Table of Contents 1. Maintenance.......................................................................................................................................... 5 1.1 Diagnosis and troubleshooting ..................................................................................................... 5 1.1.1 Start problems..................................................................................................................... 5 1.1.2 Unstable idle speed ............................................................................................................
7 1.1.3 Insufficient power................................................................................................................ 8 1.1.4 High fuel consumption ........................................................................................................ 9 1.1.5 High oil consumption ........................................................................................................ 10 1.1.6 Engine overheating........................................................................................................... 10 1.1.7 White smoke coming out of engine exhaust ....................................................................
10 1.1.8 Black smoke coming out of engine exhaust......................................................................11 1.1.9 Low oil pressure.................................................................................................................11 1.1.10 Abnormal engine noise....................................................................................................11 1.1.11 Engine cooling problem .................................................................................................. 12 1.2 Data and specifications...............................................................................................................
20 1.2.1 Data and specifications............................................................................................................ 20 1.2.2 Engine cooling .................................................................................................................. 21 1.2.3 Starting system ................................................................................................................. 21 1.2.4 Charging system............................................................................................................... 22 1.3 Maintenance standards...............................................................................................................
22 1.3.1 Engine mechanical system............................................................................................... 22 1.3.2 General terms for diesel performance.............................................................................. 24 1.4 Maintenance work....................................................................................................................... 26 1.4.1 Air filter.............................................................................................................................. 26 1.4.2 Lubricant system...............................................................................................................
27 1.4.3 Fuel system ...................................................................................................................... 28 1.4.4 Cooling system ................................................................................................................. 30 1.4.5 Drive belt adjustment........................................................................................................ 32 1.4.6 Engine control (governed speed, valve clearance, injection timing, compression pressure) ...................................................................................................................................................
33 1.5 Tightening torque ........................................................................................................................ 39 1.5.1 Torque for cylinder head, cylinder head cover and rocker shaft support ....................... 39 1.5.2 Torque for crankshaft, bearing cap, connecting rod bearing cap, crankshaft damper pulley, flywheel and oil pan ................................................................................................................. 41 1.5.3 Torque for timing pulley chamber, timing pulley, timing gear and camshaft race ............
42 1.5.4 Engine fuel system ........................................................................................................... 42 1.5.5 Torque for cooling system and lubricant system .............................................................. 43 1.5.6 Torque for intake manifold, exhaust manifold and exhaust pipe...................................... 44 1.5.7 Engine electrical system................................................................................................... 45 1.5.8 Torque for engine mounting bracket.................................................................................
46 1.6 Special tools................................................................................................................................ 47 2. Engine mechanical system ............................................................................................................... 49 2