Operation Testing Engine

SENR9834-02
June 2006
Systems Operation
Testing and Adjusting
800 Industrial Engine
UE (Engine)
UF (Engine)
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Perkins is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.
When replacement parts are required for this

product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
SENR9834-02 3
Table of Contents
Table of Contents Belt Tension Chart ................................................ 54

Electric Starting System - Test .............................. 55
Glow Plugs - Test .................................................. 55
Systems Operation Section
Index Section
General Information ................................................ 4
Fuel System ........................................................... 9 Index ..................................................................... 57
Air Inlet and Exhaust System ............................... 14
Lubrication System .............................................. 17
Cooling System .................................................... 19
Basic Engine ......................................................... 20
Electrical System ................................................. 23
Testing and Adjusting Section

Fuel System
Fuel System - Inspect ........................................... 25
Air in Fuel - Test .................................................... 25
Finding Top Center Position for No. 1 Piston ........ 26
Fuel Injection Timing - Check ............................... 26
Fuel Injector - Test ................................................ 28
Fuel Quality - Test ................................................. 30
Fuel System - Prime ............................................. 31
Air Inlet and Exhaust System

Air Inlet and Exhaust System - Inspect ................. 32
Turbocharger - Inspect .......................................... 32
Exhaust Temperature - Test .................................. 34
Compression - Test ............................................... 34
Engine Valve Lash - Inspect/Adjust ...................... 35
Valve Depth - Inspect ............................................ 36
Valve Guide - Inspect ............................................ 37
Lubrication System
Engine Oil Pressure - Test .................................... 38
Engine Oil Pump - Inspect .................................... 38
Excessive Bearing Wear - Inspect ........................ 39
Excessive Engine Oil Consumption - Inspect ....... 39
Increased Engine Oil Temperature - Inspect ........ 40
Cooling System
Cooling System - Check (Overheating) ................ 41
Cooling System - Inspect ...................................... 42
Cooling System - Test ........................................... 42
Engine Oil Cooler - Inspect ................................... 44
Water Temperature Regulator - Test ..................... 44
Basic Engine
Piston Ring Groove - Inspect ................................ 46
Connecting Rod - Inspect ..................................... 46
Connecting Rod Bearings - Inspect ...................... 47
Main Bearings - Inspect ........................................ 47
Cylinder Block - Inspect ........................................ 47
Cylinder Head - Inspect ........................................ 47
Piston Height - Inspect .......................................... 48
Flywheel - Inspect ................................................. 49
Flywheel Housing - Inspect ................................... 50
Gear Group - Inspect ............................................ 51
Electrical System
Alternator - Test .................................................... 53
Battery - Test ......................................................... 54
4 SENR9834-02

i02558828
General Information
Note: When you are ordering new parts, refer

to the engine identification number in order to
receive the correct parts. Refer to the Operation
and Maintenance Manual, “Product Identification
Information” for the correct numbers for your engine.
The 800 Series engines are in-line four cylinder

engines. The engines are controlled by a
mechanically governed fuel injection pump.
The engines have been designed for many different

applications. These engines are available in two
different types of aspiration:
• Naturally aspirated
• Turbocharged
Lifting the Engine

NOTICE
Failure to follow recommended procedures for han-
dling or transporting engines can lead to engine dam-
age.
To avoid possible engine damage, use the following

procedure.
When you are lifting or moving the engine, use the

following procedures in order to prevent engine
damage.
1. Do not tilt the engine to an extreme angle unless

the lubricating oil is first drained from the oil pan.
2. Do not turn the engine onto a side or an end

surface unless the lubricating oil is first drained
from the oil pan.
3. If the oil is not drained prior to tilting the engine or

turning the engine onto a side or an end surface,
the lubricating oil from the oil pan can flow into
the intake manifold and the cylinder bores. This
situation could cause a hydraulic lock in the
engine. Hydraulic lock can severely damage the
engine.
4. The engine oil should be refilled to the correct

level before the engine is started.
SENR9834-02 5
Naturally Aspirated Engine Views
g01280834
Illustration 1
Left side view of the naturally aspirated engine
(1) Fuel injector (8) Flywheel housing (15) Fuel injection pump
(2) Bus bar with glow plugs (9) Flywheel (16) Fan
(3) Oil filler cap (top) (10) Engine oil filter (17) Oil filler cap (front)
(4) Engine lifting bracket (11) Engine oil relief valve (18) Water pump
(5) Intake manifold (12) Oil drain plug (19) Engine oil cooler
(6) Dipstick (13) Engine oil pan
(7) Coolant drain plug (14) Engine oil pressure switch
6 SENR9834-02
g01280835
Illustration 2
Right side view of the naturally aspirated engine
(20) Valve mechanism cover (24) V-Belt
(21) Water temperature regulator housing (25) Crankshaft pulley
(22) Engine lifting bracket (26) Electric starting motor
(23) Alternator (27) Exhaust manifold
SENR9834-02 7
Turbocharged Engine Views
g01280836
Illustration 3
Left side view of the turbocharged engine
(1) Fuel injector (7) Flywheel (13) Engine oil pan
(2) Bus bar with glow plugs (8) Dipstick (14) Engine oil pressure switch
(3) Intake manifold (9) Coolant drain plug (15) Fuel injection pump
(4) Engine lifting bracket (10) Engine oil filter (16) Oil filler cap (front)
(5) Closed crankcase breather (11) Engine oil relief valve (17) Water pump
(6) Flywheel housing (12) Oil drain plug (18) Engine oil cooler
8 SENR9834-02
g01280837
Illustration 4
Right side view of the turbocharged engine
(19) Valve mechanism cover (24) Crankshaft pulley (29) Exhaust manifold
(20) Engine lifting bracket (25) Electric starting motor (30) Turbocharger
(21) Water temperature regulator housing (26) Oil supply line for turbocharger (31) Oil filler cap (top)
(22) Alternator (27) Oil drain line for turbocharger
(23) V-Belt (28) shut off valve
SENR9834-02 9
i01959149
Fuel System
g00987171
Illustration 5
Flow diagram of the fuel system
(1) Fuel injectors (4) Fuel injection pump (7) Fuel transfer pump
(2) High pressure fuel lines (5) Fuel supply line (8) Fuel filter/water separator
(3) Fuel return lines (6) Return line to the fuel tank (9) Fuel tank
The engine is equipped with a Bosch or a Denso axial When the engine is cranking, the fuel is pulled from
piston distributor injection pump that is mechanically fuel tank (9) through the primary fuel filter/water
governed. separator (8) by fuel transfer pump (7). When the fuel
passes through the water separator, any water in the
The axial piston distributor injection pump generates fuel will go to the bottom of the bowl. From the fuel
injection pressure for all cylinders in a single pump. transfer pump, the fuel passes through fuel supply
The injection pump is responsible for the distribution line (5) to fuel injection pump (4).
of fuel to the fuel injectors. The injection pressure
is generated by an axially moving piston. The
movement of the piston is parallel to the fuel injection
pump shaft.
10 SENR9834-02
The fuel is drawn by an internal fuel transfer pump

into the fuel injection pump. A portion of the fuel
is routed through the pressure regulator assembly
to the suction side of the fuel injection pump. The
fuel that is under pressure from the fuel transfer
pump flows to the interior of the pump housing.
The pressurized fuel is routed to the pumping
chamber. As the plunger rotates and as the plunger
reciprocates, high pressure fuel is routed through
high pressure fuel lines (2) to fuel injectors (1).
The fuel injectors spray atomized fuel into the

cylinder. Excess fuel is routed through fuel return
lines (3) and (6) and returned to the fuel tank.
Routing excess fuel back to the fuel tank allows air in

the fuel to flow back to the fuel tank through the fuel
return line. The fuel that flows into the housing of the
fuel injection pump performs the following functions:
• Lubricate the internal components.

• Cool the internal components.
• Remove small air bubbles.
The fuel injection pump needs fuel for lubrication.
The precision parts of the pump are easily damaged.
The engine must not be started until the fuel injection
pump is full of fuel. The system must be primed when
any part of the system is drained of fuel. The fuel
system needs priming when a fuel filter is changed,
and/or when a fuel line is removed, and/or when the
fuel injection pump is replaced.
SENR9834-02 11
Fuel Injection Pump
g00992842
Illustration 6
Components of the fuel injection pump (typical example)
(1) Control lever (6) Fuel shutoff solenoid (11) Plunger
(2) Flyweights (7) Head of the distributor (12) Cam
(3) Screw for adjusting the full load setting (8) Control sleeve (13) Timer
(4) Drive shaft (9) Transfer pump (14) Plunger spring
(5) Governor lever (10) Holder for the rollers (15) Delivery valve
The fuel injection pump is a pressurized system Fuel Delivery

that is totally enclosed. The pump sends the correct
amount of fuel under high pressure at the correct
time through the fuel injectors to the individual
cylinders. The correct timing occurs near the end
of the compression stroke. The fuel injection pump
regulates the amount of fuel that is delivered to the
fuel injectors. This action controls the engine rpm by
the governor setting or the position of the throttle
control.
The fuel lines to the fuel injectors are equal lengths.

This ensures even pressure and correct injection
timing at each fuel injector.
During operation, extra fuel is used as coolant and

g00531644
lubricant for pump parts that move. The extra fuel is Illustration 7
circulated through the pump housing. The extra fuel Cross section view of the fuel injection pump (typical example)
is then returned to the fuel tank. Fuel return lines also (4) Drive shaft
carry away any air that is trapped in the fuel injectors (6) Fuel shutoff solenoid
or in the fuel injection pump housing. (8) Control sleeve
(12) Cam
(14) Plunger spring
(15) Delivery valve
(16) Gear
12 SENR9834-02
The fuel injection pump transfers fuel to the fuel Fuel Injectors
injectors at high pressure. Cam (12) is driven from
the engine by drive shaft (4). The drive shaft is driven Naturally Aspirated Engines (Indirect
from the front gear group. Lobes on the cam cause
the plunger to reciprocate. The reciprocating motion Injection)
first draws the fuel into the pump. The reciprocating
motion then pressurizes the fuel.
The plunger also rotates with the cam in order to

sequentially align the discharge groove of the cam
with each of the ports on the fuel injection pump. The
plunger moves a distance which is established by
the lobes of the cam.
The effective stroke is established by the position of

the control sleeve. When control sleeve (8) is moved
to the left prior to the injection of fuel, the spill port
is uncovered. Uncovering the spill port reduces the
amount of fuel that is delivered to the cylinder. When
the control sleeve is moved to the right prior to the
injection of fuel, the spill port is covered. Covering
the spill port increases the amount of fuel that is
delivered to the fuel injector.
The pump also includes an internal timer (not shown).

The timer allows early fuel injection by advancing
the plunger. The plunger is advanced in relation to g00993073
Illustration 8
the camshaft. Fuel shutoff solenoid (6) is normally Cross section of the fuel injector
closed. When a voltage is applied, the plunger in the (1) Fuel inlet
solenoid moves up in order to allow the fuel delivery (2) Body
which allows the engine to run. (3) Fuel return
(4) Retaining nut
(5) Pressure spring
Timing Control System (if equipped) (6) Nozzle tip assembly
The timing control system deactivates the load The fuel injection pump forces the fuel to flow under
sensing timer when the engine coolant temperature high pressure to the hole in fuel inlet (1). The fuel
is below 60 °C (140 °F). then flows down through body (2) to the underside of
the needle in nozzle tip assembly (6). The pressure
of the fuel pushes the needle valve and pressure
spring (5). When the force of the fuel pressure is
greater than the force of the pressure spring, the
needle valve will lift up.
When the needle valve opens, fuel under high

pressure will flow through the single orifice and into
the cylinder. The fuel is injected into the cylinder as
a very fine spray. When the fuel is injected into the
cylinder, the force of the fuel pressure in the nozzle
body will decrease. The force of the pressure spring
will then be greater than the force of the fuel pressure
that is in the nozzle body. The needle valve will move
quickly to the closed position.
The seat of the needle valve has a close fit with the
inside of the nozzle. This makes a positive seal when
the valve is closed.
SENR9834-02 13
When the fuel is injected into the cylinder, a small When the fuel is injected into the cylinder, a small
quantity of fuel will leak into the chamber that contains quantity of fuel will leak into the chamber that contains
the pressure spring. This fuel lubricates the moving the pressure spring. This fuel lubricates the moving
parts of the fuel injector. This fuel then goes through parts of the fuel injector. This fuel then goes through
a passage in the body of the fuel injector to fuel return a passage in the body of the fuel injector to fuel return
(3). This excess fuel is then returned to the fuel tank. (2). This excess fuel is then returned to the fuel tank.
Turbocharged Engines (Direct Injection)
g00993074
Illustration 9
Cross section of the fuel injector
(1) Fuel inlet
(2) Fuel return
(3) Body
(4) Pressure spring
(5) Retaining nut
(6) Nozzle tip
The fuel injection pump forces the fuel to flow under

high pressure to the hole in fuel inlet (1). The fuel
then flows down through body (3) to the underside
of the needle in nozzle tip (6). The pressure of the
fuel pushes the needle valve and pressure spring (4).
When the force of the fuel pressure is greater than
the force of the pressure spring, the needle valve will
lift up.
When the needle valve opens, fuel under high

pressure will flow through the multiple orifices in the
nozzle tip and into the cylinder. The fuel is injected
into the cylinder as a very fine spray. When the fuel
is injected into the cylinder, the force of the fuel
pressure in the nozzle body will decrease. The force
of the pressure spring will then be greater than the
force of the fuel pressure that is in the nozzle body.
The needle valve will move quickly to the closed
position.
The seat of the needle valve has a close fit with the
inside of the nozzle. This makes a positive seal when
the valve is closed.
14 SENR9834-02
i01959150
g00987178
Illustration 10
Flow diagram of the air inlet and exhaust system
(1) Turbocharger (2) Exhaust (3) Air inlet
The components of the air inlet and exhaust system

control the quality of air and the amount of air that is
available for combustion.
Naturally aspirated engines pull outside air through

air inlet (3) of an air cleaner directly into the intake
manifold. The air flows through the intake manifold
which directs an even distribution of the air to each
engine cylinder. The air is pulled into the engine
cylinder during the intake stroke of the piston. Fuel is
mixed with the air in the engine cylinders during the
compression stroke. After the fuel combustion occurs
in the engine cylinder, the exhaust gases flow directly
to the outside air through the exhaust (2).
SENR9834-02 15
Turbocharged engines pull outside air through Turbocharger (if equipped)

air inlet (3) of an air cleaner into the air inlet
of turbocharger (1). The suction is caused by
the turbocharger compressor wheel. Then, the
turbocharger compressor wheel compresses the
air. The air flows through the intake manifold which
directs an even distribution of the air to each
engine cylinder. The air is pulled into the engine
cylinder during the intake stroke of the piston. Fuel
is mixed with the air in the engine cylinders during
the compression stroke. After the fuel combustion
occurs in the engine cylinder, the exhaust gases
flow to the exhaust manifold. The exhaust gases
from the exhaust manifold enter the turbine side of
the turbocharger in order to turn the turbocharger
turbine wheel. The turbine wheel is connected to
the same shaft that drives the compressor wheel.
Exhaust gases from the turbocharger pass through
the exhaust outlet and to exhaust (2).
Each piston makes four strokes for one complete

cycle in two revolutions of the crankshaft.
g00302786
Illustration 11
1. Intake
Components of a turbocharger (typical example)
During the intake stroke, the piston moves down (1) Air inlet
and air is drawn into the cylinder through the open (2) Compressor housing
(3) Compressor wheel
inlet valve. (4) Bearing
(5) Oil inlet port
2. Compression (6) Bearing
(7) Turbine housing
During the compression stroke, the valves are (8) Turbine wheel
(9) Exhaust outlet
closed and the piston moves up in the cylinder (10) Oil outlet port
in order to compress the air. As the air is (11) Exhaust inlet
compressed, the temperature increases. As the
piston nears the top of the stroke, fuel is injected The turbocharger is mounted on the exhaust
into the combustion chamber on top of the piston. manifold. All the exhaust gases from the engine go
The fuel mixes with the hot compressed air in through the turbocharger. The exhaust gases enter
order to cause combustion. the turbine housing (7) through the exhaust inlet
(11). The exhaust gases then push the blades of the
3. Power turbine wheel (8). The turbine wheel is connected by
a shaft to the compressor wheel (3).
During the power stroke, the valves are closed as
the forces from combustion push the piston and When the load on the engine increases, more fuel is
connecting rod down turning the crankshaft. injected into the cylinders. The combustion of this
additional fuel produces more exhaust gases. The
4. Exhaust additional exhaust gases cause the turbine and the
compressor wheels of the turbocharger to turn faster.
During the exhaust stroke, the inertial force of As the compressor wheel turns faster, more air is
the turning flywheel helps continue the rotation of forced into the cylinders. The increased flow of air
the crankshaft in order to push up the piston in gives the engine more power by allowing the engine
the cylinder. This action forces the burned gases to burn the additional fuel with greater efficiency.
out of the exhaust valve. This completes the four
strokes of the piston. Bearings (4) and (6) for the turbocharger use engine
oil under pressure for lubrication and cooling. The
oil comes in through the oil inlet port (5). The oil
then goes through passages in the center section in
order to lubricate the bearings. This oil also cools the
bearings. Oil from the turbocharger passes through
the oil outlet port (10) in the bottom of the center
section. The oil then returns to the engine oil pan.
16 SENR9834-02
Valve System Components
g00986774
Illustration 12
Valve system components
(1) Rocker arm
(2) Valve spring
(3) Pushrod
(4) Valve
(5) Lifter
The valve system components control the flow of

inlet air into the cylinders during engine operation.
The valve system components also control the flow
of exhaust gases out of the cylinders during engine
operation.
The crankshaft gear drives the camshaft gear

through an upper idler gear. The camshaft must be
timed to the crankshaft in order to get the correct
relationship between the piston movement and the
valve movement.
The camshaft has two camshaft lobes for each

cylinder. The lobes operate the inlet and exhaust
valves. Each cylinder has one inlet valve and one
exhaust valve. As the camshaft rotates, the lobes
cause the lifter (5) to move the pushrod (3) up and
down. The upward movement of the pushrod against
the rocker arm (1) results in downward movement
(opening) of the valve (4). The valve spring (2) closes
the valves when the lifters move down.
SENR9834-02 17
i02558237
Lubrication System
g00987199
Illustration 13
Flow diagram of the lubrication system
(1) Piston cooling jets (8) Crankshaft
(2) Rocker arm shaft (9) Engine oil pump
(3) Camshaft (10) Engine oil filter
(4) Main oil gallery (11) Engine oil pan
(5) Engine oil cooler (12) Engine oil safety valve
(6) Idler gear (13) External line (supply)
(7) Engine oil relief valve (14) Turbocharger
Pressure for the lubrication system is supplied by an Lubricating oil from the engine oil pan (11) flows
engine oil pump (9). The gerotor type pump has an through a strainer and a pipe to the suction side of
inner rotor and an outer rotor. The axis of rotation of the engine oil pump. The lubricating oil flows from
the rotors are off-center relative to each other. the outlet side of the pump through a passage to the
engine oil filter (10).
The inner rotor has four lobes which mesh with the
five lobes of the outer rotor. When the pump rotates, The oil then flows from the filter head through a pipe
the distance increases between the lobes of the outer to the engine oil cooler (5). The plate type oil cooler
rotor and the lobes of the inner rotor in order to create is located on the left side of the cylinder block. From
suction. When the distance decreases between the the engine oil cooler, the oil then flows to the main oil
lobes, pressure is created. gallery (4) that is located along the left side of the
cylinder block.
18 SENR9834-02
Lubricating oil from the main oil gallery flows through

high pressure passages to the main bearings of
the crankshaft (8). The oil then flows through the
passages in the crankshaft to the connecting rod
bearing journals.
The pistons and the cylinder bores are lubricated by

the splash of oil from piston cooling jets (1), which
are connected to the main oil gallery.
Lubricating oil from the main oil gallery flows through

passages in the cylinder block to the journals of the
camshaft (3). The oil then flows from the camshaft at
a reduced pressure to the cylinder head. The oil flows
into the rocker arm shaft (2) at a reduced pressure
to the bearings of the rocker arm levers. The valve
stems, the valve springs and the valve lifters are
lubricated by the splash and the oil mist.
The hub of the idler gear (6) is lubricated by oil from

the main oil gallery. The timing gears are lubricated
by the splash from the oil.
Turbochargers (14) are lubricated by oil from a

connection on the right hand side of the cylinder
block. An external line (13) that is connected
from the main oil gallery supplies oil to the top of
the turbocharger. The oil then flows through the
turbocharger. An external line that is connected to
the bottom of the turbocharger returns the oil to the
engine oil pan.
Engine oil relief valve (7) is installed in order to

prevent damage to the lubricating system. The engine
oil relief valve helps keep a constant oil pressure
throughout the engine. If the main system relief valve
fails to open, the high engine oil pressure can cause
damage to engine components. In order to limit the
possibility of engine damage due to a malfunctioning
relief valve, the lubrication system contains a backup
system for engine oil relief valve (7). Engine oil safety
valve (12) is located inside engine oil pan (11) on the
bottom of the cylinder block.
SENR9834-02 19
i01964002
Cooling System
g00987289
Illustration 14
Flow diagram of the cooling system
(1) Radiator (4) Bypass tube (7) Engine oil cooler
(2) Water temperature regulator housing (5) Water pump
(3) Cylinder head (6) Water jacket in the cylinder block
The coolant flows from the bottom of radiator (1) to a The coolant then passes from the entire length of the
centrifugal water pump (5). The water pump assists cylinder block through passages and into the cylinder
in the flow of the coolant through the system. The head (3).
water pump is installed on the front of the timing case
and the pump is driven by a belt from the crankshaft The coolant flows forward through the cylinder head
pulley. and into the water temperature regulator housing
(2). If the water temperature regulator is closed,
The water pump forces the coolant through a the coolant goes directly through the bypass tube
passage in the front of the water jacket in the cylinder (4) to the inlet side of the water pump. If the water
block (6). temperature regulator is open, the bypass is closed
and the coolant flows to the top of the radiator.
Some of the coolant passes into the engine oil cooler
(7). The coolant flows around the element of the oil
cooler back into the cylinder block.
20 SENR9834-02
i01959151 The journals of the camshaft run directly in the bores

of the cylinder block. Thrust washer (2) is located at
Basic Engine the rear of the block in order to control the end play
of the crankshaft.
The basic engine components are described in this Cylinder Head

section.
• Cylinder block
• Cylinder head
• Pistons and connecting rods
• Crankshaft
• Camshaft
• Timing case and gears
• Flywheel and flywheel housing
Cylinder Block
g00987347
Illustration 16
Exploded view of the cylinder head
(1) Valve mechanism cover
(2) Rocker shaft assembly
(3) Valve keepers
(4) Valve spring retainer
(5) Valve seal
(6) Valve spring
(7) Valve guide
(8) Cylinder head
(9) Cylinder head gasket
(10) Valve seat insert
g00987345 (11) Valve
Illustration 15
Exploded view of the cylinder block The cast iron cylinder head (8) is fastened to the
(1) Cylinder block top of the cylinder block by seventeen setscrews.
(2) Thrust washer A cylinder head gasket (9) is used between the
engine block and the cylinder head in order to seal
Cylinder block (1) is made of cast iron with an integral combustion gases, coolant, and oil. The inlet and
crankcase. The four cylinders are arranged in-line. exhaust ports are designed to improve the air flow.
The sides of the block extend below the centerline of
the crankshaft in order to provide added strength.
The cylinder block provides full support for the length
of the cylinder bores. The cylinder sleeves are
integral with the cylinder block.
SENR9834-02 21
The cylinder head assembly has two overhead valves Pistons (2) have a combustion chamber in the top of
(11) for each cylinder. Each valve is held in place by a the piston. The bowl in the piston head ensures an
single valve spring (6), a valve spring retainer (4), and efficient mix of fuel and air.
two valve keepers (3). The cylinder head has steel
valve seat inserts (10) for both the inlet and exhaust Piston rings (1) consist of two compression rings and
valves. The valves move in steel valve guides (7). an oil control ring. The groove in the piston for the
Each valve guide is equipped with a synthetic rubber top ring has a hard metal insert that reduces wear of
valve seal (5). The exhaust valve guides have the groove. The piston skirt has a layer of graphite in
a counterbore in order to prevent seizure of the order to improve the wear characteristics. The fully
valve stem that is caused by a buildup of carbon floating piston pin (3) is held in an axial location by
underneath the head of the valve. Both the valve seat retaining rings (4). The piston pin is placed off-center
inserts and the valve guides can be renewed. in order to reduce the noise level.
The overhead valves are operated by a rocker All engines are equipped with piston cooling jets. The
shaft assembly (2) that is installed under a valve piston cooling jets spray lubricating oil onto the inner
mechanism cover (1). The rocker arms are operated surface of the piston in order to cool the piston.
by cold drawn pushrods with hardened heads. The
rocker shaft is supported by four brackets that The correct piston height is important in order to
support the rocker shaft between each pair of valves. ensure that the piston does not contact the cylinder
The rocker shaft assembly and valve components head and that the fuel has efficient combustion. The
are lubricated by an oil flow from the hollow rocker pistons and connecting rods (6) are matched to each
shaft. The rocker shaft receives a reduced oil flow cylinder.
from the oil feed of the camshaft.
The connecting rod and the connecting rod cap
Valve lash is adjusted by adjustment screws and are machined on the surfaces in order to provide a
locknuts at the pushrod end of each rocker arm. smooth mating surface. The cap is held in position by
a pair of bolts with nuts.
The valve mechanism cover also contains an oil filler
cap and breather pipe. Crankshaft
Pistons and Connecting Rods
g00987351
Illustration 18
Exploded view of the crankshaft
g00987348
Illustration 17 (1) Main bearings
Exploded view of the piston and connecting rod (2) Crankshaft
(3) Crankshaft gear
(1) Piston rings (4) Main bearing cap
(2) Piston (5) Thrust washers
(3) Piston pin
(4) Retaining rings
(5) Piston pin bearing Crankshaft (2) is forged from chrome molybdenum
(6) Connecting rod steel. The crankshaft has five main bearing journals
(7) Connecting rod bearing and four connecting rod bearing journals. The
flywheel is attached to the large flange at the rear of
the crankshaft.
22 SENR9834-02
End play of the crankshaft is controlled by three Timing Case and Gears
thrust washers (5). Two thrust washers are located on
both sides of the rear main bearing. The third thrust
washer is located on the rear face of the cylinder
block (Illustration 15).
Main bearings (1) have steel backs with an aluminum

and tin bearing material. Main bearing caps (4) are
made of cast iron.
Crankshaft gear (3) is held on the tapered shaft of the

crankshaft by a pair of woodruff keys. The crankshaft
pulley is held in position by a nut on the front of the
crankshaft.
Camshaft Illustration 20
g00987354
Exploded view of the timing case and gears

(1) Camshaft gear
(2) Fuel injection pump gear
(3) Upper idler gear
(4) Crankshaft front seal
The timing case is constructed of either aluminum

or cast iron. The timing case cover contains the
crankshaft front seal (4).
There are two different types of timing gears, helical

gears and spur gears if a PTO is installed. The
crankshaft gear (not shown) drives an upper idler
gear (3). The upper idler gear drives the camshaft
Illustration 19
g00994980 gear (1), the fuel injection pump gear (2), and the oil
pump gear (not shown).
Exploded view of the camshaft
(1) Thrust washer The camshaft and the fuel injection pump run at half
(2) Camshaft
the speed of the crankshaft. The oil pump runs at
three quarters of the speed of the crankshaft.
The engine has a single camshaft (2) that is made of
cast iron. The camshaft has four sets of lobes. Each
set of lobes controls the movement of the inlet and
exhaust valves for each cylinder.
The camshaft is driven at the front end by the

camshaft gear. As the camshaft rotates, the camshaft
lobes move the valve system components. The valve
system components move the cylinder valves.
The camshaft gear must be timed to the crankshaft

gear. The relationship between the lobes of the
camshaft and the camshaft gear causes the valves
in each cylinder to open at the correct time. The
camshaft gear is held on the tapered shaft of the
camshaft by a woodruff key.
End play of the camshaft is controlled by thrust

washer (1) that is mounted in front of the camshaft.
The thrust washer is held in place by two bolts in the
cylinder block.
SENR9834-02 23
Flywheel and Flywheel Housing Electric Starting Motor
g00986944
Illustration 22
(1) Electric starting motor
Electric starting motor (1) turns the engine flywheel.

The rpm must be high enough in order to initiate
a sustained operation of the fuel ignition in the
Illustration 21
g00988009 cylinders.
Exploded view of the flywheel and flywheel housing
The starting motor has a solenoid. When the ignition
(1) Gasket switch is activated, voltage from the electrical system
(2) Flywheel housing
(3) Crankshaft rear seal
will cause the solenoid to move the pinion toward
(4) Flywheel the flywheel ring gear of the engine. The electrical
contacts in the solenoid close the circuit between
Flywheel (4) and the flywheel housing (2) are made the battery and the starting motor barely before the
of cast iron. The flywheel housing contains the pinion engages the ring gear. This causes the starting
crankshaft rear seal (3). motor to rotate. This type of activation is called a
positive shift.
i02558823 When the engine begins to run, the overrunning

clutch of the pinion drive prevents damage to the
Electrical System armature. Damage to the armature is caused by
excessive speeds. The clutch prevents damage by
stopping the mechanical connection. However, the
pinion will stay meshed with the ring gear until the
The electrical system is a negative ground system. ignition switch is released. A spring in the overrunning
The charging circuit operates when the engine clutch returns the clutch to the rest position.
is running. The alternator in the charging circuit
produces direct current for the electrical system.
Alternator
The components of the electrical system for the
engine are described in this section.
• Electric starting motor

• Alternator
• Glow plugs
g01280832
Illustration 23
(1) Alternator
24 SENR9834-02
Alternator (1) is an electro-mechanical component The electrically operated glow plugs are installed in
that is driven by a belt from the crankshaft pulley. the cylinder head near the fuel injection nozzles. The
The alternator charges the storage battery during the glow plugs are connected by a bus bar.
engine operation.
On naturally aspirated engines (indirect injection), the
The alternator converts the mechanical energy tips of the glow plugs reach into the precombustion
and the magnetic energy into alternating current chamber in the cylinder head.
and voltage. This conversion is done by rotating a
direct current electromagnetic field on the inside of On turbocharged engines (direct injection), the tips
a three-phase stator. The electromagnetic field is of the glow plugs reach into the combustion chamber
generated by electrical current flowing through a in the piston crown.
rotor. The stator generates alternating current and
voltage. When the glow plugs are energized, the tips become
very hot in order to improve the combustion during
The alternating current is changed to direct current cold start conditions.
by a three-phase, full-wave rectifier. Direct current
flows to the output terminal of the alternator. The
rectifier has three exciter diodes. The direct current
is used for the charging process.
A solid-state regulator is installed on the rear end of

the alternator. Two brushes conduct current through
two slip rings. The current then flows to the rotor field.
A capacitor protects the rectifier from high voltages.
The regulators are sealed and repair is not possible.
The alternator is cooled by an internal fan which is

covered by the alternator housing. The fan pulls air
through the holes in the front of the alternator. The air
exits through the holes in the back of the alternator.
The diodes, the resistors, and the brushes are also

covered by the alternator housing in order to protect
the components from dirt and moisture.
The alternator is connected to the battery through

the ignition switch. Therefore, alternator excitation
occurs when the switch is in the ON position.
Glow Plugs
g00986945
Illustration 24
Typical example
SENR9834-02 25
Testing and Adjusting 2. Install a suitable fuel flow tube with a visual sight
gauge in the fuel return line. When possible, install
Section the sight gauge in a straight section of the fuel line
that is at least 304.8 mm (12 inches) long. Do not
install the sight gauge near the following devices
that create turbulence:
Fuel System
• Elbows
i01804057
• Relief valves
Fuel System - Inspect • Check valves
Observe the fuel flow during engine cranking.
A problem with the components that send fuel to Look for air bubbles in the fuel. If there is no fuel
the engine can cause low fuel pressure. This can that is present in the sight gauge, prime the fuel
decrease engine performance. system. Refer to Testing and Adjusting, “Fuel
System - Prime” for more information. If the engine
1. Check the fuel level in the fuel tank. Ensure that starts, check for air in the fuel at varying engine
the vent in the fuel cap is not filled with dirt. speeds. When possible, operate the engine under
the conditions which have been suspect.
2. Check all fuel lines for fuel leakage. The fuel lines
must be free from restrictions and faulty bends.
Verify that the fuel return line is not collapsed.
3. Inspect the fuel filter for excess contamination. If

necessary, install a new fuel filter. Determine the
source of the contamination. Make the necessary
repairs.
4. Service the primary fuel filter (if equipped).
5. Remove any air that may be in the fuel system.

Refer to Testing and Adjusting, “Fuel System -
Prime”.
i01854200
Air in Fuel - Test
g00578151
This procedure checks for air in the fuel system. This Illustration 25
procedure also assists in finding the source of the air. (1) A steady stream of small bubbles with a diameter of
approximately 1.60 mm (0.063 inch) is an acceptable amount
of air in the fuel.
1. Examine the fuel system for leaks. Ensure that (2) Bubbles with a diameter of approximately 6.35 mm (0.250 inch)
the fuel line fittings are properly tightened. Check are also acceptable if there is two seconds to three seconds
the fuel level in the fuel tank. Air can enter the intervals between bubbles.
fuel system on the suction side between the fuel (3) Excessive air bubbles in the fuel are not acceptable.
transfer pump and the fuel tank.
3. If excessive air is seen in the sight gauge in the
fuel return line, install a second sight gauge at the
inlet to the fuel transfer pump. If a second sight
gauge is not available, move the sight gauge from
Work carefully around an engine that is running. the fuel return line and install the sight gauge
Engine parts that are hot, or parts that are moving, at the inlet to the fuel transfer pump. Observe
can cause personal injury. the fuel flow during engine cranking. Look for air
bubbles in the fuel. If the engine starts, check for
air in the fuel at varying engine speeds.
26 SENR9834-02
If excessive air is not seen at the inlet to the fuel 3. Rotate the crankshaft further by 1/8 of a turn
transfer pump, the air is entering the system after in a clockwise direction. Insert a suitable lever
the fuel transfer pump. Refer to the Testing and between the rocker lever and the valve spring cap
Adjusting, “Fuel System - Prime”. of the No. 1 inlet valve. Open the inlet valve. Put a
spacer that is approximately 5 mm (0.2 inch) thick
If excessive air is seen at the inlet to the fuel between the valve stem and the rocker lever.
transfer pump, air is entering through the suction
side of the fuel system. 4. Slowly rotate the crankshaft in a counterclockwise
direction until the piston makes contact with
the open valve. Make a temporary mark on the
damper or the pulley in order to align accurately
with the tip of the pointer.
To avoid personal injury, always wear eye and face
protection when using pressurized air. 5. Rotate the crankshaft in a clockwise direction
by one or two degrees. Remove the spacer
NOTICE that is between the valve stem and the rocker
To avoid damage, do not use more than 55 kPa (8 psi) lever. Rotate the crankshaft by 1/4 of a turn in a
to pressurize the fuel tank. counterclockwise direction. Put a spacer that is
approximately 5 mm (0.2 inch) thick between the
valve stem and the rocker lever of the No. 1 inlet
4. Pressurize the fuel tank to 35 kPa (5 psi). Do valve.
not use more than 55 kPa (8 psi) in order to
avoid damage to the fuel tank. Check for leaks in 6. Slowly rotate the crankshaft clockwise until the
the fuel lines between the fuel tank and the fuel piston makes contact with the open valve. Make
transfer pump. Repair any leaks that are found. another temporary mark on the damper or the
Check the fuel pressure in order to ensure that pulley in order to align accurately with the tip of
the fuel transfer pump is operating properly. For the pointer.
information about checking the fuel pressure, see
Testing and Adjusting, “Fuel System Pressure - 7. Make a temporary mark at the center point
Test”. between the two marks on the damper or the
pulley. Remove the other two marks. Rotate the
5. If the source of the air is not found, disconnect crankshaft by 1/8 of a turn in a counterclockwise
the supply line from the fuel tank and connect an direction. Remove the spacer between the valve
external fuel supply to the inlet of the fuel transfer stem and the rocker lever.
pump. If this corrects the problem, repair the fuel
tank or the stand pipe in the fuel tank. 8. Slowly rotate the crankshaft in a clockwise
direction until the mark on the damper or the
pulley, which was made in Step 7, aligns with the
i01959152
tip of the pointer. The No. 1 piston is now at the
Finding Top Center Position top center on the compression stroke.
for No. 1 Piston

i02326777
Fuel Injection Timing - Check

Note: The crankshaft may be turned by using a
socket wrench on the setscrew in the crankshaft
pulley. Table 1
1. Remove the valve mechanism cover.

Required Tools
2. Rotate the crankshaft clockwise when you face
the front of the engine. Rotate the crankshaft until Part Part Description Qty
the pushrod for the inlet valve of the rear cylinder Number
begins to tighten. 21825617 Dial gauge 1
21825526 Timing pin for fuel injection pump 1
Incorrect fuel injection timing can cause poor engine

performance.
SENR9834-02 27
Fuel injection timing ....................................... 5° BTC
1. Remove the valve mechanism cover. Refer to

Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install”. Rotate the crankshaft
in the normal direction of the engine until the inlet
valve of the No. 4 cylinder has just opened and
the exhaust valve of the No. 4 cylinder has not
completely closed.
g01025444
Illustration 28
g00565561 3. Remove the plug (1) that is located at the center

Illustration 26
of the rear face of the fuel injection pump. Install
Turning the engine the timing pin for the fuel injection with the dial
indicator in order to measure the cam lift.
2. Align the TC mark on the crankshaft pulley with
the pointer on the timing case. 4. Rotate the crankshaft in the opposite direction
of the engine until the reading on the dial gauge
stabilizes at the bottom of the lift of the plunger in
the pump. Set the dial indicator to zero.
g00994700
Illustration 27
(1) Plug
g01011407
Illustration 29
5. Rotate the crankshaft in the normal direction of the

engine until the 5° mark on the crankshaft pulley
is aligned with the pointer on the timing case.
6. Record the reading on the dial indicator. The

reading should be 0.5 mm (0.020 inch).
28 SENR9834-02
Bench test the fuel injectors at a temperature of

18° to 20 °C (64° to 70 °F).
g01024431
Illustration 30
Positioning the fuel injection pump
g00994438
Illustration 31
7. To adjust the timing of the fuel injection pump, (1) Connections for the high pressure fuel lines
loosen the flange nuts and move the pump in
order to achieve a reading of 0.5 mm (0.020 inch). 1. Run the engine at low idle.
8. With the cam lift at 0.5 mm (0.020 inch), secure 2. Loosen the connection for the high pressure fuel
the pump in position. line (1) at the fuel injector on No. 1 cylinder. Do not
loosen the nut more than half of a turn. Listen for
9. Remove the tooling from the rear of the fuel the low idle to decrease or become rough. Tighten
injection pump. Install the plug (1) into the the nut for the fuel supply line on No. 1 cylinder.
rear of the fuel injection pump and tighten to Perform this test on each cylinder.
1.4 to 2.0 N·m (12.3910 to 17.7015 lb in).
3. The fuel injector is faulty when the nut for the fuel
10. Install the valve mechanism cover. Refer to supply line is loosened and the following events
Disassembly and Assembly, “Valve Mechanism occur:
Cover - Remove and Install”.
• The engine rpm does not decrease.
11. Eliminate all air from the fuel system. Refer to
Testing and Adjusting, “Fuel System - Prime”. • The engine does not idle roughly.
4. Remove the fuel injector for additional testing.
i01963609
Fuel Injector - Test Note: If leakage occurs at the nut for the fuel supply
line, make sure that the fuel supply line and the nut
are correctly aligned with the inlet connection of fuel
injector. Do not tighten the nut for the fuel supply
line on the high pressure fuel line more than the
Test the Fuel Injectors recommended torque. If the nut is tightened more,
the fuel line may become restricted or the threads of
the fuel injector and the nut may be damaged.
Ensure that you wear eye protection at all times Cleaning of the fuel injectors
during testing. When fuel injectors are tested, test
fluids travel through the orifices of the nozzle tip Before a fuel injector is tested, remove any loose
with high pressure. Under this amount of pres- carbon from the tip of the fuel injector. Do not use
sure, the test fluid can pierce the skin and cause abrasive material or a wire brush in order to clean
serious injury to the operator. Always keep the tip the nozzle.
of the fuel injector pointed away from the operator
and into the fuel collector and extension. The fuel injector is not a serviceable part.
Disassembling or adjusting the nozzle will violate the
standards for emissions.
Perform the following procedures in order to
determine if a fuel injector does not work correctly.
SENR9834-02 29
Note: Extra care should be used in handling the fuel Position the fuel injector so that the fuel spray
injector in order to prevent damage to the nozzle tip. is directed into the extension (4) and the fuel
A scratch or a burr could cause needle leakage or collector (5).
spray distortion. Dirt in the orifices of the nozzle tip
can damage engine components. Dirt can also distort Use clean calibration fluid when the fuel injectors
the spray pattern of the nozzle. are tested. The calibration fluid should be
equivalent to SAE J-967 (ISO 4113) oil.
Pressure Test 2. Close the gauge protector valve. Close the shutoff
valve. Open the pump isolator valve. In order to
flush the fuel injector, operate the nozzle tester
for 10 to 15 strokes at a rate of approximately 60
Ensure that you wear eye protection at all times strokes per minute.
fluids travel through the orifices of the nozzle tip 3. Open the gauge protector valve. Slowly increase
with high pressure. Under this amount of pres- the pressure until the valve in the fuel injector
sure, the test fluid can pierce the skin and cause opens. Note the highest pressure indication on the
serious injury to the operator. Always keep the tip dial indicator before the pointer moves to 0 kPa
of the fuel injector pointed away from the operator (0 psi). This highest pressure indication is the
and into the fuel collector and extension. opening pressure of the fuel injector. The opening
pressure is defined when the valve needle is lifted
from the valve seat.
4. Refer to Specifications, “Fuel Injectors” for the

correct pressure settings.
If the opening pressure is not within the range of

the setting that is given, the fuel injector must be
replaced.
Back Leakage Test

1. Connect the fuel injector (2) to suitable tooling that
is similar to the Illustration 32.
Position the fuel injector so that the fuel spray

is directed into the extension (4) and the fuel
collector (5).
2. Pump the pressure to about 1030 kPa (150 psi)

below the opening pressure of the fuel injector.
g00804566
Illustration 32
Test equipment
Refer to Specifications, “Fuel Injectors” for the
correct setting of the opening pressure.
(1) Adapter
(2) Fuel injector
(3) Tube assembly Release the handle. When the pressure begins
(4) Extension to decrease, note the time that is required for
(5) Fuel collector the pressure to decrease to approximately 0 kPa
(6) Filter (0 psi). If the fuel injector is not faulty, the time
will not be less than 5 seconds or more than 45
NOTICE seconds.
Do not use dirty test fluids when you test fuel injectors.
Also, do not test fuel injectors unless you have the 3. When the test in Step 2 is done, look for any
correct service tools.The use of dirty test fluids and leakage from the pressure faces of the holder
the use of incorrect service tools will result in damage and the retaining nut of the fuel injector. If leaks
to the fuel injectors. are visible, make sure that the components are
tightened to the correct torque. Do not overtighten
the components in order to stop the leakage.
1. Connect the fuel injector (2) to suitable tooling that Instead, a pressure test on the fuel injector must
is similar to the Illustration 32. be conducted. This test may force any foreign
particles out of the nozzle. Replace the fuel
injector if there is excessive fuel leakage.
30 SENR9834-02
4. If the pressure decreases to 0 kPa (0 psi) in less

than 5 seconds, too much fuel is leaking around
the valve needle. The valve needle or the fuel
injector must be replaced in order to correct the
problem.
Fuel Injector and Seat Test

1. Connect the fuel injector (2) to suitable tooling that
is similar to the Illustration 32.
Position the fuel injector so that the fuel spray

is directed into the extension (4) and the fuel
collector (5).
g01007931
Illustration 33
2. Pump the pressure of the injector tester to Spray patterns of the fuel injectors
approximately 1030 kPa (150 psi) below the
(A) Spray pattern for indirect injection
opening pressure of the fuel injector. (B) Spray pattern for direct injection
Refer to Specifications, “Fuel Injectors” for the 1. Connect the fuel injector (2) to suitable tooling that
correct setting of the opening pressure. is similar to the Illustration 32.
A drop of fuel should not form on the tip of the fuel Position the fuel injector so that the fuel spray
injector for at least ten seconds. A light dampness is directed into the extension (4) and the fuel
is acceptable. If the results of the tests are not collector (5).
acceptable, clean the fuel injector. After you clean
the fuel injector and the fuel leakage still occurs, 2. Close the gauge protector valve and the shutoff
the nozzle must be replaced. valve. Open the pump isolator valve.
Test the Spray Pattern 3. Quickly pump the injector tester and look at the
spray pattern when the fluid begins to flow through
The pressure adjustment must be correct before the the orifices of the fuel injector.
spray pattern is tested.
The spray, which flows from all of the orifices,
must have the same pattern. The fuel injector is
faulty if there is a difference in the vertical patterns
or a difference in the horizontal patterns. Refer to
Ensure that you wear eye protection at all times the correct spray pattern in Illustration 33.
fluids travel through the orifices of the nozzle tip Note: Be sure that the gauge protector valve is
with high pressure. Under this amount of pres- closed before the fuel injector is removed from the
sure, the test fluid can pierce the skin and cause injector tester. Closing the valve will prevent damage
serious injury to the operator. Always keep the tip to the pressure gauge.
of the fuel injector pointed away from the operator
and into the fuel collector and extension.
i01944302
Fuel Quality - Test
Use the following procedure to test for problems

regarding fuel quality:
1. Determine if water and/or contaminants are

present in the fuel. Check the water separator (if
equipped). If a water separator is not present,
proceed to Step 2. Drain the water separator, if
necessary. A full fuel tank minimizes the potential
for overnight condensation.
SENR9834-02 31
Note: A water separator can appear to be full of fuel

when the water separator is actually full of water.
2. Determine if contaminants are present in the

fuel. Remove a sample of fuel from the bottom
of the fuel tank. Visually inspect the fuel sample
for contaminants. The color of the fuel is not
necessarily an indication of fuel quality. However,
fuel that is black, brown, and/or similar to sludge
can be an indication of the growth of bacteria or
oil contamination. In cold temperatures, cloudy
fuel indicates that the fuel may not be suitable for
the operating conditions. Refer to Operation and
Maintenance Manual, “Fuel Recommendations”
for more information. g00994438
Illustration 34
3. If fuel quality is still suspected as a possible (1) Connections for the high pressure fuel lines
cause of problems regarding engine performance,
disconnect the fuel inlet line, and temporarily 3. Loosen the connections for the high pressure fuel
operate the engine from a separate source of lines (1).
fuel that is known to be good. This will determine
if the problem is caused by fuel quality. If fuel 4. Operate the electric starting motor until fuel that is
quality is determined to be the problem, drain the free of air comes from the connections.
fuel system and replace the fuel filters. Engine
performance can be affected by the following 5. Tighten the connections for the high pressure fuel
characteristics: lines. Refer to Specifications, “Fuel Injection lines”
for the correct torque.
• Cetane number of the fuel
6. Start the engine and check for leaks.
• Air in the fuel
• Other fuel characteristics
i01977628
Fuel System - Prime
If air enters the fuel system, the air must be purged

before the engine can be started. Air can enter the
fuel system when the following events occur:
• The fuel tank is empty or the tank has been partially

drained during normal operation.
• The low pressure fuel lines are disconnected.

• A leak exists in the low pressure fuel system during
engine operation.
• The fuel filter or the fuel pump is replaced.

• The high pressure fuel lines are disconnected.
Use the following procedure in order to remove air
from the fuel system:
1. Turn the ignition key to the RUN position for three

minutes in order to energize the electric fuel
transfer pump. Do not start the engine.
2. Turn the ignition key to the OFF position.

32 SENR9834-02
Air Inlet and Exhaust i01959154
System Turbocharger - Inspect
i02281171

- Inspect Hot engine components can cause injury from
burns. Before performing maintenance on the
engine, allow the engine and the components to
cool.
Do a general visual inspection of the air inlet and
exhaust system. Make sure that there are no signs of
leaks in the system. NOTICE
Keep all parts clean from contaminants.
There will be a reduction in the performance of the
engine if there is a restriction or there is a leak in the Contaminants may cause rapid wear and shortened
air inlet system or the exhaust system. component life.
NOTICE
Care must be taken to ensure that fluids are contained
Hot engine components can cause injury from during performance of inspection, maintenance, test-
burns. Before performing maintenance on the ing, adjusting and repair of the product. Be prepared to
engine, allow the engine and the components to collect the fluid with suitable containers before open-
cool. ing any compartment or disassembling any compo-
nent containing fluids.
Dispose of all fluids according to local regulations and

mandates.
Making contact with a running engine can cause
burns from hot parts and can cause injury from Before you begin inspection of the turbocharger,
rotating parts. be sure that the inlet air restriction is within the
specifications for your engine. Be sure that the
When working on an engine that is running, avoid exhaust system restriction is within the specifications
contact with hot parts and rotating parts. for your engine. Refer to Testing and Adjusting, “Air
Inlet and Exhaust System - Inspect”.
1. Inspect the engine air cleaner inlet and ducting
in order to ensure that the passageway is not The condition of the turbocharger will have definite
blocked or collapsed. effects on engine performance. Use the following
inspections and procedures to determine the
2. Inspect the engine air cleaner element. Replace a condition of the turbocharger.
dirty element with a clean element.
• Inspection of the compressor wheel and the
3. Check for dirt tracks on the clean side of the compressor housing
engine air cleaner element. If dirt tracks are
observed, contaminants are flowing past the • Inspection of the turbine wheel and the turbine
element. housing
SENR9834-02 33
Inspection of the Compressor c. Inspect the engine crankcase breather. Clean

the breather or replace the breather if the
Wheel and the Compressor breather is plugged.
Housing
d. Remove the oil drain tube. Inspect the oil
drain hole and the oil drain tube for oil sludge.
Inspect the area between the bearings of the
rotating assembly shaft. If necessary, clean the
rotating assembly shaft, the oil drain hole, and
the oil drain tube.
e. If Steps 5.a through 5.d did not reveal the

source of the oil leakage, the turbocharger has
internal damage. Replace the turbocharger.
Inspection of the Turbine Wheel

and the Turbine Housing
g00922408
Illustration 35
Typical example of a turbocharger
(1) Compressor housing
(2) Compressor wheel
1. Remove the air cleaner from the compressor inlet.
2. Inspect the compressor wheel (2) for damage from

a foreign object. If there is damage, determine the
source of the foreign object. As required, clean
the inlet system and repair the intake system.
Replace the turbocharger. If there is no damage,
go to Step 3.
g00922420
3. Clean the compressor wheel (2) and the Illustration 36
compressor housing (1) if you find buildup of Typical example of a turbocharger
foreign material. If there is no buildup of foreign (1) Turbine housing
material, go to Step 4. (2) Turbine wheel
4. Turn the rotating assembly by hand. While you 1. Remove the air piping from the turbine housing.
turn the assembly, push the assembly sideways.
The assembly should turn freely. Compressor 2. Inspect the turbine wheel (2) for damage by a
wheel (2) should not rub the compressor housing foreign object. If there is damage, determine
(1). The turbocharger must be replaced if the the source of the foreign object. Replace the
compressor wheel rubs the compressor housing. turbocharger. If there is no damage, go to Step 3.
If there is no rubbing or scraping, go to Step 5.
3. Clean the turbine wheel (2) and the turbine
5. Inspect the compressor wheel (2) and the housing (1) if you find buildup of carbon or foreign
compressor housing (1) for oil leakage. material. If there is no buildup of carbon or foreign
material, go to Step 4.
a. Check the oil level in the crankcase. If the oil
level is too high, adjust the oil level.
b. Inspect the air cleaner element for restriction. If

restriction is found, correct the problem.
34 SENR9834-02
4. Turn the rotating assembly by hand. While you A very high temperature can indicate that too much
turn the assembly, push the assembly sideways. fuel is flowing to the cylinder. A malfunctioning fuel
The assembly should turn freely. Turbine wheel injector could cause this very high temperature.
(2) should not rub the turbine housing (1). Replace
the turbocharger if the turbine wheel rubs the Use a suitable laser infrared thermometer to check
turbine housing. If there is no rubbing or scraping, this exhaust temperature.
go to Step 5.
i01959155
5. Inspect the turbine wheel (2) and the turbine
housing (1) for oil leakage and oil coking. Some
oil coking may be cleaned. Heavy oil coking may
Compression - Test
require replacement of the turbocharger. If the oil
is coming from the turbocharger center housing
go to Steps 5.a through 5.e.
Compression
a. Remove the oil drain tube. Inspect the oil
drain hole and the oil drain tube for oil sludge. The following conditions can affect the results of the
Inspect the area between the bearings of the cylinder compression test:
rotating assembly shaft. If necessary, clean the
rotating assembly shaft, the oil drain hole, and • Battery
the oil drain tube.
• Condition of the starter motor
b. If the crankcase pressure is high, or if the
oil drain is restricted, pressure in the center • Ambient conditions
housing may be greater than the pressure of
the turbine housing (1). Oil flow may be forced • Quality of the compression gauge
in the wrong direction and the oil may not drain.
Check the crankcase pressure and correct any
problems.
c. If the oil drain tube is damaged, replace the

oil drain tube.
d. Check the routing of the oil drain tube.

Eliminate any sharp restrictive bends. Make
sure that the oil drain tube is not too close to
the engine exhaust manifold.
e. If Steps 5.a through 5.d did not reveal the

source of the oil leakage, the turbocharger has
internal damage. Replace the turbocharger.
i01962244
Exhaust Temperature - Test

g00564993
Illustration 37
Measure the Exhaust Temperature Checking compression of the engine
When the engine runs at low idle, the temperature of 1. Remove the fuel injector from the cylinder in order
an exhaust manifold port can indicate the condition to measure the compression for that cylinder.
of a fuel injector.
2. Connect a suitable compression gauge to the
A low temperature indicates that no fuel is flowing to cylinder.
the cylinder. An inoperative fuel injector or a problem
with the fuel injection pump could cause this low 3. Disconnect the fuel shutoff solenoid.
temperature.
4. Operate the starter motor and record the pressure
on the compression gauge.
SENR9834-02 35
5. Repeat for each cylinder. • Excessive dirt and oil are present on the filters for
the air inlet.
Note: Compression tests should only be used to
compare pressures between cylinders of an engine. • Incorrect fuel settings on the fuel injection pump.
If one or more cylinders vary more than 350 kPa
(51 psi) then those cylinders may be damaged. • The load capacity of the engine is frequently
exceeded.
Note: The cylinder compression test should not
be the only test for determining the condition of an Too much valve lash can cause broken valve stems,
engine. springs, and spring retainers. Too much valve lash
can be an indication of the following problems:
Table 2
Standard at • Worn camshaft and valve lifters
Repair Limit
Assembly
• Worn rocker arms
Compression 2940 kPa 2450 kPa
Pressure(1) (426 psi) (355 psi)
• Bent pushrods
(1) The compression pressure is taken at 250 rpm.
• Broken socket on the upper end of a pushrod
6. Repair procedures must be taken if the
compression is lower than the repair limit. • Loose adjustment screw for the valve lash
NOTICE If the camshaft and valve lifters show rapid wear,

Be sure to measure the compression on all of the cylin- look for fuel in the lubrication oil or dirty lubrication
ders. If all of the cylinders are not checked an improper oil as a possible cause.
diagnosis may result. The compression pressure will
vary with the change in engine rpm. It is necessary to Valve Lash Check
keep the engine rpm constant for all cylinders when
you are taking a compression reading. The valve lash is measured between the top of the
valve stem and the rocker arm lever.
i01959156 Valve Lash Setting (cold engine)
Engine Valve Lash - Inlet valve ....................... 0.25 mm (0.0098 inch)

Exhaust valve ................. 0.25 mm (0.0098 inch)
Inspect/Adjust
If the measurement is not within the acceptable
clearance, adjustment is necessary. Refer to “Valve
Lash Adjustment”.
Valve Lash Adjustment

To prevent possible injury, do not use the starter
to turn the flywheel. Note: The No. 1 cylinder is at the front of the engine.
Hot engine components can cause burns. Allow
additional time for the engine to cool before mea-
suring valve clearance.
If the valve lash requires adjustment several times

in a short period of time, excessive wear exists in a
different part of the engine. Repair the problem in
order to prevent more damage to the engine.
Not enough valve lash can be the cause of rapid

wear of the camshaft and valve lifters. Not enough
valve lash can indicate that the seats for the valves
are damaged.
g00987161
Valves become damaged due to the following causes: Illustration 38
Setting the valve lash
• The fuel injectors do not operate correctly. (1) Adjustment screw
(2) Feeler gauge
36 SENR9834-02
If adjustment is necessary, refer to Steps 1.a, 1.b,

and 1.c.
Accidental engine starting can cause injury or
Note: Lubricate the rocker shaft assembly with clean
death to personnel.
engine oil after the valves have been adjusted.
Lubricate the bearing surfaces on the rocker shaft,
To prevent accidental engine starting, turn the ig-
the tips of the valves, the pushrod sockets, and the
nition switch to the OFF position and place a do
pushrods so that the oil will drain in order to lubricate
not operate tag at the ignition switch location.
the lobes of the cam.
Remove the valve mechanism cover and perform the

i01962713
following procedure in order to adjust the valve lash:
1. Rotate the crankshaft in the normal rotation of the

Valve Depth - Inspect
engine. When the inlet valve of the No. 4 cylinder
has opened and the exhaust valve of the No. 4
cylinder has not completely closed measure the Table 3
valve lash of the inlet valve and the exhaust valve
of No. 1 cylinder. If necessary, make adjustment. Required Tools
a. Loosen the valve adjustment screw locknut

Part Part Description Qty
that is on adjustment screw (1).
Number
b. Place the appropriate feeler gauge (2) 27610272 Dial gauge 1
between the rocker arm and the valve stem.
21825496 Dial gauge holder 1
Turn adjustment screw (1) while the valve
adjustment screw locknut is being held from
turning. Adjust the valve lash until the correct
specification is achieved.
c. After each adjustment, tighten the valve

adjustment screw locknut to the correct torque
while adjustment screw (1) is being held from
turning.

cylinder has not completely closed measure the
of No. 3 cylinder.
If adjustment is necessary, refer to Steps 1.a, 1.b,

and 1.c.

has opened and the exhaust valve of the No. 1 Illustration 39
g00953530
cylinder has not completely closed measure the (1) Dial gauge
valve lash of the inlet valve and the exhaust valve (2) Dial gauge holder
of No. 4 cylinder.
1. Use the dial gauge (1) with the dial gauge holder
If adjustment is necessary, refer to Steps 1.a, 1.b, (2) to check the depths of the inlet valves and
and 1.c. the exhaust valves below the face of the cylinder
head. Use the cylinder head face (3) to zero the
4. Rotate the crankshaft in the normal rotation of the dial gauge (1).
cylinder has not completely closed measure the
of No. 2 cylinder.
SENR9834-02 37
2. Position the dial gauge holder (2) and the dial 4. Move the valve in a radial direction away from the
gauge (1) in order to measure the valve depth. dial indicator. Make sure that the valve moves
Measure the depth of the inlet valve and the away from the dial indicator as far as possible.
exhaust valve before the valve springs are Position the contact point of the dial indicator on
removed. the edge of the valve head. Set the position of the
needle of the dial indicator to zero.
Refer to Specifications, “Cylinder Head Valves”
for the minimum, the maximum, and the service 5. Move the valve in a radial direction toward the dial
wear limits for the valve depth below the cylinder indicator as far as possible. Note the distance of
head face. movement which is indicated on the dial indicator.
If the distance is greater than the maximum
If the valve depth below the cylinder head face clearance of the valve in the valve guide, replace
exceeds the service limit, use a new valve to check the valve guide. Refer to Specifications, “Cylinder
the valve depth. If the valve depth still exceeds the Head Valves” for the maximum clearance of the
service limit, renew the cylinder head or renew the valve in the valve guide.
valve seat inserts (if equipped). If the valve depth
is within the service limit, renew the valves.
3. Inspect the valves for cracks and other damage.

Check the valve stems for wear. Check that the
valve springs are the correct length under the test
force. Refer to Specifications, “Cylinder Head
Valves” for the dimensions and tolerances of the
valves and valve springs.
i01962876
Valve Guide - Inspect
Perform this test in order to determine if a valve guide

should be replaced.
g00314806
Illustration 40
(1) Valve guide
(2) Radial movement of the valve in the valve guide
(3) Valve stem
(4) Dial indicator
(5) Valve head
1. Place a new valve in the valve guide.
2. Place the dial indicator with the magnetic base on

the face of the cylinder head.
3. Lift the edge of the valve head to a distance of

15.0 mm (0.60 inch).
38 SENR9834-02
Lubrication System i01897292
Engine Oil Pump - Inspect

i02557798
Engine Oil Pressure - Test

If any part of the oil pump is worn enough in order
to affect the performance of the pump, the oil pump
must be replaced.
An oil pressure gauge that has a defect can indicate
low oil pressure. Perform the following procedures in order to inspect
the oil pump. Refer to Specifications, “Engine Oil
Use a suitable gauge that measures the oil pressure Pump” for clearances.
in the engine.
1. Ensure that the engine is filled to the correct oil

level.
2. Connect the gauge to a pressure tap location for

engine oil.
3. Operate the engine. Allow the engine to obtain

normal operating temperature.
4. Keep the oil temperature constant with the engine

at the rated rpm. Read the pressure gauge.
5. Refer to Table4 in order to determine if the engine

g00987624
oil pressure is in tolerance. Illustration 41
Exploded view of the oil pump
Table 4
(1) O-ring
Oil Pressure(1) (2) Inner rotor
(3) Shaft
300 to 500 kPa (4) Outer rotor
Oil Pressure at 1500 rpm (5) Body
(43 to 71 psi)
Oil Pressure at Idle 100 kPa (14.2 psi) 1. Remove the oil pump from the engine.
(1) The oil temperature must be 70° to 90°C (158° to 194°F).
2. Remove all of the parts. Clean all of the parts.
Find the cause of the fault and correct the fault if the Look for cracks in the metal or other damage.
results of the test do not fall within the pressure range
in Table 4. Engine failure or a reduction in engine life
can be the result if engine operation is continued with
oil pressure outside this range.
Note: A record of engine oil pressure at regular

intervals can be used as an indication of possible
faults on the engine. A record of engine oil pressure
at regular intervals can also be used as an indication
of possible damage to the engine. The engine should
be inspected and the fault should be corrected if
there is a sudden increase or a sudden decrease of
70 kPa (10 psi) in oil pressure.
g00987626
Illustration 42
Clearance of outer rotor to body
3. Install the outer rotor. Measure the clearance of

the outer rotor to the body.
SENR9834-02 39
i02487769
Excessive Engine Oil

Consumption - Inspect
Engine Oil Leaks on the Outside of

the Engine
Check for leakage at the seals at each end of the
crankshaft. Look for leakage at the gasket for the
engine oil pan and all lubrication system connections.
g00987627 Look for any engine oil that may be leaking from
Illustration 43
the crankcase breather. This can be caused by
Clearance of inner rotor to outer rotor combustion gas leakage around the pistons. A dirty
crankcase breather will cause high pressure in the
4. Install the inner rotor. Measure the clearance of crankcase. A dirty crankcase breather will cause the
the inner rotor to the outer rotor. gaskets and the seals to leak.
Engine Oil Leaks into the

Combustion Area of the Cylinders
Engine oil that is leaking into the combustion area of
the cylinders can be the cause of blue smoke. There
are several possible ways for engine oil to leak into
the combustion area of the cylinders:
• Leaks between worn valve guides and valve stems

• Worn components or damaged components
(pistons, piston rings, or dirty return holes for the
g00987628 engine oil)
Illustration 44
End play of rotors
• Incorrect installation of the compression ring and/or
the intermediate ring
5. Measure the end play of the rotors with a straight
edge and a feeler gauge. • Leaks past the seal rings in the turbocharger shaft
6. Clean the top face of the oil pump. Replace the • Overfilling of the crankcase
O-ring and install the oil pump on the engine.
• Wrong dipstick or guide tube
i01126690
• Sustained operation at light loads
Excessive Bearing Wear -
Excessive consumption of engine oil can also
Inspect result if engine oil with the wrong viscosity is used.
Engine oil with a thin viscosity can be caused by fuel
leakage into the crankcase or by increased engine
temperature.
When some components of the engine show bearing
wear in a short time, the cause can be a restriction in
an oil passage.
An engine oil pressure indicator may show that there

is enough oil pressure, but a component is worn
due to a lack of lubrication. In such a case, look at
the passage for the oil supply to the component.
A restriction in an oil supply passage will not allow
enough lubrication to reach a component. This will
result in early wear.
40 SENR9834-02
i01462628
Increased Engine Oil

Temperature - Inspect
Look for a restriction in the oil passages of the oil

cooler. The oil temperature may be higher than
normal when the engine is operating. In such a case,
the oil cooler may have a restriction. A restriction in
the oil cooler will not cause low oil pressure in the
engine.
Determine if the oil cooler bypass valve is held in the

open position. This condition will allow the oil to pass
through the valve instead of the oil cooler. The oil
temperature will increase.
SENR9834-02 41
Cooling System 7. Check the cooling system hoses and clamps.

Damaged hoses with leaks can normally be seen.
Hoses that have no visual leaks can soften during
i01962683 operation. The soft areas of the hose can become
kinked or crushed during operation. These areas
Cooling System - Check of the hose can cause a restriction in the coolant
(Overheating) flow. Hoses become soft and/or get cracks
after a period of time. The inside of a hose can
deteriorate, and the loose particles of the hose
can cause a restriction of the coolant flow.
Above normal coolant temperatures can be caused
by many conditions. Use the following procedure 8. Check for a restriction in the air inlet system. A
to determine the cause of above normal coolant restriction of the air that is coming into the engine
temperatures: can cause high cylinder temperatures. High
cylinder temperatures require higher than normal
1. Check the coolant level in the cooling system. If temperatures in the cooling system.
the coolant level is too low, air will get into the
cooling system. Air in the cooling system will 9. Check for a restriction in the exhaust system.
cause a reduction in coolant flow and bubbles A restriction of the air that is coming out of the
in the coolant. Air bubbles will keep the coolant engine can cause high cylinder temperatures.
away from the engine parts, which will prevent the
transfer of heat to the coolant. Low coolant level is a. Make a visual inspection of the exhaust system.
caused by leaks or incorrectly filling the expansion
tank. b. Check for damage to exhaust piping. Check for
damage to the exhaust elbow. If no damage
2. Check the mixture of ELC. Refer to Operation and is found, check the exhaust system for a
Maintenance, “Extended Life Coolant (ELC)”. restriction.
3. Check for air in the cooling system. Air can enter 10. Check the water temperature regulator. A water
the cooling system in different ways. The most temperature regulator that does not open, or a
common causes of air in the cooling system water temperature regulator that only opens part
are not filling the cooling system correctly and of the way can cause overheating. Refer to Testing
combustion gas leakage into the cooling system. and Adjusting, “Water Temperature Regulator -
Combustion gas can get into the system through Test”.
inside cracks, a damaged cylinder head, or
a damaged cylinder head gasket. Air in the 11. Check the water pump. A water pump with a
cooling system causes a reduction in coolant damaged impeller does not pump enough coolant
flow and bubbles in the coolant. Air bubbles keep for correct engine cooling. Remove the water
the coolant away from the engine parts, which pump and check for damage to the impeller.
prevents the transfer of heat to the coolant.
12. Consider high outside temperatures. When
4. Check the sending unit. In some conditions, the outside temperatures are too high for the rating
temperature sensor in the engine sends signals of the cooling system, there is not enough of
to a sending unit. The sending unit converts these a temperature difference between the outside
signals to an electrical impulse which is used by a air and coolant temperatures. The maximum
mounted gauge. If the sending unit malfunctions, temperature of the ambient air that enters the
the gauge can show an incorrect reading. Also if engine should not exceed 50 °C (120 °F).
the electric wire breaks or if the electric wire shorts
out, the gauge can show an incorrect reading. 13. When a load that is applied to the engine is too
large, the engine rpm does not increase with an
5. Check the radiator for a restriction to coolant flow. increase of fuel. This lower engine rpm causes
Check the radiator for debris, dirt, or deposits on a reduction in coolant flow through the system.
the inside of the core. Debris, dirt, or deposits will This combination of less air and less coolant flow
restrict the flow of coolant through the radiator. during high input of fuel will cause above normal
heating.
6. Check the filler cap. A pressure drop in the cooling
system can cause the boiling point to be lower.
This can cause the cooling system to boil. Refer
to Testing and Adjusting, “Cooling System - Test”.
42 SENR9834-02
i01626003 i01964006
Cooling System - Inspect Cooling System - Test
This engine has a pressure type cooling system. A Remember that temperature and pressure work
pressure type cooling system gives two advantages: together. When a diagnosis is made of a cooling
system problem, temperature and pressure must
• The pressure type cooling system can operate be checked. The cooling system pressure will have
safely at a higher temperature than the boiling an effect on the cooling system temperature. For
point of water at a range of atmospheric pressures. an example, refer to Illustration 45. This will show
the effect of pressure on the boiling point (steam) of
• The pressure type cooling system prevents water. This will also show the effect of height above
cavitation in the water pump. sea level.
Cavitation is the sudden generation of low pressure

bubbles in liquids by mechanical forces. The
generation of an air or steam pocket is much more
difficult in a pressure type cooling system.
Regular inspections of the cooling system should be

made in order to identify problems before damage
can occur. Visually inspect the cooling system before
tests are made with the test equipment.
Visual Inspection Of The Cooling

System
g00286266
1. Check the coolant level in the cooling system. Illustration 45
Cooling system pressure at specific altitudes and boiling points
2. Look for leaks in the system. of water
Note: A small amount of coolant leakage across

the surface of the water pump seals is normal. This
leakage is required in order to provide lubrication for Personal injury can result from hot coolant, steam
this type of seal. A hole is provided in the water pump and alkali.
housing in order to allow this coolant/seal lubricant
to drain from the pump housing. Intermittent leakage At operating temperature, engine coolant is hot
of small amounts of coolant from this hole is not an and under pressure. The radiator and all lines
indication of water pump seal failure. to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
3. Inspect the radiator for bent fins and other
restriction to the flow of air through the radiator. Remove filler cap slowly to relieve pressure only
when engine is stopped and radiator cap is cool
4. Inspect the drive belt for the fan. enough to touch with your bare hand.
5. Inspect the blades of the fan for damage.
The coolant level must be to the correct level in order
6. Look for air or combustion gas in the cooling to check the coolant system. The engine must be
system. cold and the engine must not be running.
7. Inspect the radiator cap for damage. The sealing After the engine is cool, loosen the pressure cap
surface must be clean. in order to relieve the pressure out of the cooling
system. Then remove the pressure cap.
8. Look for large amounts of dirt in the radiator core.
Look for large amounts of dirt on the engine.
9. Shrouds that are loose or missing cause poor air

flow for cooling.
SENR9834-02 43
The level of the coolant should not be more than • Seal

13 mm (0.5 inch) from the bottom of the filler pipe. If
the cooling system is equipped with a sight glass, • Surface for seal
the coolant should be to the correct level in the sight
glass. Remove any deposits that are found on these
items, and remove any material that is found on
these items.
Checking the Filler Cap
3. Install the pressure cap onto a suitable
One cause for a pressure loss in the cooling system
pressurizing Pump.
can be a faulty seal on the radiator pressure cap.
4. Observe the exact pressure that opens the filler
cap.
5. Compare the pressure to the pressure rating that

is found on the top of the filler cap.
6. If the filler cap is damaged, replace the filler cap.
Testing The Radiator And Cooling

System For Leaks
Use the following procedure to test the radiator and
the cooling system for leaks.
g00296067
Illustration 46
Typical schematic of filler cap
(1) Sealing surface between the pressure cap and the radiator
Personal injury can result from hot coolant, steam
and alkali.
At operating temperature, engine coolant is hot

Personal injury can result from hot coolant, steam and under pressure. The radiator and all lines
and alkali. to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines Remove filler cap slowly to relieve pressure only
to heaters or the engine contain hot coolant or when engine is stopped and radiator cap is cool
steam. Any contact can cause severe burns. enough to touch with your bare hand.
Remove filler cap slowly to relieve pressure only
when engine is stopped and radiator cap is cool 1. When the engine has cooled, loosen the filler cap
enough to touch with your bare hand. to the first stop. Allow the pressure to release from
the cooling system. Then remove the filler cap.
To check for the amount of pressure that opens the 2. Make sure that the coolant covers the top of the
filler cap, use the following procedure: radiator core.
1. After the engine cools, carefully loosen the filler 3. Put a suitable pressurizing Pump onto the radiator.
cap. Slowly release the pressure from the cooling
system. Then, remove the filler cap. 4. Use the pressurizing pump to increase the
pressure to an amount of 20 kPa (3 psi) more than
2. Inspect the pressure cap carefully. Look for the operating pressure of the filler cap.
damage to the seal. Look for damage to the
surface that seals. Remove any debris on the cap, 5. Check the radiator for leakage on the outside.
the seal, or the sealing surface.
6. Check all connections and hoses of the cooling
Carefully inspect the filler cap. Look for any system for leaks.
damage to the seals and to the sealing surface.
Inspect the following components for any foreign The radiator and the cooling system do not have
substances: leakage if all of the following conditions exist:
• Filler cap
44 SENR9834-02
• You do NOT observe any leakage after five 1. Place a container under the oil cooler in order to
minutes. collect any engine oil or coolant that drains from
the oil cooler.
• The dial indicator remains constant beyond five
minutes. 2. Remove the cover (4). Refer to Disassembly
and Assembly, “Engine Oil Cooler - Remove” for
The inside of the cooling system has leakage only removal of the engine oil cooler.
if the following conditions exist:
3. Thoroughly clean the flange face of the cover and
• The reading on the gauge goes down. the cylinder block.
• You do NOT observe any outside leakage.

Make any repairs, as required.
Personal injury can result from air pressure.
i01959183 Personal injury can result without following prop-

er procedure. When using pressure air, wear a pro-
Engine Oil Cooler - Inspect tective face shield and protective clothing.
Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.
4. Inspect the cooling plates (2) for cracks and dents.

Hot oil and hot components can cause personal Replace the cooling plates if cracks or dents exist.
injury. Do not allow hot oil or hot components to
contact the skin. If necessary, clean the outside and clean the inside
of the cooling plates. Use a solvent that is not
corrosive on copper. Ensure that no restrictions for
the flow of lubricating oil exist in the cooling plates.
Dry the cooling plates with low pressure air.

Flush the inside of the cooling plates with clean
lubricating oil.
5. Replace the O-rings (3) and the gasket (1).

Install the engine oil cooler. Refer to Disassembly
and Assembly, “Engine Oil Cooler - Install” for
installation of the engine oil cooler.
6. Ensure that the cooling system of the engine is

filled to the correct level. Operate the engine.
Check for oil or coolant leakage.
i01666401
Water Temperature Regulator

Illustration 47
g00987668 - Test
Exploded view of the engine oil cooler
(1) Gasket
(2) Cooling plates
(3) O-rings
(4) Cover
Personal injury can result from escaping fluid un-
Perform the following procedure in order to inspect der pressure.
the engine oil cooler:
If a pressure indication is shown on the indicator,
push the release valve in order to relieve pressure
before removing any hose from the radiator.
SENR9834-02 45
1. Remove the water temperature regulator from the

engine.
2. Heat water in a pan until the temperature of

the water is equal to the fully open temperature
of the water temperature regulator. Refer to
Specifications, “Water Temperature Regulator”
for the fully open temperature of the water
temperature regulator. Stir the water in the pan.
This will distribute the temperature throughout the
pan.
3. Hang the water temperature regulator in the pan

of water. The water temperature regulator must
be below the surface of the water. The water
temperature regulator must be away from the
sides and the bottom of the pan.
4. Keep the water at the correct temperature for ten

minutes.
5. After ten minutes, remove the water temperature

regulator. Immediately measure the opening
of the water temperature regulator. Refer to
Specifications, “Water Temperature Regulator”
for the minimum opening distance of the
water temperature regulator at the fully open
temperature.
If the distance is less than the amount listed in the

manual, replace the water temperature regulator.
46 SENR9834-02
Basic Engine Note: Some pistons have a tapered top groove and
the piston ring is wedged. The clearance for the top
piston ring cannot be checked by the above method
i01853436 when this occurs.
Piston Ring Groove - Inspect Inspect the Piston Ring End Gap
Inspect the Piston and the Piston

Rings
1. Check the piston for wear and other damage.
2. Check that the piston rings are free to move in the

grooves and that the rings are not broken.
Inspect the Clearance of the Piston

Ring
g00782363
1. Remove the piston rings and clean the grooves Illustration 49
and the piston rings. (1) Piston ring
(2) Cylinder ring ridge
(3) Feeler gauge
1. Clean all carbon from the top of the cylinder bores.
2. Place each piston ring (1) in the cylinder bore just

below the cylinder ring ridge (2).
3. Use a suitable feeler gauge (3) to measure piston

ring end gap. Refer to Specifications, “Piston and
Rings” for the dimensions.
Note: The coil spring must be removed from the oil

control ring before the gap of the oil control ring is
measured.
i01962707
Connecting Rod - Inspect
g00905732
Illustration 48
(1) Feeler gauge Inspect the Connecting Rod
(2) Piston ring
(3) Piston grooves 1. Inspect the connecting rod for wear or cracking.
2. Fit new piston rings (2) in the piston grooves (3). 2. Inspect the piston pin bearing and the piston pin
for wear and other damage. Check the piston pin
3. Check the clearance for the piston ring by placing bearing for a clogged oil hole.
a suitable feeler gauge (1) between piston
groove (3) and the top of piston ring (2). Refer Note: Be sure that the oil holes of the piston pin
to Specifications, “Piston and Rings” for the bearing and the small end of the connecting rod are
dimensions. lined up.
3. Inspect the connecting rod bolts for stripped

threads.
SENR9834-02 47
Measure Clearances and End Play i01748792
Main Bearings - Inspect
Check the main bearings for wear or other damage.

Replace both halves of the bearings and check the
condition of the other bearings if a main bearing is
worn or damaged.
Main bearings are available with a smaller inside

diameter than the original size bearings. These
bearings are for main bearing journals that have
been ground.
g00994326
Illustration 50
i01962706
1. Measure the clearance of the piston pin in Cylinder Block - Inspect

the piston pin bearing. Refer to Specifications,
“Connecting Rod” for clearance dimensions.
Inspect the top of the cylinder block for cracks

and warpage. Refer to the Specifications Module,
“Cylinder Block” topic for the tolerances.
Inspect each cylinder bore. There should be no

scoring, rust or corrosion. Use a suitable dial bore
gauge in order to measure each cylinder bore. Each
cylinder bore should be measured at the top, middle
and bottom.
If the cylinder bores are out of the service limit, the

cylinder block must be bored oversize. Refer to the
Specifications Module, “Cylinder Block” topic for the
tolerances.
g00994330
Illustration 51
2. Install the connecting rod to the connecting rod i01962703

journal. Tighten the bolts to the correct torque.
Cylinder Head - Inspect
3. Measure the end play. Refer to Specifications,
“Connecting Rod” for end play values.
1. Remove the cylinder head from the engine.
4. If the end play exceeds the service limit, replace
the connecting rod.
2. Clean the cylinder head thoroughly. Make sure
that the contact surfaces of the cylinder head and
i01748770 the cylinder block are clean, smooth and flat.
Connecting Rod Bearings - 3. Inspect the bottom surface of the cylinder head
Inspect for pitting, corrosion, and cracks. Inspect the area
around the valve seat inserts and the holes for
the fuel injectors.
Check the connecting rod bearings and the

connecting rod bearing journal for wear or other
damage.
Connecting rod bearings are available with a smaller

inside diameter than the original size bearings. These
bearings are for crankshafts that have been ground.
48 SENR9834-02
5. Measure the cylinder head for flatness. Measure

the flatness with straight edge (3) and with feeler
gauge (4).
• Measure the cylinder head from one side to the

other side (A).
• Measure the cylinder head from one end to the

other end (B).
• Measure the cylinder head from one corner to

the other corner (C).
Refer to Specifications , “Cylinder Head” for the

g00876690
requirements of flatness.
Illustration 52
Typical example
i01964003
(1) Cylinder head
(2) Cylinder head repair stand
Piston Height - Inspect
4. Place cylinder head (1) on a suitable cylinder
head repair stand (2).
Table 5
Required Tools
Part Part Description Qty

Number
27610272 Dial gauge 1
21825496 Dial gauge holder 1
If the height of the piston above the cylinder block

is not within the tolerance that is given in the
Specifications Module, “Piston and Rings”, the
g00987700
bearing for the piston pin must be checked. Refer to
Illustration 53 Testing and Adjusting, “Connecting Rod - Inspect”.
Measuring points on cylinder head If any of the following components are replaced or
(A) Side to side remachined, the piston height above the cylinder
(B) End to end block must be measured:
(C) Corner to corner
• Crankshaft
• Cylinder head
• Connecting rod
• Bearing for the piston pin
The correct piston height must be maintained in order
to ensure that the engine conforms to the standards
for emissions.
Note: The top of the piston should not be machined.

If the original piston is installed, be sure that the
g00987701
original piston is assembled to the correct connecting
Illustration 54 rod and installed in the original cylinder.
Measuring flatness
(3) Straight edge
(4) Feeler gauge
SENR9834-02 49
i01962689
Flywheel - Inspect
Inspect the Flywheel
g00953648
Illustration 55
(1) Dial gauge
(2) Dial gauge holder
1. Use the dial gauge (1) and the dial gauge holder
(2) in order to measure the piston height above
the cylinder block. Use the cylinder block face to
zero the dial gauge (1). g00987873
Illustration 56
2. Rotate the crankshaft until the piston is at the Exploded view of flywheel and flywheel housing
approximate top center. Ensure that the flame ring (1) Gasket
of the cylinder liner does not interfere with the dial (2) Flywheel housing
(3) Bolt
gauge holder (2) or the dial gauge (1). (4) Rear oil seal
(5) Flywheel
3. Position the dial gauge holder (2) and the dial (6) Setscrew
gauge (1) in order to measure the piston height
above the cylinder block. Slowly rotate the 1. Check for cracks or a damaged dowel hole.
crankshaft in order to determine when the piston
is at the highest position. Record this dimension. 2. Check the ring gear on flywheel (5) for teeth that
Compare this dimension with the dimensions that are worn or damaged.
are given in Specifications, “Piston and Rings”.
3. Inspect the setscrews for the flywheel (6) for
stripped threads.
Flatness of the Flywheel

Note: The flywheel must be removed from the engine
in order to check the flatness.
50 SENR9834-02
4. Calculate the difference between the lower

measurements and the higher measurements
that are performed at all four points. Refer to
Specifications, “Flywheel” for the correct values
of the runout.
i01961097
Flywheel Housing - Inspect
g00987717
Illustration 57
Flatness of flywheel
1. Place the flywheel on a surface plate.
2. Set a suitable dial indicator at one side of the

surface plate and move the dial indicator to the
opposite side. Refer to Illustration 57.
3. Refer to Specifications, “Flywheel” for the correct

values of the flatness.
Face Runout (Radial Eccentricity)

of the Flywheel
g00987862
Illustration 59
Exploded view of flywheel housing
(1) Setscrew
(2) Gasket
(3) Flywheel housing
(4) Rear oil seal
1. Check for cracks or a damaged dowel hole.
2. Inspect the setscrews (1) that hold the flywheel

housing in place for stripped threads.
Illustration 58
g00987720 3. Inspect rear oil seal (4) for leaks or damage.
Runout of flywheel
1. Refer to Illustration 58 and install a suitable dial

indicator. Always put a force on the crankshaft in
the same direction before the dial indicator is read.
This will remove any crankshaft end clearance.
2. Set the dial indicator to read 0.0 mm (0.00 inch).
3. Turn the flywheel at intervals of 90 degrees and

read the dial indicator.
SENR9834-02 51
i02298848 Note: If one or more of the gears need to be removed

for repair, refer to Disassembly and Assembly in
Gear Group - Inspect order to correctly remove the gears.
Measure Backlash and End Play

Inspect the Gear Group
g00987788
Illustration 62
Measuring backlash
1. Install a suitable dial indicator in Illustration 62,

as shown.
2. Measure the backlash of the gears. Refer to

Specifications, “Gear Group (Front)” for the values
g01023896 of the backlash.
Illustration 60
g00987800
Illustration 63
Measuring end play of the idler gear
1. Install the dial indicator in Illustration 63, as shown.
2. Measure the end play of the idler gear. Refer to

g00987777 Specifications, “Gear Group (Front)” for the values
Illustration 61
of the end play.
Exploded view of the front timing group
(1) Camshaft gear
(2) Upper idler gear
(3) Oil pump gear
(4) Crankshaft gear
(5) Fuel injection pump gear
Inspect the gears for wear or for damage. If the gears

are worn or damaged, use new parts for replacement.
52 SENR9834-02
g01152814
Illustration 66
g00996060
Illustration 64 3. Inspect the balancer shafts (2) and inspect the
Measuring end play of the camshaft bushing (1). Refer to Specifications, “Gear Group
(Front)” for more information.
1. Install the dial indicator in Illustration 64, as shown.
2. Measure the end play of the camshaft. Refer to

Specifications, “Camshaft” for the values of the
end play.
Note: The end play is controlled by the camshaft

thrust washer. If the end play is not within
specifications, replace the thrust washer.
Engines that have a Balancer

1. Install a suitable dial gauge.
g01151341
Illustration 65
2. Measure the backlash of the gears. Refer to

illustration 65 . Refer to Specifications, “Gear
Group (Front)” for the values of the backlash.
SENR9834-02 53
Electrical System
i01964004
Alternator - Test
1. Put the positive lead “+” of a suitable multimeter

on the “Bat” terminal of the alternator. Put the
negative “-” lead on the ground terminal or on the
frame of the alternator. Put a suitable ammeter
around the positive output wire of the alternator.
2. Turn off all electrical accessories. Turn off the fuel

to the engine. Crank the engine for 30 seconds.
Wait for two minutes in order to cool the starting
motor. If the electrical system appears to operate
correctly, crank the engine again for 30 seconds.
Note: Cranking the engine for 30 seconds partially

discharges the batteries in order to do a charging
test. If the battery has a low charge, do not perform
this step. Jump start the engine or charge the battery
before the engine is started.
3. Start the engine and run the engine at high idle.
4. Check the output current of the alternator. The

initial charging current should be equal to the
minimum full load current or greater than the
minimum full load current. Refer to Specifications,
“Alternator and Regulator” for the correct minimum
full load current.
Table 6
Fault Conditions And Possible Causes

Current At Start-up The Voltage Is Below The Voltage Is Within The Voltage Is Above
Specifications After 10 Specifications After 10 Specifications After 10
Minutes. Minutes. Minutes.
Less than the Replace the alternator. Turn on all accessories. If the -
specifications Check the circuit of the voltage decreases below the
ignition switch. specifications, replace the
alternator.
Decreases after matching Replace the alternator. The alternator and the battery Replace the alternator.
specifications match the specifications.
Turn on all accessories in
order to verify that the voltage
stays within specifications.
The voltage consistently Test the battery. Test the The alternator operates Replace the alternator.
exceeds specifications. alternator again. within the specifications. Test Inspect the battery for
the battery. damage.
5. After approximately ten minutes of operating the 6. After ten minutes of engine operation, the charging
engine at high idle, the output voltage of the current should decrease to approximately 10
alternator should be 14.0 ± 0.5 volts. Refer to the amperes. The actual length of time for the
Fault Conditions And Possible Causes in Table 6. decrease to 10 amperes depends on the following
conditions:
• The battery charge

54 SENR9834-02
• The ambient temperature

• The rpm of the engine
Refer to the Fault Conditions And Possible
Causes in Table 6.
i01899136
Battery - Test
Most of the tests of the electrical system can be done

on the engine. The wiring insulation must be in good
condition. The wire and cable connections must be
clean, and both components must be tight.
Never disconnect any charging unit circuit or bat-

tery circuit cable from the battery when the charg-
ing unit is operated. A spark can cause an explo-
sion from the flammable vapor mixture of hydro-
gen and oxygen that is released from the elec-
trolyte through the battery outlets. Injury to per-
sonnel can be the result.
The battery circuit is an electrical load on the charging

unit. The load is variable because of the condition of
the charge in the battery.
NOTICE
The charging unit will be damaged if the connections
between the battery and the charging unit are broken
while the battery is being charged. Damage occurs
because the load from the battery is lost and because
there is an increase in charging voltage. High voltage
will damage the charging unit, the regulator, and other
electrical components.
The correct procedures to test the battery can be

found in the manual that is supplied by the OEM.
i02558233
Belt Tension Chart
Note: Do not use the belt tension chart for belts with
tensioners that are spring loaded.
SENR9834-02 55
Table 7
Belt Tension Chart

Belt Type Deflection Applied Force for Specified Deflection
Type B 10 to 12 mm (0.4 to 0.5 inch) 98 N (22 lb)
i01964005 Starting motors that operate too slowly can have

an overload due to excessive friction in the engine
Electric Starting System - Test that is being started. Slow operation of the starting
motors can also be caused by a short circuit, loose
connections, and/or dirt in the motor.
Use the multimeter in the DCV range to find starting
system components which do not function. i01962219
Move the start control switch in order to activate the Glow Plugs - Test
starting solenoids. The starting solenoid’s operation
can be heard as the pinion of the starting motor is
engaged with the ring gear on the engine flywheel.
Continuity Check of the Glow Plugs
If a solenoid for a starting motor will not operate,
it is possible that the current from the battery did The following test will check the continuity of the glow
not reach the solenoid. Fasten one lead of the plugs.
multimeter to the connection (terminal) for the battery
cable on the solenoid. Connect the other lead to a 1. Disconnect the power supply and the bus bar.
good ground. A zero reading indicates that there
is a broken circuit from the battery. More testing is 2. Set a suitable digital multimeter to check continuity
necessary when there is a voltage reading on the (resistance). Turn the audible signal on the digital
multimeter. multimeter ON.
The solenoid operation also closes the electric circuit 3. Place one probe on the connection for the glow
to the motor. Connect one lead of the multimeter to plug and the other probe to a suitable ground. The
the solenoid connection (terminal) that is fastened digital multimeter should make an audible sound.
to the motor. Connect the other lead to a good Replace the glow plug if there is no continuity.
ground. Activate the starting solenoid and look at the
multimeter. A voltage reading of the battery shows 4. Check the continuity on all the glow plugs.
that the problem is in the motor. The motor must
be removed for further testing. A zero reading on
the multimeter shows that the solenoid contacts do Checking the Operation of the Glow
not close. This indicates the need for repair to the Plug
solenoid, or to the clearance for the starter motor
pinion. The following test will check the operation of the glow
plugs.
Perform a test. Fasten one multimeter lead to
the connection (terminal) for the small wire at the 1. Disconnect the power supply and the bus bar.
solenoid and fasten the other lead to the ground.
Look at the multimeter and activate the starting 2. Connect the power supply to only one glow plug.
solenoid. A voltage reading shows that the problem
is in the solenoid. A zero reading indicates that the 3. Place a ammeter on the power supply wire.
problem is in the start switch or the wires for the start
switch. 4. Connect the digital multimeter to the terminal on
the glow plug and to a suitable ground.
Fasten one multimeter lead to the start switch at the
connection (terminal) for the wire from the battery. 5. Turn the switch to the ON position in order to
Fasten the other lead to a good ground. A zero activate the glow plugs.
reading indicates a broken circuit from the battery.
Check of the circuit breaker and wiring. If there is a 6. Check the reading on all of the glow plugs. Refer
voltage reading, the problem is in the start switch or to Specifications, “Glow Plugs” for the values of
in the wires for the start switch. the current for each glow plug.
56 SENR9834-02
7. If there is no reading on the ammeter check the

electrical connections. If the readings on the
ammeter are low replace the glow plugs. If there
is still no reading replace the glow plugs.
SENR9834-02 57
Index Section
Index
A Excessive Engine Oil Consumption - Inspect........ 39
Engine Oil Leaks into the Combustion Area of the
Air in Fuel - Test..................................................... 25 Cylinders .......................................................... 39
Air Inlet and Exhaust System .......................... 14, 32 Engine Oil Leaks on the Outside of the Engine.. 39
Turbocharger (if equipped) ................................ 15 Exhaust Temperature - Test................................... 34
Valve System Components................................ 16 Measure the Exhaust Temperature.................... 34
Air Inlet and Exhaust System - Inspect.................. 32
Alternator - Test ..................................................... 53
F
B Finding Top Center Position for No. 1 Piston......... 26

Flywheel - Inspect.................................................. 49
Basic Engine.................................................... 20, 46 Face Runout (Radial Eccentricity) of the
Camshaft............................................................ 22 Flywheel ........................................................... 50
Crankshaft.......................................................... 21 Flatness of the Flywheel .................................... 49
Cylinder Block .................................................... 20 Inspect the Flywheel .......................................... 49
Cylinder Head .................................................... 20 Flywheel Housing - Inspect ................................... 50
Flywheel and Flywheel Housing ........................ 23 Fuel Injection Timing - Check ................................ 26
Pistons and Connecting Rods............................ 21 Fuel Injector - Test ................................................. 28
Timing Case and Gears ..................................... 22 Back Leakage Test............................................. 29
Battery - Test ......................................................... 54 Cleaning of the fuel injectors.............................. 28
Belt Tension Chart ................................................. 54 Fuel Injector and Seat Test ................................ 30
Pressure Test ..................................................... 29
Test the Fuel Injectors........................................ 28
C Test the Spray Pattern ....................................... 30
Fuel Quality - Test.................................................. 30
Compression - Test................................................ 34 Fuel System....................................................... 9, 25
Compression...................................................... 34 Fuel Injection Pump ............................................ 11
Connecting Rod - Inspect ...................................... 46 Fuel Injectors ..................................................... 12
Inspect the Connecting Rod............................... 46 Fuel System - Inspect............................................ 25
Measure Clearances and End Play ................... 47 Fuel System - Prime .............................................. 31
Connecting Rod Bearings - Inspect....................... 47
Cooling System ............................................... 19, 41
Cooling System - Check (Overheating) ................. 41 G
Cooling System - Inspect....................................... 42
Visual Inspection Of The Cooling System.......... 42 Gear Group - Inspect............................................. 51
Cooling System - Test............................................ 42 Engines that have a Balancer ............................ 52
Checking the Filler Cap...................................... 43 Inspect the Gear Group ..................................... 51
Testing The Radiator And Cooling System For Measure Backlash and End Play ....................... 51
Leaks................................................................ 43 General Information................................................. 4
Cylinder Block - Inspect......................................... 47 Lifting the Engine ................................................. 4
Cylinder Head - Inspect ......................................... 47 Naturally Aspirated Engine Views........................ 5
Turbocharged Engine Views ................................ 7
Glow Plugs - Test................................................... 55
E Checking the Operation of the Glow Plug.......... 55
Continuity Check of the Glow Plugs................... 55
Electric Starting System - Test............................... 55
Electrical System ............................................. 23, 53
Alternator ........................................................... 23 I
Electric Starting Motor........................................ 23
Glow Plugs......................................................... 24 Important Safety Information ................................... 2
Engine Oil Cooler - Inspect.................................... 44 Increased Engine Oil Temperature - Inspect ......... 40
Engine Oil Pressure - Test..................................... 38
Engine Oil Pump - Inspect..................................... 38
Engine Valve Lash - Inspect/Adjust ....................... 35 L
Valve Lash Adjustment ...................................... 35
Valve Lash Check .............................................. 35 Lubrication System .......................................... 17, 38
Excessive Bearing Wear - Inspect......................... 39
58 SENR9834-02
Index Section
Main Bearings - Inspect......................................... 47
Piston Height - Inspect .......................................... 48

Piston Ring Groove - Inspect................................. 46
Inspect the Clearance of the Piston Ring........... 46
Inspect the Piston and the Piston Rings ............ 46
Inspect the Piston Ring End Gap....................... 46
Systems Operation Section ..................................... 4
Table of Contents..................................................... 3
Testing and Adjusting Section ............................... 25
Turbocharger - Inspect .......................................... 32
Inspection of the Compressor Wheel and the
Compressor Housing ....................................... 33
Inspection of the Turbine Wheel and the Turbine
Housing ............................................................ 33
Valve Depth - Inspect ............................................ 36

Valve Guide - Inspect ............................................ 37
Water Temperature Regulator - Test ..................... 44

SENR9834-02 59
Index Section
Copyright © 2006 Perkins Engines Company Limited
All Rights Reserved Printed in U.K.

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SENR9834-02

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents Belt Tension Chart ................................................ 54

Testing and Adjusting Section

Air Inlet and Exhaust System

Systems Operation Section

Note: When you are ordering new parts, refer

The 800 Series engines are in-line four cylinder

The engines have been designed for many different

Lifting the Engine

To avoid possible engine damage, use the following

When you are lifting or moving the engine, use the

1. Do not tilt the engine to an extreme angle unless

2. Do not turn the engine onto a side or an end

3. If the oil is not drained prior to tilting the engine or

4. The engine oil should be refilled to the correct

Naturally Aspirated Engine Views

Turbocharged Engine Views

The fuel is drawn by an internal fuel transfer pump

The fuel injectors spray atomized fuel into the

Routing excess fuel back to the fuel tank allows air in

• Lubricate the internal components.

Fuel Injection Pump

The fuel injection pump is a pressurized system Fuel Delivery

The fuel lines to the fuel injectors are equal lengths.

During operation, extra fuel is used as coolant and

The plunger also rotates with the cam in order to

The effective stroke is established by the position of

The pump also includes an internal timer (not shown).

When the needle valve opens, fuel under high

Turbocharged Engines (Direct Injection)

The fuel injection pump forces the fuel to flow under

When the needle valve opens, fuel under high

Air Inlet and Exhaust System

The components of the air inlet and exhaust system

Naturally aspirated engines pull outside air through

Turbocharged engines pull outside air through Turbocharger (if equipped)

Each piston makes four strokes for one complete

Valve System Components

The valve system components control the flow of

The crankshaft gear drives the camshaft gear

The camshaft has two camshaft lobes for each

Lubricating oil from the main oil gallery flows through

The pistons and the cylinder bores are lubricated by

Lubricating oil from the main oil gallery flows through

The hub of the idler gear (6) is lubricated by oil from

Turbochargers (14) are lubricated by oil from a

Engine oil relief valve (7) is installed in order to

i01959151 The journals of the camshaft run directly in the bores

The basic engine components are described in this Cylinder Head

Main bearings (1) have steel backs with an aluminum

Crankshaft gear (3) is held on the tapered shaft of the

Exploded view of the timing case and gears

The timing case is constructed of either aluminum

There are two different types of timing gears, helical

The camshaft is driven at the front end by the

The camshaft gear must be timed to the crankshaft

End play of the camshaft is controlled by thrust

Flywheel and Flywheel Housing Electric Starting Motor

Electric starting motor (1) turns the engine flywheel.

i02558823 When the engine begins to run, the overrunning

• Electric starting motor