Contents Page Page 110 Remove Oil Filter and Oil Conditioning Housing . . . . . . . . . . . . . . . . . . . . . . . . . 20-4 Inspect and Replace Oil Filter Adapter . . . . . . 20-4 Remove, Inspect, and Install Valves from Oil Conditioning Housing . . . . . . . . . . . . . 20-5 Install Oil Filter and Oil Conditioning Housing . . . . . . . . . . . . . . . . . . . . . . . . . 20-6 Remove Engine Oil Cooler . . . . . . . . . . . . . 20-7 Clean, Inspect, and Install Engine Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 20-8 Check Crankshaft Gear-To-Oil Pump Drive Gear Backlash . . . . . . . . . . . . . . . . 20-9 Remove Engine Oil Pump . . . . . . . . . . . . . .
20-9 Inspect and Clean Oil Pump . . . . . . . . . . . 20-10 Check Drive Shaft End Play . . . . . . . . . . . 20-11 Check Drive Shaft Side Movement . . . . . . . 20-11 Check Pumping Gear Backlash . . . . . . . . . 20-12 Inspect Oil Pump Drive Gear . . . . . . . . . . . 20-12 Install Engine Oil Pump . . . . . . . . . . . . . . . 20-13 Install Oil Pan . . . . . . . . . . . . . . . . . . . . . 20-14 Tighten cap screws on front frame/oil sump . . . . . . . . . . . . . . . . . . . . . . . . . 20-15 Fan Belt Tension Specifications . . . . . . . . . 25-26 Group 30—Air Intake And Exhaust System Special or Essential Tools . . . . . . . . . . . . . . 30-1 Other Material . . . . . . . . . . . . . . . .
. . . . . . 30-2 Air Intake and Exhaust System Specifications . . . . . . . . . . . . . . . . . . . . . 30-2 Extending Turbocharger Life . . . . . . . . . . . . 30-4 Remove Turbocharger . . . . . . . . . . . . . . . . 30-6 Turbocharger Failure Analysis . . . . . . . . . . . 30-8 Turbocharger Seven-Step Inspection . . . . . . 30-10 Perform Radial Bearing Clearance Test . . . . 30-15 Perform Axial Bearing End Play Test . . . . . . 30-16 Repair Turbocharger . . . . . . . . . . . . . . . . . 30-16 Disassemble Turbocharger . . . . . . . . . . . . 30-17 Clean and Inspect Turbine and Compressor Housings . . . . . . . . . . . . . . 30-18 Replace Center Housing Assembly and Assemble Turbocharger . .
. . . . . . . . . . . 30-19 Prelube Turbocharger . . . . . . . . . . . . . . . . 30-20 Install Turbocharger . . . . . . . . . . . . . . . . . 30-20 Remove, Inspect, and Install Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . 30-22 Remove Vertically-Mounted Aftercooler and Intake Manifold . . . . . . . . . . . . . . . . 30-23 Remove and Disassemble Horizontally-Mounted Aftercooler Assembly . . . . . . . . . . . . . . . . . . . . . . . 30-25 Inspect and Repair Aftercooler . . . . . . . . . . 30-26 Inspect and Repair Intake Manifold and Cover . . . . . . . . . . . . . . . . . . . . . . . . . 30-26 Install Intake Manifold and Vertically-Mounted Aftercooler . . . . . . . . .
30-27 Assemble and Install Horizontally-Mounted Aftercooler Assembly . . . . . . . . . . . . . . . . . . . . . . . 30-29 Remove, Inspect, and Install Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . 30-31 115 199 INDX Group 25—Cooling System Special or Essential Tools . . . . . . . . . . . . . . 25-1 Other Material . . . . . . . . . . . . . . . . . . . . . . 25-2 Cooling System Specifications . . . . . . . . . . . 25-3 Service Equipment and Tools . . . . . . . . . . . . 25-5 Replace Bearings in Standard Duty, Adjustable Fan Drive Assembly . . . . . . . . . 25-6 Replace Bearings in Heavy Duty, Adjustable Fan Drive Assembly . . . . . . . . .
25-8 Water Manifold Mounted Fixed Fan Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . 25-10 Replace Bearing in Injection Pump Drive Gear Mounted Fan Drive . . . . . . . . . . . . 25-12 Inspect and Check Belt Tensioner Spring Tension . . . . . . . . . . . . . . . . . . . . . . . . 25-13 Replace Belt Tensioner Assembly . . . . . . . . 25-14 Remove Water Pump . . . . . . . . . . . . . . . . 25-14 Disassemble Water Pump . . . . . . . . . . . . . 25-15 Inspect Water Pump Parts . . . . . . . . . . . . . 25-18 Assemble Water Pump . . . . . . . . . . . . . . . 25-19 Install Water Pump . . . . . . . . . . . . . . . . . . 25-21 Remove and Test Thermostats . . . . . . . . . .
25-22 Install Thermostats . . . . . . . . . . . . . . . . . . 25-23 Remove Water Manifold . . . . . . . . . . . . . . 25-23 Install Water Manifold . . . . . . . . . . . . . . . . 25-24 Remove Coolant Heater . . . . . . . . . . . . . . 25-24 Install Coolant Heater . . . . . . . . . . . . . . . . 25-25 Complete Final Assembly . . . . . . . . . . . . . 25-26 Group 35—Fuel System Special or Essential Tools . . . . . . . . . . . . . . 35-1 Other Material . . . . . . . . . . . . . . . . . . . . . . 35-4 Diesel Fuel System Specifications . . . . . . . . . 35-4 Relieve Fuel System Pressure . . . . . . . . . . . 35-6 Replace Rectangular Fuel Filter Element . . . . 35-6 Replace Fuel Check Valve . . .
. . . . . . . . . . 35-7 Remove Round Fuel Filter Element . . . . . . . . 35-8 Identification of fuel supply and fuel injection pumps . . . . . . . . . . . . . . . . . . . 35-9 Remove Mechanical Fuel Supply Pump . . . . 35-10 Continued on next page CTM42 (24MAR95) iv 6076 Diesel Engines—S.N. (500000— ) 160101 PN=441