it is clean.
1
1 1 1.
O-Rings
Figure 216: Trochoid Trochoid Feed Pump Pump
4. Place Place the the new new trocho trochoid id feed feed pump pump on the injection pump. 5. Install Install and and tighten tighten four hex head screws screws that that attach the trochoid feed pump to the injection pump. Torque the hex head screws to 6 to 7 ft-lb (8 (8 to 10 10 N•m). N•m). NOTE: The hex head head screws screws have have sealant sealant on the threads. The screws can be be reused once, once, but must be replaced replaced if removed a second second time.
2
1.
Alle Allen n Hea Head d Scr Screw ews s
2.
Hex Hea Head d Sc Screw rews
1
Figure 217: Trochoid Trochoid Feed Pump Removal Removal
3. Remove Remove the the trocho trochoid id feed feed pump pump cover cover from from the trochoid feed pump body and remove the trochoid feed pump body from the injection pump. NOTE: The gear on the trochoid feed pump is lubricated with engine oil. Some engine oil might leak out of the injection pump when the trochoid feed pump is removed. The trochoid feed pump pump does not need to be timed when it is installed.Clean the area on the injection pump from which the trochoid feed pump was removed. removed. 4. Place Place a new O-ring for the the trochoid trochoid feed pump cover on the trochoid feed pump body and make sure it is clean.
108
Fuel System
5. Place Place the the trochoi trochoid d feed feed pump pump cover cover on the the trochoid feed pump body and install the two Allen head screws. Torque the Allen head screws screws to 6 to 7 ft-lb (8 to 10 N•m). N•m). NOTE: The Allen head head screws have have sealant on the threads. The screws can can be reused once, but must be replaced if removed removed a second time.
Cold Start Device Tier 2 Engines The Tier 2 engine has a cold start device located on the fuel injection pump. The cold start device has a plunger that retracts at engine coolant temperature temperaturess below below 41 F (5 C) to advanc advancee the injection timing approximately 2 degrees. The plunger controls the position of a piston in the injection pump to change the timing. The plunger is extended and the injection timing is normal at engine engine coolant coolant tempera temperatures tures above above 41 F (5 C). Check the operation of the cold start device if it is difficult to start the engine in cold weather. weather. NOTE: Do not pull the plunger plunger out of a cold start device because that will damage damage it.
4 2
3
1 3
5 1 1.
Alle Allen n Head ead Screw crew
2.
Troch rochoi oid d Fee Feed d Pum Pump p Cov Cover er
3.
O-rings
4.
Troch rochoi oid d Fee Feed d Pum Pump p Bod Body y
5.
Hex Head Screw rew
Figure 218: Trochoid Trochoid Feed Pump Components Components
6. Place Place the the new O-rin O-rings gs on the the trocho trochoid id feed feed pump and make sure it is clean. 7. Place Place the the trochoi trochoid d feed feed pump pump on the the injec injection tion pump. 8. Install Install and and tighten tighten four hex head screws screws that that attach the trochoid feed pump to the injection pump. Torque the hex head screws to 6 to 7 ft-lb (8 to 10 N•m). NOTE: The hex head head screws screws have have sealant sealant on the threads. The screws can be reused once, once, but must be replaced replaced if removed a second time.
1.
Plung lunger er (Ext (Exten ende ded) d)
Figure 219: Cold Start Start Device Device
Checking Cold Start Device Operation Use the following procedure to check the operation of the cold start device. The engine coolant coolant tempera temperature ture must must be below below 32 F (0 C) to start the procedure. 1. Check Check the the coolant coolant temperature temperature to make make sure sure it is bel below ow 32 F (0 C). C). 2. Start Start the engine, engine, then then check check the engine engine rpm. The engine rpm should be approximately 100 rpm higher than normal (see Specifications in unit Maintenance Manual).
109
Fuel System
3. Let the the engi engine ne run run to warm warm up up and and check check the coolant temperature and engine rpm. When the coolant temperature rises above 41 41 F (5 C), the engine rpm should drop drop back to normal. Replace the cold start device if the engine rpm does not drop approximately 100 rpm when the engine warms up.
1
2
Cold Start Device Replacement 1. Drai Drain n the the engi engine ne coo coola lant nt.. 2. Remove Remove the banjo bolt that fastens fastens the the engine engine coolant fitting to the cold start device. Use a backup wrench on the cold start device if necessary.
1.
Cold Co ld Start art Dev Devic ice e
2.
Inje Inject ctio ion nP Pum ump p Fit Fitti ting ng
Figure 221: Remove Cold Cold Start Start Device
1
4. Make Make sure sure the pist piston on insid insidee the injec injectio tion n pump fitting is clean.
2
3 1
1.
Banjo Bo Bolt
2.
Engi Engine ne Co Cool olan antt Fit Fitti ting ng
3.
Cool Co olant ant Ho Hose ses s to Col Cold d Sta Start rt Dev Devic ice e
Figure 220: Remove Engine Engine Coolant Fitting Fitting
3. Remove Remove the cold cold star startt device device from from the the injection pump fitting. Use a backup wrench on the injection pump fitting if necessary. necessary.
1.
Piston
Figure 222: Clean Piston
5. Instal Installl the new new cold cold start start devic devicee with a new new O-ring in the injection pump fitting. Torque the cold start device to 22 to 26 ft-lb (30 to 35 N•m) N•m).. 6. Install Install the coolant coolant fitting fitting and banjo bolt on the the cold start device. Torque the banjo bolt to 16 to 18 ft-lb (22 to 25 N•m). 7. Refill Refill the the engine engine cool cooling ing syst system em and and make make sure to bleed the air from the cooling system.
110
Fuel System
Fuel Injection Nozzles The fuel injection nozzles for Tier 1 and earlier engines are not interchangeable with the fuel injection nozzles for the Tier 2 engine. The testing and repair procedures are the same except for the different opening pressures.
b. Each Each hole hole in the the nozzl nozzlee shoul should d form form a straight conical spray pattern. The spray patterns should be uniform and separated by an angle of approximately 150 degrees.
Testing 1. Attach Attach the the injectio injection n nozzle nozzle to a nozzle nozzle tester tester (P/N 204-290). NOTE: Use only testing fluid or clean filtered diesel fuel to test test injection nozzles. CAUTION: Keep your hands away from the nozzle spray. spray. The nozzle spray is at such high pressure pressure that it can break break the skin and penetrate penetrate into the underlying tissue. Such an injury is very painful and and can lead to serious serious complications such such as blood poisoning.
AEA698
Figure 224: Acceptable Acceptable Spray Pattern Pattern
AGA131
Figure 225: Unacceptable Unacceptable Spray Spray Pattern
3. Open the press pressure ure gauge gauge valve and check check the opening pressure by pushing the hand lever completely down several times. a. The inject injection ion nozzle nozzle should should make make a buzzing sound.
AGA130
Figure 223: Testing Injection Injection Nozzles
2. Close the pressu pressure re gauge gauge valve valve and and push push the hand lever completely down several times.
b. The open opening ing pres pressur suree should should be be 2,800 2,800 to 3,000 psi (19,600 to 20,600 kPa) for Tier 1 and earlier engines, or 3,100 to 3,300 psi (21,600 to 22,600 kPa) for Tier 2 engines. c. Adjust Adjust the the openi opening ng press pressure ure by by changi changing ng the size or number of adjustment shims above the spring. See the repair procedure on page page 112. 12.
a. The inje injecti ction on nozzl nozzlee should should make make a shri shrill ll whistling or buzzing noise.
111 111
Fuel System
4. Leave Leave the the pressur pressuree gauge gauge valve valve open open and and check to see if the injection nozzle drips. Slowly press on the hand lever to bring the pressure up to 300 psi (2068 kPa) below the opening pressure of the injection nozzle. Maintain this pressure for at least 5 seconds. Fuel should not drip from injection nozzle in less than 5 seconds. 5. Repair Repair the the injecti injection on nozzl nozzlee if it fails fails any any of these tests or if fuel leaks out of the return tube during the tests.
Repair 1. Clamp Clamp the the nozzl nozzlee body body in a vise vise with with the nozzle nut up. Use a vise that has aluminum jaws or jaw covers.
1
2
3 4 5
2. Loosen Loosen and remove remove the nozzle nozzle nut. nut.
6
3. Remove Remove the nozzle nozzle valve valve and and seat seat set set from from the nozzle nut and submerge them in diesel fuel. Make sure to keep them together as a set.
7 8
4. Remove Remove the nozz nozzle le body body from from the the vise. vise. 5. Remove Remove the spacer spacer,, pins, pins, spring spring seat, spring, spring, and adjustment shim(s) from the nozzle holder.
9 AGA132
6. Inspect Inspect the spacer spacer.. Replac Replacee the spacer spacer if any wear or damage is evident.
1.
Nozzle Body
2.
Adjustment Shims
3.
Spring
4.
Spring Seat
5.
Pin
6.
Spacer
a. Clean Clean the the carb carbon on off off the the outsi outside de of of the nozzle seat with a cloth and solvent.
7.
Nozzle Valve
8.
Nozzle Seat
b. Clean Clean the the inside inside of of the nozz nozzle le with with the the cleaning tools and solvent.
9.
Nozzle Nut
7. Inspect Inspect the spring. spring. Replac Replacee the spring spring if it it is bent, scratched, or rusted. 8. Use a nozz nozzle le clea cleanin ning g tool tool kit to clea clean n the nozzle valve and seat set.
c. Thorou Thoroughl ghly y rinse rinse the nozzl nozzlee seat seat and valve valve with cleaning spray and submerge them separately in diesel fuel.
Figure 226: Injection Injection Nozzle Assembly Assembly
9. Test the the nozz nozzle le valve valve and and seat seat set. set. a. Place Place the the nozzl nozzlee valve valve in in the nozzl nozzlee seat seat while holding the nozzle seat in a vertical position. b. Pull Pull the noz nozzle zle valv valvee about about one one third third of the the way out of the nozzle seat.
112
Fuel System
Fuel Return Line Replacement
AGA133
Figure 227: Testing Nozzle Valve Valve and Seat Set
c. Relea Release se the the nozzle nozzle valv valve. e. The The nozzle nozzle valv valvee should slide into the nozzle seat by itself. d. Rotate Rotate the the nozzl nozzlee valve valve in the the nozzle nozzle seat seat about 90 degrees at a time, and repeat this test four or five times. e. Replac Replacee the nozz nozzle le valve valve and and seat seat set set if the the nozzle valve does not slide smoothly into the nozzle seat. NOTE: A new nozzle nozzle valve and seat seat set should be thoroughly thoroughly cleaned and tested before being installed. installed. 10. Clamp the nozzle nozzle body in a vise with the nozzle nut end up. 11. Place the adjustment adjustment shim(s) in the nozzle nozzle body. body. If the opening pressure needs to be adjusted, change the shims as required. Add shims or replace the present shim with a larger one to increase the opening pressure. Remove shims or replace the present shim with a smaller one to decrease the opening pressure. 12. Place the spring, spring, spring seat, seat, and pins pins in the nozzle body. 13. Place the spacer spacer over the pins and check the alignment.
In November of 2003 the fuel return lines li nes (hoses) on TK486E and TK486EH engines were upgraded with a new hose material featuring a Viton inner liner. Viton is highly resistant to the additives that are currently used in diesel fuel systems. Units built after unit serial number 103XXXXXXX use fuel return lines that contain the new material. The new fuel return lines start at engine serial number L77626 for the TK486E, and L78616 for the TK486EH. The new fuel return lines look similar to those used previously, so identification must be done by unit or engine serial number. Units built before the serial number above use the original hose material, units built after that number contain Viton. Thermo King recommends that fuel return lines l ines be changed every 10,000 engine operating hours in all units equipped with the new Viton-lined hoses. Units built before that date should have their fuel return lines changed at 5,000 engine operating hours. Fuel Return Line Replacement TK482/486 Engine Units Interval 5,000 Hours
Original lines on units built before October 2003
10,000 Hours
Lines on units built before October 2003 that have had kit P/N 10-368 installed
10,000 Hours
All units built in October 2003 and later
The return line kit (P/N 10-368) contains new return lines, clamps, an end cap, and a decal like the one shown below. This decal is was added to production units in January of 2005. The decal is located near the unit serial plate. The date and engine hours must be entered on the decal when the fuel return lines are changed.
14. Place the nozzle valve valve and seat set set on the pins and check the alignment. 15. Install the nozzle nozzle nut and torque it to 29 29 to 33 ft-lb (39 (39 to 44 44 N•m). N•m). 16. Test the injection nozzle nozzle and adjust the opening pressure as necessary.
Figure 228: Fuel Return Return Line Replacement Replacement Decal
113
Fuel System
Use the following procedure to replace the fuel return lines and end cap. 1. Remove Remove the clamps, clamps, the the end end cap, cap, the the short short fuel fuel return lines between the injection nozzles, and the long fuel return line from the injection nozzle to the banjo fitting on the t he injection pump. 1 3
2
Fuel Transfer Pump Fuel Transfer Pump Operation The fuel transfer pump is driven by a cam on the fuel injection pump gear. The cam actuates the piston through the tappet assembly and push rod. Fuel is forced through the outlet check valve to the area behind the piston when the cam moves towards the piston and compresses the spring. The inlet check valve closes to prevent fuel from flowing back through the inlet. 2
3 1
4
3 3 5
4
3 1.
End Cap
4.
Short Fuel Return Lines
2.
Larger Clamp
5.
Long Fuel Return Lines
3.
Smaller Cl Clamps Figure 229: Fuel Return Line Line Replacement Replacement
2. Discar Discard d the old old clamp clamps, s, end end cap, cap, and fuel fuel return lines. 3. Install Install the the end end cap cap and and clamp. clamp. Note that the end cap has a larger OD than the other hoses and requires the larger clamp.
1.
Piston
3.
Outlet Check Valve
2.
Cam
4.
Inlet Check Valve
Figure 230: Outlet Stroke
The spring pushes the piston towards the cam when the cam moves away from the piston. This draws fuel through the inlet check valve and forces fuel out of the outlet. The outlet check valve closes to prevent fuel from flowing back behind the piston. 2
4. Install Install the the fuel fuel return return lines and clamps. clamps. It It may be necessary to adjust the banjo fitting fitt ing slightly to obtain the straightest routing for the long return line.
1
3
5. Be sure sure all all the fittings fittings are are tight tight and check check for leaks. 6. Write Write the the date date and and engine engine hours on the the decal. decal.
4 AGA136
1.
Piston
3.
Outlet Check Valve
2.
Cam
4.
Inlet Check Valve
Figure 231: Inlet and Delivery Delivery Stroke Stroke
114
Fuel System
When the fuel pressure at the outlet is i s more than approximately 7 psi (48 kPa), it stops the spring from pushing the piston back toward the cam. This prevents fuel from being forced out of the t he outlet. When the pressure drops, operation resumes. This limits the outlet fuel pressure to approximately 7 psi (48 kPa).
Testing 1. Instal Installl the fuel fuel tran transfe sferr pump pump if it was was removed for inspection. 2. Disconnec Disconnectt the fuel solenoid solenoid wire connector connector.. 3. Disconnec Disconnectt the inlet and outlet outlet fuel fuel lines lines from from the fuel transfer pump. 4. Attach Attach a fuel fuel hose about about 6 feet feet (2 (2 meters) meters) long to the inlet fitting on the fuel transfer pump.
2
1 3
5. Position Position a container container of diesel diesel fuel about about 3 feet (1 meter) below the level of the fuel transfer pump, and place the end of the inlet hose in the diesel fuel. 6. Attach Attach a fuel fuel hose hose to the the outlet outlet fittin fitting g on the the fuel transfer pump and place the end of this hose in a bucket or can.
4 AGA137
1.
Piston
3.
Outlet Check Valve
2.
Cam
4.
Inlet Check Valve
Figure 232: Pressure Controlled Controlled Delivery Delivery Stroke
Inspection Refer to Figure 233 on page 116. 116. 1. Remov Removee and insp inspec ectt the check check valv valves es and and check valve springs. Replace any that are worn or damaged and reassemble the check valves. 2. Remov Removee the trans transfer fer pump pump from from the the gear gear case case cover. 3. Carefu Carefully lly remov removee the retai retainer ner.. It is under under spring pressure. 4. Remove Remove and inspect inspect the the spring spring and and piston. piston. Replace the spring if it is worn or damaged. Replace the transfer pump if the piston or pump body is damaged or worn. 5. Reassemb Reassemble le the the piston piston,, spring, spring, and retainer retainer..
7. Turn Turn the engine engine over over with with the starter starter. The fuel transfer pump should pump fuel out of the outlet within 60 revolutions of the engine, and there should be a good flow of solid fuel coming out of the pump. Repair or replace the fuel transfer pump if more than t han 120 revolutions of the engine are required to pump fuel through the pump. You can also use a compound gauge to check a fuel transfer pump. 1. Install Install a block off fitting on the the fuel fuel transfer transfer pump inlet with a compound gauge attached. Crank the engine and check the gauge reading. The compound gauge should show vacuum of at least a 10 in. (-34 kPa). 2. Install Install a block off fitting on the the fuel fuel transfer transfer pump outlet with a compound gauge attached. Crank the engine and check the gauge reading. The compound gauge should show a pressure of at least 7 psi (48 kPa). 3. If either either of of these these pressu pressure re checks checks is incorre incorrect, ct, the problem is usually caused by one of the check valves.
6. Press Press on the tappet tappet and release release it. Repeat Repeat this this a few times. Check to see that the tappet moves in and out of the pump body smoothly without sticking or binding. Replace the transfer pump if the tappet sticks or binds.
115
Fuel System
5
4 1
6 2
3
7 3
2
9
10
1.
Priming Pump
6.
Pump Body
2.
Check Valve Spring
7.
Push Rod
3.
Check Valve
8.
Piston
4.
Inlet Strainer (P (Prefilter)
9.
Spring
5.
Tappet Assembly
10.
Retainer
Figure 233: Fuel Transfer Transfer Pump Pump
116
AGA134
8
Fuel System
10
8 11
5
4
9
6 7
12
3 2
1
1.
Fuel Tank
7.
Fuel Injection Pump
2.
Supply from Fu Fuel Tank to Fu Fuel Transfer Pu Pump
8.
Fuel Injection Nozzle
3.
Fuel Transfer Pump
9.
Return from Injection Nozzles to Injection Pump
4.
Suppl upply y ffro rom m Fue Fuell Tra Trans nsfe ferr Pum Pump p to to Fue Fuell Fil Filte terr
10. 10.
Retu Re turn rn from from Inj Injecti ection on Pump Pump to Fuel Fuel Filt Filter er
5.
Fuel Filter Assembly
11.
Relief Valve
6.
Suppl upply y fro from m Fue Fuell Fil Filte terr to to Fue Fuell Inj Injec ecti tion on Pum ump p
12. 12.
Retur eturn n fro from m Fue Fuell Fil Filte terr to to Fue Fuell Tan Tank k
Figure 234: 234: Fuel System System Diagram Diagram
117
Fuel System
Fuel System Operation and Diagnosis The following section discusses some characteristics of the fuel system and some things to consider when troubleshooting the fuel system.
Normal Fuel System Operation The transfer pump creates a vacuum in the supply line and the atmospheric pressure in the tank pushes the fuel up the pickup tube and into the 3/8 in. plastic fuel supply line and and on to the the unit in the front of the trailer. It may travel directly to the transfer pump, or in later units, to fittings located at the bottom of the unit. These bulkhead fittings were added so that the routing of fuel lines was done at the factory and would be standardized on all units. The pressure in the pickup line should always be negative when the engine is running. It will be negative or at atmospheric pressure when the engine is off.
Fuel Transfer Pump
If either of these pressure checks is incorrect, the problem is usually caused by one of the check valves. You can also check the transfer pump by cranking the engine with the outlet line placed in a bucket or can. There should be a good flow of solid fuel coming out of the pump when the engine is cranked.
Fuel Filter Assembly The fuel filter assembly removes air, removes water, and filters the fuel. There are four openings on the filter housing; the inlet for fuel from the transfer pump, the outlet for clean fuel to t o the injection pump, the inlet for fuel returning from the injection pump and nozzles, and the outlet that returns air, water, and excess fuel to the fuel tank. 5
3
7
2 4 1
The piston in the fuel transfer pump is driven by a cam located on the front of the injection i njection pump gear. gear. A return r eturn spring pushes the piston back out against the cam. There are two check valves. One is the inlet valve and the other is the outlet valve. See “Fuel Transfer Transfer Pump Operation” on on page 114 for a detailed description of the operation. The important thing to remember is that it i t is not a positive displacement pump and the outlet pressure is limited to approximately 7 psi (48 kPa). It is not not the cam pushing pushing on the the piston, but the spring pushing the piston back against the cam that forces fuel out of the transfer pump. You can use a compound gauge to check che ck a transfer pump. •
•
118
Instal Installl a block block off off fitti fitting ng on the transf transfer er pump pump inlet with a compound gauge attached. Crank the engine and check the gauge reading. r eading. The compound gauge should show vacuum of at least a 10 in. (-34 kPa). Instal Installl a block block off off fitti fitting ng on the transf transfer er pump pump outlet with a compound gauge attached. Crank the engine and check the gauge reading. r eading. The compound gauge should show a pressure of at least 7 psi (48 kPa).
6 1.
Inle Inlett from from Trans ransffer Pump Pump
2.
Outlet tlet to Inj Injec ecttion Pump
3.
Inlet Inlet for Re Retu turn rn from from Inj Injec ecti tion on Pump Pump and Nozzles
4.
Outl Outlet et for for Re Retu turn rn to Fuel Fuel Tank ank
5.
Air Outlet Hole
6.
Water ater Pic Pickup kup Tube ube Inle Inlett
7.
Water ater Outl Outlet et (Ble (Bleed ed)) Hol Hole e Figure 235: 235: Fuel Filter Filter Assembly Assembly
Fuel System
First, the air is removed. As the fuel is pushed in to the filter assembly, any air in the fuel rises to the top. There is a small outlet hole drilled in the top of the assembly that allows air out into the return fuel passage where it returns to the fuel f uel tank with the return fuel. There is a limit to the amount of air that can flow through the outlet hole, and eventually the engine will stop if enough air passes through the filter assembly to the injection pump. The small bleed hole also causes a small drop in fuel pressure as it bleeds off air and fuel. Under normal conditions there is plenty of extra flow and the small reduction of flow (and pressure) isn't significant. Next, the water is removed. The filter media contains a coating that attracts water. It is called coalescing media. The water builds up on the coalescing media and forms drops that fall to the bottom of the filter can. The Thermo King filter has a patented system to remove the water that collects at the bottom of the filter. The filter has a long rubber tube that extends almost to the bottom. The tube is sealed to the small metal pipe that protrudes down through the filter spud. The pipe is screwed into the filter housing. There is a small (0.030 in.) bleed hole drilled from the passage the pipe is screwed into up into the return fuel passage in the filter head. The water is pushed up the rubber tube, through the pipe and bleed hole into the return fuel passage because because the pressure in the return fuel passage is lower than the pressure in the filter. This also causes a small drop in fuel pressure as it bleeds off water and fuel.
The second thing to be aware of is that the pressure drop is proportional to the amount of dirt the filter has trapped in the media. If there is a lot of dirt, there is a lot of restriction, and more of a pressure drop. As the dirt builds up, the outlet pressure keeps dropping, and eventually the engine dies. The outlet pressure from the fuel filter is a good measurement of how clogged the filter is.
Injection Pump Tier 1 and Earlier Engines
On Tier 1 and earlier engines, the clean fuel enters the injection pump at the fitting farthest from the gear end of the pump. It then travels tr avels in the pump gallery and provides fuel to each plunger. plunger. The transfer pump provides more fuel than the engine needs so a return outlet port is i s provided at the gear end of the pump. Yanmar found that a problem called cavitation could occur in the pump gallery if the internal pressure in the pump falls below 5 psi (34 kPa). Cavitation can damage damage the plungers. To prevent cavitation, Yanmar put a 5-psi (34-kPa) relief valve in the injection pump return outlet on units built before 1999. The relief valve will not open until the fuel f uel pressure rises above 5 psi (34 kPa). That protects the injection pump. Unfortunately, it can also cause some problems that are discussed later in this section. 1 2
As the air and water are being removed, fuel is also being forced through the filter media. The fuel is now free of air, water, water, and dirt. It then travels to the injection pump. However, there are still some things to consider. The first is that there will be a pressure drop through the filter media and the outlet pressure to the injection pump is a few psi (or kPa) less than the outlet pressure from the transfer pump. 1.
Inle Inlett from from Trans ransfe ferr Pum ump p
2.
Retu Re turn rn Out Outle lett to Fue Fuell Filt Filter er Ass Assem embl bly y
Figure 236: Tier 1 and Earlier Earlier Injection Pump Pump
119
Fuel System
Tier 2 Engines
On Tier 2 engines, the clean fuel enters the injection pump at the fitting on the side of the pump farthest from the engine. The injection pump on the Tier 2 engine has a trochoid feed pump that supplies fuel to the pump gallery at a pressure of 65 to 87 psi (450 to 600 kPa). The Tier 2 injection pump has only one plunger called a mono-plunger. The mono-plunger and a distributor head are used instead of individual plungers. This design is less likely l ikely to experience cavitation. The return outlet is located on side of the injection pump nearest the engine and does not have a relief valve. 2
takes the return fuel from the injection pump and injection nozzles and transfers it to the return fuel outlet in the filter head. The air and water bleed ports also empty into this passage so this combines all the fuel, air, and water returning to the fuel tank. The long length of the 1/4 in. return line going back to the fuel tank acts as a natural restriction and usually holds a pressure of 3 to 5 psi (21 to 34 kPa) in the return system. You You will usually see a pressure of about 5 psi (34 kPa) in the return line between the fuel injection pump and the fuel filter head. As long l ong as the engine is running this system functions well, however, however, when the engine is shut off some things can happen that can cause the engine to be hard starting.
1
Static Pressures
1.
Inle Inlett from from Trans ransfe ferr Pump Pump
2.
Retu Re turn rn Out Outle lett to Fue Fuell Filt Filter er Ass Assem embl bly y Figure 237: Tier 2 Injection Injection Pump Pump
Return System (All Engines) There are three sources of return fuel that goes back to the fuel tank: •
Exce Excess ss fuel fuel from from the the inje inject ctio ion n pum pump. p.
•
Fuel Fuel tha thatt leak leakss from from the the inj injec ectio tion n nozz nozzle les. s.
•
Fuel Fuel tha thatt is bled bled thr throu ough gh the the air air and and wat water er bleed ports in the filter housing.
The excess fuel from the injection pump and the leakage fuel from the injection nozzles are combined at a fitting on the outlet of the injection pump. This is located after the relief valve in the early units. The combined return fuel from the injection pump and injection nozzles travels through a return line to the return passage in fuel filter head. The return passage in the filter head
120
When the engine is shut off the return fuel that is in the return line wants to t o drain back down into the tank. To do that the drain-back fuel would need to be replaced with air pulled into the system or fuel pulled from the system. When the engine stops there is positive pressure in the fuel system. This pressure closes the inlet check valve in the transfer pump. As long as the pressure in the system stays positive, the inlet check valve stays closed. The fuel in the supply line also tries to to drain back and it helps keep the inlet check valve closed. If there is no air and there is no fuel to replace the drain-back fuel, a vacuum starts to form in the system. The air and water bleed holes in the filter head connect the pressure (supply side) of the system to the return side of the t he system so when the vacuum occurs, it occurs throughout the whole system, right to the inlet check valve in the transfer pump. If there are no air leaks in the system, it will stay like this until the engine is started again. There is no air so the engine starts easily.
Fuel System
Static Air Leaks Tier 1 and Earlier Engines There are two places where air can leak into the t he static fuel system: •
•
One One is the the thro throug ugh h the the plu plung nger erss in the the injection pump. It leaks from the pump camshaft and lifter area around the plungers and into the fuel galley in the pump. Over the years the plunger clearances have been reduced to try to prevent air leaks. The The oth other er is anyw anywhe here re else else..
If air is leaking through the plungers the engine will not start, not even try to fire because the air is in the injection pump. If the air is getting in anywhere else, it will end up in the fuel filter and the engine will start, run for a few seconds, and then die. In this case you may see an Alarm Code 63 on a unit with wit h a microprocessor.
Solution for Static Air Leaks Understanding the problem helped find a solution. The vacuum cannot be stopped from forming in return line. The air leakage at the injection i njection pump plungers can be minimized, but not stopped. The solution was to stop the vacuum from forming in the whole system by moving the 5-psi (34-kPa) relief valve from the outlet of the injection pump to the return fuel outlet in the fuel filter head. NOTE: Even though it is often often called a check check valve, it functions as a relief valve, not a check valve. A check valve would close when return fuel tried to go to the tank. This This functions a 5-psi (34-kPa) relief valve. When the return fuel pressure reaches reaches 3 to 5 psi psi (21 to 34 kPa), the spring in the relief valve valve allows the piston to retract, which allows the return fuel to flow back to the fuel tank. When When the engine stops, stops, the spring pushes the piston closed and and traps a positive pressure pressure in the fuel system. The relief valve is not always a perfect seal, but as the pressure side drops from leakage, leakage, the spring pushes the piston closed tighter. tighter. By the time the pressure reaches reaches zero, the piston is usually completely sealed.
This relief valve has been installed on production units since 1999 and many units have been retrofitted with kit P/N 10-342. This solution provides a positive way to keep 5 psi (34 kPa) in the injection pump when the engine is running to answer Yanmar's requirement, and prevents a vacuum from forming in the fuel system when the engine is off. NOTE: You You must remove the original Yanmar Yanmar relief valve from the injection pump when installing kit P/N 10-342. If not, it will take a pressure of at at least 10 psi (69 kPa) kPa) to overcome the relief valves. This will make it much harder harder to prime the system system with the hand pump.
FAQ (Frequently Asked A sked Questions) If the unit is leaking l eaking air when it’s off, why doesn't it leak fuel when it runs?
It is probably a matter of time and size. Most of the hard starting problems caused by air take a long engine off period, usually days or weeks, indicating they are extremely small. It could be that the fuel boils off a warm engine before it is even seen. Why can't I find the leaks when I pressurize the fuel system?
Again, it is time and size. If I f you pressurize the fuel tank, do not go over 5 to 10 psi (34 to 69 kPa). Never pressurize a fuel system without a relief valve in the supply regulator set at 10 psi [69 kPa] maximum. A leak that pulls in 50 cc of air in a week (enough to affect starting) is going to take hours or days to show under pressure. How can I check the t he fuel return relief valve?
Probably the quickest way is to replace it. If that fixes it, then that was the problem. If not, it means it is something else, or you have another faulty relief valve. The only sure way of checking a relief valve is to take a clear hose at least 8 ft (2.4 m) long and immerse it in water or fuel. Make sure the hose fills completely with liquid. Keep the hose immersed and insert the outlet end of the valve into the hose. Slowly raise the valve out of the liquid with the hose following it. The liquid should not drop out of the hose. Raise the valve 8 ft (2.4 m) in the air and keep keep the other end end of the 121
Fuel System
hose in the container of liquid. Fasten the valve at the 8 ft (2.4 m) level. Watch Watch it to see how long it holds fluid. It should hold for an hour or more. That why it is probably quicker to replace relief valve if there is a problem. How do I know if air is leaking through the injection pump plungers?
If the engine does not fire at all, it is probably air leaking through the injection pump plungers. If the engine starts, runs a little, and then and dies, the air is in the fuel filter and the leak is somewhere other than the injection pump. Use clear fuel lines to confirm the problem if it is not obvious. What can I do if air is leaking through the injection pump plungers?
Newer injection pumps, built in 2000 or later, rarely leak through the plungers. The best thing to do is to make sure the relief valve is functioning so the system will not go into a vacuum when the engine is not running. What if there t here is air coming from somewhere else and I just cannot find it?
The best thing to do is to make sure the relief valve is functioning so the system will not go into a vacuum when the engine is not running. The system usually does not leak air if it does not go into a vacuum. Occasionally, Occasionally, changing the whole filter head has stopped an air leak. It may have been porosity in the fuel filter head casting, or it may have been a fitting. That would be a last resort. Pressurizing the system for 24 hours, if possible, may show a small leak. Use clear fuel lines fuel lines and pressure gauges to diagnose problems that are difficult to find. Why doesn't other diesel-powered equipment have air leakage problems when they are off?
Refrigeration units on trailers are one of the few pieces of equipment that mount the fuel tank so far below the engine.
Using Clear Fuel Lines To Diagnose Problems To use clear fuel f uel lines most effectively use the t he following lines and gauges. 1. Remove Remove the the suppl supply y line line from the the fuel fuel tank tank at the transfer pump. Add on about two or three t hree feet of clear line and attach it to the inlet of the transfer pump. This allows you to se if the fuel drops down after the engine stops. If it does, either the transfer pump inlet check valve is not working, or air is being pulled in at the banjo fitting. You do not normally need a gauge at this point. This line is usually in a vacuum when the engine is off or running. 2. Instal Installl a clear clear line line from from the trans transfer fer pump pump outlet to the fuel filter filt er.. It should have a compound gauge in the middle of it. This line allows you to see air coming from the tank fittings, supply line, or transfer pump fittings. The gauge shows the outlet pressure of transfer pump. 3. Install Install a clear line from the fuel fuel filter filter outlet outlet to the injection pump. A compound gauge is optional. This line allows you to see fuel f uel come from the fuel filter to the injection pump when the engine starts. If a gauge is used it should show a pressure a couple psi (or kPa) lower than the fuel filter inlet pressure because of drop from the filter. 4. Install Install a clear line from the return outlet outlet of the injection pump to the fuel filter head. A gauge is optional. This line allows you to see air that comes from the pump when the engine starts. The gauge should show the 3 to 5 psi (21 to 34 kPa) of return line back pressure. pressure. 5. You can can also also add a foot foot or two two of clear clear line line to the return line right after the relief valve. A gauge is optional. About the only thing to see in this line is that if the relief valve leaks, you will see the air form as the return fuel drops to the fuel tank. A gauge would show the vacuum form and then disappear as the fuel system allows air in. By observing the formation and travel of air and the gauge pressures, along with some basic knowledge of the fuel system, you should be able to diagnose and repair most problems.
122
Electrical Battery Cables Units with Tier 2 engines typically use 0-gauge battery cables to ensure reliable starting in extremely cold weather. Units with Tier 1 and earlier engines typically use 2-gauge negative battery cables and 4-gauge positive battery cables. Make sure to use the t he 0-gauge battery cables when replacing the battery cables for a Tier 2 engine. Refer to the unit Parts Manual for f or the correct part numbers. Do not use the 0-gauge battery cables on Tier 1 and earlier engines because the battery cables are sized to match the starter performance. Figure 238: Tier 1 and Earlier Earlier Starter Starter
Cold Weather Battery Recommendation for Tier 2 Engines Thermo King recommends that units with Tier 2 engines be equipped with a 950 CCA (cold cranking amp) battery for operation at temperatures below -15 F (-26 C).
Starter The Tier 1 and earlier engines and Tier 2 engines use different starters. The Tier 2 engine has a more powerful starter to ensure reliable starting in extremely cold weather. Identify the starters by looking at the through bolts. The Tier 2 starter has external through bolts, but the Tier 1 starter does not.
1 1.
Extern ernal Thro hrough Bolt
Figure 239: 239: Tier 2 Starter Starter
Other than the through bolts, the basic design is the same. Therefore, except where noted, the t he service procedures are the same. Do not try to put a Tier Tier 1 starter on a Tier Tier 2 engine. The Tier 1 starter does not fit on the Tier 2 engine because it is too long. The Tier 2 starter does fit on the Tier 1 engine. The Tier 2 starter requires heavier battery cables (see “Battery Cables” above). Cables” above).
123
Electrical
TK482/TK486 Starters Not Interchangeable with di2.2/se2.2 Starters The starters for Yanmar TK482/TK486 engines are not interchangeable with starters for Isuzu di2.2/se2.2 engines. Although the starters will fit, the diameter of the pinion gear is different: •
Star Starte ters rs for for TK4 TK482 82/T /TK4 K486 86 eng engin ines es hav havee a 1.38 in. (35.1 mm) diameter pinion gear.
•
Starte Starters rs for for di2. di2.2/s 2/se2 e2.2 .2 engi engines nes have have a 1.25 1.25 in. in. (31.8 mm) diameter pinion gear.
If the wrong starter is installed, the pinion will not mesh properly with the ring gear on the flywheel, fl ywheel, resulting in failure of both the t he ring gear and the starter.
1 1.
Pini Pinion on Gea Gearr Diam Diamet eter er 1.2 1.25 5 in. in. (31. (31.8 8 mm) mm) Figure 241: di2.2/se2.2 di2.2/se2.2 Starter Starter
1
1.
Pini Pinion on Gea Gearr Diam Diamet eter er 1.3 1.38 8 in. in. (35. (35.1 1 mm) mm) Figure 240: TK482/TK486 TK482/TK486 Starter Starter (Tie (Tierr 1 and and Earl Earlie ierr Show Shown) n)
124
Electrical
Description The major components of the starter are the starter motor, the starter solenoid, and the pinion assembly. assembly. The starter motor turns the pinion pini on assembly with a small gear on the end of the armature.
2 1 3 4 5
2 1 3 4
AGA138
7
6
5
AGA139
7
1.
Heavy Du Duty Co Contacts
2.
Starter Solenoid
3.
Shift Lever
4.
Pinion Assembly
5.
Pinion Gear
6.
Ring Gear
7.
Starter Motor
6
Figure 242: De-energized De-energized Starter Starter
When the starter solenoid is energized, it energizes the starter motor through a set of heavy duty contacts. When the starter solenoid is energized, it also pulls the shift lever. lever. This extends the pinion gear to engage the ring gear on the t he engine’s engine’s flywheel. The pinion assembly includes an overrunning clutch that allows the pinion gear to turn freely if the engine is turning faster than the starter while the starter is energized.
1.
Heavy Du Duty Co Contacts
2.
Starter Solenoid
3.
Shift Lever
4.
Pinion Assembly
5.
Pinion Gear
6.
Ring Gear
7.
Starter Motor
Figure 243: Energized Energized Starter Starter
Disassembly 1. Disconnec Disconnectt the stator stator lead lead from from the M terminal terminal on the starter solenoid. 2. Remove Remove the two two 4x10 4x10 mm mm screws screws from from the rear cover. These screws fasten the brush holder assembly to the rear r ear cover. 3. Remove Remove the the two two through through bolt boltss from the the rear rear cover and remove the rear cover from the starter motor. motor. 4. Place the brush springs springs on on the the sides sides of the the brush holders. 5. Remove Remove the the positi positive ve brushes brushes (the brushes brushes connected to the stator) from the brush holders.
125
Electrical
10 9 11 6
7
8
12 13
5
14
4 15 2
3
16 17
1
18 19
20
AGA140
21
1.
Pinion Shaft
12 .
Shims
2.
5x16 mm Screw
13 .
Plunger
3.
Pinion Assembly Retainer
14 .
Shift Lever Spring
4.
Clutch
15 .
Shift Lever
5.
Pinion Return Spring
16.
4x10 mm Screw
6.
Stop Ring
17.
Through Bolt
7.
Snap Ring
18 .
Rear Cover
8.
6x35 mm Bolt
19 .
Brush Ring
9.
Gear Housing
20.
Stator
10 .
Dust Cover
21 .
Armature
11.
Start tarter er Sole Soleno noid id Figure 244: 244: Starter Starter Assembly Assembly
126
Electrical
6. Pull Pull the negat negative ive brus brushe hess (the brus brushes hes connected to the brush holder assembly) part way out of the brush holders and place the brush springs on top of the brush holders against the sides of brushes. This is called the locked position and it holds the brushes in place off the commutator. 7. Remov Removee the brus brush h holder holder asse assembl mbly y from from the commutator.
AEA370
8. Remove Remove the the armatur armaturee and and stator stator from the gear housing. 9. Remove Remove the the armat armature ure from from the the stator stator..
Figure 245: 245: Check Brush Brush Holders Holders
10. Remove the two 6x35 mm bolts that fasten the starter solenoid to the gear housing. 11. Remove the starter solenoid, shims, shift lever spring, shift lever, and dust cover from the gear housing. 12. Remove the three 5x16 mm screws from the pinion assembly retainer and remove the pinion assembly from the gear housing.
AEA371
Major Component Inspection Starter Motor 1. Check Check the the brus brush h ring ring asse assembl mbly y. a. Check Check the brush brush holde holders rs with an ohmmeter. ohmmeter. The positive brush holders should have infinite resistance to the brush ring plate. The negative brush holders should have continuity to the brush ring plate.
Figure 246: Measure Brushes
c. Check Check the the brus brush h sprin springs. gs. Replac Replacee the the brush springs if they are discolored, deformed, or if the spring tension is less than 7.1 lb (3.2 kg). The spring tension should be checked with the brush ring assembly installed on the commutator. commutator.
b. Check Check the the brushe brushes. s. Repla Replace ce the the brushe brushess if they are chipped or cracked, or measure less than 0.4 0.4 in. (9 mm) on the short short side. Replace the brushes as a set, or replace the brush ring assembly.
127
Electrical
2. Chec Check k the the sta stato torr.
3. Chec Check k the the arma armatu ture re..
a. Check Check the the field field coil coil with with an ohmm ohmmete eterr. There should be continuity between the stator lead and both positive brushes. Replace the stator if there is no continuity or high resistance in the field coil.
a. To check check the the beari bearings ngs,, turn turn them them by hand. hand. Replace the bearings if they are rough or seem loose. b. Visually isually check check the armature. armature. Replace Replace the armature if there is any sign of thrown solder, discolored windings, bubbled insulation, burned or damaged commutator bars, damaged shafts, or a damaged gear. c. Place Place the the armatu armature re in a lath lath and check check the the commutator and the core with a dial indicator. indicator. The distortion, run out, or out of round should not exceed 0.008 in. (0.2 (0.20 0 mm). mm).
AEA373
2
1
Figure 247: 247: Check Field Field Coil Coil
b. Check Check the the stat stator or insu insulat lation ion with with an ohmmeter set on the Rx1000 scale. There should be infinite resistance between the stator lead and the stator frame. Replace the stator if there is any continuity between the stator lead and the stator frame.
AGA141
1.
Commutator
2.
Core
Figure 249: Check Armature Armature Distortion Distortion
d. Turn Turn the the commu commutat tator or or the the core core down down if they exceed this limit. Also turn the commutator down to remove any wear grooves made by the brushes. e. Replac Replacee the armatu armature re if the the comm commuta utator tor has an outside diameter that is less than 1.40 in. (35.5 mm) after being turned t urned down. f. If the the commu commutat tator or is only only dirty dirty,, clean clean it up up with 500-600 grit sandpaper. sandpaper. AEA373
Figure 248: Check Stator Stator Insulation Insulation
128
Electrical
h. Check Check the the armatu armature re coils coils with with a grow growler ler and an ammeter. Place the ammeter leads on each pair of commutator bars that are directly opposite each other. The ammeter will show no current in an open coil and lower than normal current in a shorted coil. Replace the armature if any of the coils are defective. i.
AEA375
Check Check the armatu armature re insula insulatio tion n with with an ohmmeter set on the Rx1000 scale. There should be infinite resistance between each commutator bar and the armature core or shafts. Replace the armature if there is any continuity between the armature coils and the core.
Figure 250: 250: Clean Up Commuta Commutator tor
g. After turning turning down down the commutator commutator,, check check the undercut of the mica. The standard undercut is 0.02 to 0.03 in. (0.5 to 0.8 mm). Cut the undercu undercutt down to the proper depth if it is i s less than 0.01 in. (0.2 (0.2 mm). mm). 2 1
AEA377
Figure 252: Check Armature Armature Insulation Insulation
Pinion Assembly 3
AGA142
1.
Correct
2.
0.02 0.02 to 0.03 0.03 in. in. (0. (0.5 5 to to 0.8 0.8 mm mm))
3.
Incorrect
Figure 251: Check Commutator Commutator Undercut Undercut
1. Inspect Inspect each each part of the the pinion pinion assembly assembly and replace any part that shows significant wear or damage. Push the stop ring off the snap ring and remove the snap ring from the end of the pinion shaft to disassemble the pinion assembly. 2. Check Check the overru overrunni nning ng clutch clutch.. a. Hold Hold the the pinio pinion n clutc clutch h assem assembly bly.. b. Place Place the the pinion pinion shaf shaftt in the pinio pinion n clutch clutch and try to rotate the pinion shaft in both directions.
129
Electrical
c. The pinion pinion shaf shaftt should should rota rotate te freel freely y in one direction and should not rotate in the other direction. d. Replac Replacee the the pinion pinion clut clutch ch if the the pini pinion on shaft does not rotate smoothly in the proper direction, or if it rotates in both directions.
3. Push the plunger plunger in in and and check check the continuity continuity between the B terminal and the M terminal on the starter solenoid. Replace the starter solenoid if there is no continuity or high resistance.
Starter Solenoid 1. Check Check the the continu continuity ity betwee between n the the S terminal terminal and the chassis on the starter solenoid. Replace the starter solenoid if there is no continuity or high resistance. r esistance.
AGA145
Figure 255: Check Contact Contacts s
Assembly AGA143
Figure 253: 253: Check Shunt Shunt Coil Coil
2. Check Check the the continu continuity ity betwee between n the the S terminal terminal and the M terminal on the starter solenoid. Replace the starter solenoid if there is no continuity or high resistance. r esistance.
1. Place the pinion pinion assemb assembly ly in the gear housing housing and install the three 5x16 mm screws. 2. Place the shims and the shift shift lever lever spring over the plunger in the starter solenoid. 3. Place Place the the shift shift lever lever in the the hole hole in the end end of the plunger, and place the shift lever spring in the notch in the t he shift lever.
AGA146 AGA144
Figure 254: 254: Check Series Series Coil Coil
130
Figure 256: Install Install Shift Lever and Spring Spring
Electrical
4. Place Place the asse assembl mbled ed starte starterr solenoi solenoid d (with shift lever) and the dust cover in the gear housing.
2
3
1
5. Fasten Fasten the the starter starter soleno solenoid id to the gear housing housing with the two 6x35 mm bolts. 6. Place Place the the arma armatur turee in the the stat stator or.. 4
7. Place Place the the armatur armaturee and and the the stator stator in the the gear gear housing. Make sure the armature bearing is seated in the gear housing. 8. Make Make sure sure the nega negativ tivee brushe brushess are in in the locked position and place the brush ring on the commutator.
5 AGA147
9. Place Place the the positiv positivee brushe brushess in the brus brush h holders. 10. Move the brushes brushes and the brush holders holders to their normal positions. Make sure that the brushes move freely in the brush holders and that the brush springs hold the brushes against the commutator. 11. Place the rear rear cover in position on the the armature and stator. Make sure the armature bearing is seated in the rear cover. 12. Install Install the two through through bolts. bolts.
1.
Battery
4.
Tachometer
2.
Ammeter
5.
Voltmeter
3.
Switch Figure 257: 257: No Load Test Test
Air Heater The air heater is mounted on the open end of the intake manifold. It heats the intake air to help the engine start in cold weather. weather.
13. Install the two 4x10 mm screws screws that fasten the brush holder assembly to the rear cover.
1
14. Connect the stator lead to the M terminal on the starter solenoid.
No Load Test CAUTION: Do not run the starter without a load for more than 30 seconds. seconds. AEA693
1. Clamp Clamp the starte starterr in a vise vise.. 2. Conne Connect ct the star starter ter to a 12 12 volt volt batter battery y as shown in the illustration. 3. When When the switch switch is is turned turned on, chec check k the current, voltage, and starter speed. The standard values are: 140 amps, 11 volts, and 3900 3900 rpm. rpm.
1.
M6 Terminal
Figure 258: Air Heater
Check the resistance of the air heater with an ohmmeter between the M6 terminal on the front of the air heater and the screw on the back of the air heater (or the air heater case). The resistance should be 0.14 ± 0.02 ohms.
131
Electrical
Check the current draw of the air heater with a clamp-on ammeter at the H1 wire near the M6 terminal on the front of the t he air heater. During preheat the current draw should be approximately 70 amps. The air heater is defective if the resistance is more than 0.2 ohms and the current draw is less than 60 amps, or if the current draw is more than 100 amps.
Fuel Solenoid See “Fuel Solenoi Solenoid” d” on page 153 for 153 for information about the different versions of the fuel solenoid. When the fuel solenoid is energized, it places the fuel rack in the on position. This allows fuel f uel to flow in the fuel injection i njection pump. The fuel solenoid has two coils, the pull-in coil and the hold-in coil. The pull-in coil must be momentarily energized to place the fuel rack in the on position. The energized hold-in coil can then hold the fuel rack in the on position. Use the following procedure to test the fuel solenoid. NOTE: On some units units the 8D circuit goes goes through the HPCO (high pressure cutout switch). Check for an intermittent contact contact in the HPCO if the engine starts, starts, but then stops stops because the fuel fuel solenoid de-energizes, de-energizes, and the fuel solenoid passes passes the following tests. tests. 1. Place Place a jumpe jumperr wire betw between een the the black black wire wire (CH - pin C) in the fuel solenoid connector and a good chassis ground.
make a definite click when the pull-in coil is energized and should click again when the pull-in coil is de-energized. de-energized. NOTE: The pull-in coil will draw draw 35 to 45 amps so do not leave the jumper jumper connected connected to the white wire (8DP - pin pin B) for more than a few seconds. a. If the the pull-i pull-in n coil coil does does ener energiz gize, e, go go to step 3. b. If the pull-in coil does not energ energize, ize, check check the resistance of the pull-in coil by placing an ohmmeter between the white wire (8DP - pin B) and the black wire (CH - pin C) in the fuel solenoid connector. The resistance of the pull-in coil should be 0.2 to 0.3 ohms. If the resistance of the pull-in coil is not in this range, replace the fuel solenoid. 3. Test est the the hol holdd-in in coil. coil. a. Energ Energize ize the the hold hold-in -in coil coil by by placin placing ga jumper between the red wire (8D - pin A) in the fuel solenoid connector and the positive battery terminal. b. Momen Momentari tarily ly ener energiz gizee the pull-i pull-in n coil by by placing a jumper between the white wire (8DP - pin B) in the fuel solenoid connector and the positive battery terminal. The fuel solenoid should make a definite click when the pull-in coil is is energized, but should not click when the pull-in coil is de-energized. c. De-ene De-energ rgize ize the the holdhold-in in coil coil by remov removing ing the jumper from the white wire (8DP - pin B) and the positive battery terminal. The fuel solenoid should make a definite click when the hold-in coil is de-energized.
AEA633
1.
Red (8D)
2.
White (8DP)
3.
Black (CH)
Figure 259: Fuel Solenoid Solenoid Connecto Connectorr Pin Identif Identificat ication ion
2. Test the the pull-in pull-in coil coil by by momenta momentarily rily placin placing ga jumper between the white white wire (8DP - pin B) in the fuel solenoid connector and the positive battery terminal. The fuel solenoid should 132
d. If the the holdhold-in in coil coil does does not not funct function ion properly, properly, check the resistance of the hold-in coil by placing an ohmmeter between the red wire (8D - pin A) and the black wire (CH - pin C) in the fuel solenoid connector. connector. The resistance r esistance of the hold-in coil should be 24 to 29 ohms. If the resistance of the hold-in coil is not in this range, replace the fuel solenoid.
Electrical
Fuel Solenoid Replacement
Fuel Solenoid Timer
This procedure assumes the engine is mounted in the unit. If the engine is not in the unit, use jumper wires to energize the fuel solenoid at the three pin connector. connector. Place a jumper between the black wire (CH - pin C) and ground (–). Place a jumper between the red wire (8D - pin A) and 12 Vdc (+). Momentarily place a jumper between the white wire (8DP - pin B) and 12 Vdc (+).
Some units use a fuel solenoid timer to momentarily energize the pull-in coil in the fuel solenoid. (This function is built into the relay or interface boards on later controllers such as the µ P-VI and SR-2.) The fuel solenoid timer consists of a small PC board that contains some electrical components, a four-pin wire connector, connector, and one removable relay. relay. The relay is called the fuel solenoid relay. relay. The fuel solenoid timer ti mer is typically mounted inside the control box. There are two styles of fuel solenoid timers (see “Fuel Solenoid Timer” Timer” on page 153). 153). Both styles function the same and are interchangeable.
1. Disconnec Disconnectt the the fuel fuel solenoid solenoid wire connector connector and remove the old fuel solenoid. 2. Connect Connect the fuel solenoid solenoid wire connector connector to the new fuel solenoid. 3. If necess necessary ary,, disable disable the the engine engine reset reset switch switch or the CYCLE-SENTRY CYCLE-SENTRY system on units so equipped.
1
2
4. Turn Turn the the unit unit on to energ energize ize the the fuel fuel solenoid. solenoid. Use the Service Test Mode to energize the fuel solenoid if the unit has a microprocessor. NOTE: The fuel solenoid solenoid must be energized energized when it is being installed. If not, the plunger and the linkage linkage may not line up correctly correctly and the fuel solenoid will not function function properly. properly. 5. Place Place the the O-ring O-ring in in the groove groove in the the end end of the fuel injection pump. Make sure the O-ring is positioned correctly during installation to avoid damage and leaks. 6. Instal Installl the the new new fuel fuel sole solenoi noid. d. 7. Turn Turn the the unit unit off off and make sure to enable enable any disabled systems.
AEA635
1.
Fuel Solenoid
2.
O-ring
3.
Groo Groov ve in in Fue Fuell Inj Injec ecti tion on Pum ump p
Figure 260: Fuel Solenoid Solenoid Components Components
AGA337
1.
Four-Pin Co Connector
2.
Fuel Fuel Sole Soleno noid id Re Rela lay y (FS (FSR R)
Figure 261: 261: Fuel Solenoid Solenoid Timer Timer
Fuel Solenoid Timer Operation The fuel solenoid hold-in coil is connected to the 8D circuit. The fuel solenoid relay coil is also connected to the 8D circuit and it is grounded through the fuel solenoid timer. The fuel solenoid pull-in coil is connected to the 2A circuit through the normally open contacts of the fuel solenoid relay when the fuel solenoid relay is energized. When the 8D circuit is energized, it supplies power to the fuel solenoid hold-in coil and to the fuel solenoid relay coil. The hold-in coil is energized and remains energized as long as there is power on 8D. The fuel solenoid relay is energized momentarily by the fuel solenoid timer when the 8D circuit is first fir st energized. After approximately 2.5 seconds, the fuel solenoid timer de-energizes de-energizes the fuel solenoid relay by opening the circuit to ground.
133
Electrical
During the time the fuel solenoid relay is momentarily energized, the fuel solenoid pull-in coil is energized by the 2A circuit through the normally open contacts of the fuel solenoid relay and the 8DP circuit. When power is removed from the 8D circuit the t he fuel solenoid hold-in coil is de-energized, and the fuel solenoid resets. 1 2
2. Turn Turn the the unit unit on to energ energize ize the the fuel fuel solenoid solenoid circuits. If the unit has a microprocessor mi croprocessor,, use the microprocessor keypad to enter the t he Relay Board Test Mode. Energize the fuel solenoid circuits by energizing the run relay [RUNR] with the Relay Board Test Mode. 3. Check Check the the voltag voltagee on the the 8D circui circuitt (pin A) A) in the main wire harness connector for the fuel solenoid. Refer to the following illustrations to identify the pins in the wire connectors. a. If batte battery ry volta voltage ge is not pres present ent on on the 8D circuit, check the 8D circuit and the related circuits and components for a fault. b. If batte battery ry volta voltage ge is prese present nt on the the 8D 8D circuit, go to step 4.
3
AEA704
AGA310
5
4
1.
Fuel Fuel Sole Soleno noid id Re Rela lay y Cont Contac actts
2.
Fuel Fuel Sol Solenoi enoid d Pul Pulll-In In Coil oil
3.
Fuel Fuel Sol Solenoi enoid d Hol Holdd-In In Co Coiil
4.
Fuel So Solenoid Ti Timer
5.
Fuel uel So Solenoid oid Re Relay Co Coil
Figure 263: 263: Main Wire Wire Harness Harness Connect Connector or Pin Identifi Identificati cation on
Figure 262: Simplified Simplified Schematic Schematic Diagram of Fuel Solenoi Solenoid d System System
Troubleshooting the Fuel Solenoid Timer System NOTE: The fuel solenoid solenoid pull-in coil will require 35 to 45 45 amps to turn on the fuel. The unit’s unit’s battery must be in good condition. If the battery has enough enough power to crank crank the engine over, over, it has enough power power to energize energize the fuel solenoid pull-in coil. If you suspect that the engine does not run because the fuel solenoid is not operating correctly, correctly, use the following procedure: 1. Disconnec Disconnectt the the fuel fuel soleno solenoid id wire wire connector connector from the main wire harness.
134
AEA633
1.
Red (8D)
2.
White (8DP)
3.
Black (CH)
Figure 264: Fuel Solenoid Solenoid Connect Connector or Pin Identifi Identificati cation on
4. Check Check the the CH circu circuit it (pin (pin C) in the the main main wire wire harness connector for continuity to a good chassis ground. a. If there there is is no cont continu inuity ity betw between een the CH CH circuit and a good chassis ground, check the CH wire for an open circuit. b. If there there is is conti continui nuity ty betwe between en the the CH circuit in the main wire harness at the t he fuel solenoid wire connector and a good chassis ground, go to step 5.
Electrical
5. Place Place a jumpe jumperr wire betw between een the the black black wire wire (CH—pin C) in the fuel solenoid connector and a good chassis ground. 6. Test the the pull-in pull-in coil by momenta momentarily rily placin placing ga jumper between the white wire (8DP—pin B) in the fuel solenoid connector and the positive battery terminal. The fuel solenoid should make a definite click when the pull-in coil is energized and should click again when the pull-in coil is de-energized. de-energized. NOTE: The pull-in coil will draw draw 35 to 45 amps so do not leave leave the jumper connected connected to the white wire (8DP—pin B) for more more than a few seconds. a. If the pull pull-in -in coil coil does does not ener energiz gize, e, check check the resistance of the pull-in coil by placing an ohmmeter between the white wire (8DP—pin B) and the black wire (CH— pin C) in the fuel solenoid connector. The resistance of the pull-in coil should be 0.2 to 0.3 ohms. If the resistance of the pull-in coil is not in this range, replace the fuel solenoid. NOTE: If the pull-in coil fails, make make sure to replace the fuel solenoid solenoid relay with relay P/N 41-893. This particular particular relay is needed needed for the high current current flow through the hold-in coil. b. If the the pull-in pull-in coil coil does does ener energiz gize, e, go go to step 7. 7. Test est the the hol holdd-in in coi coil. l. a. Energ Energize ize the the hold hold-in -in coil coil by by placin placing ga jumper between the red red wire (8D—pin A) in the fuel solenoid connector and the positive battery terminal. b. Moment Momentari arily ly ener energiz gizee the pull-i pull-in n coil by by placing a jumper between the white wire (8DP—pin B) in the fuel solenoid connector and the positive battery terminal. The fuel solenoid should make a definite click when the pull-in coil is is energized, but should not click when the pull-in coil is de-energized. de-energized.
c. De-ene De-energi rgize ze the the hold-i hold-in n coil coil by remov removing ing the jumper from the red wire (8D—pin A) and the positive battery terminal. The fuel solenoid should make a definite click when the hold-in coil is de-energized. d. If the the holdhold-in in coil coil doe doess not not functi function on properly, check the resistance of the hold-in coil by placing an ohmmeter between the red wire (8D—pin A) and the black wire (CH—pin C) in the fuel f uel solenoid connector. connector. The resistance of the hold-in coil should be 24 to 29 ohms. If the resistance of the hold-in coil is not in this range, replace the fuel solenoid. e. If the holdhold-in in coil coil does does functio function n properl properly y, go to step 8. 8. Reconnec Reconnectt the fuel solenoid solenoid conne connector ctor and the main wire harness connector. connector. 9. Remove Remove the fuel solenoid solenoid relay relay from its its socket socket and make sure the unit is turned on, and is in the Relay Board Test Test Mode [RUNR] if it has a microprocessor. 10. Check the voltage on the 8D circuit at the 86 terminal in the fuel solenoid relay socket. Refer to the following illustration to identify the terminals in the relay socket. a. If batte battery ry volta voltage ge is not pres presen entt on the the 8D circuit, check the 8D circuit and the related circuits and components for a fault (minimum voltage is 10 volts). b. If batte battery ry volta voltage ge is presen presentt on the the 8D circuit, go to step 11. 11. 1
4
2
3
1.
30 Termi ermina nal— l—2A 2A Circ Circui uitt
2.
86 Terminal nal—8D Wire
3.
87 Te Termina minall—8DP Wi Wire
4.
85 Termi ermina nall to to Cap Capac acit itor or and and Dio Diode de
Figure 265: Relay Socket Terminal Terminal Identification Identification
135
Electrical
11. Check the voltage on the 2A circuit at the 30 terminal in the fuel solenoid relay socket. a. If volta voltage ge is not pres present ent on on the 2A circu circuit, it, check the 2A circuit for an open or a short. b. If batte battery ry volta voltage ge is presen presentt on the the 2A circuit, go to step 12. 12. 12. Test the relay. relay. a. Use a jumpe jumperr to conn connect ect the 86 term termina inall on the relay to the positive battery terminal. b. Use anothe anotherr jumper jumper to to connec connectt the 85 85 terminal on the relay to a CH circuit. c. If the the relay relay does does not not ener energiz gize, e, it it is defective. Replace the relay. d. If the the relay relay does does energ energize ize,, the timer timer is defective. Replace the fuel solenoid timer PC board. 13. Turn the unit Off after completing the test procedure.
136
Run In The run in of a rebuilt engine will often determine the oil consumption, power output, and other variables during the service life of the engine. It is important to run in a rebuilt engine properly. properly. How an engine will be run in is determined by the type of equipment and the time that is available. Thermo King recommends an engine be run in on a dynamometer if possible.
Dynamometer Run In Procedure 1. Pressurize Pressurize the lubrication lubrication system system of the engine engine with an oil pressure tank if the t he engine has been stored for any length of time. This prevents a dry start. 2. Start Start the the engine engine and and run run it at 1450 1450 rpm rpm with a load that is 6 to 8% of the engine’s rated output for a short time. 3. Run the the engin enginee at 1450 1450 rpm rpm with with a load load that that is 15% of the engine’s engine’s rated output for 15 minutes. 4. Run the the engin enginee at 2200 2200 rpm rpm with with a load load that that is 22 to 25% of the engine’s rated output for 30 minutes. 5. Run the the engin enginee at 1450 1450 rpm rpm with with a load load that that is 15% of the engine’s engine’s rated output for 30 minutes. 6. Run the the engin enginee at 2200 2200 rpm rpm with with a load load that that is 30 to 35% of the engine’s rated output for 10 minutes. 7. If time time permit permits, s, addit addition ional al run run in time time is desirable. Vary the speed and load in ranges between 1450 to 2200 rpm and 10 to 25% of the engine’s rated output.
CAUTION: DO NOT run a newly rebuilt engine without a load for a long period of time. This can cause cause the engine’s engine’s oil consumption to be higher than normal. normal. 2. Mount the engine engine in a unit and run the the unit unit on on high speed heat for 2 hours. Occasionally place the unit in low speed heat to vary the compression pressures and engine temperatures. 3. Mount Mount the the unit unit on a truc truck k and and run the the unit unit in in high speed heat with truck doors open for 2 to 10 hours.
Valve Clearance Adjustment 1. Remove Remove the rocke rockerr arm arm cove coverr. 2. Remove Remove the the round round cove coverr (plug) (plug) from from the the timing mark access hole on the front of the bell housing. CAUTION: Loosen all of the injection lines at the injection nozzles to prevent the possibility of the engine engine firing while it is being rotated. rotated. 3. Place Place the the engine engine at at top dead dead cent center er of the the compression stroke for the number one cylinder. cylinder. The number 1 cylinder is on the flywheel (rear) end of the engine. a. Rotate Rotate the the engi engine ne in the norm normal al direc directio tion n of rotation (clockwise viewed from the water pump end) until the 1-4 timing ti ming mark on the flywheel lines up with the index mark in the timing mark access hole. 1
2
Run In Procedure without Dynamometer 1. Run the engin enginee on a test test stand stand with no load load for for approximately 15 minutes in both low speed (1450 rpm) and high speed (2200 rpm). Check the engine for abnormal noises, coolant, fuel, or oil leaks.
AEA701
1.
Index Mark
2.
Top De Dead ad Ce Cent nter er Ma Mark rk for for 1 and and 4
Figure 266: Top Dead Center One and Four Four 137
Run In
b. Check Check the the rocker rocker arms arms on on the numb number er one one cylinder to see if they are loose. c. If the the rocker rocker arms arms are are loose loose,, the engi engine ne is at top dead center of the compression stroke for the number one cylinder.
5. Adjust Adjust the valves valves if necessary necessary by loose loosening ning the lock nut and turning the adjustment screw until the valve clearance is correct. 1 2
d. If the the rocker rocker arms arms are are tight, tight, the the engi engine ne is at at top dead center of the exhaust stroke for the number one cylinder. Rotate the engine 360 degrees to place the engine at top dead center of the compression stroke for the number one cylinder. 4. Use a feeler feeler gaug gaugee to chec check k the valve valve clearance on both valves for the number one cylinder, the intake valve for the number two cylinder, and the exhaust valve for the number three cylinder. The valve clearance for both the intake valves and tthe he exhaust valves should be 0.006 to 0.010 in. (0.15 to 0.25 0.25 mm). mm).
AGA148
1.
Adjustment Screw
2.
Lock Nut
Figure 267: 267: Valve Clearance Clearance
6. Hold Hold the adju adjustm stment ent scre screw w in place place and tighten the lock nut.
NOTE: Check to make sure that the valve stem cap is in good condition and is positioned squarely squarely on the top of the valve valve stem. Replace the valve stem cap if it shows significant wear. wear.
AGA114
Figure 268: Adjusting Adjusting Valves Valves
Valve Adjustments and Cylinder Configurations Rear Flywheel End Cylinder No. Valve arrangement Piston in No. 1 cylinder is at TDC on compression stroke Piston in No. 4 cylinder is at TDC on compression stroke
138
Front Pulley End
1 E
2 I
E
3 I
E
4 I
E
I
Run In
7. Rechec Recheck k the the valv valvee clea clearan rance ce.. 8. Rotate Rotate the the engine engine one full turn (360 degrees) degrees) in the normal direction of rotation (clockwise viewed from the water pump end), and align the 1-4 timing mark on the t he flywheel with the index mark in the timing mark access hole. This is top dead center of the compression stroke for the number four cylinder. 9. Check Check and and adjust adjust the exhaust exhaust valve valve for for the number two cylinder, the intake valve for the number three cylinder, and both valves for the number four cylinder. 10. Replace the rocker rocker arm cover, cover, the cover for the timing mark access hole, and tighten the fuel injection lines when finished.
Compression Test Compression Test Equipment A TK482/486 adapter (P/N 204-1056) is now available for compression tester (P/N 204-542). An adapter can be fabricated, but it must meet the following guidelines. If not, the compression readings will not be accurate. Combustion chambers in diesel engines are relatively small, and the compression ratios are relatively high. Therefore, to obtain accurate and consistent compression readings: •
The The adap adapte terr used used to to conn connec ectt a comp compre ress ssio ion n tester to an engine must closely approximate the size and shape of the part being replaced.
•
A Schr Schrade aderr valv valvee must must be instal installed led in the end end of the adapter that is facing the combustion chamber.
•
The compre compressi ssion on tester tester and connec connectin ting g hose hose must have a small internal volume.
Compression Test Procedure 1. Run the the engin enginee until until it reach reaches es the the normal normal operating temperature and then stop the engine.
NOTE: The compression compression should be tested tested when the engine is near the normal operating temperature. temperature. If it is not possible possible to run the engine, follow the rest of this procedure. The The compression pressures will will be approximately 10 percent lower than those on a warm engine. 2. Discon Disconnec nectt the wires wires from from the fuel fuel solenoi solenoid d and loosen the injection lines at the injection nozzles. CAUTION: The fuel solenoid must be disconnected and and the injection lines must must be loosened loosened to prevent the injection of fuel into the cylinders during the test. If a cylinder fires during the test, the resulting resulting pressure will destroy destroy the test equipment. equipment. The manufacturer of the test equipment disclaims all responsibility responsibility for damage or injury resulting from a cylinder firing during the test. 3. Remove Remove all all of the the fuel fuel injecti injection on nozzl nozzles. es. 4. Disco Disconne nnect ct the air clean cleaner er.. 5. Connect Connect the the compres compression sion tester tester (P/N (P/N 204-542 204-542)) to a cylinder with the TK482/486 adapter (P/N 204-1056). 6. Turn Turn the engi engine ne over over with with the star starter ter and and observe the pressure gauge. Stop cranking the engine when the pressure stabilizes. 7. Note the final reading, reading, release release the pressure, pressure, and disconnect the tester. tester. 8. Repeat Repeat this this procedure procedure on each cylinder cylinder.. 9. Compar Comparee the fina finall readin readings gs of all all the the cylinders. 10. An engine in good condition will have a minimum compression pressure of approximately 400 psi (2758 kPa) at cranking speed (250 rpm) using the Thermo King compression tester (P/N 204-542) and the TK482/486 adapter (P/N 204-1056). 11. Because the compression pressures will vary vary depending on what kind of equipment is used, the most important factor is the variation between cylinders. The variation between cylinders should not exceed 10 percent.
139
Run In
140
Special Procedures Checking Oil Pump
5. Remove Remove the sound sound shield shield and and gear gear case case cover cover..
Use the following procedure to check the oil pump without removing the engine from the unit. 1. Remo Remove ve the the bel belts ts.. 2. Remov Removee the the fuel fuel transf transfer er pump. pump. 3. Early engines engines have have an oil oil line line connec connected ted to to the gear case cover. Disconnect Disconnect the oil line from the gear case cover or remove it from the engine.
Figure 271: 271: Remove Sound Sound Shield Shield and and Gear Gear Ca Case se Cove Coverr
NOTE: On Tier Tier 2 engines the oil oil pump is located in the gear case cover. 1
2
5
3 4
1 2
AGA01
1.
Oil Oil Li Line (Ear (Early ly Engi Engine nes s Onl Only) y)
2.
Transfer Pump
Figure 269: Early Engine Engine Shown Others Similar Similar
4. Remov Removee the the crank cranksha shaft ft pulle pulley y.
1.
Crankshaft Gear
4.
Inner Rotor
2.
Oil Pump Cover
5.
Gear Case Cover
3.
Outer Rotor
Figure 272: 272: Oil Pump Located Located in Gear Case Cover Cover on Tier 2 Engines
Figure 270: Remove Crankshaf Crankshaftt Pulley 141
Special Procedures
6. Remove Remove the the oil oil pump pump from from Tier Tier 1 and and earlie earlierr engines.
NOTE: On Tier Tier 1 and earlier earlier engines you can sometimes sometimes see if the intake intake pipe gasket gasket is out of place by using using a light to look between between the gear case and the engine block below where the oil pump mounts.
1 1. Figure 273: 273: Remove Oil Oil Pump Tier Tier 1 and and Earl Earlie ierr Engi Engine nes s
7. Insp Inspec ectt the the oil oil pump pump.. See See “Oil Pump for Tier 1 and Earlier Earlier Engines” Engines” on page page 61, 61, or “Oil Pump for Tier Tier 2 Engines” on page 62. 62. Replace the oil pump if it is defective. If the oil pump is not defective, pull the engine and remove the oil pan. Check the inlet screen, the intake pipe, the intake pipe gasket or o-ring, and pressure check engine for internal leaks.
Look Th Through H He ere
Figure 274: Check Intake Intake Pipe Gasket Gasket Tier Tier 1 and and Earl Earlie ierr Engi Engine nes s
8. Instal Installl the oil oil pump pump on on Tier Tier 1 and and earlie earlierr engines. 9. Coat Coat the lip lip of the the front front seal seal with engi engine ne oil. oil. 10. Place new O-rings (Tier (Tier 2 engines only) in the gear case. NOTE: Tier Tier 1 and earlier engines engines do not use use these O-rings. 1
1
2 1.
Dowel Pins
2.
O-Ri O-Ring ngs s (Tie (Tierr 2 Engi Engine nes s Only Only)) Figure 275: Gear Case
142
Special Procedures
11. Place a thin layer of sealant sealant on the sealing sealing surface of the gear case cover. 12. Place the gear gear case cover cover in position and make sure to align the dowel pins. NOTE: The oil pump is located in the timing gear cover cover on on Tier Tier 2 engines. The inner rotor of the oil pump fits around around the crankshaft crankshaft gear. gear. Make sure that the flat sides of the inner rotor are aligned with the flat sides on the crankshaft crankshaft gear when installing installing the timing gear cover. cover. 1
2
16. Install the crankshaft crankshaft pulley and and align it with the dowel pin in the crankshaft gear. Torque the mounting bolt to 83.2 to 90.4 ft-lb f t-lb (112.8 to 122.6 N•m). NOTE: Make sure to align align the dowel pin with the mating hole in the crankshaft pulley. If not, the pulley will not pull pull down on the tapered end of the crankshaft crankshaft and will be loose. The pulley can also crack where it contacts the the dowel pin. This can can cause the front seal to leak oil. Check Check the pulley for cracks if the front seal seal leaks. Replace Replace the dowel pin if it is damaged. damaged.
5
3
1
4
2
7
6
1.
Crankshaft Gear
2.
Oil Pump Cover
3.
Outer Rotor
4.
Inner Rotor
1.
Dowel Pin
5.
Timing Gear Cover
2.
Mati Ma ting ng Ho Hole le in Cran Cranks ksha haft ft Pull Pulley ey
6.
Flat Flat Side Sides s on Inne Innerr Rotor otor
7.
Flat Flat Side Side on Crank ranksh shaf aftt Gea Gearr
Figure 277: 277: Dowel Pin Pin Alignment Alignment
Figure 276: Align Flat Sides Sides of Crankshaft Gear with Flat Sides of Inner Rotor in Timing Gear Cover
13. Install and tighten tighten the gear gear case cover cover mounting bolts that are covered by the sound shield. 14. If the sponge on the back of the sound sound shield is damaged, replace it before installing the sound shield. 15. Place the sound sound shield in position and and install and tighten the mounting bolts. AGA124
Figure 278: Install Install Crankshaft Crankshaft Pulley
143
Special Procedures
17. On early engines, engines, attach or install the oil line that goes from the cylinder block to the t he fuel injection pump to the gear case cover.
16. Remove the oil pump from Tier 1 and earlier engines. On Tier 2 engines the oil pump is located in the gear case cover (see ( see page page 36). 36).
18. Install Install the fuel transfer transfer pump.
17. Remove the two bolts from the idler gear gear shaft (see page page 36). 36).
19. Install Install and tighten the belts. belts.
Gear Case Replacement The following outlines the procedure to replace a broken gear case. See the Engine Disassembly Chapter and the Engine Assembly Chapter for details about removing and installing the components. 1. Remove Remove the engine engine from from the the unit unit.. 2. Remo Remove ve the the val valve ve cove coverr (see (see page page 31). 31). 3. Remove Remove the rocker rocker arm assem assembly bly ( see page page 31). 31). 4. Remove Remove the valve valve stem stem caps caps ( see see page page 31). 31). 5. Remo Remove ve the the pus push h rod rodss (see (see page page 31). 31). 6. Remove Remove the oil oil line line that that goes goes from from the the cylinder block to the fuel injection pump and the gear case cover (see ( see page page 32). 32). 7. Remove Remove the the fuel fuel transf transfer er pump pump from from the gear gear case cover (see (see page page 32). 32).
18. Remove the idler gear and and the idler gear gear shaft from the cylinder block (se ( seee page page 36). 36). 19. Turn the engine upside down to make the tappets move off the camshaft and to prevent the tappets from interfering with the removal r emoval of the camshaft. 20. Remove the mounting bolts from the camshaft thrust plate by turning the camshaft gear to access the bolts through the holes in the gear (see page page 38). 38). 21. Carefully remove remove the camshaft camshaft to avoid scratching or marring the camshaft bearings. The engine must be upside down to prevent the tappets from interfering with the removal r emoval of the camshaft (see ( see page page 39). 39). NOTE: Make sure to keep the engine upside down until the camshaft camshaft is reinstalled. The tappets will will fall out of the block if the engine engine is turned right side up after the camshaft is removed.
8. Remove Remove the front front cranks crankshaf haftt bolt bolt (see (see page page 32). 32).
22. Remove the lower part of the oil pan (see (see page page 38). 38).
9. Remove Remove the the crank cranksh shaft aft pulle pulley y by using using a suitable puller (se (seee page page 32). 32).
23. Remove the four bolts that fasten fasten the upper upper part of the oil pan to the gear case.
10. Remove the gear case case cover and sound sound shield (see see page page 33). 33).
24. Remove the gear case. Also remove the two O-rings from the oil passages between the gear case and the cylinder block on Tier 1 and earlier engines (see (see page page 39). 39).
11. Note the timing marks marks on the timing gears. The timing marks must be aligned when the engine is assembled. 12. Remove the fuel injection pump gear nut and and lock washer (se (seee page page 33). 33). 13. Remove the fuel injection pump gear by using a suitable puller (see (see page page 33). 33). 14. Note the alignment alignment of the index index marks on the injection pump and the gear case (see ( see page page 35). 35). 15. Remove the fuel injection pump from the gear case (see (see page page 36). 36).
144
25. Clean all gasket gasket and sealing sealing surfaces. surfaces. 26. Place new O-rings (Tier 1 and earlier engines only) on the front of the t he engine block and make sure the dowel pins are in place ( see page page 75). 75). NOTE: Tier 2 engines do not not use these O-rings. 27. Place a thin layer of silicone sealant on the back and the bottom sealing surfaces of the gear case (see ( see page page 75). 75).
Special Procedures
28. Install the gear gear case. Make sure to align the dowel pins and tighten the mounting bolts (see ( see page page 75). 75). 29. Install and tighten the four four bolts that fasten the upper part of the oil pan to the gear case. 30. Place a thin layer of sealant sealant on the sealing sealing surface of the lower part of the oil pan. 31. Install Install the lower part part of the oil pan (see (see page page 81). 81). 32. Lubricate the camshaft camshaft bearing, journals, and lobes with engine assembly compound or engine oil. 33. Carefully install the camshaft camshaft to avoid avoid damaging the camshaft bearings (see ( see page page 75). 75). 34. Install and tighten the camshaft thrust plate mounting bolts (see (see page page 76). 76).
42. Place new O-rings (Tier (Tier 2 engines only) only) in the gear case (se ( seee page page 84). 84). NOTE: Tier Tier 1 and earlier engines do not use these O-rings. 43. Place a thin layer of sealant sealant on the sealing surface of the gear case cover. cover. 44. Place the gear gear case cover cover in position and make sure to align the dowel pins (see ( see page page 84). 84). NOTE: The oil pump is located located in the timing gear cover cover on Tier 2 engines. engines. The inner rotor rotor of the oil pump fits around around the crankshaft crankshaft gear. gear. Make sure that that the flat sides of the inner rotor are aligned with the flat sides on the crankshaft crankshaft gear when installing installing the timing gear cover. cover. 45. Install and tighten the gear case case cover mounting bolts that are covered by the sound shield (see (see page page 84). 84).
35. On Tier Tier 1 and earlier engines, install the oil pump with a new gasket and tighten the mounting bolts. On Tier 2 engines the oil pump is located in the gear case cover and is installed with the gear case cover (see ( see page page 76). 76).
46. If the sponge on the back of the sound sound shield is damaged, replace it before installing the sound shield.
36. Install a new O-ring for the fuel fuel injection pump in the gear case.
48. Install the crankshaft crankshaft pulley and and align it with the dowel pin in the crankshaft gear. Torque the mounting bolt to 83.2 to 90.4 ft-lb f t-lb (112.8 to 122.6 N•m) (see (see page page 85). 85).
37. Install the fuel injection pump, align align the index marks as they were when the fuel injection pump was removed, and tighten the mounting nuts (se (seee page page 76). 76). 38. Install the fuel injection pump gear, lock washer, washer, and mounting nut. Make sure the key is aligned properly. Torque the mounting nut to 43.4 to 50.6 ft-lb (58.8 ( 58.8 to 68.6 N•m) on Tier 1 and earlier earlier engines, or 57.9 to 65.1 65.1 ft-lb (78.5 to 88.3 N•m) on Tier 2 engines (see ( see page page 77). 77). 39. Install the idler gear gear and the idler shaft and align the timing marks (se ( seee page page 78). 78). 40. Install and tighten the idler shaft mounting bolts (see (see page page 78). 78). 41. Coat the lip of the front seal with engine oil.
47. Place the sound sound shield in position and and install and tighten the mounting bolts (see ( see page page 84). 84).
49. Install the oil line that goes from the cylinder block to the fuel injection pump and the gear case cover (see (see page page 86). 86). 50. Install the fuel transfer transfer pump in the gear case case cover (se (seee page page 86). 86). 51. Place the valve stem stem caps on the valve valve stems (see page page 79). 79). 52. Install the push push rods in their respective respective openings. Make sure the push rods are seated properly in the tappets. Lubricate the socket in the top end of each push rod with engine oil (see page page 79). 79). 53. Place the rocker rocker arm assembly assembly in position. Make sure all the valve adjustment screws are loose and have been backed out a few turns (see page page 79). 79).
145
Special Procedures
54. Install the rocker arm mounting bolts. bolts. Alternately turn each bolt one turn at a time to evenly apply the valve spring pressure to the rocker arm assembly. Make sure the valve adjustment screws all seat properly in the sockets on the ends of the push rods while the rocker arm assembly is being tightened (see ( see page page 79). 79). 55. Torque the rocker arm mounting mounting bolts to 16.6 to 21.0 ft-lb (22.6 (22.6 to 28.4 N•m). N•m). 56. Adjust both the intake and the the exhaust valves. valves. See “Valve Clearance Adjustment” on page page 137 137. 57. Install the valve cover with a new gasket and put new O-rings on the special cap nuts ( see page page 81). 81). 58. Install Install the engine engine in the unit.
146
Engine History Engine History
Rear Seal
The following describe changes made to the TK482 and TK486 families of engines.
The rear seal was changed from a radial seal (P/N 33-2759) to an axial axial seal (P/N 33-2974). TK482 engines start using the axial seal at serial number K00203. TK486 engines start using the axial seal at serial number K00152.
Released When the TK482 and TK486 engines were released, the serial numbers for both engines started at K00101.
Front Pulley
Special tools are required to remove and install the axial seal. See page 37 for 37 for information about removing the rear seal. See page 82 for 82 for information about installing the rear seal.
The front pulley was changed. The inside diameter of the pilot hole for f or the pulley spacer was changed changed from 2.83 in. (72 mm) to 2.40 in. (61 mm). Both the TK482 TK482 and TK486 engines start using the front pulley with a pilot hole diameter of 2.40 in. at serial number K00202.
1
The early front pulley with a pilot hole diameter of 2.83 in. uses pulley spacer P/N 11-8710.
2 3
The late front pulley with a pilot hole diameter of 2.40 in. uses pulley spacer P/N 11-8902. The pulley spacer is typically used on Model 30 trailer units that attach a fan belt pulley to the front pulley. 1 2
4 3 5
1.
Front Pulley
2.
Pulley Spacer
3.
Fan Belt Pulley
Figure 279: Front Pulley Pulley and Spacer Spacer
1.
Flywheel Housing
2.
Rear Seal
3.
Rear Seal Housing
4.
Axia Axiall Rear Rear Sea Seall Inst Instal alla lati tion on Too Tooll P/N P/N 204204-952 952
5.
Axia Axiall Rea Rearr Sea Seall Rem Remov oval al Tool ool P/N P/N 204 204-9 -994 94 Figure 280: Front Pulley Pulley and Spacer Spacer
Flywheel Housing The flywheel housing (bellhousing) was changed to be universally compatible. The positions of the threaded holes for the engine mounting and snubber brackets were changed slightly. TK482 engines start using the universal flywheel housing at serial number K00203. TK486 engines start using the universal flywheel housing at serial number K00409.
147
Engine History
Water Pump The water pump was changed from a high mount water pump to a low mount water pump. TK482 engines start using the low mount water pump at serial number K00250. TK486 engines start using the low mount water pump at serial number K02406. 1
2
1.
High High Mo Moun untt Wat Water er Pump Pump P/N P/N 1111-94 9451 51
2.
Low Low Mou Mount nt Water ater Pump Pump P/N P/N 1111-94 9499 99
NOTE: Later the engines engines were changed changed to comply with EPA EPA Tier 2 regulations. See “EPA Tier 2 Compliance” on page 150 .
Oil Line The long oil line (P/N 11-8668) 11-8668) that goes from the block to the injection pump and on to the t he gear case cover was changed to a short oil line (P/N 11-8992). 11-8992). The short short oil line only goes from the block to the injection pump. The opening in gear case cover is plugged with a screw (P/N 55-8441). TK482E engines engines start using the short oil line at serial number A00261. TK486E/EH engines start using the short oil line at serial number L00261. 3
1 2
Figure 281: 281: Water Water Pumps Pumps
EPA EPA Tier 1 Compliance The engines were changed to comply with EPA Tier 1 regulations. The injection pumps were changed and the injection timing was changed. The EPA Tier 1 compliant engines are called the TK482E, TK486E, and TK486EH (2600 rpm high speed). The TK482E has a new serial number range that starts at A00101. The TK486E and TK486EH have a new serial number range that starts at L00101. L00101 . The EPA EPA compliant engines engi nes have two injection timing marks on the flywheel. One is at 10 degrees BTDC (before top dead center), and the other is at 12 degrees BTDC. See “Injection Pump Timing Tier 1 and Earlier Engines” Engines” on on page page 97 for 97 for more information. See the following table for injection pump part numbers and the timing specifications. Engine
Initial Injection Serial Pump Number P/N
Injection Timing Degrees BTDC
TK482
K00101
101-296
12
TK486
K00101
101-297
12
TK482E
A00101
101-322
10
TK486E
L0 0 1 01
101-321
10
TK486EH
L 0 01 0 1
101-331
11
148
1.
Long Long Oil Oil Line Line P/N P/N 11-86 1-8668 68
2.
Shor Shortt Oil Oil Line Line P/N P/N 11-89 1-8992 92
3.
Plug Sc Screw rew P/ P/N 55 55-844 8441 Figure 282: Oil Lines
ELC Compatible Water Pumps The low mount water pump (P/N 11-9499) was changed to be compatible with ELC (Extended Life Coolant). TK482E engines start using the ELC compatible water pump at serial number A05679. TK486E/EH engines start using the ELC compatible water pump at serial number L16553.
Engine History
An ELC compatible high mount water pump (P/N 11-9451) 11-9451) is available, but no engines engines were made with ELC compatible high mount water pumps. A unit can be retrofitted with ELC by flushing the cooling system with hot water until all traces of the precious coolant are gone and then filling the cooling system with ELC. The water pump must also be replaced on engines that are not equipped with an ELC compatible water pump. Replace the water pump and water pump gasket on engines with a high mount water pump. Replace the parts listed in Figure 283 (below) 283 (below) on engines with a low mount water pump. 1
EMI 3000 Oil Filter The oil filter (P/N 11-7382) 11-7382) and oil filter head head (P/N 11-8962) were changed to an EMI 3000 oil filter (P/N 11-9182) 11-9182) and EMI 3000 3000 oil filter head head (P/N 11-9354). 11-9354). TK482E engines engines start using using the EMI 3000 oil filter and filter head at serial number A08750. TK486E/EH engines start using the EMI 3000 oil filter and filter head at serial number L32014. An engine can be retrofitted to EMI 3000 by replacing the oil filter head and oil filter with the EMI 3000 oil filter head and EMI 3000 oil filter. Use EMI 3000 Oil Filter Kit P/N 90-336. Engine oil of API classification CI-4 (ACEA rating E3 in Europe) or better is also required to allow 3000 hour oil change intervals. 1
3
2
2 4
4 3 1.
Join Jointt Gask Gasket et P/N P/N 33-3 33-309 097 7
2.
Joint oint O-R O-Ring ing P/N 33-3 33-309 098 8
3.
Water Pump P/ P/N 11 11-94 -9499
4.
Water ater Pum ump p Gas Gaske kett P/N P/N 33-3 33-309 096 6
Figure 283: 283: Retrofitting Retrofitting Low Mount Mount ELC Compatible Compatible Water Water Pump
1.
Oil Oil Fil Filte terr Hea Head d P/N P/N 11-89 1-8962 62
2.
Oil Fi Filter P/ P/N 11 11-7382 382
3.
EMI EMI 30 3000 00 Oil Oil Fil Filte terr Hea Head d P/N P/N 11-93 1-9354 54
4.
EMI EMI 300 3000 0O Oil il Filt Filter er P/N P/N 1111-91 9182 82
Figure 284: 284: Oil Filter Heads Heads and Oil Filters
149
Engine History
Screw-In Oil Level Switch The oil level switch was changed from a push-in oil level switch to a screw-in oil level switch. TK482E engines start using the screw-in oil level switch at serial number A15446. TK486E and TK486E engines start using the screw-in oil level switch at serial number L49456.
•
Oil Oil Pump Pump – Oil Oil pump pump is is moun mounte ted d in the the fron frontt gear case cover and is driven by the crankshaft
•
Fron Frontt Gear Gear Cas Casee Cove Coverr – Oil Oil pum pump p is moun mounte ted d in the front gear case cover
•
Piston Pistonss – Have Have a differ different ent profile profile and contai contain n steel inserts for the top ring
•
Pist Piston on Rin Rings gs – Hav Havee diff differ eren entt dime dimens nsio ions ns
•
Valve alve Cove Coverr – Has Has a new new des desig ign n
•
Start Starter er – Has Has higher higher torque torque,, but but is smal smaller ler in size than the Tier 1 and earlier starter
•
Water ater Pum Pump p – Has Has extra extra ports ports to pro provi vide de coolant to the cold start device
•
Engi Engine ne Coo Coola lant nt The Therm rmos osta tatt - Open Openss at 160 160 F (71 C)
•
950 950 CCA CCA batt batter ery y requ requir ired ed for for –15 –15 F (–26 (–26 C) C) ambient or below starting.
2
1
1.
Push Push-I -In n Oil Oil Leve Levell Swi Switc tch h P/N P/N 41-4 41-402 02
2.
Scre Screww-In In Oil Oil Lev Level el Swi Switc tch h P/N P/N 41-4 41-447 470 0 Figure 285: 285: Oil Level Level Switches Switches
EPA EPA Tier 2 Compliance The engines were changed to comply with EPA Tier 2 regulations. The EPA Tier 2 compliant engines are called the TK482V, TK486VB (Bus), and TK486VH (2600 rpm high speed). The TK486V has a new serial number range that starts at V00151. The TK486VH have a new serial number range that starts at V00153.
The most noticeable difference between a Tier 1 (and earlier) engine and a Tier 2 engine is the fuel injection pump (see the following photographs). The Tier 1 and earlier engines use an in-line injection pump. The Tier 2 engines use a mono-plunger and distributor injection pump. The mono-plunger and distributor injection pump uses a higher injection pressure than the in-line injection pump. The higher injection i njection pressure atomizes the fuel more efficiently, efficiently, which reduces the emissions.
The Tier 2 engines share many common parts with the earlier engines, however the following major parts are new on the Tier 2 engines: •
Cylind Cylinder er Head Head Assemb Assembly ly – Compre Compressi ssion on ratio ratio is slightly higher and the injection nozzles are at a different angle
•
Inject Injection ion Nozzle Nozzless – Inject Injection ion nozzle nozzless have have a higher popping pressure and use a different mounting system
•
Inje Inject ctio ion n Pump Pump – Inj Injec ecti tion on pum pump p is a rot rotar ary y head design
•
150
Troch Trochoid oid Feed Feed Pump Pump – Rais Raises es the pressu pressure re of of the fuel before it enters the t he injection pump
1
1.
In-L n-Line In Injection Pump
Figure 286: 286: Tier 1 (and Earlier) Earlier) Engine Engine
Engine History
1
1.
MonoMo no-Pl Plung unger er and Dist Distri ribut butor or Inje Inject ctio ion n Pum Pump p Figure 287: 287: Tier 2 Engine
Engine History Chart Change
Engine Model and Serial Number for Start of Change TK482
TK482E
TK486
Released
K 00 1 0 1
K00101
Small Front Pulley
K 00 2 0 2
K00152
Axial Rear Seal
K 00 2 0 3
K00202
Universal Flywheel Housing
K 00 2 0 3
K00409
Low Mount Water Pump
K 00 2 5 0
K02406
TK486E TK486EH TK486V TK486VB
EPA EPA Tier 1 Compliant
A 00 1 0 1
L0 0 1 0 1
L 0 0 10 1
Short Oil Line
A 00 2 6 1
L0 0 2 6 1
L 0 0 26 1
ELC Water Pump
A 05 6 7 9
L1 6 5 5 3
L 1 6 55 3
EMI 3000 Oil Filter
A 08 7 5 0
L3 2 0 1 4
L 3 2 01 4
Screw In Oil Level Switch
A 15 4 4 6
L4 9 4 5 6
L 4 9 45 6 V00151
V00152
V 0 0 15 3
101-331
101-355
101-353
101-354
11
NA
NA
NA
EPA EPA Tier 2 Compliant Injection Pump P/N Injection Timing Degrees BTDC
101-296 101-322 101-297 101-321 12
10
12
10
TK486VH
151
Engine History
Engine Model Identification
1
The engine model is listed above the serial number on the serial number nameplate. The serial number nameplate is located on the side of the valve cover on Tier 1 and earlier engines. The serial number nameplate is located on the top of the valve cover on Tier 2 engines. 1
1. 1.
Engine Model
Figure 290: Serial Number Number Nameplate Location Location Tier Tier 2 Engi Engine ne
Figure 288: Typical Serial Number Number Nameplate
1
1.
Seri erial Num umbe berr Na Name mepl plat ate e
Figure 289: Serial Number Number Nameplate Location Location Tier 1 and Earlier Engines
152
Seri Serial al Nu Numb mber er Nam amep epllate ate
Engine History
History of Engine Related Components
Fuel Solenoid Timer
Fuel Solenoid The first fuel solenoid (P/N 41-1386) has a gray plastic sleeve on its wires. It was replaced in a campaign so it is seldom seen in the field. fi eld. The second fuel solenoid (P/N 41-3291) has a clear plastic sleeve on its wires and the part number is stamped on its metal housing. It was changed to the third fuel solenoid to improve reliability.
Some units use a fuel solenoid timer to momentarily energize the pull-in coil in the fuel solenoid. The fuel solenoid timer was changed in June of 1997 to improve its reliability. The early style fuel solenoid timer (P/N 41-1533) used a large capacitor for the timing circuit. The late style fuel solenoid timer (P/N 41-2191) used a small capacitor and a transistor for the timing timi ng circuit. Both styles function the same and are interchangeable. 1
The third fuel solenoid (P/N 41-4306) has a brown plastic sleeve on its wires and the part number is stamped on its metal housing. TK482E engines start using the third fuel solenoid at serial number A12790. TK486E/EH engines start using the third fuel solenoid at serial number L45560. The fourth fuel solenoid (P/N 41-6383) has a blue plastic sleeve on its wires and the part number is stamped on its metal housing. The hole in i n the end of the solenoid has been enlarged to 0.455 in. (11.56 mm). Tier 2 engines start using the fourth fuel solenoid at serial number V01034. The latest version replaces all earlier versions. 1
1.
Capacitor
Figure 292: Early Style Style Fuel Solenoid Timer Timer P/N 41-1533 41-1533 1
2
2
1.
Plastic Sleeve • Gray = First First Version ersion P/N 41-1386 41-1386 • Clear Clear = Seco Second nd Vers Version ion P/N 41-3291 41-3291 • Brown Brown = Third Third Version ersion P/N 41-4306 41-4306 • Blue Blue = Fourt Fourth h Versi Version on P P/N /N 41-6 41-6383 383
2.
AGA337
1.
Capacitor
2.
Transistor
Figure 293: Late Style Style Fuel Solenoid Solenoid Timer P/N 41-2191 41-2191
0.455 in. (11.56 mm) Hole P/N 41-6383 Only Figure 291: Fuel Solenoid Solenoid
153
Engine History
Alternator Mounting Brackets for Model 30 Trailer Units The alternator mounting brackets used on some Model 30 trailer units were changed in March of 1998 when the high mount water pump was changed to a low mount water pump.
The alternator mounting brackets used on some Model 30 trailer units with low mount water pumps were changed to improve reliability. The secondary alternator bracket is not used with the late style alternator brackets. Refer to the unit Parts Manual for more specific information. 2 1
3
Figure 294: Alternator Alternator Mounting Brackets Brackets for for High High Moun Mountt Water ater Pump Pump
1.
Alternator tor Bracket
2.
Alte Altern rnat ator or Adju Adjust stin ing g Brac Bracke kett
3.
Seco Second ndar ary y Alte Altern rnat ator or Brac Bracke kett
Figure 295: Early Style Style Alternator Mounting Mounting Brackets for Low Mount Water Pump 1
2
1.
Alternat nator Brac racket
2.
Alte Altern rnat ator or Adju Adjust stin ing g Brac Bracke kett
Figure 296: Late Style Alternator Alternator Mounting Mounting Brackets for Low Mount Water Pump
154
Index A
F
air heater, 131 alternator mounting brackets, 154
fuel filter assembly, 118 fuel injection nozzle installation, 87 repair, 112 testing, 111 fuel injection pump see injection pump fuel return line replacement, 113 fuel solenoid history, 153 replacement, 133 testing, 132 fuel solenoid timer, 133 history, 153 operation, 133 troubleshooting, 134 fuel system, 93 air leaks, static, 121 bleeding air from, 96 description, 93 FAQ (frequently asked questions), 121 normal operation, 118 operation and diagnosis, 118 return system, 120 solution for static air leaks, 121 static pressures, 120 using clear fuel lines to diagnose problems, 122 fuel transfer pump, 114 inspection, 115 operation, 114 testing, 115
B battery cables, 123 battery, cold weather recommendation for tier 2 engine, 123 bleeding air from fuel system, 96
C camshaft inspection and measurement, 50 installation, 75 specifications, 13, 18 camshaft bearing installation, 69 measurement, 43 cold start device, 109 checking operation, 109 replacement, 110 compression test, 139 connecting rod inspection and measurement, 48 specifications, 14 connecting rod bearing installation, 73, 74 crankcase breather system Tier 1 and earlier engines, 65 Tier 2 engine, 66 crankcase pressure, checking, 67 crankshaft inspection and measurement, 45 specifications, 14, 20 crankshaft bearings specifications, 14, 20 cylinder boring, 41, 43 measurement, 41 sleeve installation, 42 cylinder block inspection and measurement, 41 specifications, 15, 20 cylinder head assembly, 56 disassembly, 51 inspection and measurement, 51 installation, 78 specifications, 15, 20 cylinder head bolts, torque sequence, 79
G gear case replacement, 144 general specifications, 11, 17
I idler gear bushing, measurement, 49 idler gear shaft, measurement, 49 idler gear, installation, 78 injection nozzle see fuel injection nozzle injection pump installation, 76 removal and installation, 105 timing, Tier 1 and earlier engines, 97 timing, Tier 2 engines, 102
L low oil pressure, diagnosis, 90, 91 lubrication system, 89 pressure check, 80
E engine assembly, 69 disassembly, 27 history, 147 model identification, 152 exhaust gas specifications, 22
M main bearing bores checking alignment, 44 measurement, 44 main bearing, installation, 69 manifolds, inspection and measurement, 65 155
Index
O oil pan, installation, 81 oil pressure, low, diagnosis, 90, 91 oil pump inspection and measurement, 61 Tier 1 and earlier engines, 61 Tier 2 engine, 62 installation, Tier 1 and earlier engines, 76 specifications, 16, 21
timing gear lash, checking, 33 timing gears inspection and measurement, 49 specifications, 15, 20 timing, 78 timing marks, 78 torque values, 23 trochoid feed pump, 107 o-ring replacement, 108 replacement, 107
P piston inspection and measurement, 46 installation, 72 specifications, 13, 19 piston rings installation, 72 measurement, 47 specifications, 13, 19 push rod, inspection and measurement, 60
R rear seal installation, 82 removal, 37 rear seal housing, installation, 82 rocker arm assembly inspection, 58 installation, 79 rocker arm bushing, measurement, 59 rocker arm shaft, measurement, 59 rod, connecting see connecting rod rod, push see push rod run in, 137 dynamometer run in procedure, 137 procedure without dynamometer, 137
S special tools, 24 specifications, 11 exhaust gas, 22 Tier 1 and Earlier - TK482, TK482E, TK486, TK486E, and TK486EH, 11 Tier 2 - TK486V, TK486VB, and TK486VH, 17 starter, 123 assembly, 130 description, 125 disassembly, 125 motor inspection, 127 no load test, 131 pinion assembly, inspection, 129 solenoid, inspection, 130 specifications, 16, 21
T tappet inspection and measurement, 60 installation, 75 tappet bores, measurement, 44
156
V valve clearance, adjustment, 137 valve depth, 52 measurement, 53 valve guide measurement, 52 replacement, 52 valve seat grinding, 54 inspection, 54 replacing, 55 width measurement, 54 valve spring, inspection and measurement, 56 valve train specifications, 12, 17 valves grinding, 53 inspection and measurement, 53 valve margin, measurement, 53
W water pump, inspection, 64 wrist pin inspection and measurement, 47 specifications, 13, 19 wrist pin bushing, replacement, 49
