Contents Page Page Test Mechanical Fuel Supply Pump for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . 35-11 Disassemble Mechanical Fuel Supply Pump (Nippondenso) . . . . . . . . . . . . . . . 35-12 Inspect and Repair Mechanical Fuel Supply Pump (Nippondenso) . . . . . . . . . . 35-14 Assemble Mechanical Fuel Supply Pump (Nippondenso) . . . . . . . . . . . . . . . . . . . 35-15 Disassemble Mechanical Fuel Supply Pump (Robert Bosch) . . . . . . . . . . . . . . 35-16 Inspect and Repair Mechanical Fuel Supply Pump (Robert Bosch) . . . . . . . . . 35-17 Assemble Mechanical Fuel Supply Pump (Robert Bosch) . . . . . . . . . . . . . . . . . . . 35-18 Install Mechanical Fuel Supply Pump . .
. . . 35-18 Remove and Install Electric Fuel Supply Pump . . . . . . . . . . . . . . . . . . . . . . . . . 35-19 Clean or Replace Electric Fuel Supply Pump Filter Screen . . . . . . . . . . . . . . . . 35-20 Repair Aneroid . . . . . . . . . . . . . . . . . . . . 35-21 Remove Hydraulic Aneroid Activator . . . . . . 35-21 Disassemble and Clean Hydraulic Aneroid Activator Parts . . . . . . . . . . . . . 35-22 Assemble and Install Hydraulic Aneroid Activator . . . . . . . . . . . . . . . . . . . . . . . 35-22 Service Injection Pump Overflow Valve . . . . 35-22 Remove and Install Fuel Shutoff Solenoid . . . 35-24 Identification of In-Line Injection Pumps . . . .
35-25 Remove In-Line Fuel Injection Pump . . . . . . 35-26 Install In-Line Fuel Injection Pump . . . . . . . 35-29 Remove Rotary Fuel Injection Pump—Stanadyne DB4 . . . . . . . . . . . . . 35-33 Install Rotary Fuel Injection Pump—Stanadyne DB4 . . . . . . . . . . . . . 35-34 Remove Fuel Injection Nozzles . . . . . . . . . 35-37 Diagnose Injection Nozzle Malfunction . . . . . 35-40 Test Fuel Injection Nozzles . . . . . . . . . . . . 35-42 Perform Opening Pressure Test . . . . . . . . . 35-43 Injection Nozzle Specifications . . . . . . . . . . 35-44 Perform Nozzle Leakage Test . . . . . . . . . . 35-45 Perform Chatter and Spray Pattern Test . . . 35-46 Disassemble Fuel Injection Nozzle . . . .
. . . 35-47 Clean and Inspect Fuel Injection Nozzle Assembly . . . . . . . . . . . . . . . . . . . . . . . 35-49 Perform Nozzle Slide Test . . . . . . . . . . . . . 35-50 Clean Spray Orifices . . . . . . . . . . . . . . . . . 35-50 Inspect Nozzle Holder . . . . . . . . . . . . . . . . 35-51 Inspect Gland Nut . . . . . . . . . . . . . . . . . . 35-53 Assemble Fuel Injection Nozzle . . . . . . . . . 35-54 Adjust Injection Nozzles . . . . . . . . . . . . . . 35-57 Inspect and Clean Cylinder Head Nozzle Bore . . . . . . . . . . . . . . . . . . . . . . . . . . 35-58 Inspect and Clean Nozzle Seating Surface . . . . . . . . . . . . . . . . . . . . . . . . 35-59 Install Fuel Injection Nozzles . . .
. . . . . . . . 35-59 Group 100—Engine Tune-Up and Break-In Effects of Altitude and Temperature on Engine Performance . . . . . . . . . . . . . . . 100-1 Preliminary Engine Testing . . . . . . . . . . . . 100-2 General Tune-Up Recommendations . . . . . . 100-3 Dynamometer Test . . . . . . . . . . . . . . . . . . 100-4 Engine Break-In Guidelines . . . . . . . . . . . . 100-5 Perform Engine Break-In . . . . . . . . . . . . . . 100-6 Check Crankcase Ventilation System . . . . . . 100-7 Check Air Intake System . . . . . . . . . . . . . . 100-7 Check Exhaust System . . . . . . . . . . . . . . . 100-8 Check and Service Cooling System . . . . . . . 100-8 Check Electrical System . . . . . . . . . .
. . . 100-10 Group 105—Engine System Operation and Test Special or Essential Tools . . . . . . . . . . . . . 105-1 Engine Test Specifications . . . . . . . . . . . . . 105-3 Engine—Sectional View . . . . . . . . . . . . . . 105-4 General Engine Description . . . . . . . . . . . . 105-5 How the Lubrication System Works . . . . . . . 105-6 How the Cooling System Works . . . . . . . . 105-10 Head Gasket Joint Construction and Operation . . . . . . . . . . . . . . . . . . . . . 105-12 Diagnosing Head Gasket Joint Failures . . . 105-14 Head Gasket Inspection and Repair Sequence **M:CTM42,G105,18 -19- . . . . 105-17 Diagnosing Engine Malfunctions . . . . . . . .
105-18 Test Engine Compression Pressure . . . . . . 105-21 Check Engine Oil Pressure . . . . . . . . . . . 105-22 Inspect Thermostat and Test Opening Temperature . . . . . . . . . . . . . . . . . . . 105-24 Group 110—Air Intake System Operation and Test Special or Essential Tools . . . . . . . . . . . . . 110-1 Air Intake and Exhaust System Test Specifications . . . . . . . . . . . . . . . . . . . . 110-2 Diagnosing Air Intake Malfunctions . . . . . . . 110-3 How the Air Intake and Exhaust System Works . . . . . . . . . . . . . . . . . . . . . . . . . 110-4 Air Cleaner Operation . . . . . . . . . . . . . . . . 110-4 Diagnosing Turbocharger Malfunctions . . . . .
110-6 How The Turbocharger Works . . . . . . . . . . 110-7 How The Turbocharger is Lubricated . . . . . . 110-7 Continued on next page CTM42 (24MAR95) v 6076 Diesel Engines—S.N. (500000— ) 160101 PN=442