Overhaul Manual

TK482 and TK486

TK 50136-2-OM (Rev. 2, 02/06)

Copyright ©  1998 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in

U.S.A.
This manual is published for informational purposes only and the information so provided should
not be considered as all-inclusive or covering all contingencies. If further information is required,
Thermo King Corporation should be consulted.

Sale of product shown in this manual is subject to Thermo King’s terms and conditions
including, but not limited to, the Thermo King
Ki ng Limited Express Warranty.
Warranty. Such terms and
conditions are available upon request. Thermo King’s warranty will not apply to any
equipment which has been “so repaired or altered
alter ed outside the manufacturer’s plants as,
in the manufacturer’s judgment, to effect its stability.”
stability.”

No warranties, express or implied, including warranties of fitness for a particular

purpose or merchantability, or warranties arising from course of dealing or usage of
trade, are made regarding the information, recommendations, and descriptions
contained herein. Manufacturer
Manufacturer is not responsible and will
wil l not be held liable in contract
or in tort (including negligence) for any special, indirect or consequential damages,
including injury or damage caused to vehicles, contents or persons, by reason of the
installation of any Thermo King product or its mechanical failure.

2
Table of Contents
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TK482 & TK486 Diesel Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tier 1 and Earlier - TK482, TK482E, TK486, TK486E, and TK486EH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tier 2 - TK486V, TK486VB, and TK486VH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Exhaust Gas Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TK482, TK482E, TK486, TK486E, and TK486EH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TK486V, TK486VB, and TK486VH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Inspection and Reconditioning
Recondit ioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Wrist Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Timing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Valve Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Valve Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Push Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Oil Pump for Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Oil Pump for Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Crankcase Breather System Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Crankcase Breather System Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Checking Crankcase Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Assembly Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Bleeding Air from the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Injection Pump Timing Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Attaching Injection Pump Gear to Flange on Tier 1 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Injection Pump Timing Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Injection Pump Removal and Installation (All Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
105
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Trochoid Feed Pump Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Trochoid Feed Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Trochoid Feed Pump O-Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Cold Start Device Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Checking Cold Start Device Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Cold Start Device Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

3
Table of Contents

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Fuel Return Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Fuel Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Fuel Transfer Pump Operation Operatio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Fuel System Operation and Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Normal Fuel System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Static Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Static Air Leaks Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Solution for Static Air Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
FAQ (Frequently Asked Questions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Using Clear Fuel Lines To Diagnose Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122 . 122
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Battery Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Cold Weather Battery Recommendation for Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
TK482/TK486 Starters Not Interchangeable with di2.2/se2.2 Starters . . . . . . . . . . . . . . . . . . . . . . . . . . . .124 . 124
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Major Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Fuel Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Fuel Solenoid Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Run In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Dynamometer Run In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Run In Procedure without Dynamometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137 . 137
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Compression Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Compression Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Special Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Checking Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Gear Case Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Engine History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Engine History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Released . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Front Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Rear Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Flywheel Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
EPA Tier 1 Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Oil Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
ELC Compatible Water Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
EMI 3000 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Screw-In Oil Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
EPA Tier 2 Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Engine History Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Engine Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
History of Engine Related Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153 . 153
Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Fuel Solenoid Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Alternator Mounting Brackets for Model 30 Trailer Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

4
List of Figures
Figure 1: Valve Guide Removal Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 2: Valve Guide Installation Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 3: Valve Stem Seal Installation Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 4: Connect
Connecting
ing Rod Bushing
Bushing Removal
Removal and Installation
Installation Tool Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 5: Camshaft Bearing Removal Tool To ol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 6: Front View of Early Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 7: Front View of Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 8:
8: Remove
Remove Fuel Injectio
Injectionn Lines Tier
Tier 1 and Earlier
Earlier Engines
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 9:
9: Remove
Remove Fuel Injection
Injection Lines Tier
Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 10:
10: Remove
Remove Fuel Injectio
Injection
n Nozzles
Nozzles Tier 1 and Earlier Earlier Engines
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 11:
11: Remove Fuel
Fuel Injection
Injection Nozzles
Nozzles Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 12: Remove Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 13:
13: Disconnect
Disconnect Coolant
Coolant Hoses
Hoses on Tier 2 Engines Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 14: Remove Valve Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 15: Remove Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 16: Remove Valve Stem Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 17: Remove Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 18: Remove Oil Filter and Oil Filter Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 19: Remove Oil Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 20: Remove Fuel Transfer
Tran sfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 21: Remove Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 22:
22: Remove
Remove Gear Case Case Cover and Sound Shield Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 23: Check Timing Gear Lash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 24:
24: Remove
Remove Fuel Injection
Injection Pump
Pump Gear Nut Nut and Lock Washer Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 25: Use Puller
Puller to Remove
Remove Fuel
Fuel Injection
Injection Pump Gear Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 26:
26: Single-Pie
Single-Piece
ce Fuel Injection
Injection Pump Gear Gear Early
Early Engines
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 27:
27: Three-Piece
Three-Piece Fuel
Fuel Injection
Injection Pump Gear Tier Tier 1 Engine
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 28:
28: Three-Piece
Three-Piece Fuel
Fuel Injection
Injection Pump Gear Gear Tier 2 Engine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 29: Tier 1 and Earlier Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 30:
30: Typical Tier
Tier 1 and Earlier
Earlier Index
Index Mark Alignment
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 31: Tier 2 Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 32: Typical Tier 2 Index Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 33:
33: Remove
Remove Fuel Injection
Injection Pump
Pump Tier 1 and Earlier Earlier Engines
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 34:
34: Remove Fuel
Fuel Injection
Injection Pump Tier Tier 2 Engines
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 35:
35: Remove
Remove Oil Pump
Pump Tier 1 and Earlier
Earlier Engines
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 36: Remove Idler Gear and Idler Gear Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 37: Remove Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 38: Remove Bellhousing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 39: Rear Seal Removal Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 40: Remove Rear Seal Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 41: Remove Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 42: Remove Oil Pump Intake Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 43: Remove Camshaft Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 44: Remove Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 45: Remove Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 46: Remove Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 47: Remove Piston and Rod Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 48: Remove Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 49: Measuring Cylinder Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 50: Cylinder Measuring Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 51: Pressing Tool Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Figure 52: Cylinder Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Figure 53: Cylinder Sleeve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure 54: Measuring Front
Fron t Camshaft Bearing Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure 55: Main Bearing Cap Marks
Ma rks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 56: Measuring Main Bearing Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 57: Checking Main Bearing Bore Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 58: Measuring Main Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5
List of Figures

Figure 59: Measuring Rod Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Figure 60: Measuring Crankshaft Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Figure 61: Crankshaft Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Figure 62: Piston Measuring Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Figure 63: Measuring Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 64: Checking Ring Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Figure 65: Measuring Wrist Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 66: Measuring Rod Bearing or Bearing Bear ing Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Figure 67: Measuring Connecting Rod Twist and Parallelism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 . 48
Figure 68: Measuring Wrist Pin Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 69: Measuring Idler Gear
Gea r Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 70: Measuring Idler Gear
Ge ar Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 71: Measuring Camshaft Journals
Jour nals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Figure 72: Measuring Cam Lobes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Figure 73: Measuring Camshaft Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Figure 74: Checking Thrust Plate Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Figure 75: Checking Cylinder Head Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 76: Cylinder Head Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 77: Removing or Installing Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Figure 78: Valve Guide Projection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Figure 79: Valve Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Figure 80: Measuring Valve Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 81: Measuring Valve Stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 82: Valve Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 83: Intake Valve Seat Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Figure 84: Exhaust Valve Seat Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Figure 85: Measuring Valve Seat Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Figure 86:
86: Dimensions
Dimensions for Replacem
Replacement ent Valve
Valve Seat Bores Tier Tier 1 and Earlier
Earlier Engines
Engines . . . . . . . . . . . . . . . . . . . 55
Figure 87:
87: Dimensions
Dimensions for Replacement
Replacement Valve Seat Bores Tier Tier 2 Engines
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Figure 88: Measuring Valve Spring Free Fre e Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Figure 89: Checking Valve Spring Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Figure 90: Valve Spring Measurements
Measuremen ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Figure 91: Installing Valve Stem Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Figure 92: Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Figure 93: Lapping Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Figure 94: Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Figure 95: Measuring Rocker Arm Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 96: Measuring Rocker Arm Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Figure 97: Checking Bend in Push Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Figure 98: Tappet Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Figure 99: Measuring Tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Figure 100:
100: Oil Pump Assembly
Assembly Tier 1 and Earlier Earlier Engines
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 . 61
Figure 101: Checking
Checking Clearan
Clearancece Between
Between Oil Pump Body and and Outer Rotor Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Figure 102: Checking Clearance Between Inner Rotor and Outer Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Figure 103: Checking Clearance Between Rotor Plate and Rotors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 . 62
Figure 104: Mark on Outer
Outer Rotor Faces
Faces Oil Pump Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Figure 105: Oil Pump Located in Gear Case Cover on Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 106: Oil Pump Components Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Figure 107:
107: Measure Inner
Inner Rotor to Cranksh
Crankshaft aft Gear Boss ClearanceClearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Figure 108: Oil Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Figure 109: Water
Water Pump
Pump and Thermostat
Thermostat Assembli Assemblies es Tier
Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . 64
Figure 110: Water
Water Pump and Thermostat
Thermostat Assembly Assembly Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Figure 111: Crankcase
Crankcase Breather
Breather Tier
Tier 1 and Earlier
Earlier Engines
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Figure 112: Crankcase Breather Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Figure 113: Magnehelic Gauge Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 114: Measuring Crankcase PressurePre ssure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 115: Install Camshaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Figure 116: Install Upper Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Figure 117: Install Upper Thrust Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 118: Install Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

6
 List of Figures

Figure 119: Install Lower Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Figure 120: Install Lower Thrust Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 121: Main Bearing Cap Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 122: Install Main Bearing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 123: Check Plastigauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 124: Check End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 125: Assemble Piston and Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Figure 126:
126: Ring Placemen
Placementt Tier 1 and Earlier Earlier Engines
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Figure 127:
127: Ring Placemen
Placementt Tier 2 Engines
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Figure 128: Check Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Figure 129: Mark on Ring Faces
Face s Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Figure 130: Oil Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Figure 131: Ring Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Figure 132: Install Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Figure 133: Install Rod Cap and Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Figure 134: Check Plastigauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Figure 135: Front of Engine Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 136: Install Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 137: Install Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 138: Install Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 139: Install Camshaft Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 140:
140: Install
Install Oil Pump Tier
Tier 1 and Earlier
Earlier Engines
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 141:
141: Install
Install Fuel
Fuel Injection
Injection Pump
Pump Tier 1 and Earlier Earlier Engines
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 142:
142: Install
Install Fuel
Fuel Injection
Injection Pump
Pump Tier 2 Engines Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 143: Tier 1 and Earlier Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Figure 144:
144: Typical
Typical Tier 1 and Earlier
Earlier Index
Index Mark Alignment
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Figure 145: Tier 2 Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Figure 146: Typical Tier 2 Index
Ind ex Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Figure 147: Install Fuel Injection Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Figure 148: Install Idler Gear and Idler Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 149: Align Timing Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 150: Install Cylinder Head and Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 151: Cylinder Head Bolt Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 152: Install Valve Stem Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 153: Install Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 154: Adjust Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 155: Install Oil Filter Head and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Figure 156: Install Valve Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Figure 157: Install Oil Pump Intake Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Figure 158: Install Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Figure 159: Install Rear Seal Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Figure 160: Install Rear Seal with Tool P/N 204-952 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Figure 161: Install Bellhousing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Figure 162: Install Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Figure 163: Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Figure 164: Align Flat Sides of Crankshaft Gear with Flat Sides of Inner Rotor in Timing Gear Cover . . . . . . . 84
Figure 165:
165: Install
Install Gear Case Cover
Cover and Sound Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Figure 166: Install Front Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 167: Dowel Pin Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 168: Install Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 169: Install Oil Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 170: Install Fuel Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 171: Install Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 172:
172: Connect
Connect Coolant
Coolant Hoses
Hoses on Tier 2 Engines Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 173:
173: Install
Install Fuel
Fuel Injection
Injection Nozzles
Nozzles Tier Tier 1 and Earlier
Earlier Engines
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Figure 174:
174: Install
Install Fuel Injection
Injection Nozzles
Nozzles Tier Tier 2 Engines
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Figure 175:
175: Install
Install Fuel
Fuel Injection
Injection Lines
Lines Tier 1 and Earlier Earlier Engines
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Figure 176:
176: Install
Install Fuel Injection
Injection Lines
Lines Tier 2 Engines
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Figure 177:
177: Fuel Injection
Injection Line Connections
Connections on Tier 2 Engines Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Figure 178: Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

7
List of Figures

Figure 179: Typical Fuel System for Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Figure 180: Typical Fuel System for Tier Tie r 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Figure 181: Tier 1 and Earlier Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Figure 182: Tier 2 Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Figure 183: Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Figure 184: Top Dead Center One and Four . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Figure 185:
185: Fuel Solenoid
Solenoid Connector
Connector Pin Identificati
Identification on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Figure 186: Timing Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Figure 187: Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Figure 188: Correct Timing Mark Alignment for TK482 and TK486 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 . 99
Figure 189: Correct Timing Mark Alignment for TK482E and TK468E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 . 99
Figure 190: Correct
Correct Timing
Timing Mark
Mark Alignment
Alignment for TK486EH TK486EH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 . 99
Figure 191: Three-Piece Fuel Injection Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Figure 192: Timing Mark on Injection Pump Gear with Transfer Pump Cam Installed . . . . . . . . . . . . . . . . . . .100 . 100
Figure 193: Timing Mark on Injection Pump Gear without Transfer T ransfer Pump Cam Installed . . . . . . . . . . . . . . . . . 100
Figure 194: Flange and Injection Pump Gear Alignment with Transfer Pump Cam Installed . . . . . . . . . . . . . .101
Figure 195: Flange and Injection Pump Gear Alignment without without Transfer Pump Cam Installed Installed . . . . . . . . . . .101 . 101
Figure 196: Timing Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 197: Tier 2 Index Mark Location
Loca tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Figure 198: Tier 2 Index Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 . 102
Figure 199: Marking Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Figure 200: Place
Place Injectio
Injection
n Angle
Angle Sticker
Sticker on Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Figure 201: Injection Angle Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Figure 202: Removing Injection Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 203: Injection Angle Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 204: Injection Angle Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 205: Injection Pump Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 206: Examples of Injection Pump Index Mark Alignment with Injection Angle Sticker . . . . . . . . . . . . . .104 .10 4
Figure 207: Timing Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Figure 208: Align Flat Sides of Crankshaft Gear with Flat Sides of Inner Rotor in Timing Gear Cover . . . . . . 104
Figure 209: Tier 1 and Earlier Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Figure 210:
210: Typical
Typical Tier 1 and Earlier
Earlier Index
Index Mark Alignment
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Figure 211: Tier 2 Index Mark Location
Loca tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Figure 212: Typical Tier 2 Index Mark
Mar k Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Figure 213: Injection Pump Gear Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Figure 214: Trochoid Feed Pump Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Figure 215: Trochoid Feed Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Figure 216: Trochoid Feed Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Figure 217: Trochoid Feed Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Figure 218: Trochoid Feed Pump Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109 . 109
Figure 219: Cold Start Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Figure 220: Remove Engine Coolant Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Figure 221: Remove Cold Start Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Figure 222: Clean Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Figure 223: Testing Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Figure 224: Acceptable Spray Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Figure 225: Unacceptable Spray Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 . 111
Figure 226: Injection Nozzle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Figure 227: Testing Nozzle Valve and Seat Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Figure 228: Fuel Return Line Replacement Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Figure 229: Fuel Return Line Replacement
Replaceme nt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Figure 230: Outlet Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Figure 231: Inlet and Delivery Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Figure 232: Pressure Controlled Delivery Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Figure 233: Fuel Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Figure 234: Fuel System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Figure 235: Fuel Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Figure 236: Tier 1 and Earlier Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Figure 237: Tier 2 Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Figure 238: Tier 1 and Earlier Starter
Star ter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

8
 List of Figures

Figure 239: Tier 2 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Figure 240: TK482/TK
TK482/TK486 486 Starter
Starter (Tier
(Tier 1 and Earlier
Earlier Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Figure 241: di2.2/se2.2 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Figure 242: De-energized Starter
Star ter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Figure 243: Energized Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Figure 244: Starter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Figure 245: Check Brush Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Figure 246: Measure Brushes
Brushe s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Figure 247: Check Field Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Figure 248: Check Stator Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Figure 249: Check Armature Distortion
Distortio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Figure 250: Clean Up Commutator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Figure 251: Check Commutator Undercut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Figure 252: Check Armature Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Figure 253: Check Shunt Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Figure 254: Check Series Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Figure 255: Check Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Figure 256: Install Shift Lever and SpringSpr ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Figure 257: No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Figure 258: Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Figure 259:
259: Fuel Solenoid
Solenoid Connector
Connector Pin Identificatio
Identification n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Figure 260: Fuel Solenoid Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Figure 261: Fuel Solenoid Timer
Time r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Figure 262:
262: Simplified
Simplified Schematic
Schematic Diagram
Diagram of Fuel Solenoid Solenoid System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Figure 263:
263: Main Wire
Wire Harness Connect
Connector or Pin Identificatio
Identification n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Figure 264:
264: Fuel Solenoid
Solenoid Connector
Connector Pin Identificatio
Identification n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Figure 265: Relay Socket Terminal Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Figure 266: Top Dead Center One and Four . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Figure 267: Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Figure 268: Adjusting Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Figure 269: Early Engine Shown Others Similar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Figure 270: Remove Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Figure 271:
271: Remove
Remove Sound Shield Shield and and Gear Case Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Figure 272: Oil Pump Located in Gear Case Cover on Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Figure 273:
273: Remove
Remove Oil PumpPump Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Figure 274:
274: Check
Check Intake
Intake Pipe Gasket
Gasket Tier Tier 1 and Earlier
Earlier Engines
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Figure 275: Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Figure 276: Align Flat Sides of Crankshaft Gear with Flat Sides of Inner Rotor in Timing Gear Cover . . . . . . 143
Figure 277: Dowel Pin Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Figure 278: Install Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Figure 279: Front Pulley and Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Figure 280: Front Pulley and Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Figure 281: Water Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Figure 282: Oil Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Figure 283:
283: Retrofitting
Retrofitting Low Mount ELC Compatible Compatible Water Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Figure 284: Oil Filter Heads and Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Figure 285: Oil Level Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Figure 286: Tier 1 (and Earlier)
Earlier ) Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Figure 287: Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Figure 288: Typical Serial Number Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Figure 289:
289: Serial Number
Number Nameplat
Nameplate e Location
Location Tier 1 and Earlier Earlier Engines
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Figure 290:
290: Serial Number
Number Nameplat
Nameplate e Location
Location Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Figure 291: Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Figure 292: Early
Early Style
Style Fuel Solenoid
Solenoid Timer Timer P/N 41-1533 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Figure 293:
293: Late Style
Style Fuel
Fuel Solenoid
Solenoid Timer P/N 41-2191 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Figure 294:
294: Alternator
Alternator Mountin
Mounting g Brackets
Brackets for High Mount Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Figure 295: Early Style Alternator Mounting Brackets for Low Mount Water Pump . . . . . . . . . . . . . . . . . . . . . 154
Figure 296: Late Style Alternator Mounting Brackets for Low Mount Water Pump . . . . . . . . . . . . . . . . . . . . . . 154

9
List of Figures

10
TK482 & TK486 Diesel Engine Specifications

This manual contains information about the TK482 and TK486 engine families.
 The TK482
TK482 engi
engine
ne fami
family
ly inclu
includes
des the TK482
TK482 and
and TK48
TK482E.
2E.
• The TK486
TK486 engine
engine family
family include
includess the TK486,
TK486, TK486
TK486E,
E, TK486EH
TK486EH,, TK486V
TK486V,, TK486VB,
TK486VB, and
and
TK486VH.
• The TK482
TK482 and TK486
TK486 were made before
before the requiremen
requirementt to comply
comply with EPA
EPA regulation
regulations.
s.
• The TK482E,
TK482E, TK486E
TK486E,, and
and TK486EH
TK486EH comply
comply with
with EPA
EPA Tier
Tier 1 regulation
regulations.
s.
• The TK486V
TK486V,, TK486VB
TK486VB (used
(used in bus applic
application
ations),
s), and TK486
TK486VH
VH comply
comply with any
any EPA
EPA Tier
Tier 2
regulations.
• Tier
Tier 1 and earlier
earlier engine
enginess (TK482,
(TK482, TK486,
TK486, TK482
TK482E,
E, TK486E,
TK486E, and
and TK486EH
TK486EH)) use an
an in-line
in-line injection
injection
pump.
• Tier
Tier 2 engines
engines (TK486V
(TK486V,, TK486VB,
TK486VB, and TK486
TK486VH)
VH) use a mono-plu
mono-plunger
nger and
and distributor
distributor injection
injection
pump.
See “Engine Model
Model Identification”
Identification” on page 152 for
152 for information about identifying the engine models. See
“Engine
“Engine History”
History” on page 147 more
147 more information about the engine models and changes.
 NOTE: The number 1 cylinder is on the flywheel (rear) end of
of the engine.

Tier 1 and Earlier -

TK482, TK482E, TK486, TK486E, and TK486EH
Except where noted, the specifications for these engines are the same.

General
Type Four Stroke Cycle Water Cooled
Number of Cylinders 4
Cylinder Arrangement In-line Vertical, Number 1 on Flywheel End
Bore
TK482, and TK482E 3.23 in. (82.0 mm)
TK486, TK486
486E, and TK486EH 3.39 in. (86.0 mm)
Stroke 3.54 in. (90.0 mm)
Displacement
TK482, and TK482E 116 cu. in. (1.90 liters)
TK48
TK486,
6, TK48
TK486E
6E,, and
and TK48
TK486E
6EH
H 128
128 cu.
cu. in.
in. (2.0
(2.09
9 lite
liters
rs))
Power Rating
TK482, and TK482E 30.3 hp (22.6 kW) @ 2200 rpm
TK486, and TK486E 33.9 hp (25.3 kW) @ 2200 rpm
TK486EH 35.0 hp (26.1 kW) @ 2600 rpm
Compression Ratio 18.0 to 1
Direction of Rotation Counterclockwise (Viewed from Flywheel)
Firing Order 1-3-4-2 (Number 1 on Flywheel End)
Fuel Injection Timing
TK482 and TK486 12 ± 1 Degrees BTDC
TK482E and TK486E 10 ± 1 Degrees BTDC
TK486EH 11 ± 1 Degrees BTDC
Nozzle Injection Pressure 2,800-3,000 psi (19,600-20,600 kPa)

11
TK482 & TK486 Diesel Engine Specifications

Tier 1 and Earlier -

TK482, TK482E, TK486, TK486E, and TK486EH (Continued)
General (Continued)
Oil Pressure 18.5 psi (127 kPa) Minimum @ 230 F (110 C) & 1600 rpm
45-57 psi (310-390 kPa) @ 230 F (110 C) & 2200 rpm
Engine Coolant Thermostat 180 F (82 C)
Valve Clearance (Static @ 70 F [21 C])
Intake 0.006-0.010 in. (0.15-0.25 mm)
Exhaust 0.006-0.010 in. (0.15-0.25 mm)

Valve Train Standard Dimensions Wear Limit

Valve Spring
Free Length 1.75 in. (44.5 mm) 1 . 6 7 i n. ( 42 . 5 m m )
Inclination (Top to Bottom from 0-0.04 in. (0-1.1 mm) 0.04 in. (1.1 mm)
Vertical)
Valve Guide Inside Diameter
Intake 0.3154-0.3159 in. (8.010-8.025 mm) 0.3189 in. (8.100 mm)
Exhaust 0.3156-0.3161 in. (8.015-8.030 mm) 0.3189 in. (8.100 mm)
Valve Stem Outside Diameter
Intake 0.3132-0.3140 in. (7.955-7.975 mm) 0.3110 in. (7.900 mm)
Exhaust 0.3132-0.3138 in. (7.955-7.970 mm) 0.3110 in. (7.900 mm)
Valve Stem to Valve Guide Clearance
Intake 0.0014-0.0028 in. (0.035-0.070 mm) 0.0079 in. (0.200 mm)
Exhaust 0.0018-0.0030 in. (0.045-0.075 mm) 0.0079 in. (0.200 mm)
Valve Margin
Mar gin
Intake 0.0490-0.0569 in. (1.244-1.444 mm) 0.020 in. (0.50 mm)
Exhaust 0.0531-0.0610 in. (1.350-1.550 mm) 0.020 in. (0.50 mm)
Valve Depth (Cylinder Head Deck to
Valve)
Intake 0.0120-0.0199 in. (0.306-0.506 mm) 0.039 in. (1.00 mm)
Exhaust 0.0118-0.0197 in. (0.300-0.500 mm) 0.039 in. (1.00 mm)
Valve Guide Projection (Above Valve
Spring Seat in Cylinder Head)
Intake 0.591 in. (15.00 mm)
Exhaust 0.591 in. (15.00 mm)
Valve Angle
Intake 30 Degrees
Exhaust 45 Degrees
Valve Seat Angle
Intake 30 Degrees
Exhaust 45 Degrees
Valve Seat Width
Intake 0.042-0.049 in. (1.07-1.24 mm) 0.069 in. (1.74 mm)
Exhaust 0.049-0.057 in. (1.24-1.45 mm) 0.076 in. (1.94 mm)
Rock
Rocker
er Arm
Arm Bush
Bushin
ing
g Insi
Inside
de Dia
Diame
meter
ter 0.629
0.6299-
9-0.6
0.630
307
7 in.
in. (16.0
(16.000
00-1
-16.0
6.020
20 mm)
mm) 0.63
0.6335
35 in.
in. (16.0
(16.090
90 mm)
mm)
Rock
Rocker
er Arm
Arm Shaf
Shaftt O
Out
utsi
side
de Diam
Diamet
eter
er 0.628
0.6286-0
6-0.6
.6293
293 in.
in. ((15.
15.96
966-1
6-15.
5.98
984
4 mm)
mm) 0.62
0.6280
80 in.
in. ((15
15.9
.950
50 mm
mm))

12
 TK482 & TK486 Diesel Engine Specifications

Tier 1 and Earlier -

TK482, TK482E, TK486, TK486E, and TK486EH (Continued)
(Continu ed)
Valve Train (Continued) Standard Dimensions Wear Limit
Rocker Arm Bushing to Rocker Arm 0.00
0.0006
06-0
-0.0
.002
021
1 in.
in. (0.0
(0.016
16-0
-0.0
.054
54 mm)
mm) 0.00
0.0055
55 in.
in. (0.
(0.14
140
0 mm)
mm)
Shaft Clearance
Tappet O
Ou
utside Di
Diameter 0.4715-0.4720 in
in. ((1
11.975-11.990 mm
mm) 0.4697 in
in. ((1
11.930 mm
mm)
Tappet Bo
Bore In
Inside Di
Diameter 0.4724-0.4731 in
in. (1
(12.000-12.018 mm
mm) 0.4744 in
in. (1
(12.050 mm
mm)
Tappe
appett To Tappe
appett Bore
Bore Clea
Cleara
ranc
nce
e 0.00
0.0004
04-0
-0.0
.001
017
7 in.
in. (0.0
(0.010
10-0
-0.0
.043
43 mm
mm)) 0.00
0.0047
47 in.
in. (0.1
(0.120
20 mm
mm))
Push Rod Bend 0-0.001 in. (0-0.03 mm) 0.001 in. (0.03 mm)

Camshaft
Cam Lobe Height 1.5211-1.5262 in. (38.635-38.765 mm) 1.5118 in. (38.400 mm)
Camshaft Journal Outside Diameter
Timing Gear End 1.7687-1.7697 in. (44.925-44.950 mm) 1.7657 in. (44.850 mm)
Middle 1.7681-1.7691 in. (44.910-44.935 mm) 1.7657 in. (44.850 mm)
Flywheel End 1.7687-1.7697 in. (44.925-44.950 mm) 1.7657 in. (44.850 mm)
Camshaft Bearing Inside Diameter
Timin
iming
g Gea
Gearr End
End Bear
Bearin
ing
g Ins
Inser
ertt 1.77
1.7713
13-1
-1.7
.773
738
8 in.
in. (44.
(44.99
990-
0-45
45.0
.055
55 mm
mm)) 1.77
1.7756
56 in.
in. (45
(45.1
.100
00 mm
mm))
Middle Be
Bearing (N
(No In
Insert) 1.7717-1.7726 in
in. (4
(45.000-45.025 mm
mm) 1.7756 in
in. (4
(45.100 mm
mm)
Flyw
Flywhe
heel
el End
End Bea
Beari
ring
ng (No
(No Ins
Insert
ert)) 1.771
1.7717-1
7-1.7
.7726
726 in.
in. ((45.
45.000
000-4
-45.0
5.025
25 mm
mm)) 1.775
1.7756
6 in.
in. (45.1
(45.100
00 mm
mm))
Camshaft
Camshaft Journal to Camshaft Bearing
Bearing
Clearance
Timing Gear End 0.0016-0.0051 in. (0.040-0.130 mm) 0.0079 in. (0.200 mm)
Middle 0.0026-0.0045 in. (0.065-0.115 mm) 0.0079 in. (0.200 mm)
Flywheel End 0.0020-0.0039 in. (0.050-0.100 mm) 0.0079 in. (0.200 mm)
Camshaft Deflection 0.001 in. (0.02 mm) 0.002 in. (0.05 mm)
Camshaft End Play 0.002-0.010 in. (0.05-0.25 mm) 0.016 in. (0.40 mm)

Piston, Piston Rings, and Wrist Pin

Piston Outside Diameter Measuring 0.95 in. (24.0 mm)
Point (From Bottom of Piston
Perpendicular to Wrist Pin)
Piston Outside Diameter
TK482 and TK482E
Standard 3.2260-3.2272 in. (81.940-81.970 mm) 3.2244 in. (81.900 mm)
1st Oversi
Oversize
ze 0.01
0.010
0 in.
in. (0.25
(0.25 mm)
mm) 3.2358-3
3.2358-3.237
.2370
0 in.
in. (82.190-
(82.190-82.2
82.220
20 mm) 3.2343
3.2343 in. (82.150
(82.150 mm)
2nd Overs
Oversize
ize 0.0
0.020
20 in.
in. (0.50
(0.50 mm)
mm) 3.2457-
3.2457-3.24
3.2469
69 in.
in. (82.44
(82.440-8
0-82.47
2.470
0 mm)
mm) 3.2441
3.2441 in.
in. (82.4
(82.400
00 mm)
mm)
TK486, TK486E, and TK486EH
Standard 3.3835-3.3846 in. (85.940-85.970 mm) 3.3819 in. (85.900 mm)
1st Oversi
Oversize
ze 0.01
0.010
0 in.
in. (0.25
(0.25 mm)
mm) 3.3933-3
3.3933-3.394
.3945
5 in.
in. (86.190-
(86.190-86.2
86.220
20 mm) 3.3917
3.3917 in. (86.150
(86.150 mm)
2nd Overs
Oversize
ize 0.0
0.020
20 in.
in. (0.50
(0.50 mm)
mm) 3.4031-
3.4031-3.40
3.4043
43 in.
in. (86.44
(86.440-8
0-86.47
6.470
0 mm)
mm) 3.4016
3.4016 in.
in. (86.4
(86.400
00 mm)
mm)
Pist
Piston
on to Cyli
Cylind
nder
er Wall
all Clea
Cleara
ranc
nce
e 0.00
0.0012
12-0
-0.0
.003
035
5 in.
in. (0.0
(0.030
30-0
-0.0
.090
90 mm
mm))
Piston Top Clearance (Between Top of 0.026-0.033 in. (0.65-0.83 mm)
Piston at TDC and Combustion
Chamber with Cylinder Head
Installed)

13
TK482 & TK486 Diesel Engine Specifications

Tier 1 and Earlier -

TK482, TK482E, TK486, TK486E, and TK486EH (Continued)
Piston, Piston Rings, and Wrist Pin
(Continued) Standard Dimensions Wear Limit
Piston Ring Groove Width
Top Ring Groove 0.0813-0.0819 in. (2.065-2.080 mm)
Middle Ring Groove 0.0801-0.0807 in. (2.035-2.050 mm)
Bottom Ring Groove 0.1581-0.1587 in. (4.015-4.030 mm)
Piston Ring Width
Top Ring 0.0776-0.0783 in. (1.970-1.990 mm)
Middle Ring
TK482 and TK482E 0.0776-0.0783 in. (1.970-1.990 mm)
TK48
TK486,
6, TK4
TK486
86E,
E, and
and TK4
TK486E
86EH
H 0.07
0.0768-
68-0.
0.07
0776
76 in.
in. (1.
(1.95
950-1
0-1.9
.970
70 mm)
mm)
Bottom Ring 0.1563-0.1571 in. (3.970-3.990 mm)
Piston Ring to Ring Groove Clearance
Top 0.0030-0.0043 in. (0.075-0.110 mm) 0.0098 in. (0.250 mm)
Middle
TK482 and TK482E 0.0018-0.0031 in. (0.045-0.080 mm) 0.0098 in. (0.250 mm)
TK48
TK486,
6, TK48
TK486E
6E,, and
and TK48
TK486E
6EH
H 0.00
0.0026
26-0
-0.0
.003
039
9 in.
in. (0.0
(0.065
65-0
-0.1
.100
00 mm
mm)) 0.00
0.0098
98 in.
in. (0.2
(0.250
50 mm
mm))
Bottom 0.0010-0.0024 in. (0.025-0.060 mm) 0.0079 in. (0.200 mm)
Piston Ring End Gap
Top Ring 0.008-0.016 in. (0.20-0.40 mm) 0.059 in. (1.50 mm)
Middle Ring 0.008-0.016 in. (0.20-0.40 mm) 0.059 in. (1.50 mm)
Bottom Ring 0.008-0.016 in. (0.20-0.40 mm) 0.059 in. (1.50 mm)
Piston
Piston Wrist
Wrist Pin Bore
Bore Insi
Inside
de Diamete
Diameterr 1.0236-
1.0236-1.0
1.0240
240 in. (26.000-
(26.000-26.
26.009
009 mm) 1.0244
1.0244 in. (26.020
(26.020 mm)
Wrist Pin Outside Diameter 1.0231-1.0236 in. (25.987-26.000 mm) 1.0197 in. (25.900 mm)
Wrist Pin to Piston Wrist Pin Bore 0-0.0009 in. (0-0.022 mm) 0.0047 in. (0.120 mm)
Clearance

Connecting Rod
Wrist
rist Pin
Pin Bus
Bushi
hing
ng Insi
Inside
de Diam
Diamet
eter
er 1.02
1.0246
46-1
-1.0
.025
251
1 in.
in. (26.
(26.02
025-
5-26
26.0
.038
38 mm
mm)) 1.02
1.0276
76 in.
in. (26
(26.1
.100
00 mm
mm))
Wrist Pin Outside Diameter 1.0231-1.0236 in. (25.987-26.000 mm) 1.0197 in. (25.900 mm)
Wrist Pin to Wrist Pin Bushing 0.00
0.0010
10-0
-0.0
.002
020
0 in.
in. (0.0
(0.025
25-0
-0.0
.051
51 mm)
mm) 0.00
0.0079
79 in.
in. (0.
(0.20
200
0 mm)
mm)
Clearance
Larg
Large
eEEnd
nd Bore
Bore (Wit
(Witho
hout
ut Bear
Bearin
ing)
g) 2.00
2.0079
79-2
-2.0
.008
083
3 in.
in. (51.
(51.00
000-
0-51
51.0
.010
10 mm
mm))
Rod Bearing Clearance 0.0015-0.0029 in. (0.038-0.074 mm) 0.0063 in. (0.160 mm)
Side Clearance (Crank to Rod) 0.008-0.016 in. (0.20-0.40 mm) 0.022 in. (0.55 mm)
Twist per 4 in. (100 mm) 0.001 in. (0.03 mm) 0.003 in. (0.08 mm)
Parallelism per 4 in. (100 mm) 0.001 in. (0.03 mm) 0.003 in. (0.08 mm)

Crankshaft and Crankshaft Bearings

Main Journal Outside Diameter
Standard 1.9666-1.9670 in. (49.952-49.962 mm) 1.9650 in. (49.910 mm)
Undersize 1.9568-1.9572 in. (49.702-49.712 mm) 1.9551 in. (49.660 mm)
Main Bearing Inside Diameter
Standard 1.9685-1.9693 in. (50.000-50.020 mm) 1.9709 in. (50.060 mm)
Undersize 1.9587-1.9594 in. (49.750-49.770 mm) 1.9610 in. (49.810 mm)
Main Bearing Clearance 0.0015-0.0027 in. (0.038-0.068 mm) 0.0059 in. (0.150 mm)

14
 TK482 & TK486 Diesel Engine Specifications

Tier 1 and Earlier -

TK482, TK482E, TK486, TK486E, and TK486EH (Continued)
(Continu ed)
Crankshaft and Crankshaft Bearings
(Continued) Standard Dimensions Wear Limit
Main Bearing Bore Inside Diameter 2.1260-2.1267 in. (54.000-54.019 mm)
(Without Bearing)
Rod Journal Outside Diameter
Standard 1.8879-1.8883 in. (47.952-47.962 mm) 1.8862 in. (47.910 mm)
Undersize 1.8780-1.8784 in. (47.702-47.712 mm) 1.8764 in. (47.660 mm)
Rod Bearing Inside Diameter
Standard 1.8898-1.8908 in. (48.000-48.026 mm) 1.8925 in. (48.070 mm)
Undersize 1.8799-1.8809 in. (47.750-47.776 mm) 1.8827 in. (47.820 mm)
Rod Bearing Clearance 0.0015-0.0029 in. (0.038-0.074 mm) 0.0063 in. (0.160 mm)
End Play 0.0035-0.0107 in. (0.090-0.271 mm) 0.0130 in. (0.330 mm)
Deflection 0.0008 in. (0.020 mm)

Cylinder Block
Cylinder Inside Diameter
TK482 and TK482E
Standard 3.2283-3.2295 in. (82.000-82.030 mm) 3.2362 in. (82.200 mm)
1st Oversize 3.2382-3.2394 in. (82.250 -82.280 mm) 3.2461 in. (82.450 mm)
2nd Oversize 3.2480-3.2492 in. (82.500-82.530 mm) 3.2559 in. (82.700 mm)
TK486, TK486E, and TK486EH
Standard 3.3858-3.3870 in. (86.000-86.030 mm) 3.3937 in. (86.200 mm)
1st Oversize 3.3957-3.3969 in. (86.250-86.280 mm) 3.4035 in. (86.450 mm)
2nd Oversize 3.4055-3.4067 in. (86.500-86.530 mm) 3.4134 in. (86.700 mm)
Cylinder Roundness 0-0.0004 in. (0-0.010 mm) 0.0012 in. (0.030 mm)
Cylinder Taper (Cylindricity) 0-0.0004 in. (0-0.010 mm) 0.0012 in. (0.030 mm)
Deck Distortion 0.002 in. (0.05 mm)

Cylinder Head
Distortion 0-0.002 in. (0-0.05 mm) 0.006 in. (0.15 mm)

Timing Gears
Timing Gear Lash
Crankshaft
aft Gear to Idler Gear 0.00
.0028-0.0
0.0059 in. (0.070-0.
-0.150 mm) 0.0079
079 in. (0.200
200 mm)
Cran
Cranks
ksha
hafft Gea
Gearr to
to Oil
Oil Pump
Pump Gear
Gear 0.00
0.0028
28-0
-0.0
.005
059
9 in.
in. (0.0
(0.070
70-0
-0.1
.150
50 mm
mm)) 0.00
0.0079
79 in.
in. (0.
(0.20
200
0 mm)
mm)
Idler Gear to Camshaft Gear 0.0028-0.0059 in. (0.070-0.150 mm) 0.0079 in. (0.200 mm)
Idler Gear to Fuel Injection Pump 0.00
0.0028
28-0
-0.0
.005
059
9 in.
in. (0.0
(0.070
70-0
-0.1
.150
50 mm)
mm) 0.00
0.0079
79 in.
in. (0.
(0.20
200
0 mm)
mm)
Gear
Idle
Idlerr Gear
Gear Bus
Bushi
hing
ng Ins
Insid
ide
e Diam
Diamet
eter
er 1.81
1.8110
10-1
-1.8
.812
120
0 in.
in. (46.
(46.00
000-
0-46
46.0
.025
25 mm)
mm) 1.81
1.8142
42 in.
in. (46
(46.0
.080
80 mm)
mm)
Idle
Idlerr Gea
Gearr Sha
Shaft
ft Outs
Outsid
ide
e Dia
Diame
mete
terr 1.80
1.8091
91-1
-1.8
.810
100
0 in.
in. (45.
(45.95
950-
0-45
45.9
.975
75 mm
mm)) 1.80
1.8083
83 in.
in. (45
(45.9
.930
30 mm
mm))
Idler Gear Shaft to Idler Gear Bushing 0.00
0.0010
10-0
-0.0
.003
030
0 in.
in. (0.0
(0.025
25-0
-0.0
.075
75 mm)
mm) 0.00
0.0059
59 in.
in. (0.
(0.15
150
0 mm)
mm)
Clearance

15
TK482 & TK486 Diesel Engine Specifications

Tier 1 and Earlier -

TK482, TK482E, TK486, TK486E, and TK486EH (Continued)
Oil Pump
Type Trochoid
Oute
Outerr Rot
Rotor
or to Pum
Pump
p Bod
Body
y Cle
Clear
aran
ance
ce 0.00
0.0039
39-0
-0.0
.006
063
3 in.
in. (0.
(0.10
100-
0-0.
0.16
160
0 mm)
mm) 0.00
0.0098
98 in.
in. (0.2
(0.250
50 mm)
mm)
Inner Rotor Tip to Outer Rotor Lobe 0.0059 in. (0.150 mm)
Clearance
Rotor Plate to Rotor Clearance 0.0012-0.0035 in. (0.030-0.090 mm) 0.0059 in. (0.150 mm)
Rotor Shaft to Rotor Shaft Bore 0.00
0.0005
05-0
-0.0
.001
017
7 in.
in. (0.0
(0.013
13-0
-0.0
.043
43 mm)
mm) 0.00
0.0079
79 in.
in. (0.
(0.20
200
0 mm)
mm)
Clearance
Pressure C
Co
ontrol Va
Valve Se
Setting 36-50 ps
psi (2
(245-343 kP
kPa)

Starter Standard Dimensions Wear Limit

No Load Test
Voltage 11 volts
Current Maximum of 140 amps @ 11 volts
Speed Minimum of 3900 rpm @ 11 volts
Loaded Properties
Voltage 8.76 volts
Current 300 amps
Commutator Outside Diameter 1.44 in. (36.5 mm) 1.40 in. (35.5 mm)

16
Tier 2 - TK486V, TK486VB, and TK486VH
Except where noted, the specifications for these engines are the same.

General
Type Four Stroke Cycle Water Cooled
Number of Cylinders 4
Cylinder Arrangement In-line Vertical, Number 1 on Flywheel End
Bore 3.39 in. (86.0 mm)
Stroke 3.54 in. (90.0 mm)
Displacement 128 cu. in. (2.09 liters)
Power Rating
TK486V and TK486VB 33.9 hp (25.3 kW) @ 2200 rpm
TK486VH 35.0 hp (26.1 kW) @ 2600 rpm
Compression Ratio 19.1 to 1
Direction of Rotation Counterclockwise (Viewed from Flywheel)
Firing Order 1-3-4-2 (Number 1 on Flywheel End)
Fuel Injection Timing See “Injection Pump Timing
Timing Tier 2 Engines” on page 102
102..
Nozzle Injection Pressure 3,100-3,300 psi (21,600-22,600 kPa)
Oil Pressure 18.5 psi (127 kPa) Minimum @ 230 F (110 C) & 1600 rpm
45-57 psi (310-390 kPa) @ 230 F (110 C) & 2200 rpm
Engine Coolant Thermostat 160 F (71 C)
Valve Clearance (Static
( Static @ 70 F [21 C])
Intake 0.006-0.010 in. (0.15-0.25 mm)
Exhaust 0.006-0.010 in. (0.15-0.25 mm)

Valve Train Standard Dimensions Wear Limit

Valve Spring
Free Length 1.65 in. (42.0 mm) 1.63 in. (41.5 mm)
Inclination (Top to Bottom from 0-0.04 in. (0-1.4 mm) 0.06 in. (1.4 mm)
Vertical)
Valve Guide Inside Diameter
Intake 0.3154-0.3159 in. (8.010-8.025 mm) 0.3189 in. (8.100 mm)
Exhaust 0.3156-0.3161 in. (8.015-8.030 mm) 0.3189 in. (8.100 mm)
Valve Stem Outside Diameter
Intake 0.3132-0.3140 in. (7.955-7.975 mm) 0.3110 in. (7.900 mm)
Exhaust 0.3132-0.3138 in. (7.955-7.970 mm) 0.3110 in. (7.900 mm)
Valve Stem to Valve Guide Clearance
Intake 0.0014-0.0028 in. (0.035-0.070 mm) 0.0071 in. (0.180 mm)
Exhaust 0.0018-0.0030 in. (0.045-0.075 mm) 0.0071 in. (0.180 mm)
Valve Margin
Intake 0.053 in. (1.34 mm) 0.020 in. (0.50 mm)
Exhaust 0.057 in. (1.45 mm) 0.020 in. (0.50 mm)

17
TK482 & TK486 Diesel Engine Specifications

Tier 2 - TK486V,
TK486V, TK486VB, and TK486VH (Continued)
(Conti nued)
Valve Train (Continued) Standard Dimensions Wear Limit
Valve Depth (Cylinder Head Deck to
Valve)
Intake 0.012-0.020 in. (0.30-0.50 mm) 0.031 in. (0.80 mm)
Exhaust 0.012-0.020 in. (0.30-0.50 mm) 0.031 in. (0.80 mm)
Valve Guide Projection (Above Valve
Spring Seat in Cylinder Head)
Intake 0.579-0.591 in. (14.70-15.00 mm)
Exhaust 0.579-0.591 in. (14.70-15.00 mm)
Valve Angle
Intake 30 Degrees
Exhaust 45 Degrees
Valve Seat Angle
Intake 30 Degrees
Exhaust 45 Degrees
Valve Seat Width
Intake 0.042-0.049 in. (1.07-1.24 mm) 0.069 in. (1.74 mm)
Exhaust 0.049-0.057 in. (1.24-1.45 mm) 0.076 in. (1.94 mm)
Rock
Rocker
er Arm
Arm Bush
Bushin
ing
g Insi
Inside
de Dia
Diame
meter
ter 0.629
0.6299-
9-0.
0.630
6307
7 in.
in. (16.0
(16.000-
00-16.
16.02
020
0 mm)
mm) 0.63
0.6327
27 in.
in. (16.0
(16.070
70 mm)
mm)
Rock
Rocker
er Arm
Arm Shaf
Shaftt O
Out
utsi
side
de Diam
Diamet
eter
er 0.628
0.6286-0
6-0.6
.6293
293 in.
in. ((15.
15.96
966-1
6-15.
5.98
984
4 mm)
mm) 0.62
0.6276
76 in.
in. ((15
15.9
.940
40 mm
mm))
Rocker Arm Bushing to Rocker Arm 0.00
0.0006
06-0
-0.0
.002
021
1 in.
in. (0.0
(0.016
16-0
-0.0
.054
54 mm)
mm) 0.00
0.0051
51 in.
in. (0.
(0.13
130
0 mm)
mm)
Shaft Clearance
Tappet O
Ou
utside Di
Diameter 0.4715-0.4720 in
in. ((1
11.975-11.990 mm
mm) 0.4707 in
in. ((1
11.955 mm
mm)
Tappet Bo
Bore In
Inside Di
Diameter 0.4724-0.4734 in
in. (1
(12.000-12.025 mm
mm) 0.4742 in
in. (1
(12.045 mm
mm)
Tappe
appett To Tappe
appett Bore
Bore Clea
Cleara
ranc
nce
e 0.00
0.0004
04-0
-0.0
.002
020
0 in.
in. (0.0
(0.010
10-0
-0.0
.050
50 mm
mm)) 0.00
0.0035
35 in. (0.0
(0.090
90 mm
mm))
Push Rod Bend 0-0.001 in. (0-0.03 mm) 0.001 in. (0.03 mm)

Camshaft Standard Dimensions Wear Limit

Cam Lobe Height 1.5197-1.5276 in. (38.600-38.800 mm) 1.5098 in. (38.350 mm)
Camshaft Journal Outside Diameter
Timing Gear End 1.7687-1.7697 in. (44.925-44.950 mm) 1.7673 in. (44.890 mm)
Middle 1.7681-1.7691 in. (44.910-44.935 mm) 1.7667 in. (44.875 mm)
Flywheel End 1.7687-1.7697 in. (44.925-44.950 mm) 1.7673 in. (44.890 mm)
Camshaft Bearing Inside Diameter
Timin
iming
g Gea
Gearr End
End Bear
Bearin
ing
g Ins
Inser
ertt 1.77
1.7713
13-1
-1.7
.773
738
8 in.
in. (44.
(44.99
990-
0-45
45.0
.055
55 mm
mm)) 1.77
1.7768
68 in.
in. (45
(45.1
.130
30 mm
mm))
Middle Be
Bearing (N
(No In
Insert) 1.7717-1.7726 in
in. (4
(45.000-45.025 mm
mm) 1.7756 in
in. (4
(45.100 mm
mm)
Flyw
Flywhe
heel
el End
End Bea
Beari
ring
ng (No
(No Ins
Inser
ert)
t) 1.771
1.7717-1
7-1.7
.772
726
6 in.
in. (45.0
(45.000-
00-45
45.0
.025
25 mm
mm)) 1.775
1.7756
6 in.
in. (45.
(45.100
100 mm
mm))
Camshaft
Camshaft Journal to Camshaft
Camshaft Bearing
Clearance
Timing Gear End 0.0016-0.0051 in. (0.040-0.130 mm) 0.0094 in. (0.240 mm)
Middle 0.0026-0.0045 in. (0.065-0.115 mm) 0.0089 in. (0.225 mm)
Flywheel End 0.0020-0.0039 in. (0.050-0.100 mm) 0.0082 in. (0.210 mm)
Camshaft Deflection 0.001 in. (0.02 mm) 0.002 in. (0.05 mm)
Camshaft End Play 0.002-0.008 in. (0.05-0.20 mm) 0.012 in. (0.30 mm)

18
 TK482 & TK486 Diesel Engine Specifications

Tier 2 - TK486V,
TK486V, TK486VB, and TK486VH (Continued)
(Conti nued)
Piston, Piston Rings, and Wrist Pin Standard Dimensions Wear Limit
Piston Outside Diameter Measuring 0.95 in. (24.0 mm)
Point (From Bottom of Piston
Perpendicular to Wrist Pin)
Piston Outside Diameter
Standard 3.3835-3.3846 in. (85.940-85.970 mm) 3.3817 in. (85.895 mm)
1st
1st Over
Oversi
size
ze 0.0
0.010
10 in.
in. (0.
(0.25
25 mm)
mm) 3.39
3.3935
35-3
-3.3
.394
941
1 in.
in. (86.
(86.19
195-
5-86
86.2
.210
10 mm)
mm) 3.39
3.3917
17 in.
in. (86
(86.1
.150
50 mm)
mm)
2nd
2nd Ove
Overs
rsiz
ize
e 0.0
0.020
20 in.
in. (0.
(0.50
50 mm
mm)) 3.403
3.4033-
3-3.
3.403
4039
9 in.
in. (86.4
(86.445
45-86
-86.4
.460
60 mm
mm)) 3.401
3.4016
6 in.
in. (86.
(86.400
400 mm
mm))
Piston to Cylinder Wall Clearance
Standard 0.0018-0.0030 in. (0.045-0.075 mm)
1st
1st Over
Oversi
size
ze 0.01
0.010
0 in.
in. (0.25
(0.25 mm) 0.001
0.0016-
6-0.0
0.003
033
3 in.
in. (0.04
(0.040-0
0-0.0
.085
85 mm
mm))
2nd
2nd Ove
Overs
rsiz
ize
e 0.0
0.020
20 in.
in. (0.50
(0.50 mm
mm)) 0.00
0.0016-
16-0.
0.003
0033
3 in.
in. (0.0
(0.040-
40-0.
0.08
085
5 mm)
mm)
Piston Top Clearance (Between Top of 0.0262-0.0306 in. (0.666-0.778 mm)
Piston at TDC and Combustion
Chamber with Cylinder Head
Installed)
Piston Ring Groove Width
Top Ring Groove 0.0813-0.0819 in. (2.065-2.080 mm)
Middle Ring Groove 0.0801-0.0807 in. (2.035-2.050 mm)
Bottom Ring Groove 0.1581-0.1587 in. (4.015-4.030 mm)
Piston Ring Width
Top Ring 0.0776-0.0783 in. (1.970-1.990 mm) 0.0768 in. (1.950 mm)
Midd
Middle
le Ring
Ring 0.07
0.0768-
68-0.
0.077
0776
6 in.
in. (1.9
(1.950-
50-1.
1.97
970
0 mm
mm)) 0.076
0.0760
0 in.
in. (1.9
(1.930
30 mm
mm))
Bottom Ring 0.1563-0.1571 in. (3.970-3.990 mm) 0.1555 in. (3.950 mm)
Piston Ring to Ring Groove Clearance
Top 0.0030-0.0043 in. (0.075-0.110 mm) 0.0098 in. (0.250 mm)
Middle 0.0026-0.0039 in. (0.065-0.100 mm) 0.0098 in. (0.250 mm)
Bottom 0.0010-0.0024 in. (0.025-0.060 mm) 0.0079 in. (0.200 mm)
Piston Ring End Gap
Top Ring 0.008-0.016 in. (0.20-0.40 mm) 0.019 in. (0.49 mm)
Middle Ring 0.012-0.020 in. (0.30-0.50 mm) 0.023 in. (0.59 mm)
Bottom Ring 0.008-0.016 in. (0.20-0.40 mm) 0.019 in. (0.49 mm)
Piston
Piston Wrist
Wrist Pin Bore
Bore Insi
Inside
de Diamet
Diameter
er 1.0236-
1.0236-1.02
1.0240
40 in. (26.000-
(26.000-26.
26.009
009 mm) 1.0252
1.0252 in. (26.039
(26.039 mm)
Wrist Pi
Pin Ou
Outside D
Diiameter 1.0234-1.0236 in
in. (2
(25.995-26.000 mm
mm) 1.0222 in
in. (2
(25.965 mm
mm)
Wrist Pin to Piston Wrist Pin Bore 0-0.0006 in. (0-0.014 mm) 0.0029 in. (0.074 mm)
Clearance

Connecting Rod Standard Dimensions Wear Limit

Wris
Wristt Pin
Pin Bush
Bushin
ing
g Ins
Insid
ide
e Dia
Diame
mete
terr 1.02
1.0246
46-1
-1.0
.025
251
1 in.
in. (26.
(26.02
025-
5-26
26.0
.038
38 mm
mm)) 1.02
1.0263
63 in.
in. (26
(26.0
.068
68 mm
mm))
Wrist Pi
Pin Ou
Outside D
Diiameter 1.0234-1.0236 in
in. (2
(25.995-26.000 mm
mm) 1.0223 in
in. (2
(25.967 mm
mm)
Wrist Pin to Wrist Pin Bushing 0.00
0.0010
10-0
-0.0
.001
017
7 in.
in. (0.0
(0.025
25-0
-0.0
.043
43 mm)
mm) 0.00
0.0040
40 in.
in. (0.
(0.10
101
1 mm)
mm)
Clearance
Larg
Large
eEEnd
nd Bore
Bore (Wit
(Witho
hout
ut Bear
Bearin
ing)
g) 2.00
2.0079
79-2
-2.0
.008
083
3 in.
in. (51.
(51.00
000-
0-51
51.0
.010
10 mm
mm))
Rod Bearing Clearance 0.0015-0.0029 in. (0.038-0.074 mm) 0.0059 in. (0.150 mm)
Side Clearance (Crank to Rod) 0.008-0.016 in. (0.20-0.40 mm) 0.022 in. (0.55 mm)
Twist per 4 in. (100 mm) 0.001 in. (0.03 mm) 0.003 in. (0.08 mm)
Parallelism per 4 in. (100 mm) 0.001 in. (0.03 mm) 0.003 in. (0.08 mm)

19
TK482 & TK486 Diesel Engine Specifications

Tier 2 - TK486V,
TK486V, TK486VB, and TK486VH (Continued)
(Conti nued)
Crankshaft and Crankshaft Bearings Standard Dimensions Wear Limit
Main Journal Outside Diameter
Standard 1.9666-1.9670 in. (49.952-49.962 mm) 1.9646 in. (49.902 mm)
Undersize 1.9568-1.9572 in. (49.702-49.712 mm) 1.9548 in. (49.652 mm)
Main Bearing Inside Diameter
Standard 1.9685-1.9693 in. (50.000-50.020 mm) 1.9705 in. (50.052 mm)
Undersize 1.9587-1.9594 in. (49.750-49.770 mm) 1.9607 in. (49.802 mm)
Main Bearing Clearance 0.0015-0.0027 in. (0.038-0.068 mm) 0.0059 in. (0.150 mm)
Main Bearing Bore Inside Diameter 2.1260-2.1267 in. (54.000-54.019 mm)
(Without Bearing)
Rod Journal Outside Diameter
Standard 1.8879-1.8883 in. (47.952-47.962 mm) 1.8859 in. (47.902 mm)
Undersize 1.8780-1.8784 in. (47.702-47.712 mm) 1.8761 in. (47.652 mm)
Rod Bearing Inside Diameter
Standard 1.8898-1.8908 in. (48.000-48.026 mm) 1.8918 in. (48.052 mm)
Undersize 1.8799-1.8809 in. (47.750-47.776 mm) 1.8820 in. (47.802 mm)
Rod Bearing Clearance 0.0015-0.0029 in. (0.038-0.074 mm) 0.0059 in. (0.150 mm)
End Play 0.0051-0.0091 in. (0.130-0.230 mm) 0.0110 in. (0.280 mm)
Deflection 0.0008 in. (0.020 mm)

Cylinder Block
Cylinder Inside Diameter
Standard 3.3858-3.3870 in. (86.000-86.030 mm) 3.3937 in. (86.200 mm)
1st Oversize 3.3957-3.3969 in. (86.250-86.280 mm) 3.4035 in. (86.450 mm)
2nd Oversize 3.4055-3.4067 in. (86.500-86.530 mm) 3.4134 in. (86.700 mm)
Cylinder Roundness 0-0.0004 in. (0-0.010 mm) 0.0012 in. (0.030 mm)
Cylinder Taper (Cylindricity) 0-0.0004 in. (0-0.010 mm) 0.0012 in. (0.030 mm)
Deck Distortion 0.002 in. (0.05 mm)

Cylinder Head Standard Dimensions Wear Limit

Distortion 0-0.002 in. (0-0.05 mm) 0.006 in. (0.15 mm)

Timing Gears
Timing Gear Lash
Crank
ankshaft Gear to Idler Gear 0.002
0028-0.0059
059 in. (0.
(0.070-0.
-0.150 mm) 0.006
0067 in. (0.170 mm)
Idler Gear to Camshaft Gear 0.0028-0.0059 in. (0.070-0.150 mm) 0.0067 in. (0.170 mm)
Idler Gear to Fuel Injection Pump 0.00
0.0028
28-0
-0.0
.005
059
9 in.
in. (0.0
(0.070
70-0
-0.1
.150
50 mm)
mm) 0.00
0.0067
67 in.
in. (0.
(0.17
170
0 mm)
mm)
Gear
Idle
Idlerr Gear
Gear Bus
Bushi
hing
ng Ins
Insid
ide
e Diam
Diamet
eter
er 1.81
1.8110
10-1
-1.8
.812
120
0 in.
in. (46.
(46.00
000-
0-46
46.0
.025
25 mm)
mm) 1.81
1.8140
40 in.
in. (46
(46.0
.075
75 mm)
mm)
Idle
Idlerr Gea
Gearr Sha
Shaft
ft Outs
Outsid
ide
e Dia
Diame
mete
terr 1.80
1.8091
91-1
-1.8
.810
100
0 in.
in. (45.
(45.95
950-
0-45
45.9
.975
75 mm
mm)) 1.80
1.8071
71 in.
in. (45
(45.9
.900
00 mm
mm))
Idler Gear Shaft to Idler Gear Bushing 0.00
0.0010
10-0
-0.0
.003
030
0 in.
in. (0.0
(0.025
25-0
-0.0
.075
75 mm)
mm) 0.00
0.0069
69 in.
in. (0.
(0.17
175
5 mm)
mm)
Clearance

20
 TK482 & TK486 Diesel Engine Specifications

Tier 2 - TK486V,
TK486V, TK486VB, and TK486VH (Continued)
(Conti nued)
Oil Pump
Type Trochoid
Outer Rotor to Gear Case Cover 0.004
0.0047-
7-0.0
0.008
083
3 in.
in. (0.12
(0.120-0
0-0.2
.210
10 mm
mm)) 0.01
0.0118
18 in.
in. (0.
(0.30
300
0 mm)
Clearance
Oil Pump Cover to Outer Rotor 0.00
0.0008
08-0
-0.0
.002
028
8 in.
in. (0.0
(0.020
20-0
-0.0
.070
70 mm)
mm) 0.00
0.0047
47 in.
in. (0.
(0.12
120
0 mm)
mm)
Clearance
Inner Rotor Inside Diameter 2.1043-2.1083 in. (53.450-53.550 mm)
Crankshaft Gear Boss Outside 2.0886-2.0925 in. (53.050-53.150 mm)
Diameter
Inner Rotor to Crankshaft Gear Boss 0.01
0.0118
18-0
-0.0
.019
197
7 in.
in. (0.3
(0.300
00-0
-0.5
.500
00 mm)
mm) 0.02
0.0236
36 in.
in. (0.
(0.60
600
0 mm)
mm)
Clearance
Inner Rotor Wi
Width Ac
Across Fl
Flat 1.9665-1.9705 in
in. (49.950-50.050 mm)
Crankshaft Gear Boss Width Across 1.9468-1.9587 in. (49.450-49.750 mm)
Flat
Inner Rotor to Crankshaft Gear Boss 0.00
0.0079
79-0
-0.0
.023
236
6 in.
in. (0.2
(0.200
00-0
-0.6
.600
00 mm)
mm) 0.02
0.0276
76 in.
in. (0.
(0.70
700
0 mm)
mm)
Clearance Between Flats
Pressure C
Co
ontrol Va
Valve Se
Setting 43-57 ps
psi (2
(294-392 kP
kPa)

Starter
No Load Test
Voltage 11 volts
Current Maximum of 130 amps @ 11 volts
Speed Minimum of 3900 rpm @ 11 volts
Loaded Properties
Voltage 8.5 volts
Current 400 amps
Commutator Outside Diameter 1.44 in. (36.5 mm) 1.40 in. (35.5 mm)

21
TK482 & TK486 Diesel Engine Specifications

Exhaust Gas Specifications

The following specifications are provided to help design a system to remove exhaust gas from a shop or garage.
Exhaust Gas Temperature at Muffler
Outlet
1 4 5 0 r pm 340 F (171 C)
2 2 0 0 r pm 450 F (232 C)
2 6 0 0 r pm 450 F (232 C)
Exhaust Gas Flow Rate
1 4 50 r p m 49 cubic feet/minute (1.4 cubic meters/minute)
2 2 00 r pm 106 cubic feet/minute (3.0 cubic meters/minute)
2 6 00 r pm 124 cubic feet/minute (3.5 cubic meters/minute)

22
 Torque Values

Torque Values

TK482, TK482E, TK486, TK486E, and TK486EH

Dia. x Pitch
Description N•m ft-lb kgm
(mm)
Connecting Rod Bolt 9x1.0 44.1-53.9 32.5-39.8 4.5-5.5
Crankshaft Pulley Bolt 14x1.5 112.8-122.6 83.2-90.4 11.5-12.5
Cylinder Head Mtg. Bolt 10x1.25 85.3-91.2 62.9-67.3 8.7-9.3
Flywheel Mtg. Bolt 10x1.25 83.4-88.3 61.5-65.1 8.5-9.0
Fuel Injection Line Nut 12x1.5 29.4-34.3 21.7-25.3 3.0-3.5
Fuel Injection Nozzle Mtg. Nut 6x1.0 6.9-8.8 5.1-6.5 0.7-0.9
Fuel Injection Nozzle Nut 39.2-44.1 28.9-32.5 4.0-4.5
Fuel Injection Pump Gear Mtg. Nut 12x1.75 58.8-68.6 43.4-50.6 6.0-7.0
Main Bearing Bolt 12x1.5 96.1-100.0 70.9-73.8 9.8-10.2
Rocker Arm Support Mtg. Bolt 8x1.25 22.6-28.4 16.6-21.0 2.3-2.9
Standard 6 mm Bolt and Nut 6x1.0 9.8-11.8 7.2-8.7 1.0-1.2
Standard 8 mm Bolt and Nut 8x1.25 22.6-28.4 16.6-21.0 2.3-2.9
Standard 10 mm Bolt and Nut 10x1.5 44.1-53.9 32.5-39.8 4.5-5.5
Standard 12 mm Bolt and Nut 12x1.75 78.5-98.1 57.9-72.3 8.0-10.0

NOTE: For standard bolts in aluminum parts use 80% of the specified torque.

TK486V, TK486VB, and TK486VH

Dia. x Pitch
Description N•m ft-lb kgm
(mm)
Connecting Rod Bolt 9x1.0 44.1-49.0 32.5-36.2 4.5-5.0
Crankshaft Pulley Bolt 14x1.5 112.8-122.6 83.2-90.4 11.5-12.5
Cylinder Head Mtg. Bolt 10x1.25 85.3-91.2 62.9-67.3 8.7-9.3
Flywheel Mtg. Bolt 10x1.25 83.4-88.3 61.5-65.1 8.5-9.0
Fuel Injection Line Nut 12x1.5 29.4-34.3 21.7-25.3 3.0-3.5
Fuel Injection Nozzle Mtg. Bolt 8x1.25 24.4-28.4 18.0-21.0 2.5-2.9
Fuel Injection Nozzle Nut 39.2-44.1 28.9-32.5 4.0-4.5
Fuel Injection Pump Gear Mtg. Nut 14x1.5 78.5-88.3 57.9-65.1 8.0-9.0
Main Bearing Bolt 12x1.5 93.2-98.1 68.7-72.4 9.5-10.0
Oil Pump Cover Mtg. Screw 5.4-8.4 3.9-6.2 0.6-0.9
Rocker Arm Support Mtg. Bolt 8x1.25 22.6-28.4 16.6-21.0 2.3-2.9
Standard 6 mm Bolt and Nut 6x1.0 9.8-11.8 7.2-8.7 1.0-1.2
Standard 8 mm Bolt and Nut 8x1.25 22.6-28.4 16.6-21.0 2.3-2.9
Standard 10 mm Bolt and Nut 10x1.5 44.1-53.9 32.5-39.8 4.5-5.5
Standard 12 mm Bolt and Nut 12x1.75 78.5-98.1 57.9-72.3 8.0-10.0

NOTE: For standard bolts in aluminum parts use 80% of the specified torque.

23
Special Tools

Special Tools

The following special tools for all versions of TK482/486 engines are available from the Thermo King
Service Parts Department. Refer to the Tool Catalog (TK 5955).

Description Part Number

Fuel Injection Nozzle Puller 204-902

Rear Seal Installation Tool 204-952
Rear Seal Remover 2 04 - 99 4
Injection Pump Remover 204-1011
Compression
Compression Test
Test Adapter
Adapter (For use with Compressi
Compression
on Tester
Tester 204-542)
204-542) 204-1056
Inje
Inject
ctio
ion
n Pum
Pump
p Plu
Plung
nger
er Sprin
pring
g Too
Tooll (T
(Tier
ier 1 and
and Ear
Earli
lier
er Engi
Engine
nes)
s) 204-
204-10
1083
83
Front Seal Installation Tool 204-1138

The following drawings show dimensions for special tools that are to be made a locally. The tools are for
all versions of TK482/486 engines.

L1.
L1. 0.79
0.79 in.
in. (20
(20.0
.0 mm
mm))
L2.
L2. 2.95
2.95 in.
in. (75
(75.0
.0 mm
L1.
L1. 0.59
0.59 in. (15.
(15.0
0 mm)
mm)
d1.
d1. 0.30
0.30 in.
in. (7.
(7.5
5 mm)
mm)
L2.
L2. 2.56
2.56 in. (65.
(65.0
0 mm)
mm)
d2.
d2. 0.43
0.43 in.
in. (11.
(11.0
0 mm
mm))
d1.
d1. 0.55
0.55 in. (14.
(14.0
0 mm)
mm)
Figure 1: Valve Guide Removal
Removal Tool
Tool d2.
d2. 0.79
0.79 in. (20.
(20.0
0 mm)
mm)
Figure 2: Valve Guide Installation Tool

24
 Special Tools

L1.
L1. 0.79
0.79 in.
in. (20
(20.0
.0 mm
mm))
L2.
L2. 3.94
3.94 in.
in. (10
(100.
0.0
0 mm
mm))
d1.
d1. 1.02
1.02 in.
in. (26
(26.0
.0 mm
mm))
d2.
d2. 1.14
1.14 in.
in. (29
(29.0
.0 mm
mm))
Figure 4: Connecting
Connecting Rod Bushing
Bushing
Removal
Removal and Install
Installati
ation
on Tool

L1.
L1. 0.74
0.74 in. (18.
(18.8
8 mm)
mm)
L2.
L2. 2.56
2.56 in. (65.
(65.0
0 mm)
mm)
L3.
L3. 0.16
0.16 in. (4.0
(4.0 mm
mm)) L1.
L1. 0.71
0.71 in.
in. (18
(18.0
.0 mm
mm))
d1.
d1. 0.64
0.64 in. (16.
(16.2
2 mm)
mm) L2.
L2. 2.76
2.76 in.
in. (70
(70.0
.0 mm
mm))
d2.
d2. 0.87
0.87 in. (22.
(22.0
0 mm)
mm) d1.
d1. 1.77
1.77 in.
in. (45
(45.0
.0 mm
mm))
d3.
d3. 0.53
0.53 in. (13.
(13.5
5 mm)
mm) d2.
d2. 1.89
1.89 in.
in. (48
(48.0
.0 mm
mm))
Figure 3: Valve Stem Seal Installation
Installation Tool Figure 5: Camshaft
Camshaft Bearing Removal Tool
Tool

25
Special Tools

26
Engine Disassembly

 NOTE: Most of the illustrations in this manual Before disassembling the engine, drain the engine
 show the early engine
engine with the in-line fuel oil and coolant, disconnect the battery cables, and
injection pump and the high mount water pump. remove the engine from the unit.
The other engines are similar and significant
 differences are
are noted.

2 3

1 4

16 5

7
15

8
14

13
AGA01

12
11 10

1. Lift Bracket 9. Oil Pan

2. Fuel Injection Line 10 . Fuel Transfer Pump
3. Valve Cover 11. Oil Level Switch
4. Crankcase Breather Hose 12 . Dipstick
5. Water Pump 13 . Oil Filter
6. In-Line Fuel Injection Pump 14. Oil Line
7. Gear Case Cover 15 . Starter
8. Crankshaft Pulley 16 . Intake Manifold
Figure 6: Front View
View of Early Engine
Engine

27
Engine Disassembly

2 3 4
1

17
5

16 6

15
7

14
8

13

12
11
10 9

1. Lift Bracket 1 0. Oil Level Switch

2. Fuel Injection Line 11. Dipstick
3. Crankcase Breather Hose 12 . Oil Filter
4. Valve Cover 13 . Trochoid Feed Pump
5. Water Pump 14. Mono-Plunger and Distributor Fuel Injection Pump
6. Gear Case Cover 15 . Cold Start Device
7. Crankshaft Pulley 1 6. Starter
8. Oil Pan 17.
17. Int
Intake
ake Man
Manif
ifol
old
d
9. Fuel Transfer Pump
Figure 7: Front View
View of Tier 2 Engine
Engine

28
 Engine Disassembly

While disassembling the engine, note things such

as the position of dowel pins and O-rings, and the
existing timing marks and bearing cap marks.
2
Identical components in the valve train and the 1
crankshaft assembly should be kept in order or
marked. This prevents mixing up these
components and allows the components to be
placed in their original positions when the engine
is assembled.
1. Remov
Removee the
the exhaus
exhaustt mani
manifol
fold.
d.
2. Remov
Removee the cran
crankc
kcase
ase brea
breathe
therr hose.
hose.
 NOTE: The crankcase breather hose hose on Tier
1 and earlier engines is not interchangeable
with the crankcase breather hose on the Tier
 2 engine. See “Crankcase Breather System
Tier 1 and Earlier
Earlier Engines” on page 65 and
65  and
“Crankcase Breather System Tier 2 Engine”
 on page 66  for
 for more information.
3. Remove
Remove thethe fuel
fuel injection
injection lines. Cover
Cover all the 1. Fuel Injection Lines
injection lines, fuel lines, and fittings with 2. Fuel Re
Return Li
Lines
plastic covers or tape. The smallest amount of
Figure 9: Remove Fuel Injectio
Injection
n Lines
dirt can damage the fuel system. Tier
Tier 2 Engi
Engine
ness

4. Remove
Remove the fuel return lines.
lines. Do not reuse the
1 fuel return lines if they are old style lines. See
“Fuel Return Line Replacement” on page 113.
5. Remove
Remove the intake
intake manifol
manifold.
d.
6. Remove
Remove the
the lift
lift bracke
brackets
ts from
from the cyli
cylinde
nderr
2 head.

AGA02

1. Fuel Injection Lines

2. Fuel Re
Return Li
Lines
Figure 8: Remove Fuel
Fuel Injection
Injection Lines
Tier
Tier 1 and
and Earli
Earlier
er Engi
Engine
ness

29
Engine Disassembly

7. Remove
Remove the
the fuel injec
injectio
tion
n nozzle
nozzle mount
mounting
ing 8. Remove
Remove the
the fuel
fuel injec
injectio
tion
n nozzle
nozzles.
s. Use
Use
nuts and retainers from Tier 1 and earlier injection nozzle puller P/N 204-902 if
engines. Remove the fuel injection nozzle necessary.
mounting bolts and retainers from Tier 2
9. Remo
Remove
ve the
the wat
water
er pump
pump..
engines.

1
1

3
4 2

1. High Moun
ount Wate
ater Pump
1. Retainer
2. Low Mo
Mount Wa
Water Pu
Pump
2. Fue
Fuel In
Injection Noz
Nozz
zle
3. Nozzle Protector Figure 12:
12: Remove Water
Water Pump
Pump
4. Nozzle Gasket  NOTE: Tier
Tier 2 engines have
have two coolant
Figure 10: Remove Fuel
Fuel Injection Nozzles
Nozzles  hoses that go from
from the water pump to a the
Tier
Tier 1 and
and Earl
Earlier
ier Engi
Engines
nes  cold start device
device on the fuel injection pump.
 Disconnect the hoses
hoses from the water
water pump
1  before removing it.

2 1
3
4

1. Coolant Hoses
Figure 13: Disconnect
Disconnect Coolant Hoses
Hoses on
Tier
Tier 2 Engi
Engine
nes
s

1. Retainer
2. Fue
Fuel In
Injection Noz
Nozz
zle
3. Nozzle Protector
4. Nozzle Gasket
Figure 11:
11: Remove Fuel Injection
Injection Nozzles
Nozzles
Tier
Tier 2 Engi
Engine
nes s

30
 Engine Disassembly

10. Remove the valve cover byby removing the three 12. Remove the valve stem
stem caps and keep
keep them in
special cap nuts. Inspect the O-rings
O-r ings under order.
these cap nuts and replace the O-rings, if
necessary, during assembly.
 NOTE: The valve cover
cover on Tier 1 and earlier
engines is not interchangeable with the valve
 cover on the Tier
Tier 2 engine. See
See “Crankcase
 Breather System Tier 1 and Earlier Engines”
 on page 65 and
65 and “Crankcase Breather System
Tier
Tier 2 Engine”
Engine” on page
page 66  for
 for more
information.
AGA07

Figure 16: Remove Valve

Valve Stem Caps
Caps

13. Remove the push

push rods and keep them in order
if they will be reused.
14. Break each cylinder head bolt
bolt loose 1/4 to 1/2
turn in a crisscross pattern starting at the ends.
Then remove the cylinder head bolts.
15. Remove the cylinder head from the cylinder
cylinder
block.

AGA05

Figure 14: Remove Valve

Valve Cover
Cover

11. Remove the rocker arm assembly

assembly by removing
the bolts that mount the rocker arm supports.
Alternately loosen each bolt one turn at a time
to evenly release the spring pressure on the
rocker arm assembly.

AGA08

Figure 17:
17: Remove Cylinder
Cylinder Head
Head

AGA06

Figure 15: Remove Rocker

Rocker Arm Assembly
Assembly

31
Engine Disassembly

16. Remove the oil filter and the oil filter head. 18. Remove the fuel transfer pump from the gear
case cover.

AGA09

AGA11

Figure 18: Remove Oil Filter

Filter and Oil Filter
Filter Head Figure 20: Remove Fuel Transfer
Transfer Pump
Pump

17. Remove the oil line that goes

goes from the 19. Remove the front crankshaft bolt.
cylinder block to the fuel injection pump and
the gear case cover. 20. The end of the crankshaft
crankshaft is tapered. Remove
the crankshaft pulley by using a suitable
 NOTE: On later model engines
engines the oil line puller. Check the pulley for a crack in the area
 stops at the fuel injection pump and
and does not
not near the dowel pin (see Figure 167 on page
 go to the gear case
case cover.
cover. The hole in the 85).
85). A cracked pulley can leak oil and should
 gear case cover
cover is plugged with
with a screw be replaced.
(P/N 55-5768). Tier
Tier 2 engines
engines do not have
 the hole
hole in the gear
gear case
case cover
cover and do not use
 the plug screw.
screw.

AGA12

Figure 21: Remove Crankshaf

Crankshaftt Pulley
AGA10

Figure 19:
19: Remove Oil
Oil Line

32
 Engine Disassembly

21. Remove the gear

gear case cover and sound shield. 23. Note the timing marks on the timing gears.
The timing marks must be aligned when the
 NOTE: On TierTier 2 engines the oil pump is
engine is assembled.
located in the gear case cover.
cover. The inner
 rotor of the oil pump fits around the 24. Remove the fuel injection pump gear nut and
and
 crankshaft gear
gear.. See “Oil Pump for Tier 2 lock washer.
 Engines” on page
page 62.

AGA13

Figure 22:
22: Remove Gear
Gear Case Cover
Cover
and Sound
Sound Shie
Shield
ld Figure 24: Remove Fuel Injection
Injection Pump
Pump Gear
Nut and Lock
Lock Washer
Washer
22. Check the timing gear lash.
lash. If the gear lash is
within specifications (refer to Specifications), 25. The fuel injection pump shaft is tapered. The
the gears can probably be reused. If the gear fuel injection pump gear must be removed to
lash is excessive, some or all of the gears must remove the fuel injection pump. Remove the
be replaced to meet the specifications. fuel injection pump gear by using a suitable
puller.
 NOTE: See “Injection Pump Removal and
 Installation (All Engines)”
Engines)” on page 105 for
105 for
information about removing the injection
 pump without removing the crankshaft
crankshaft
 pulley and gear case cover.
cover.

AGA14

Figure 23: Check Timing

Timing Gear Lash
Lash

Figure 25:
25: Use Puller
Puller to Remove
Remove
Fuel Injecti
Injection
on Pump
Pump Gear
Gear

33
Engine Disassembly

 NOTE: Early engines (before Tier

Tier 1) use a
 single-piece fuel injection pump gear (see
 Figure 26  ).
Tier 1 engines use a three-piece fuel
injection pump gear assembly (see Figure
(see  Figure
 27 
 ). Do not loosen or remove the four bolts
bolts
1
 that fasten the injection pump
pump gear to the
 flange because that changes the timing. See
See
“Attaching Injection Pump Gear to Flange
 on Tier 1 Engines” on page
page 100 if
100 if the 2
injection pump gear is detached from the 3
4
 flange.
5
Tier 2 engines use a three-piece fuel
injection pump gear assembly (see Figure
(see  Figure 28 6
 on page 35 ). Do not loosen or remove the
 four bolts
bolts that
that fasten the injection
injection pump gear
 to the flange because
because that changes the 7
 timing. That will cause the engine
engine to violate
 EPA,
 EPA, CARB, or other emission
emission control 1. Fuel In
Injection Pu
Pump
 regulations and require
require recertification. 2. Key
3. Flange
4. Injection Pu
Pump Ge
Gear
5. Transfer Pump Cam
6. Nutt ((In
Nu Inje
ject
ctio
ion
n Pum
Pump
p Gea
Gear)
r)
7. Do No
Nott Rem
Remov
ove
e Gea
Gearr Fro
From
m Fl
Flange
ange

1 Figure 27: Three-Piece

Three-Piece Fuel
Fuel Injection
Injection Pump
Pump Gear
Tier 1 Engine

2
3

1. Fuel In
Injection Pu
Pump
2. Key
3. Injection Pu
Pump Ge
Gear
4. Nutt ((In
Nu Injjecti
ection
on Pump
Pump Gear
Gear))
Figure 26: Single-Piece
Single-Piece Fuel Injection
Injection Pump Gear
Early
Early Engines
Engines

34
 Engine Disassembly

2
3
4 1
5 1. Index Marks

6 Figure 29: Tier 1 and Earlier

Earlier Index Mark Location
Location

1. Fuel In
Injection Pu
Pump
2. Key
3. Flange
4. Injection Pu
Pump Ge
Gear
5. Transfer Pump Cam
6. Nut (Inj
(Injec
ecti
tion
on Pum
ump
p Gea
Gear)
r)
7. Do Not
Not Re
Remo
mov
ve Gea
Gearr Fro
From
m Fla
Flang
nge
e
Figure 28: Three-Piece
Three-Piece Fuel
Fuel Injection
Injection Pump
Pump Gear
Tier 2 Engine
1 2
26. Note the alignment
alignment of the index
index marks on
on the
1. Inde
Index
x Mar
Mark
k on
on Inj
Injec
ecti
tion
on Pum
ump
p
injection pump and the gear case. On
On Tier 1
2. Cent
Center
er Inde
Index
x Mar
Mark
k on
on Gea
Gearr Cas
Case
e
and earlier engines, the index mark on the
injection pump is usually aligned with the Figure 30: Typical Tier 1 and Earlier
center (long) index mark on the gear case. On Index
Index Ma
Mark
rk Align
Alignmen
mentt
Tier 2 engines, the index mark on the injection
i njection
pump is usually aligned with the single index
mark on the gear case. If not, mark it so the
injection pump can be returned to the same
position when it is reinstalled.

1. Index Marks
Figure 31: Tier 2 Index
Index Mark Location
Location

35
Engine Disassembly

28. Remove the oil pump from Tier 1 and earlier

engines. On Tier 2 engines the oil pump is
located in the gear case cover.
 NOTE: See “Checking Oil Pump” on
 page 141 for
141 for information about check and
 changing the oil pump without pulling the
engine from the unit.

1 2

1. Inde
Index
x Mar
Mark
k on
on Inj
Injec
ecti
tion
on Pum
ump
p
2. Index Mark
ark on Gear
ear Case
Figure 32: Typical Tier 2 Index Mark Alignment
Alignment

27. Remove the fuel injection pump from the gear

case.

AGA17

Figure 35:
35: Remove Oil Pump
Pump
Tier
Tier 1 and
and Earl
Earlie
ierr Engi
Engine
nes
s

29. Remove the two bolts from the idler gear

shaft.
30. Remove the idler gear and
and the idler gear
gear shaft
from the cylinder block.

AGA16

Figure 33: Remove Fuel

Fuel Injection
Injection Pump
Tier
Tier 1 and
and Earl
Earlier
ier Engi
Engines
nes

AGA18

Figure 36: Remove Idler

Idler Gear and Idler Gear Shaft
Shaft

Figure 34: Remove Fuel

Fuel Injection
Injection Pump
Tier
Tier 2 Engi
Engine
nes s

36
 Engine Disassembly

31. Remove
Remove the flywheel
flywheel.. housing and the rubber portion of the seal. The
metal ring can then be removed by carefully
cutting it with a chisel.
 NOTE: Any scratches,
scratches, nicks or damaged
damaged
 areas of the crankshaft
crankshaft must be cleaned
cleaned up
 or the new metal
metal ring may not seal
seal to the
 crankshaft.
a. Remov
Removee the
the two hex head
head screw
screwss and
and the
removable part of the tool from the
t he seal
removal tool.

AGA19 1
Figure 37: Remove Flywheel
Flywheel

32. Remove
Remove the bellhousing
bellhousing..
2
3

8
7 6

1. Crankshaft
2. Outer Lip on
on Me
Metal Ri
Ring
3. Lip
Lip on Tool
ool (Fi
(Fits
ts Behi
Behind
nd Lip
Lip on Met
Metal
al Ring
Ring))

AGA20
4. Stati
ationar
onary
y Par
Partt of
of T
Too
ooll
5. Removal Bolt
Figure 38:
38: Remove Bellhous
Bellhousing
ing
6. Coun
Counter
tersu
sunk
nk Scre
Screw
w (Mu
(Must
st Be Kept
Kept Tigh
Tight)
t)
33. Some early engines
engines use a radial rear seal.
seal. No 7. Hex Head Screw
special tools are needed to remove the radial
8. Removable Pa
Part of To
Tool
rear seal. It is removed with the
t he rear seal
housing (see step
step 34).
34). The radial rear seal can Figure 39: Rear Seal Removal
Removal Tool
Tool
be replaced with an axial rear seal if the rear b. Press
Press the
the station
stationary
ary part
part of
of the tool
tool past
past
seal housing is also replaced. and behind the outer lip on the metal ring
of the seal.
Use the rear seal removal tool P/N 204-994 to
remove the axial rear seal. If the seal has been c. While
While holdi
holding
ng the
the stati
stationa
onary
ry side
side of
of the
previously replaced using Loctite or a similar tool engaged on the lip, press the
sealant on the metal ring, the possibility exists removable part of the tool in and behind
that the removal tool will straighten the lip on the outer lip on the other side of the metal
the metal ring instead of removing the seal ring.
assembly.
assembly. If this occurs, remove the rear seal

37
Engine Disassembly

d. Reinst
Reinstall
all the
the hex head
head screw
screwss that secu
secure
re 36. Remove the upper part of the oil pan.
the removable part of the tool. At this
37. Remove the oil pump intake pipe.
point the removable part will not be flat
against the top of the tool, but will be close
enough to get the hex head screws started.
e. Carefu
Carefully
lly tight
tighten
en the
the hex
hex head
head scre
screws
ws
while holding the tool behind the lip on
the metal ring. As the
t he screws are tightened
the tool will pull together and firmly grip
the lip.
f. With the
the tool
tool firmly
firmly locked
locked behind
behind the lip,
tighten the removal bolt. The entire seal
assembly will be pulled out.
34. Remove the rear seal housing.
housing. Use the slots
slots on
the sides to pry it off if necessary.
necessary.

Figure 42: Remove Oil Pump

Pump Intake
Intake Pipe

38. Remove the mounting bolts from the camshaft

thrust plate by turning the camshaft gear to
access the bolts through the holes in the gear.

AGA21

Figure 40: Remove Rear

Rear Seal Housing
Housing

35. Make sure the

the oil has been drained and
remove the lower part of the oil pan. The
lower part of the oil pan must be removed to
access some of the mounting bolts for the
upper part of the oil pan.

AGA24

Figure 43: Remove Camshaft

Camshaft Mounting
Mounting Bolts

AGA22

Figure 41: Remove Oil Pan

Pan

38
 Engine Disassembly

39. Carefully remove the camshaft

camshaft to avoid
avoid 41. Remove the gear case. Also remove the two
scratching or marring the camshaft bearings. O-rings from the oil passages between the
The engine must be upside down to prevent gear case and the cylinder block on Tier 1 and
the tappets from interfering with the removal earlier engines.
of the camshaft.
 NOTE: Removal of the camshaft gear from
 the camshaft can
can damage the gear
gear and
 camshaft. Therefore,
Therefore, it is not recommended.
recommended.

AGA27

Figure 46: Remove Gear Case

Case

42. Remove the ring ridge from the top of each

cylinder, if necessary.
AGA25
43. Mark the connecting
connecting rod caps,
caps, connecting
connecting
Figure 44:
44: Remove Camshaf
Camshaftt rods, pistons, and main bearing caps so they
can be placed in the same position when
40. Remove the tappets (valve lifters) with a valve
valve
assembled. The main bearing caps are marked
lapping tool or a magnet. Keep the tappets in as shown in Figure 55 on page 44.
44 .
order so they will be placed in the same
position when assembled. 44. Remove the connecting rod caps.
caps.
45. Carefully remove the
the piston and connecting
rod assemblies through the top of the cylinders
to avoid scratching or marring the cylinder
walls.

AGA28

AGA26

Figure 45: Remove Tappet

Tappets
s

Figure 47: Remove Piston

Piston and Rod Assemblies
Assemblies

39
Engine Disassembly

46. Remove the main bearing caps.

 NOTE: The rear
rear main bearing
bearing cap (flywheel
(flywheel
end) has a thrust bearing on each side. Make
 sure to remove these two thrust bearings.
bearings.
47. Carefully remove the crankshaft
crankshaft from the
block.
 NOTE: The upper rear
rear main bearing
bearing
(flywheel end) has a thrust bearing on each
 side. Make sure to remove these two thrust
 bearings.

AGA29

Figure 48:
48: Remove Crankshaft
Crankshaft

40
Inspection and Reconditioning

 NOTE: Refer to the Specifications

Specifications Chapter for
1
 specific dimensions that are not given in this
this
 chapter.
 chapter.
This chapter covers the cleaning, inspection,
overhaul, and assembly of individual engine
components. After disassembling the engine,
check the components and discard unusable parts
such as gaskets, O-rings, burned valves, and
broken rings. Check the items that may need
machine shop work first so this work can be
completed by the time the rest of the engine is
ready to assemble.

Cylinder Block AGA31

1. Inspect
Inspect the
the cylinde
cylinderr block
block for
for cracks,
cracks, damage,
damage,
and distortion. Use a straight edge and a feeler
1. Dial Bo
Bore Ga
Gauge
gauge to check the cylinder block deck for
distortion. Check all four sides, both Figure 49: Measuring
Measuring Cylinder Diameter
Diameter
diagonals, and the center lines of the cylinder
block deck. If there is more than 0.002 in.
(0.05 mm) distortion, resurface the cylinder
cylinder
block. Do not remove more than 0.002 in.
(0.05 mm) from the surface of the t he cylinder
block.
2. Check
Check each
each cylind
cylinder
er for
for out of round,
round, taper,
taper,
pocketing, or any other damage that would
require boring the cylinders. Use a dial bore
gauge or a snap gauge to measure the
cylinders. Measure each cylinder both parallel AGA32

and perpendicular to the crankshaft, at the top,

the middle, and the bottom of the cylinder
bore. The cylinder out of roundness and taper 1. Top
should not exceed 0.0012 in. (0.030 mm). If 2. Middle
the cylinders are in good condition, deglaze 3. Bottom
the cylinders with a glaze breaker.
breaker.
4. Perpe
erpend
ndic
icul
ular
ar to
to Cran
Cranks
ksha
hafft
3. If the cyli
cylinde
nders
rs must
must be bore
bored,
d, deter
determin
minee 5. Paral
rallel to Cr
Crankshaft
aft
which oversize pistons should be used. Pistons
Figure 50: Cylinder
Cylinder Measuring Positions
Positions
are available in 0.010 and 0.020 in. (0.25 and
0.50 mm) oversizes.

41
Inspection and Reconditioning

 NOTE: If the 0.020 in. (0.50 mm) oversize is b. Press the cylinder
cylinder sleeves
sleeves into
into the cylinder
cylinder
 not large enough to clean up the cylinders,
cylinders, block using a hydraulic press and a
 cylinder sleeves and standard
standard pistons must be pressing tool.
installed. Cylinder sleeves are available from
The pressing tool can be fabricated using
 the Service Parts
Parts Department.
the dimensions in the preceding
Use P/N 11-9036 for all TK482 engines. illustration.
Use P/N 11-8919 for all TK486 engines. • Plan
Planes
es A and
and B mus
mustt be
be par
paral
alle
lel.
l.
Use the following procedure to install • Plan
Planes
es A and
and B mus
mustt be
be per
perpe
pend
ndic
icul
ular
ar
 cylinder sleeves:
sleeves: to the center line of the tool.
a. Bore
Bore and hone
hone the cyli
cylinde
nderr block
block to acce
accept
pt • Relie
Relieve
ve area
area C slig
slight
htly
ly as show
shown
n to
to
the cylinder sleeves. The recommended prevent interference with the sleeve.
interference fit for the cylinder sleeves is
0.0024 to 0.0047 in. (0.060 to 0.120 mm). • Beve
Bevell all
all the
the edge
edgess sli
sligh
ghtl
tly
y.

Measure each cylinder sleeve and subtract c. Use a hydr

hydraul
aulic
ic press
press to
to press
press the
the cylind
cylinder
er
0.0035 in. (0.090 mm). Bore and hone sleeves into the block.
each cylinder to match this dimension. Place the pressing tool in the top end of
The final surface finish should have an RA the cylinder sleeve.
(Roughness Average) less than 248 micro
inches (6.3 microns). The bottom end of a cylinder sleeve has a
slightly smaller outside diameter than the
rest of the sleeve.

AGA33

1. 1.575 in
in. ((4
40.00 mm
mm)
2. TK48
TK482
2 — 3.81
3.819
9 in.
in. (97.
(97.00
00 mm
mm))
TK486 — 3.976 in. (101.00 mm)
AGA34
3. 0.591 in
in. ((1
15.00 mm
mm)
4. TK482
TK482 — 3.17
3.177-
7-3.
3.18
181
1 in.
in. (80.7
(80.70-
0-80
80.80
.80 mm
mm))
TK486 — 3.335-3.33.9 in. (84.70-84.80 mm) 1. Top
5. P l an e B 2. Bottom
6. P l an e A Figure 52: Cylinder
Cylinder Sleeve
Sleeve
7. Area
Area C - Re
Reli
liev
eve
e thi
this
s are
area
a as
as sho
shown
wn..
Figure 51: Pressing
Pressing Tool
Tool Dimensions

42
 Inspection and Reconditioning

Spray oil on the outside of the cylinder 5. Measure

sleeve or on the inside of the cylinder bore
in the block.
Place the cylinder sleeve in the block and
press the sleeve into place. The pressing
load should be 2200 to 4400 lb. (1000 to
2000 kg).
The top of the cylinder sleeve must be
flush with the top of the block. The
cylinder sleeve cannot protrude above the
top of the block at all.
Measure the front camshaft
camshaft bearing
bearing insert
insert.. If
the front camshaft bearing insert is larger than
1.7756 in. (45.100 mm) on Tier 1 and earlier
engines, 1.7768 in. (45.130 mm) on Tier 2
engines, or has a damaged surface, remove the
bearing insert with a bearing driver. If the
block will be boiled out, remove the bearing
insert and all the core plugs.
 NOTE: The middle and rear camshaft
camshaft
 bearings do not have
have bearing inserts.
inserts.

AGA35
AGA36

1. Cylinder Bl
Block Figure 54: Measuring
Measuring Front Camshaft Bearing
Bearing
Insert
2. Cylinder Sleeve
3. The
The cyl
cylin
inde
derr sle
sleev
eve
e mus
mustt be
be flu
flush
sh.. 6. This
This engine
engine does
does not
not have
have middl
middlee and rear
rear
4. The
The cyl
cylin
inde
derr slee
sleeve
ve cann
cannot
ot pro
protr
trud
ude
e camshaft bearing inserts. The bearing surfaces
above the block. for middle and rear camshaft bearings are
machined into the block. Measure the middle
Figure 53: Cylinder
Cylinder Sleeve Installation
Installation
and rear camshaft bearings. If the middle or
d. Bore
Bore and
and hone
hone each
each cyli
cylinde
nderr sleeve
sleeve to
to rear camshaft bearings are larger than
obtain the correct piston clearance. 1.7756 in. (45.100 mm), or if the surfaces
have been damaged significantly, replace the
4. Measure
Measure each piston.
piston. Bore
Bore and hone each
block.
cylinder to obtain the correct piston to
cylinder wall clearance (see Specifications). Minor damage to the middle and rear camshaft
bearings can be cleaned up with a brake
CAUTION: The pistons will vary slightly cylinder hone. The middle and rear
r ear camshaft
in diameter. Therefore, each piston must bearings should also be lightly honed after the
 be measured and each cylinder
cylinder must be block has been boiled out.
 bored and honed
honed to match each piston.
The final surface finish in the cylinders should
have an RA (Roughness Average) of 10 to 35
micro inches
inches (0.25 to 0.90 microns).

43
Inspection and Reconditioning

7. Install
Install the
the main
main bearin
bearing
g caps
caps in their
their prope
properr 9. Check
Check the
the main
main bearin
bearing
g bore
bore alignme
alignment
nt with
with a
positions. The cast arrows are labeled FW and straight edge and a 0.0015 in. (0.038 mm)
should point to the rear (flywheel end) of the feeler gauge. Lay the straight edge in main
engine. The main bearing cap that is machined bearing bores of the block and place the feeler
for the thrust bearing goes to the rear end of gauge between the straight edge and each
the engine. The main bearing caps with main bearing bore. There should be some drag
numbers stamped on them go to the middle of on the feeler gauge at each main bearing bore.
the engine with the main bearing cap marked If there is no drag on the feeler gauge at any
number one closest to the rear of the engine. main bearing bore, the block must be align
The main bearing cap with no number goes to bored.
the front end of the engine. Torque the main
bearing cap bolts to 70.9 to 73.8 ft-lb (96.1 to
100.0 N•m) on Tier
Tier 1 and earlier engines, or
68.7 to 72.4 ft-lb (93.2 to 98.1 N•m) on Tier
Tier 2
engines.

AGA37
Front Rear
Pulley End Flywheel End

1. Rear Main Beari

aring Cap AGA39

Figure 55:
55: Main Bearing
Bearing Cap Marks
Marks Figure 57: Checking
Checking Main Bearing Bore Alignment
Alignment

8. Measur
Measuree the main
main beari
bearing
ng bore
boress both
both 10. Measure each
each tappet bore
bore in the block.
block. If any
vertically and horizontally. The standard of the tappet bores are larger than 0.4744 in.
dimension is 2.1260 to 2.1267 in. (54.000 to (12.050 mm) on Tier 1 and earlier engines, or
54.019 mm). If the main bearing bores are 0.4742 in. (12.045 mm) on Tier 2 engines, the
more than 0.001 in. (0.25 mm) out of round, block must be replaced. Small scratches or
the block must be align bored. nicks should be cleaned up with a brake
cylinder hone. The tappet bores should also be
lightly honed after the block has been boiled
out.
11. Check or replace
replace all of the
the core plugs.
plugs.

AGA38

Figure 56: Measuring

Measuring Main Bearing
Bearing Bore

44
 Inspection and Reconditioning

Crankshaft 3. Measur
Measuree the rod
rod journa
journals.
ls. If
If any of
of the rod
rod
 journals are smaller than 1.8862 in.
1. Check
Check the crankshaft
crankshaft for cracks
cracks and check
check the (47.910 mm) on Tier
Tier 1 and earlier
earlier engines,
main journals, rod journals, and the oil seal 1.8859 in. (47.902
(47.902 mm) on Tier Tier 2 engines,
engines, or
surface for excessive wear or damage. Check tapered or out of round more than 0.0010 in.
to see that the oil passages are not clogged or (0.025 mm), the rod journals must be ground
dirty. undersize.
2. Measu
Measure
re the main
main jour
journal
nals.
s. If any
any of the
the main
main Only the 0.010 in. (0.25 mm) undersize rod
 journals are smaller than 1.9650 in. bearings are available. The wear limit for the
(49.910 mm) on Tier
Tier 1 and earlier engines, outside diameter of undersized rod journals is
1.9646 in. (49.902 mm) on TierTier 2 engines, or 1.8764 in. (47.660 mm) on Tier 1 and earlier
tapered or out of round more than 0.0010 in. engines, or 1.8761 in. (47.652
(47.652 mm) on Tier
Tier 2
(0.025 mm), the main journals must be ground engines.
undersize.
Only the 0.010 in. (0.25 mm) undersize main
bearings are available. The wear limit for the
outside diameter of undersized main journals
is 1.9551 in. (49.660 mm) on Tier 1 and earlier
engines, or 1.9548 in. (49.652 mm) on Tier
Tier 2
engines.

AGA41

Figure 59:
59: Measuring
Measuring Rod Journal
Journal

 NOTE: The most accurate

AGA40
Figure 58:
58: Measuring
Measuring Main Journal
Journal
 NOTE: The most accurate
accurate method of
 determining the outside
outside diameter of the
undersized main journals is to install the
 main bearing caps
caps with the undersized
undersized
 bearing inserts
inserts in place. Properly
Properly torque the
 main bearing caps
caps to the block and measure
 the inside diameter of the main bearings.
Subtracting the suggested oil clearance of
0.0015 to 0.0027 in. (0.038 to 0.068 mm)
 from the inside diameter
diameter of the main
 bearings results
results in the correct
correct outside
 diameter for the undersized
undersized main journals.
journals.
accurate method of
 determining the outside
outside diameter of the
undersized rod journals is to install the rod
 caps with the undersized
undersized bearing inserts
inserts in
 place. Properly torque the rod caps
caps to the
 rods and measure
measure the inside diameter
diameter of the
 rod bearings. Subtracting the suggested
suggested oil
 clearance of 0.0015
0.0015 to 0.0029 in. (0.038
(0.038 to
0.074 mm) from the inside diameter of the
 rod bearings results
results in the correct
correct outside
 diameter for the undersized
undersized rod journals.
journals.
4. Measure
Measure the crankshaft
crankshaft deflection
deflection by placing
placing
the front and rear main journals in a set of “V”
blocks, or place the crankshaft in the block
resting on only the old front and rear upper
main bearing inserts. Set a dial indicator on
the middle main journal and rotate the
crankshaft one full turn. The crankshaft
deflection equals one half of the largest
difference in readings on the dial indicator.
indicator. If
the crankshaft deflection is greater than
0.0008 in. (0.020 mm) the crankshaft
crankshaft must be
replaced.

45
Inspection and Reconditioning

 NOTE: A radial rear

rear seal can be replaced
replaced
with an axial rear seal if the
t he rear seal
 housing is also replaced.
replaced. See step
See step 56  on
 on
 page 82 .

AGA352
Pistons
1. Remove
Remove and
and disca
discard
rd the
the old pist
piston
on rings
rings..
2. Remove
Remove thethe wrist
wrist pin
pin circl
circlips
ips and
and push
push the
the
1. Dial In
Indicator
wrist pin out of the piston. If it is difficult to
push the wrist pin out of the piston, heat the
2. “V” block
piston in hot water that is at 120 to 140 F (49
Figure 60: Measuring
Measuring Crankshaft
Crankshaft Deflection to 60 C).
 NOTE: Do not clamp a connecting rod in a
vise with steel jaws. Instead, use a vise that
 has soft jaws, or
or use soft jaw covers.
Clamping a connecting rod in the steel jaws
 of a vise will put small nicks
nicks in the
 connecting rod. These
These nicks raise the stress
 on the connecting rod and can cause
cause the
AGA353
 connecting rod to break while the engine
engine is
 running.
1. Differenc
ence in
in Re
Readings 3. Remove
Remove the the carbo
carbon
n from
from the toptop of the
the piston
piston
2. Deflection but do not scratch the piston. Clean the piston
Figure 61: Crankshaft
Crankshaft Deflection
Deflection and inspect it for damage. Replace the piston
if it has any cracks, or if the top of the piston is
5. Inspect
Inspect the
the cranksh
crankshaft
aft timing
timing gear for chippe
chippedd significantly burned or damaged.
or worn teeth and for any cracks on or
between the teeth. To remove the gear use a 4. Measure
Measure the outside
outside diameter
diameter of each
each piston.
piston.
standard gear puller. Install the gear by This measurement should be taken
pressing it onto the crankshaft. Apply a perpendicular to the wrist pin 0.95 in.
sealant to the inside of the gear to prevent oil (24.0 mm) above the bottom of the piston
leaks. skirt. If the piston is smaller than the wear
limit (see Specifications), replace the piston.
 NOTE: Removal of the crankshaft
crankshaft timing
 gear from the crankshaft
crankshaft can damage
damage the
 gear.
 gear. Therefore, it is not
not recommended
except when necessary.
6. Check
Check the
the area
area on the
the end ofof the cran
cranks
kshaf
haftt
from which the metal seal ring for the axial
rear seal was removed. Any scratches, nicks,
or damage to this area of the crankshaft must
be cleaned up, or the new metal seal ring may
not seal to the crankshaft. Remove the metal
seal ring for the rear seal if it has not yet been
removed. The metal seal ring can be removed
by carefully cutting it with a sharp chisel. AGA44

1. 0.95 in
in. ((2
24. 0 m
mm
m)
Figure 62: Piston Measuring
Measuring Point
Point

46
 Inspection and Reconditioning

7. Measur
Measuree the insid
insidee diamet
diameter
er of the
the wrist
wrist pin
bore. If the inside diameter of the wrist pin
bore is larger than 1.0244 in. (26.020 mm) on
Tier 1 and earlier engines, or 1.0252 in.
(26.039 mm) on Tier 2 engines, replace the
piston.

AGA45 Wrist Pins

The wrist pin and the connecting rod bushing
carry a large load concentrated in a small area.
Therefore a precise fit is critical. If
I f possible, a
Figure 63:
63: Measuring
Measuring Piston
Piston
qualified machine shop should fit new wrist pins
to new connecting rod bushings when an engine is
5. Clean
Clean the
the ring
ring groves
groves with a ring
ring groove
groove overhauled.
cleaner.
cleaner. Be careful to
t o avoid scraping any
1. Measure
Measure the
the outsid
outsidee diamete
diameterr of the wrist
wrist pins
pins
metal off the piston. If a ring groove cleaner is
with a micrometer. If a wrist pin is smaller
not available, break a used ring
ri ng and sharpen
than 1.0197 in. (25.900 mm) on Tier 1 and
the end. This can be used to clean the ring
earlier engines, or 1.0222 in. (25.965 mm) on
grooves.
Tier 2 engines, replace the wrist pin.
 NOTE: Tier 2 engines have
have a steel insert in
 the top ring groove
groove for added endurance.
endurance.
6. Use a new
new set of
of piston
piston ring
ringss and
and a feele
feelerr
gauge to check the clearance between the
rings and the ring grooves. If the clearance
between a new ring and its respective ring
groove is greater
greater than 0.0098
0.0098 in. (0.250
(0.250 mm)
for the top and middle rings or 0.0079 in.
(0.200 mm) for the bottom ring, the t he piston
must be replaced.
AGA47
 NOTE: The top ring on on Tier 2 engines is a
 keystone ring so
so the clearance cannot be
 measured.
Figure 65:
65: Measuring
Measuring Wrist Pin
Pin

2. If a micrometer
micrometer with this
this degree
degree of accura
accuracy
cy is
not available, the fit between the wrist pin and
the connecting rod bushing can be checked by
oiling the wrist pin and inserting it into the
connecting rod bushing. The fit should be
snug and it should take a slight push to move
AGA46 the wrist pin through the connecting rod
bushing, but the wrist pin should rotate freely.

Figure 64: Checking

Checking Ring Clearance
Clearance

47
Inspection and Reconditioning

Connecting Rods
The procedures used to recondition a connecting
rod, which include honing the connecting rod
bearing bore, straightening the connecting rod,
and replacing the connecting rod bushing, require
various pieces of expensive equipment. If this
equipment is not available, most machine shops
can recondition serviceable connecting rods to
meet standard specifications.
1. If possib
possible,
le, bead
bead blast the connectin
connecting
g rods
rods
with glass beads. Bead blasting does an
exceptional job of cleaning the rods, and it
also relieves stress by removing minor surface AGA48
damage that tends to increase stress.
 NOTE: Bead blasting the connecting rods is Figure 66: Measuring
Measuring Rod Bearing or Bearing
Bearing Bore
 highly recommended.
recommended. Most machine shopsshops 6. Use a conn
connect
ecting
ing rod
rod alignme
alignment
nt fixture
fixture to
to
 offer this service
service and the price
price is usually check each rod for twist and parallelism. The
quite reasonable. wear limit for both twist and parallelism is
2. Check
Check each
each conne
connecti
cting
ng rod
rod bearing
bearing by
by 0.003 in. per 4 in. (0.08 mm per 100 mm). If
installing the connecting rod cap with the the twist or parallelism exceeds the wear limit,
original bearing inserts in place and torquing straighten or replace the rod.
the rod cap bolts to 32.5 to 39.8 ft-lb (44.1 to
53.9 N•m) on Tier 1 and earlier engines, or
32.5 to 36.2 ft-lb (44.1 to 49.0 N•m) on Tier
Tier 2
engines.
3. Measure
Measure the inside
inside diamete
diameterr of the connectin
connecting
g
rod bearings. If any of the connecting rod
bearings are larger than the wear limit (see
Specifications), or show significant damage,
replace the entire set of connecting rod
bearing inserts.
4. Check
Check each
each conne
connecting
cting rod bearing
bearing bore
bore by
installing the rod caps with the rod bearing
inserts removed and properly torquing the rod
cap bolts to 32.5 to 39.8 ft-lb (44.1 to AGA49
53.9 N•m) on Tier
Tier 1 and earlier engines, or
32.5 to 36.2 ft-lb (44.1 to 49.0 N•m) on Tier
Tier 2 1. 4 in. (100 mm)
engines. 2. Parallelism

5. Measure
Measure each connecting
connecting rod bearing
bearing bore 3. Twist
both parallel and perpendicular to the rod. The Figure 67: Measuring
Measuring Connecting Rod Twist
Twist
standard dimension is 2.0079 to 2.0083 in.
i n. and Paralle
Parallelis
lism
m
(51.000 to 51.010 mm). If the rod bearing bore
is more than 0.001 in. (0.25 mm) out of round
the rod must be reconditioned or replaced.

48
 Inspection and Reconditioning

7. Measur
Measuree the insi
inside
de diame
diameter
ter of
of the wrist
wrist pin
pin  NOTE: The crankshaft
crankshaft gear uses
uses a press fit.
bushings. If the wrist pin bushings are larger Use a hydraulic press to remove and install
than 1.0276 in. (26.100 mm) on Tier 1 and  the crankshaft gear
gear.. Removing the
earlier engines, 1.0263 in. (26.068 mm) on  crankshaft gear
gear can damage it. Therefore, it
Tier 2 engines, or show significant damage, is not recommended except when necessary.
replace the wrist pin bushings.
The camshaft gear uses a very secure press
 fit. It cannot be removed
removed without damaging
 the camshaft and the camshaft gear
gear.
Therefore, the camshaft gear and camshaft
 must be replaced as an assembly.
assembly.
2. Measure
Measure the inside
inside diamete
diameterr of the idler gear
bushing. If the idler gear bushing is larger than
1.8142 in. (46.080 mm) on Tier 1 and earlier
engines, 1.8140 in. (46.075 mm) on Tier 2
engines, or is significantly damaged, replace
the idler gear bushing. To
To replace the bushing,
press the old bushing out of the idler gear and
press the new bushing into the idler gear.

AGA50

Figure 68: Measuring

Measuring Wrist Pin Bushing
Bushing

8. To replace
replace a wrist
wrist pin bushing,
bushing, press the old
old
bushing out of the connecting rod. Press the
new bushing into the rod and make sure to
align the oil hole in the bushing with the oil
hole in the top of the rod. The bushing is
pre-finished.

Timing Gears AGA51

Figure 69: Measuring

Measuring Idler Gear Bushing
Bushing
1. Inspec
Inspectt the timi
timing
ng gears
gears for
for chipp
chipped
ed or
or
excessively worn teeth, and for any cracks on 3. Measure
Measure the outside
outside diame
diameter
ter of
of the idler gear
or between the teeth. The gear lash should shaft. If the idler gear shaft is smaller than
have been checked during the disassembly of 1.8083 in. (45.930
(45.930 mm) on TierTier 1 and earlier
the engine. If not, check the gear lash during engines, 1.8071 in. (49.090 mm) on Tier 2
the assembly of the engine. engines, or is significantly damaged, replace
the idler gear shaft.

AGA52

Figure 70: Measuring

Measuring Idler Gear Shaft
Shaft

49
Inspection and Reconditioning

Camshaft 4. Measure
Measure the camshaft
camshaft deflection
deflection by placing
placing
the front and rear camshaft journals in a set of
 NOTE: The camshaft
camshaft gear cannot
cannot be removed
“V” blocks. Set a dial indicator on the middle
without damaging the camshaft and the
camshaft journal and rotate the camshaft one
 camshaft gear.
gear. Therefore,
Therefore, the camshaft
camshaft gear and
and
full turn. The camshaft deflection equals one
 camshaft must be
be replaced as an assembly.
assembly.
half of the largest difference in readings on the
1. Check
Check the
the camshaf
camshaftt journals
journals,, the
the cam
cam lobes,
lobes, dial indicator. If the camshaft deflection
the thrust plate, and the camshaft gear for exceeds 0.002 in. (0.05 mm), the camshaft
wear or damage. assembly must be replaced.

2. Measur
Measuree the camsh
camshaft
aft journ
journals
als.. If any of the
the
camshaft journals are smaller than the wear
limit (see Specifications) or significantly
damaged, replace the camshaft assembly.

Figure 73: Measuring

Measuring Camshaft Deflection
Deflection

5. Check
Check the
the thrust
thrust plate
plate clearance
clearance (end play) by
placing a feeler gauge between the thrust plate
and the camshaft journal (or camshaft gear). If
the clearance exceeds the 0.016 in. (0.40 mm)
on Tier 1 and earlier engines, or 0.012 in.
Figure 71: Measuring
Measuring Camshaft
Camshaft Journals (0.30 mm) on Tier 2 engines, replace the
camshaft assembly.
3. Measur
Measuree the cam lobe
lobes.
s. If any
any of
of the cam
cam
lobes are smaller than 1.5118 in. (38.400 mm)
on Tier 1 and earlier engines, 1.5098 in.
(38.350 mm) on Tier 2 engines, or
significantly damaged, replace the camshaft
assembly.

AGA56

Figure 74: Checking

Checking Thrust Plate
Plate Clearance

Figure 72:
72: Measuring
Measuring Cam Lobes
Lobes

50
 Inspection and Reconditioning

Cylinder Head 1
 NOTE: The cylinder head on Tier
Tier 1 and earlier
earlier 2
engines is not interchangeable with the cylinder 3
 head on the Tier
Tier 2 engine.
4
8
1. Clean all the
the carbon
carbon and any other deposits
deposits 5
from the cylinder head with a gasket scraper
6
or a wire brush. Visually
Visually inspect the cylinder
head for cracks and check the sealing surfaces
for damage.
2. Use a straig
straight
ht edge
edge and
and a feel
feeler
er gauge
gauge to
check the cylinder head deck for distortion.
Check all four sides, both diagonals, and the
center lines of the cylinder head deck.
Resurface or replace the head if the distortion
exceeds 0.006 in. (0.15 mm). AGA58

 NOTE: When resurfacing

resurfacing the cylinder head,
head,
 remove only enough
enough material to make it flat.
7
 Do not remove more than 0.008 in.
(0.20
(0.20 mm).
mm).

1. Valve Stem Cap

2. Valve Keeper
3. Valve
alve Sprin
pring
g Re
Rettaine
ainerr
4. Valve Spring
5. Valve Stem Seal
6. Valve Guide
7. Valve
AGA57
8. Driv
Drive
e Val
Valve
ve Gui
Guide
des
s in this
this Dire
Direct
ctio
ion
n
Figure 75: Checking
Checking Cylinder Head Distortion
Distortion Figure 76: Cylinder
Cylinder Head Components
Components

Disassembly
1. Use a valve
valve spring
spring compres
compressor
sor to remove
remove the
valve keepers.
2. Remov
Removee the keep
keepers
ers,, the valve
valve spri
spring
ng
retainers, the valve springs, and the valves.
Mark each valve or keep them in order so they
can be returned to their original positions
when assembled.
3. Remov
Removee the valv
valvee stem
stem seals
seals and
and boil
boil out the
the
head if possible.

51
Inspection and Reconditioning

Valve Guides
Gui des 4. Instal
Installl the new
new valve
valve guid
guides
es using
using a valv
valvee
guide installation tool (see Figure 2 on page
1. Remove
Remove the
the carbon
carbon from the valve guides
guides with
with
24)
24) and a press or a hammer.
hammer. Drive the valve
a valve guide carbon beater.
guide into the top of the cylinder head until
2. Measur
Measuree the insi
inside
de diame
diameterter of the
the valve
valve the valve guide projection (the distance
guides with a small hole gauge or a graduated between the top of the valve guide and the top
set of tapered pilots. If the valve guides are of the valve spring seat) is 0.591 in.
larger than 0.3189 in. (8.100 mm), replace the (15.00 mm) on TierTier 1 and earlier engines, or
valve guides. 0.579 to 0.591
0.591 in. (14.70 to 15.00 mm) on Tier
Tier
2 engines.
 NOTE: If the engine has been in use for
 some time and has accumulated many hours
 of running time, it is advisable to replace
replace the
valve guides because they usually show
 significant wear after numerous hours
hours of
 service. Because
Because the valve seat
seat grinding
 procedure is centered by a pilot placed
placed in the
valve guide, new straight valve guides allow
 the valve seats to be ground accurately
accurately..
3. Remove
Remove the
the valve
valve guid
guides
es by usin
using
g a valve
valve
guide removal tool (see Figure 1 on page 24)
24 ) AGA60

and a press or a hammer to drive the valve

guides out through the combustion chamber. 1. Valve
alve Guid
Guide
e Proje
roject
ctiion
Figure 78: Valve Guide Projection
Projection

5. After installation
installation,, ream
ream the
the new
new valve
valve guides.
guides.
Use a 0.3155 in. (8.010 mm) ream for the
intake valve guides. Use a 0.3155 in.
i n. (8.015
mm) ream for the exhaust valve guides.

Valve Depth
D epth
The valve depth is the distance between the
cylinder head deck and the valve.

AGA59

1. Valve Guide Tool

2. Cylinder Head
3. Valve Guide
AGA61
Figure 77: Removing or Installing
Installing Valve
Valve Guides

1. Cylinder Head Deck

2. Valve Depth
3. Valve
Figure 79:
79: Valve
Valve Depth
Depth

52
 Inspection and Reconditioning

The valve depth is a critical dimension for most

diesel engines. Grinding the valve or the valve
seat increases the valve depth. As the valve depth
increases, the volume of the combustion chamber
also increases and the compression ratio
decreases. Decreasing the compression ratio can
cause hard starting or poor performance.
Therefore it is very important to check the valve
depth of each valve before and after grinding the
valve, and before and after grinding the valve seat.
If the valve depth is near the wear limit before AGA63

grinding the valve or valve seat, the valve, the Figure 81: Measuring
Measuring Valve
Valve Stem
valve seat or both may need replacement. If the
valve depth exceeds the wear limit after grinding 3. The valv
valves
es can
can be ground
ground to clea
cleann up any
any
the valve or the valve seat, the valve, the valve wear or minor damage on the valve faces.
seat or both must be replaced. Grind the valves until all signs of wear or
damage are removed. Grind the valve faces to
To check the valve depth, install the valves in
in the following angles:
their respective valve seats and measure the valve
depth of each with a depth gauge or a caliper. The Intake 30 degrees
wear limit for both the intake and exhaust valve Exha
Exhaus
ustt 45 deg
degre
rees
es
depth is 0.039 in. (1.00 mm) on Tier 1 and earlier
engines, or 0.031
0.031 in. (0.80 mm) on Tier
Tier 2 engines. 4. After
After grindin
grinding
g the valve
valves,
s, check
check the
the valve
valve
margin. Replace any valve with a valve
margin that is less than 0.020 in. (0.50 mm).

AGA64

AGA62
1. 0.02
0.020
0 in.
in. (0.5
(0.50
0 mm)
mm) Mini
Minimu
mum
m
Figure 80: Measuring
Measuring Valve
Valve Depth Figure 82:
82: Valve
Valve Margin
Margin

Valves  NOTE: Valves

Valves with a valve margin that is not
even after being ground are slightly bent.
1. Clean and inspect
inspect the
the valves
valves.. Replace
Replace valves
valves
These valves should be replaced if the valve
that are cracked, bent, or have valve faces that
 margin is less than 0.020 in. (0.50 mm) at the
are significantly damaged.
 narrowest point.
2. Measu
Measure
re the outs
outside
ide diam
diamete
eterr of the valv
valvee
5. After grinding
grinding the
the valves
valves,, install
install the
the valves
valves in
stems. If the valve stem is smaller than
t han
their respective valve seats and check thet he
0.3110
0.3110 in. (7.900 mm), replace the valve.
valve.
valve depth of each. Replace any valve that
has a valve depth over the wear limit.

53
Inspection and Reconditioning

Valve Seats 3. After grinding

grinding the valve
valve seats
seats,, install
install the
valves in their respective valve seats and
1. Inspect
Inspect the
the valve
valve seats
seats for
for any
any major
major damag
damagee
check the valve depth of each. Replace any
that would require valve seat replacement.
valve that has been ground and now has a
2. Grind each valve seat to remove
remove any sign of valve depth over the wear limit. Replace any
wear or minor damage. Valve seats that show valve seat that has a new valve installed and
no wear or damage should also be ground still has a valve depth over the wear limit.
limi t.
lightly to clean up any slight imperfections.
4. Check
Check the
the width
width of the
the valv
valvee seats
seats with
with a
Grind the valve seats to the following angles:
caliper.
Intake 30 degrees
Exha
Exhaus
ustt 45 deg
degre
rees
es

AGA67
AGA65
Figure 85: Measuring
Measuring Valve
Valve Seat Width
1. Valve Seat Width
5. Use Prus
Prussia
sian
n Blue
Blue or a simila
similarr dye to chec
check
k
Figure 83: Intake
Intake Valve
Valve Seat Angles
the alignment of the each valve seat and valve
face. The valve seat should contact the middle
of the valve face.
6. Use 15 and
and 70
70 degree
degree grinding
grinding stone
stoness to size
and align the valve seats to meet the width
specifications (see Specifications), and
alignment recommendation above.

AGA66

1. Valve Seat Width

Figure 84: Exhaust Valve
Valve Seat Angles
Angles

54
 Inspection and Reconditioning

Valve Seat Replacement

The original cylinder head is not equipped with
removable valve seats. The cylinder head must be
machined to accept replacement valve seats.
Replacement valve seats are available from the
Service Parts Department. The following
illustrations show the dimensions for replacement
valve seat bores.
1. After
After machi
machinin
ning
g the head,
head, chill
chill each
each
replacement valve seat and install it with a
valve seat installation tool.
2. Grind the new valve seats
seats after
after instal
installation
lation..

1. Beve
Bevell 0.01
0.016
6 to
to 0.03
0.031
1 in.
in. (0.
(0.4
4 to
to 0.8
0.8 mm)
mm)
Depth 0.321 to 0.329 in.
2.
(8.15 to 8.35 mm)
Exhaust Diameter 1.2402 to 1.2408 in.
3.
(31.500 to 31.516 mm)
Intake Diameter 1.4961 to 1.4967 in.
4.
(38.000 to 38.016 mm)
5. Exha
Exhaus
ustt Bev
Bevel
el Angl
Angle
e 30
30 to
to 45
45 Deg
Degre
rees
es
Exhaust Bevel Outside Diameter
6.
1.311 to 1.319 in. (33.3 to 33.5 mm)
m m)
Intake Bevel Outside Diameter
AGA68 7.
1.642 to 1.650 in. (41.7 to 41.9)
1. Beve
Bevell 0.0
0.016
16 to
to 0.0
0.031
31 in.
in. (0.
(0.4
4 to
to 0.
0.8
8mmm)
m) 8. Inta
Intake
ke Beve
Bevell Ang
Angle
le 45 to 60 De
Degr
gree
ees
s
Depth 0.321 to 0.329 in. Figure 87: Dimensions
Dimensions for Replacement
Replacement
2.
(8.15 to 8.35 mm) Valv
alve
e Seat
Seat Bores
Bores Tier 2 Engines
Engines
Exhaust Diameter 1.2402 to 1.2408 in.
3.
(31.500 to 31.516 mm)
Intake Diameter 1.4567 to 1.4573 in.
4.
(37.000 to 37.016 mm)
Figure 86: Dimensions
Dimensions for Replacement
Replacement
Valve
Valve Seat Bores Tier 1 and Earlier
Earlier Engines
Engines

55
Inspection and Reconditioning

Valve Springs
1. Clean and inspect
inspect the valve springs.
springs. Replace
Replace
valve springs that are cracked, or significantly
scratched or damaged.
2. Measure
Measure the free length
length of
of the valve
valve springs
springs
with a caliper. Replace any valve springs that
are shorter than 1.67 in. (42.5 mm) onon Tier 1
and earlier engines,
engines, or 1.63 in. (41.5 mm) on
Tier 2 engines.
AGA71

1. Inclination
2. Free Length
Figure 90: Valve
Valve Spring Measurements
Measurements

4. Inspect
Inspect the
the valve
valve stem
stem caps,
caps, the valve
valve spring
spring
retainers, and the valve keepers. Replace any
of these components that show significant
wear or damage.

Cylinder Head Assembly

AGA69
Assemble the cylinder head after all the
Figure 88: Measuring
Measuring Valve
Valve Spring Free Length components have been reconditioned or replaced.
3. Check
Check the inclination
inclination of the
the valve
valve springs
springs with
with Thoroughly clean the cylinder head and all the
a square. Replace any valve springs with components before assembly.
inclinations larger than 0.04 in. (1.1 mm) on 1. Lightl
Lightlyy oil the
the valve
valve stem
stem seals
seals and
and place
place
Tier 1 and earlier engines, or 0.06 in. (1.4 mm) them on the valve guides. The intake and
on Tier 2 engines. exhaust valve stem seals are different from
each other. The exhaust valve stem seals are
marked with yellow paint. Make sure to put
the intake and exhaust valve stem seals on the
matching valve guides.
 NOTE: New valve stem
stem seals should always
always
 be used when assembling the cylinder
cylinder head.

AGA70 2
Figure 89: Checking
Checking Valve Spring
Spring Inclination

AGA72

1. Valve Stem Seal

2. Valve Guide
Figure 91: Installing
Installing Valve
Valve Stem Seals

56
 Inspection and Reconditioning

2. Oil the
the valve
valve stem
stem and
and place
place the valve
valvess in their c. Lift
Lift the valve
valve off
off the
the valve
valve seat
seat,, rotate
rotate the
the
respective valve seats. Oiling the valve stems valve about a quarter of a turn, and drop
prevents them from seizing to the new valve the valve back onto the valve seat. Spin
stem seals. the valve against the valve seat again for a
short time. Repeat this several times.
3. Install
Install the valve springs.
springs. The end of a valve
spring that has less pitch (this end is wound
tighter and may have some paint on it) should 1
be placed on the cylinder head.

1
AGA74
AGA52

1. Valve Lappi
pping Tool
2
Figure 93:
93: Lapping Valves
Valves
AGA73
d. Remov
Removee the valve
valve and
and wipe
wipe the
the lappi
lapping
ng
1. Top—More Pitch compound off the valve seat and the valve
2. Bott
Bottom
om—L
—Les
ess
s Pit
Pitch
ch—P
—Pla
lace
ce On Cyli
Cylind
nder
er He
Head
ad face. The valve seat should appear smooth
and be an even gray color. The valve face
Figure 92:
92: Valve Spring
Spring
should show a smooth, even gray ring
4. Place the valve spring
spring retaine
retainers
rs in the valve where it contacts the valve seat. Repeat the
springs and compress the valve springs with a lapping procedure if either the valve seat
valve spring compressor. or the valve face does not appear smooth
and even.
5. Install
Install the valve keepers
keepers and remove
remove the
the valve
valve
spring compressor. 7. Recheck
Recheck the valves
valves for
for leaks
leaks after they have
been lapped.
6. After installing
installing the valves,
valves, place
place the cylinder
cylinder
head on the intake side and fill the exhaust
ports with diesel fuel. Check to see if any
diesel fuel is leaking
l eaking past the exhaust valves.
Turn the cylinder head over and check the
intake valves in the same way. Minor seeping
is acceptable, but any valves that leak
significantly must be removed and lapped.
l apped.
a. To lap a valve
valve plac
placee a small
small amou
amount
nt of
medium grit valve lapping compound on
the valve face.
b. Place
Place the
the valve
valve in the
the valve
valve seat
seat and
and use a
valve lapping tool to spin the valve against
the valve seat for a short time.

57
Inspection and Reconditioning

Rocker Arm Assembly 2. Remove

Remove the
the rocker
rocker arm
arm suppor
supports,
ts, the
the rocker
rocker
arms, and the springs from the rocker arm
1. Remove
Remove the stud
studss from
from the rock
rocker
er arm
arm shaft. Keep these parts in order to make sure
supports on both ends of the rocker arm shaft they will be assembled correctly.
and from the rocker arm support in the center
of the rocker arm shaft. 3. Clean
Clean and
and inspec
inspectt all the componen
components
ts of
of the
rocker arm assembly. Replace any parts that
show significant wear or damage.

1
2

3
8

7 6
5
4
AGA75

1. Rocker Arm Shaft 5. Spring

2. Locknut 6. Rocker Arm
3. Valve Ad
Adjustment Sc
Screw 7. Rocker Ar
Arm Su
Support
4. Stud 8. Intake (Front) Side
Figure 94:
94: Rocker Arm
Arm Assembly
Assembly

58
 Inspection and Reconditioning

4. Measu
Measurere the outs
outside
ide diam
diamete
eterr of the rocke
rockerr 6. Loosen
Loosen the
the lockn
locknut
ut and
and remove
remove the
the valve
valve
arm shaft at the pivot point of each rocker adjustment screw from each rocker arm.
arm. Replace the rocker arm shaft if it is Inspect each valve adjustment screw and
smaller than 0.6280 in. (15.950 mm) on Tier 1 replace any that show significant wear or
and earlier engines, or 0.6276 in. (15.940 mm) damage. Place the valve adjustment screws
on Tier 2 engines, at any of the rocker arm back in the rocker arms but do not tighten the
pivot points. locknuts.
7. Reasse
Reassembl
mblee the rocke
rockerr arm assem
assembly
bly and
and
make sure the parts are in the correct order.
order.
See Figure 94 on page 58 and
58  and note the
following items:
a. The rocker
rocker arm shaft
shaft is symme
symmetric
trical.
al.
b. The inta
intake
ke and
and exhaus
exhaustt rocker
rocker arms
arms are
are
identical. The valve adjustment screws go
AGA76
to the push rod (back) side.
Figure 95: Measuring
Measuring Rocker Arm Shaft
Shaft
c. The three
three middl
middlee rocker
rocker arm
arm suppo
supports
rts are
are
5. Measure
Measure the inside
inside diamete
diameterr of each rocker
rocker identical. They go on the rocker arm shaft
arm bushing. If a rocker arm bushing is larger with the long mounting bolts to the intake
than 0.6335 in. (16.090 mm) on Tier 1 and (front) side.
earlier engines, 0.6327 in. (16.070 mm) on
Tier 2 engines, or shows significant damage, d. The center
center rock
rocker
er arm
arm suppor
supportt and both
both
replace the rocker arm. end rocker arm supports are fastened to the
rocker arm shaft with studs. The studs go
through the tops of the rocker arm
supports into holes in the rocker arm shaft.
e. The two rocke
rockerr arm suppor
supports
ts on
on the
the ends
ends
of the rocker arm shaft are identical. Each
has an oil passage in its bottom. This oil
passage carries oil from the cylinder head
to the rocker arm shaft. The oil passage
must go to the push rod (back) side and
align with the oil passage in the cylinder
AGA77 head.
Figure 96: Measuring
Measuring Rocker Arm Bushing
Bushing

59
Inspection and Reconditioning

Push Rods
1. Clean and inspect
inspect the
the push
push rods.
rods. Repla
Replace
ce any
any
push rods that show significant wear or
damage.
2. Place
Place each
each push
push rod
rod on a compl
complete
etely
ly flat
flat
surface and use a feeler gauge to check how
AGA79
much the push rod is bent. Replace any push
rod that is bent more than 0.001 in. (0.03 mm).
1 2

1. Abnormal Wear
2. Normal Wear
Figure 98:
98: Tappet Wear
Wear

2. Measure
Measure the outside
outside diameter
diameter of
of each
each tappe
tappet.
t.
Replace any tappets that are smaller than
0.4697 in. (11.930
(11.930 mm) on Tier 1 and earlier
engines, or 0.4707
0.4707 in. (11.955
(11.955 mm) on Tier 2
engines.

AGA78

Figure 97: Checking Bend

Bend in Push Rods
Rods

Tappets
1. Clean and inspect
inspect the
the tappet
tappets.
s. Normal
Normally
ly the
the
tappets rotate while the engine is running.
This causes normal wear to appear as AGA80
concentric rings on the surface of the tappet Figure 99: Measuring
Measuring Tappet
Tappet
that contacts the cam lobe. A tappet that does
not rotate shows an abnormal wear pattern
straight across its contact surface. Replace any
tappet that shows an abnormal wear pattern,
significant wear, or significant damage.

60
 Inspection and Reconditioning

Oil Pump
Oil Pump for Tier 1 and Earlier
Engines
1. Remov
Removee the rotor
rotor plate
plate and
and inspe
inspect
ct the
the oil
pump. If the rotor plate, the inner rotor, the
outer rotor, or the oil pump body show
significant wear, scratches, or damage, replace
the oil pump.

AGA82
2
4 Figure 101: Checking
Checking Clearance Between
Between
3 Oil Pump
Pump Body and Outer
Outer Rotor
Rotor

8
7

6
AGA81

1. Rotor Plate
2. Outer Rotor
3. Rotor Shaft
4. Oil Pres
Pressu
sure
re Contr
ontrol
ol Valve
alve
5. Gear
AGA83
6. Pump Body
Figure 102: Checking
Checking Clearance Between
Between
7. Inner Rotor
Inner Rotor and
and Outer Rotor
8. Rotor Shaft Bore
4. Check
Check the
the clearan
clearance
ce betwee
betweenn the
the rotor
rotor plate
plate
Figure 100:
100: Oil Pump
Pump Assembly
Assembly
Tier
Tier 1 and
and Earl
Earlie
ierr Engi
Engine
nes
s and both rotors. Place a straight edge across
the oil pump body and insert a feeler
f eeler gauge
2. Use a fee
feeler
ler gauge
gauge to
to check
check the
the cleara
clearance
nce between the straight edge and the rotors. If
I f the
between the oil pump body and the outer rotor. clearance between the rotor plate and either
If the clearance between the oil pump body rotor exceeds 0.0059 in. (0.150 mm), replace
and the outer rotor exceeds 0.0098 in. the oil pump.
(0.250
(0.250 mm), replace
replace the oil
oil pump.
3. Use a fee
feeler
ler gauge
gauge to
to check
check the
the cleara
clearance
nce
between the inner rotor and the outer rotor
r otor..
Place the feeler gauge between the tip of a
vane on the inner rotor and the high point of a
lobe on the outer rotor.
rotor. If the clearance
between the inner rotor and the outer rotor
exceeds 0.0059 in. (0.150 mm), replace the oil
pump.

61
Inspection and Reconditioning

Oil Pump for Tier 2 Engines

On Tier 2 engines the oil pump is located in the
gear case cover. The inner rotor of the
t he oil pump
fits around the boss on the crankshaft gear.
 NOTE: Replace the oil pump pump as an assembly
assembly
when replacing the oil pump. Make sure the
 mark on the side of of the outer rotor faces
faces the oil
 pump cover when installing the oil pump.
pump. Torque
Torque
 the oil pump cover mounting screws to 3.9 3.9 to
6.2 ft-lb (5.4
(5.4 to 8.4 N•m).
N•m).

AGA84

Figure 103: Checking

Checking Clearance Between
Between
Rotor Plate and Rotors
Rotors

5. Measure
Measure the outsid
outsidee diamet
diameter
er of
of the rotor shaft
shaft
and the inside diameter of the rotor shaft bore
in the rotor plate. Subtract the diameter of
rotor shaft from the diameter of the rotor shaft
bore to obtain the rotor shaft clearance. If the
rotor shaft clearance exceeds 0.0079 in.
(0.200
(0.200 mm), replace
replace the oil pump.
pump.
1
6. Hold
Hold the oil pump
pump body
body in
in one
one hand
hand and
and the
the
oil pump gear in the other hand. Wiggle the
gear to check the clearance between the rotor 1. Mark on Outer Rotor
shaft and the oil pump body. The wear limit is Figure 104:
104: Mark on Outer
Outer Rotor
0.0079 in. (0.200 mm). If the clearance Face
Faces
s Oil
Oil Pump
Pump Cove
Coverr
exceeds this, replace the oil pump.
1
7. Press on the
the oil pressure
pressure control
control valve
valve piston
piston 2
5
from the cylinder block side of the oil pump. 3
Check to make sure that the piston moves 4
smoothly and is returned by the spring. If not,
replace the oil pump.

1. Crankshaft Gear 4. Inner Rotor

2. Oil Pump Cover 5. Gear Case Cover
3. Outer Rotor
Figure 105: Oil Pump Located
Located in Gear Case Cover
Cover
on Tier 2 Engines

62
 Inspection and Reconditioning

1. Remov
Removee the oil
oil pump
pump cover
cover and
and inspec
inspectt the oil
oil
pump components. If the oil pump cover, the
inner rotor, or the outer rotor show significant
wear, scratches,
scratches, or damage, replace the oil 1
pump.
2
2

3
1
3
4 4

1. Cranks
nkshaft Gear Boss
2. Widt
Width
h Acr
Acros
oss
s Fla
Flats
ts of Inne
Innerr Rot
Rotor
or
3. Insi
Inside
de Diam
Diamet
eter
er of Inne
Innerr Ro
Roto
torr
1. Oil Pres
Pressu
sure
re Contr
ontrol
ol Valve
alve 4. Flat
Flat of Cran
Cranks
ksha
hafft Gea
Gearr Bos
Boss
s
2. Oil Pump Cover Figure 107:
107: Measure Inner
Inner Rotor
Rotor to
3. Outer Rotor Cranksh
Crankshaf
aftt Gear
Gear Boss
Boss Cle
Clearan
arance
ce

4. Inner Rotor 5. Measure

Measure the
the width
width across
across the flats of the
the inner
inner
Figure 106: Oil Pump Components
Components Tier
Tier 2 Engines rotor and the width across the flats of the
crankshaft gear boss. Subtract the width
2. Place the outer
outer rotor in the
the gear
gear case
case cover
cover.. across the flats of the inner rotor from the
Use a feeler gauge to
t o check the clearance width across the flats of the crankshaft gear
between the outer rotor and the gear case boss to obtain the inner rotor to crankshaft
cover.
cover. If the clearance between the outer rotor gear boss clearance between flats. If the inner
and the gear case cover exceeds 0.0118 in. rotor to crankshaft gear boss clearance
(0.300 mm), replace the oil pump. between flats exceeds
exceeds 0.0276
0.0276 in. (0.700
(0.700 mm),
3. Check
Check the
the cleara
clearance
nce betw
between
een the
the oil
oil pump
pump replace the oil pump.
cover and the outer rotor. Place a straight edge 6. Check
Check the oil pressu
pressure
re contro
controll valve
valve to make
make
across the gear case cover where the oil pump sure that the piston moves smoothly and is
cover mounts. Insert a feeler
f eeler gauge between returned by the spring. If not, replace the oil
the straight edge and the outer rotor. If the pump.
clearance between the oil pump cover and the
outer rotor exceeds 0.0047 in. (0.120 mm),
replace the oil pump. 1
4. Measure
Measure the
the inside
inside diameter
diameter of
of the inner rotor
2
and the outside diameter of the crankshaft gear
boss. Subtract the inside diameter of inner
3
rotor from the outside diameter of the
crankshaft gear boss to obtain the inner rotor
to crankshaft gear boss clearance. If the inner 4
rotor to crankshaft gear boss clearance
exceeds 0.0236 in. (0.600 mm), replace the oil
pump. 1. Cap
2. Spring
3. Piston
4. Oil Pump Cover
Figure 108: Oil Pressure Control
Control Valve
Valve

63
Inspection and Reconditioning

Water Pump 2. Check

Check the
the water
water pump
pump beari
bearing.
ng. If
If the water
water
pump shaft does not rotate smoothly,
smoothly, or if it
i t is
1. Check
Check the
the weep
weep hole
hole on
on the
the bottom
bottom of
of the loose or wobbly, replace the water pump.
water pump for any signs of leaking coolant.
If coolant is leaking out of the weep hole, the
mechanical seal is leaking and the water pump
must be replaced.
1
 NOTE: Check the cooling
cooling system to make
 sure it is clean. A dirty
dirty cooling system can
can
 cause water pump
pump leaks.
3
2

1 1

1. Ther
hermostat 16
160 F (71 C)
2 2. Tier 2 Water Pump
3
3. Cool
Coolant
ant Line
Line Con
Conne
nect
ctio
ions
ns for
for Col
Cold
d Sta
Start
rt Dev
Devic
ice
e
Figure 110:
110: Water
Water Pump and Thermostat
Thermostat Assembly
Tier
Tier 2 Engi
Engine
ne
AGA85

 NOTE: The water pump

pump for the Tier
Tier 2 engine
 can be used on
on Tier 1 engines if the coolant
coolant line
1. Ther
hermostat 180 F (82 C)
C)  connections for the cold start
start device are plugged
2. High
igh Moun
ount Water Pum
ump
p  securely.
 securely.
3. Low Mo
Mount Wa
Water Pu
Pump
Figure 109: Water
Water Pump and Thermostat
Thermostat
Asse
Assembl
mblie
iess Tier
Tier 1 and Earli
Earlier
er Engi
Engines
nes

 NOTE: Do not use the 180 F (82 C) thermostat

thermostat
in the Tier 2 engine.

64
 Inspection and Reconditioning

Manifolds The following items can effect the crankcase

pressure readings.
1. Inspect
Inspect the
the manifold
manifoldss for cracks,
cracks, damage,
damage, or a
build up of carbon. Crankcase
Pressure Typical Cause
2. Use a straig
straight
ht edge
edge and
and a feel
feelerer gauge
gauge to Effect
check the manifolds for distortion. Resurface
Increase Piston Rings Stuck or Worn
or replace the manifold if it is distorted more
Breather Hose or Restrictor
than 0.006 in. (0.15 mm). Increase
Plugged with Dirt or Ice
Decre
ecreas
ase
e Air
Air Cle
Clean
aner
er Dirt
Dirty
y or
or Plu
Plugg
gged
ed
Crankcase Breather System
 NOTE: The breather
breather hose must be routed so it
Tier 1 and Earlier Engines
 slopes down from the crankcase breather to the
The crankcase breather system ducts crankcase intake manifold. This prevents condensation
condensation
gases formed in the crankcase directly to the air  from collecting in the breather
breather hose. The
The
intake. Harmful vapors that would otherwise  condensation cancan plug the breather hose if it
collect in the crankcase and contaminate the oil,  collects and freezes
freezes in the hose.
hose. The insulation
or escape to the outside, are drawn back into the  prevents freezing.
freezing. It must be in place and
engine and burned. undamaged.
The crankcase breather is located on top of the 2 3
valve cover. A breather hose connects the 1
crankcase breather to the intake manifold. A
restrictor is placed in the breather hose to limit the
flow of gases from the crankcase to the intake and
keep the crankcase pressure from getting too low.
Normal crankcase pressures with a new air
cleaner are 5 to 10 in. (127 to 254 mm) H 2O of
vacuum at 1450 rpm and 7 to 11 in. (178 to
279
279 mm)
mm) H2O of vacuum at 2200 rpm. The
vacuum will increase as the air cleaner gets dirty 5 4
and becomes more restrictive. Inspect the
Insulation (Covers breather hose
crankcase breather and the breather hose to make 1.
to prevent freezing.)
sure they are not plugged or damaged. Inspect the
2. Restrictor
insulation to make sure it is in place and
undamaged. The insulation is used to prevent 3. Crankcase Br
Breather
freezing in cold weather. 4. Air Re
Rest
stri
rict
ctio
ion
n Ind
Indic
icat
ator
or
5. Intake Manifold
See “Checking Crankcase Pressure” on on page 67 to
67  to
check the crankcase pressure. If your readings are Figure 111
111:: Crankcase
Crankcase Breather
Tier
Tier 1 and
and Earl
Earlie
ierr Engi
Engine
nes
s
significantly more positive than 5 to 11 in. (127 to
279 mm) H2O of vacuum, you may have excess
blowby past the rings. A compression check
should be performed to confirm this.

65
Inspection and Reconditioning

Crankcase Breather System Normal crankcase pressures with a new air

Tier 2 Engine cleaner are 2 to 12 in. (50 to 300 mm) H 2O of
vacuum. The vacuum will increase as the air
The crankcase breather system on the Tier 2 cleaner gets dirty and becomes more restrictive.
engine is similar to the system on the Tier 1 and Check the air restriction indicator before checking
earlier engines. Gases formed in the crankcase are the crankcase pressure. Replace the air cleaner ifif
directed to the intake manifold. Harmful vapors the reading on the air restriction indicator exceeds
that would otherwise collect in the crankcase and 20 in. (508
(508 mm) H2O of vacuum. A dirty air
contaminate the oil, or escape to the outside, are
cleaner may cause oil carry over and lead to high
drawn back into the engine and burned.
oil consumption.
The crankcase breather is located in the valve
Inspect the crankcase breather and the breather
cover.
cover. A restrictor is molded into the fitting for the
hose to make sure they are not plugged or
breather hose on the intake manifold. The
damaged. Inspect the insulation to make sure it is
restrictor limits the flow of gases from the
in place and undamaged. The insulation is used to
crankcase to the intake manifold and keeps the
prevent freezing in cold weather.
crankcase pressure from getting too low. A
breather hose connects the crankcase breather to See “Checking Crankcase
Crankcase Pressure” onon page 67 to
67  to
the intake manifold. check the crankcase pressure. If your readings are
significantly more positive than 2 to 12 in. (50 to
3 300 mm) H2O of vacuum, you may have excess
2 blowby past the rings. A compression check
1
4 should be performed to confirm this.
The following items can effect the crankcase
pressure readings.
8
Crankcase
Pressure Typical Cause
Effect
Increas
ease Piston Rings
ngs Stuc
tuck or Worn
Breather Hose or Restrictor
7 Increase
Plugged with Dirt or Ice
6 5
Decr
Decrea
ease
se Air
Air Cle
Clean
aner
er Dirty
irty or Plug
Plugge
ged
d
1. Breather Hose 5. Baffle Breather
2. Insulation 6. Baffle Plate
3. Breather Cover 7. Intake Manifold
4. O-Ring 8. Restrictor Location
Figure 112:
112: Crankcase
Crankcase Breather Tier 2 Engine

66
 Inspection and Reconditioning

Checking Crankcase Pressure

1. An adapte
adapterr to check
check crankca
crankcase
se pressu
pressure
re can
can be
made from a TK482/486 dipstick (P/N
11-8667)
11-8667) and a fitting (P/N 55-2857).
2. Cut the
the dipst
dipstick
ick off
off of
of the cap and
and cut
cut a
section out of the tab on top of the cap. Make
the section cut out of the tab
t ab wide enough to
install the fitting (P/N 55-2857).
3. Drill a 11/32
11/32 in.
in. (8.7
(8.7 mm) hole in the cap. Tap
the hole with an 1/8 in. NPT tap and install the
fitting.
1
4. This adapter
adapter provides
provides a conve
convenient
nient hook-up
hook-up
for the Magnehelic gauge to monitor
crankcase pressure.

1 2 3 4 2

1. Adapter
2. Magnehelic Ga
Gauge
Figure 114:
114: Measuring
Measuring Crankcase Pressure

1. Fitting
2. Cut Se
Section
tion Out of
of T
Ta
ab
3. Dipstick Cap
4. Cut Dipstick Off
Figure 113:
113: Magnehelic
Magnehelic Gauge Adapter

5. To use the adapte

adapter,
r, remov
removee the oil dipstic
dipstick
k and
replace it with the adapter. Connect
Connect the low
pressure side of the Magnehelic gauge (10 in.
[254 mm] minimum) to the adapter and
observe the readings on high and low speed.

67
Inspection and Reconditioning

68
Engine Assembly

Assembly Precautions
 NOTE: Refer to the Specifications
Specifications chapter for
 specifications not given
given in this chapter.
chapter.
After the components of the engine have been
repaired, reconditioned, or replaced, the engine
can be assembled. It is very important to keep the
engine as clean as possible while it is being
assembled, because
because dirt is one of the major factors
that contributes to the failure of rebuilt engines. AGA86

To avoid problems, take these precautions:

1. Do not
not assem
assemble
ble the engine
engine in an area
area where Figure 115:
115: Install
Install Camshaft
Camshaft Bearing
any type of grinding is done. 3. Place
Place the
the new uppe
upperr main
main bearin
bearingg insert
insertss in
2. Keep your workbench
workbench,, tools,
tools, and hands
hands clean.
clean. the cylinder block. The upper main bearing
inserts are identical and have oil holes and oil
3. Keep sub-assem
sub-assemblies
blies covered
covered until they are groves in them. Make sure the holes in the
needed. bearing inserts line up with the holes in the
4. If the
the engin
enginee must
must be left,
left, even
even for
for a shor
shortt main bearing bores.
period of time, cover the engine until you
CAUTION: The lower main bearing
return.
inserts are plain and do not have oil holes
5. Make sure to follow
follow the
the seque
sequence
nce of assemb
assemblyly  and grooves.
grooves. If they are placed
placed in the
exactly.
exactly. If certain parts are not installed in the  cylinder block, oil
oil will not flow to the
correct order, the engine may require some  crankshaft
 crankshaft bearings. The crankshaft
crankshaft will
disassembly to install these parts properly.  be damaged andand the engine may seize.
seize.

6. Check
Check all
all the assembly
assembly tolerances
tolerances such as
bearing clearance, end play, and gear lash
carefully.
carefully. Neglecting these tolerances can
cause serious reliability problems in a rebuilt
engine.

Assembly Procedure
1. Install
Install the
the front
front camsh
camshaft
aft bearin
bearing
g insert
insert using
using
a bearing driver. Make sure the oil holes in the
bearing insert line up with the oil holes in the
front camshaft bearing bore. The camshaft
bearing insert is pre-finished.
2. Instal
Installl new oil gall
gallery
ery and
and core
core plug
plugs.
s.
AGA87

Figure 116:
116: Install
Install Upper Main Bearings
Bearings

69
Engine Assembly

4. Place the upper

upper thrust
thrust bearings
bearings in positio
position
n in 6. Place
Place the
the new lowe
lowerr main
main bearin
bearing
g insert
insertss in
the cylinder block on each side of the upper the main bearing caps. The lower main
rear main bearing. The grooves on the thrust bearing inserts are plain and identical.
bearings should face away from the upper rear
main bearing. Use a little grease to help hold
them in place.

AGA90

Figure 119:
119: Install
Install Lower Main Bearings
Bearings

7. Place
Place the
the lower
lower thrust
thrust bearings
bearings in positio
position
n on
each side of the rear main bearing cap. The
lower thrust bearings each have a tab on the
bottom. The grooves on the thrust bearings
AGA88 should face away from the rear main bearing
cap.
1. Groo
Groove
ves
s Fac
Face
e Awa
Away
y Fro
From
mMMai
ain
n Bea
Beari
ring
ng
Figure 117:
117: Install
Install Upper Thrust Bearings
Bearings

5. Carefully
Carefully lay
lay the
the cranks
crankshaft
haft in the
the upper
upper main 1
bearing inserts.

AGA91

1. Groo
Groove
ves
s Fac
Face
e Awa
Away
y Fro
From
mMMai
ain
n Bea
Beari
ring
ng
Figure 120: Install
Install Lower Thrust
Thrust Bearings

AGA89

Figure 118:
118: Install
Install Crankshaft
Crankshaft

70
 Engine Assembly

8. Place
Place a piec
piecee of plasti
plastigau
gauge
ge on eac
each
h main
main 10. Remove the main bearing
bearing caps and check the
bearing journal and install the main bearing plastigauge to determine the clearance of each
caps in their proper positions. The cast arrows main bearing. The recommended main
on the main bearing caps are labeled FW and bearing clearance is 0.0015 to 0.0027 in.
should point to the rear (flywheel end) of the (0.038 to 0.068 mm).
engine. The main bearing cap with the thrust
bearings goes to the rear end of the engine.
The main bearing caps with numbers stamped
on them go to the middle of the engine with
the main bearing cap marked number one
closest to the rear main bearing. The main
bearing cap with no number goes to the front
end of the engine.

AGA354

Figure 123:
123: Check Plastigau
Plastigauge
ge

11. Lubricate the main bearings, the main

 journals, and the thrust
thrust bearings with engine
AGA37 assembly compound or engine oil. Install the
Front Rear main bearing caps and torque the bolts. Check
Pulley End Flywheel End to make sure the crankshaft rotates freely.
freely.
1. Rear
ear Main Bearing Cap 12. Use a dial indicator to check
check the crankshaft
crankshaft
Figure 121: Main Bearing
Bearing Cap Placement
Placement end play.
play. The wear limit
l imit is 0.0130 in.
i n.
(0.330 mm) on Tier
Tier 1 and earlier engines, or
9. Instal
Installl and torq
torque
ue the
the main
main bearin
bearing
g bolts
bolts to 0.0110 in. (0.280 mm) on Tier 2 engines. If the
70.9 to 73.8
73.8 ft-lb (96.1 to 100.0
100.0 N•m) on Tier end play is larger than the wear limit, the
1 and earlier engines, or 68.7 to 72.4 ft-lb thrust bearings must be replaced.
(93.2 to 98.1 N•m) on TierTier 2 engines, in two
or three equal increments.

AGA94

Figure 124:
124: Check End Play
Play

AGA92

Figure 122: Install

Install Main Bearing Bolts
Bolts

71
Engine Assembly

13. Install each piston on its respective connecting

rod by heating the piston in hot water and then
pressing the wrist pin into the piston and
through the rod bushing. Install the circlips.
The swirl chamber on the top of the piston
must be positioned so it is on the identification
mark side of the connecting rod.

AGA96

1. Barrel Face Ring

2. Tapered Face Ring
3. Oil Ri
Ring with Ex
Expander
Figure 126:
126: Ring Placement
Placement
Tier
Tier 1 and
and Earl
Earlie
ierr Engi
Engine
nes
s

AGA95

1. Swirl Chamber
2. Identificati
ation Marks
Figure 125:
125: Assemble
Assemble Piston and Rod
Rod

14. Each piston has three piston rings.

a. The top ring
ring for
for Tier
Tier 1 and
and earl
earlier
ier engi
engines
nes 1. Keystone Ring
is a barrel faced compression ring. The top 2. Tapered Face Ring
ring for Tier 2 engines is a keystone
3. Oil Ri
Ring with Ex
Expander
compression ring.
Figure
Figure 127:
127: Ring
Ring Placem
Placement
ent Tier
Tier 2 Engine
Engines
s
b. The midd
middle
le ring
ring is compr
compress
ession
ion ring
ring with
with
a tapered face.
c. The bottom
bottom ring
ring is an oil
oil ring
ring with a
separate internal expander.
expander.

72
 Engine Assembly

15. Before installing the

the piston rings, check the
end gap of each ring. Place a ring in its
respective cylinder.
cylinder. Level the ring in the
cylinder with a piston and check the end gap
with a feeler gauge. The recommended end
gap is 0.008 to 0.016 in. (0.20 to 0.40 mm),
1
except for the middle ring in Tier 2 engines, 2
which is 0.012 to 0.020 in. (0.30 to 0.50 mm).
If the end gap is not correct, check to make
sure that the cylinder bore is the correct size
and that the ring is the correct size.

AGA99

1. Oil Ring End Gap

2. Expander Joint
Figure 130: Oil Ring Install
Installation
ation

c. Place
Place the
the comp
compres
ressio
sion
n ring
ring with
with the
the
tapered face in the middle ring groove.
d. On Tier
Tier 1 and
and earlie
earlierr engine
engines,
s, place
place the
the
barrel faced compression ring in the top
AGA97
ring groove. On Tier 2 engines, place the
keystone compression ring in the top ring
groove.
Figure 128:
128: Check Ring
Ring End Gap
Gap
17. Place the connecting
connecting rod bearing
bearing inserts in the
16. Place the piston
piston rings on their respective connecting rods and the rod caps.
pistons in the proper order.
order. Use a ring spreader 18. Stagger the end gaps of the piston rings on
to install the rings, but do not spread the rings each piston so the end gaps are at 120 degree
more than necessary. The manufacturer’s intervals. Make sure that the end gap for the
mark near the end gap of each ring should top ring is not above either end of the wrist
always face the top of the piston. pin.

AGA98

Figure 129:
129: Mark on Ring
Ring Faces
Faces Up

a. Place
Place the
the oil ring
ring expa
expande
nderr in the
the bottom
bottom
ring groove. AGA100

b. Place
Place the
the oil
oil ring
ring in
in the
the botto
bottom
m ring
ring 1. Top Ring End Gap
groove over the expander.
expander. Position the end 2. Oil Ring End Gap
gap of the oil ring 180 degrees from the 3. Middle Ring End Gap
 joint in the expander.
expander.
Figure 131: Ring Alignment
Alignment

73
Engine Assembly

19. Oil each cylinder,

cylinder, piston,
piston, piston ring, wrist
pin, and rod bushing, with engine oil.
20. Use a ring compressor to install each piston
piston
assembly.
assembly. The swirl chamber on top of the
piston and the identification marks on the
connecting rod should face toward the intake
side of the engine, away from the camshaft
bearings.

2
AGA103

Figure 133: Install

Install Rod Cap and Bolts
Bolts

23. Remove the rod cap

cap and check the
the plastigauge
to determine the clearance of each connecting
rod bearing. The recommended rod bearing
3 clearance is 0.0015 to 0.0029 in. (0.038 to
0.074 mm).

AGA102
AGA93

1. Swirl Chamber Figure 134:

134: Check Plastigaug
Plastigauge
e
2. Identi
ntification Mark
24. Lubricate the rod journal and the rod bearings
3. Camshaft Bearing
of each connecting rod with engine assembly
Figure 132:
132: Install
Install Piston
Piston compound or engine oil. Install the rod caps
and torque the bolts.
21. Place a piece
piece of plastigauge
plastigauge on each
each rod
 journal. Install each rod cap correctly by 25. After installing each piston assembly,
assembly, turn the
matching the identification marks with those crankshaft over several times. Check to see
on the connecting rod. that the bearings move freely and that the
pistons and rings slide through the cylinders
22. Install and torque the connecting rod bolts to
easily.
32.5 to 39.8 ft-lb (44.1 to 53.9 N•m) on Tier 1
and earlier engines, or 32.5 to 36.2 ft-lb (44.1
to 49.0 N•m) on Tier
Tier 2 engines, in two or three
equal increments.

74
 Engine Assembly

26. Use a feeler gauge

gauge to check
check the side clearance
clearance 30. Lubricate the tappets
tappets with engine
engine assembly
between the crankshaft and each connecting compound or engine oil. Insert each tappet
rod. The standard dimension is 0.008 to into its respective tappet bore.
0.016
0.016 in. (0.20
(0.20 to 0.40 mm).
mm).
27. Place new O-rings (Tier 1 and earlier engines
only) on the front of the engine block and
make sure the dowel pins are in place.
 NOTE: Tier 2 engines do not
not use these
O-rings.

AGA26
1
Figure 137: Install
Install Tappets
Tappets

31. Lubricate the camshaft

camshaft bearing, journals, and
1 2
lobes with engine assembly compound or
AGA105
engine oil.
1. Dowel Pins
32. Carefully install the camshaft
camshaft to avoid
avoid
2. O-Ri
O-Ring
ngs
s (Ti
(Tier
er 1 and
and Earl
Earlie
ierr Eng
Engine
ines
s Onl
Only)
y) damaging the camshaft bearing.
Figure 135:
135: Front of Engine
Engine Block
Block

28. Place a thin layer of silicone sealant on the

back sealing surface of the gear case.
29. Install the gear
gear case. Make sure to align the
dowel pins and tighten the mounting bolts.

AGA25

Figure 138:
138: Install
Install Camshaft
Camshaft

AGA484

Figure 136:
136: Install
Install Gear Case
Case

75
Engine Assembly

33. Install and tighten the camshaft thrust plate
mounting bolts.
35. Install the fuel injection pump, align the index
marks (as they were when the fuel injection
pump was removed, see step step 26 on pag
pagee 35),
35),
and tighten the mounting nuts.
 NOTE: TheThe injection timing will be correct
correct if
 the original injection pump is being
 reinstalled and the index marks are aligned
 as they were when
when the fuel injection pump
pump
was removed. If not, see “Injection Pump
Timing Tier 1 and Earlier Engines” on
 page 97  or
 or “Injection Pump Timing Tier 2
 Engines” on page
page 102 .

AGA24

Figure 139: Install

Install Camshaft Mounting
Mounting Bolts

34. On Tier
Tier 1 and earlier
earlier engines, install the oil
pump with a new gasket and tighten the
mounting bolts. On Tier 2 engines the oil
pump is located in the gear case cover and is
installed with the gear case cover.
AGA107

Figure 141: Install

Install Fuel Injection
Injection Pump
Tier
Tier 1 and Earli
Earlier
er Engin
Engines
es

AGA106

Figure 140:
140: Install
Install Oil Pump
Pump
Tier
Tier 1 and
and Earl
Earlie
ierr Engi
Engine
nes
s Figure 142: Install
Install Fuel Injection
Injection Pump
Tier
Tier 2 Engi
Engine
ness

76
 Engine Assembly

1 1 2

1. Index Marks 1. Inde

Index
x Mar
Mark
k on
on Inj
Injec
ecti
tion
on Pum
ump
p
Figure 143: Tier 1 and Earlier
Earlier Index Mark Location
Location 2. Index Mark on
on Gear Case
Figure 146: Typical Tier
Tier 2 Index Mark Alignment

36. Install the fuel injection

injection pump gear,
gear, lock
lock
washer,
washer, and mounting nut. Make sure the key
is aligned properly. Torque the mounting nut
to 43.4 to 50.6 ft-lb (58.8 to 68.6 N•m) on
Tier 1 and earlier engines, or 57.9 to 65.1
65.1 ft-lb
(78.5 to 88.3 N•m) on Tier
Tier 2 engines.
engines.

1 2

1. Inde
Index
x Mar
Mark
k on
on Inj
Injec
ecti
tion
on Pump
Pump
2. Cente
enterr Ind
Index
ex Ma
Mark
rk on Gear
Gear Case
ase
Figure 144: Typical Tier
Tier 1 and Earlier
Index
Index Mark
Mark Alig
Alignme
nmentnt

AGA108

Figure 147: Install

Install Fuel Injection
Injection Pump Gear

1. Index Marks
Figure 145:
145: Tier 2 Index
Index Mark Location
Location

77
Engine Assembly

37. Install the idler gear

gear and the idler shaft and 38. Install and tighten the idler shaft mounting
align the timing marks. The A mark on the bolts.
idler gear should line up with the A mark on
39. Use a dial
dial indicator to check
check the gear
gear lash
the crankshaft gear. The B mark on the idler
between the timing gears, if it has not been
gear should line up with the B mark on the
checked already.
injection pump gear.
gear. The C mark on the idler
gear should line up with the C mark on the 40. Make sure the dowel pins are in place in the
camshaft gear. top of the block.
41. Place a new head
head gasket on the block. Align
the head gasket with the dowel pins and make
sure the engine model inscription is facing up.
42. Place the cylinder
cylinder head on
on top of the block
and the head gasket. Make sure to align the
head with the dowel pins.

AGA109

Figure 148: Install

Install Idler Gear and Idler Shaft
Shaft

1 3
2

AGA111
5
4 Figure 150: Install
Install Cylinder Head
Head and Gasket

AGA110

1. Fuel Inj
Inje
ection Pu
Pump Ge
Gear
2. Idler Gear
3. Camshaft Gear
4. Crankshaft Gear
5. Oil
Oil Pum
Pump
p Gea
Gearr (No
(Nott on
on Tie
Tierr 2 Eng
Engin
ines
es))
Figure 149:
149: Align Timing
Timing Marks
Marks

78
 Engine Assembly

43. Install the cylinder head

head bolts. Torque
Torque the
cylinder head bolts to 62.9 to 67.3 ft-lb (85.3
to 91.2 N•m) in two or three equal increments
using the sequence shown in the following
illustration.

AGA112

Figure 151: Cylinder

Cylinder Head Bolt Torque Sequence
Sequence

44. Place the valve stem caps on the valve stems.

AGA113

Figure 153: Install

Install Rocker Arm Assembly
Assembly

48. Torque the rocker

rocker arm mounting bolts to 16.6
to 21.0 ft-lb (22.6
(22.6 to 28.4
28.4 N•m).
49. Adjust both the intake and the exhaust valves.
valves.
See “Valve Clearance Adjustment” on
page
page 137
137.
AGA07

Figure 152: Install

Install Valve
Valve Stem Caps

45. Install the push rods in their respective

respective
openings. Make sure the push rods are seated
properly in the tappets. Lubricate the socket in
the top end of each push rod with engine oil.
46. Place the rocker
rocker arm assembly
assembly in position.
position.
Make sure all the valve adjustment screws are
loose and have been backed out a few turns.
AGA114
47. Install the rocker arm mounting bolts.
bolts.
Figure 154:
154: Adjust Valves
Valves
Alternately turn each bolt one turn at a time to
evenly apply the valve spring pressure to the
rocker arm assembly.
assembly. Make sure the valve
adjustment screws all seat properly in the
sockets on the ends of the push rods while the
rocker arm assembly is being tightened.

79
Engine Assembly

50. Install the oil filter head

head and the oil filter.
filter. b. Cap off
off any
any other
other open
open oil
oil system
system fittin
fittings
gs
such as the fitting for the oil line to the
 NOTE: The EMI 3000 oil filter started at
fuel injection pump and gear case cover.
 serial number A08750
A08750 on TK482 engines
 and serial number L32014 on TK486E/EH
TK486E/EH c. Press
Pressuriz
urizee the tank
tank to 60 psi (413
(413 kPa)
kPa) and
engines. Earlier engines can be retrofitted open the outlet line to the engine.
with EMI 3000 Oil Filter Kit P/N 90-336. See
d. The tank
tank will
will fill
fill the oil
oil filter
filter first
first and
and will
will
“EMI 3000
3000 Oil Filter” on page
page 149 for
149 for more
then pressurize the whole lubrication
information.
system. The oil pressure control valve may
release some oil into the bottom end.
e. Check
Check each
each main
main beari
bearing
ng and
and rod bear
bearing
ing..
Oil should drip from each bearing at a
fairly good rate, but there should be no
large streams of oil from any of the
bearings.
f. Check
Check the
the idle
idlerr gear
gear shaf
shaftt and
and the
the front
front
camshaft bearing on Tier 1 and earlier
engines. Oil should drip from each at a
fairly good rate, but there should be no
large streams of oil from either.
g. Check
Check the
the rocker
rocker arm assem
assembly
bly.. Oil flows
flows
AGA115
to the rocker arm assembly through
Figure 155: Install
Install Oil Filter Head and Oil Filter
Filter
internal oil passages in the cylinder block,
51. Pressure check
check the engine’s
engine’s lubrication the cylinder head, the two end rocker arm
system, if possible. A pressure check can point supports, and the rocker arm shaft. Oil
out problem areas in the lubrication system, should drip from each rocker arm bushing
and it eliminates the possibility that any of the and from the hole in each rocker arm at a
engine components are dry when the engine is fairly good rate, but there should be no
first started. large streams of oil from any of the
t he rocker
arms or bushings.
 NOTE: On Tier
Tier 2 engines the gear case
 cover must be installed for the pressure
pressure h. Turn
Turn the engi
engine
ne over
over sever
several
al times
times and
and
 check because
because the oil pump is located
located in the check the components again.
 gear case cover
cover.. See steps 64 through
64 through 72 i. Lack
Lack ofof oil
oil or a low
low flow
flow rat
ratee at
at any
any of
 starting on
 starting on page 84 to
84 to install the gear case these components indicates there is a
 cover.
 cover. restriction in an oil gallery or passage
a. Fill
Fill the pres
pressur
suree tank
tank with
with engin
enginee oil and
and leading to the component. Excessive oil
attach the outlet line to the engine at the flow at any of the components indicates
fitting for an oil pressure gauge or oil that the oil clearance is too large, the
pressure switch. wrong part has been used, or a component
is damaged or missing.

80
 Engine Assembly

52. Install the valve cover with a new gasket and 54. Install
Install the oil
oil pan.
put new O-rings on the special cap nuts.
a. Place
Place a thin
thin layer
layer of seal
sealant
ant on the
the top
top
sealing surface of the upper part of the oil
pan.
b. Place
Place the
the uppe
upperr part
part of the oil pan
pan in
in
position on the bottom of the block.
c. Instal
Installl the moun
mountin
ting
g bolts
bolts for
for the uppe
upperr
part of the oil pan. Make sure the rear end
of the block and the upper part of the oil
pan are flush before tightening the
mounting bolts.
d. Place
Place a thin
thin layer
layer of
of sealan
sealantt on the sea
sealing
ling
surface of the lower part of the oil pan.
e. Place
Place the lower
lower part
part of the
the oil
oil pan
pan in
in
position on the upper part of the oil pan.
AGA116

Figure 156: Install

Install Valve
Valve Cover f. Instal
Installl and
and tighte
tighten
n the
the mount
mounting
ing bolts
bolts for
for
the lower part of oil pan.
53. Install the oil pump
pump intake pipe.
pipe. Tier
Tier 1 and
earlier engines use a gasket between the oil
pump intake pipe and the block. Tier 2 engines
use an O-ring between the oil pump intake
pipe and the block. Make sure the gasket or
O-ring is installed properly because a missing
gasket or O-ring will cause low oil pressure.

1 2

1. Gask
Gasket
et on Tier
ier 1 and
and Ear
Earli
lier
er Engi
Engine
nes
s
2. O-Ring on
on Ti
Tier 2 En
Engines
AGA118
Figure 157: Install
Install Oil Pump Intake
Intake Pipe
Figure 158:
158: Install
Install Oil Pan
Pan

81
Engine Assembly

55. Check to make

make sure the dowel pins are
are in 60. Install the axial
axial rear seal using installation tool
position in the rear of the block. There are two P/N 204-952 andand the following procedure.
procedure.
for the rear seal housing and two for the
bellhousing. CAUTION: Do not attempt to install this
 seal without using the installation
installation tool.
56. Make sure the old rear
rear seal has been
been removed  Driving the seal in by
by hand will crush the
from the rear seal housing. If not, remove it.  rubber lip into the metal
metal ring and cause
cause
 NOTE: Some earlyearly engines useuse a radial rear
rear  the seal to burn up
up when the engine is
 seal. Later engines use
use an axial rear
rear seal. No  run.
 special tools are needed to remove
remove or install  NOTE: If necessary,
necessary, the inside diameter of
 the radial rear seal.
seal. Install the radial
radial rear  the metal seal
seal ring can be lightly coated with
 seal by pressing
pressing it into the rear
rear seal housing.
housing.  Loctite 620 or silicone
silicone gasket sealant.
sealant. The
Coat the lip of the
t he radial rear seal with  original seal ring was
was installed without
engine oil before installing the rear seal  sealant, but the use of sealant offers some
 housing. The radial
radial rear
rear seal
seal can
can be replaced insurance against leaks if the crankshaft has
with an axial rear seal if the rear seal  some surface damage. However
However, sealant will
 housing is also replaced.
replaced. The axial rear
rear seal  make future removal
removal of the metal ring more
 requires special
special tools for removal andand  difficult. If necessary,
necessary, a light coat of silicone
installation (see step
(see step 60 ).  sealer may also
also be applied to the outside
outside
57. Place a thin layer of sealant
sealant on the sealing  diameter of the seal.
seal.
surface of the rear seal housing. a. If neces
necessar
sary
y, remove
remove the
the old
old metal
metal ring
ring
58. Place the rear
rear seal housing
housing in position and (see step
step 33 on pag
pagee 37)
37) and any
make sure to align the dowel pins. imperfections from the surface of the
crankshaft that contacts the metal ring of
the seal. Check your work by placing the
installation tool cup over the end of the
crankshaft to check the fit. The cup must
fit smoothly over the crankshaft or it will
bind when installing the seal.
 NOTE: The cups for some of the early
installation tools were slightly
undersized. If you have trouble fitting the
 cup over the end
end of the crankshaft,
crankshaft, have
 a a machine shop remove 0.005 in.
(0.13 mm) from the inside diameter of the
 cup.
b. Attach
Attach the
the install
installati
ation
on tool
tool mandrel
mandrel to the
the
AGA119 crankshaft using three flywheel bolts as
Figure 159: Install
Install Rear Seal Housing
Housing shown in Figure 160 on page 83 83.. If a point
of the hex on a bolt is facing directly out it
59. Install and tighten the mounting bolts
bolts for the
may extend past the mandrel. Grind down
rear seal housing.
the points as required.
 NOTE: The bolts atat the bottom of the rear
c. Place
Place the
the seal
seal over
over the
the instal
installat
lation
ion tool
tool
 seal housing screw
screw into the oil pan and
and are
mandrel with the metal face of thet he seal
longer than the other bolts that fasten the
toward the engine.
 rear seal housing
housing to the block.

82
 Engine Assembly

d. Place
Place the
the tool
tool cup
cup over
over the mand
mandrel
rel and
and 62. Install and tighten the mounting bolts for the
against the seal. Align the cutout on the bellhousing.
cup away from the bolts on the mandrel as
 NOTE: The bolts atat the bottom of the
shown. This allows you to see when the
 bellhousing screw into the oil pan and are
are
cup has completely bottomed on the
longer than the other bolts that fasten the
mandrel.
 bellhousing to the block.
block.
4

2
1

AGA120

1. Nut
2. Cup AGA121

3. Seal Figure 161: Install

Install Bellhousing
Bellhousing
4. Mandrel 63. Install the flywheel
flywheel and align
align it with the dowel
5. Check
Check Cu
Cuto
tout
ut To Be
Be Sure
Sure pin in the end of the crankshaft. Torque
Torque the
Mandrel Contacts Cup flywheel mounting bolts to 61.5 to 65.1 ft-lb
Figure 160: Install Rear Seal with Tool
Tool P/N 204-952 (83.4 to 88.3 N•m).
e. Carefu
Carefully
lly tight
tighten
en the
the install
installati
ation
on tool
tool nut.
This pulls the cup over the mandrel and
presses the seal into place. When the nut
stops turning, check the cutout on the cup
to be sure it is completely bottomed on the
mandrel. The seal is now installed to the
proper depth.
f. Remo
Remove
ve the
the ins
insta
talla
llatio
tion
n tool
tool..
 NOTE: If there are any imperfections
imperfections on
 the crankshaft
crankshaft the cup may jam and and be
 difficult to remove. Tapping
Tapping alternately
 on each side will assist
assist in removing a
 jammed cup. This problem
problem can be
AGA122
eliminated by testing the fit of the cup on
 the crankshaft
crankshaft before installing the seal. Figure 162:
162: Install
Install Flywheel
Flywheel

61. Place the bellhousing

bellhousing in position on the rear of
the block and make sure to align the dowel
pins.

83
Engine Assembly

64. Check to make

make sure the dowel pins are
are in
1
position in the gear case (see Figure 163).
163). 2
5
65. Replace the front seal
seal by pressing the old
old seal 3
out and pressing a new seal into the gear case 4
cover.
cover. The front seal can also be installed to
the proper depth after the gear case cover has 7
been installed using the front seal installation
tool P/N 204-1138 (see step
step 73).
73).
6
66. If the front seal has been installed, coat the lip
of the front seal with engine oil.
67. Place new O-rings (Tier
(Tier 2 engines only)
only) in the
gear case. 1. Crankshaft Gear
 NOTE: Tier
Tier 1 and earlier engines do not use 2. Oil Pump Cover
 these O-rings because
because of the different
different oil 3. Outer Rotor
 pump configuration. 4. Inner Rotor
5. Timing Gear Cover
1
6. Flat Si
Sides on
on In
Inner
ner Ro
Rotor
7. Flat
Flat Side
Side on Cran
Cranks
ksha
hafft Gea
Gearr
Figure 164: Align Flat Sides of Crankshaft
Crankshaft Gear
with Flat Sides of Inner Rotor in Timing Gear Cover

70. Install and tighten the gear case

case cover
mounting bolts that are covered by the sound
1 shield.
71. If the sponge on the back of the sound
sound shield
is damaged, replace it before installing the
sound shield.
2
72. Place the sound
sound shield in position and
and install
and tighten the mounting bolts.
1. Dowel Pins
2. O-Ri
O-Ring
ngs
s (Tie
(Tierr 2 Engi
Engine
nes
s Only
Only))
Figure 163: Gear Case

68. Place a thin layer of sealant

sealant on the sealing
surface of the gear case cover.
69. Place the gear
gear case cover in position and make
sure to align the dowel pins.
 NOTE: The oil pump is located in the timing
 gear cover
cover on
on Tier
Tier 2 engines. The inner rotor
 of the oil pump fits around
around the crankshaft
crankshaft
AGA123
 gear.
 gear. Make sure that
that the flat sides of the
inner rotor are aligned with the flat sides on
 the crankshaft
crankshaft gear when installing
installing the Figure 165: Install
Install Gear Case Cover
Cover
 timing gear cover.
cover. and Sound
Sound Shie
Shield
ld

84
 Engine Assembly

73. Use the front seal installation tool P/N 74. Install the crankshaft
crankshaft pulley and
and align it with
204-1138
204-1138 to install the front seal (if not yet the dowel pin in the crankshaft gear. Torque
installed). the mounting bolt to 83.2 to 90.4 ft-lb
f t-lb (112.8
to 122.6 N•m).
a. Place
Place a thin
thin layer
layer of
of sealan
sealantt on the
the outsid
outsidee
diameter or the front seal.  NOTE: Make sure to alignalign the dowel pin
with the mating hole in the crankshaft pulley.
b. Place the front seal in the
the gear
gear case
case cover
cover
 If not, the pulley will not pull
pull down on the
and press it in slightly so it
i t stays in place.
 tapered end of the crankshaft
crankshaft and will be
c. Place
Place the
the front
front seal
seal insta
installa
llatio
tion
n tool
tool over
over loose. The pulley can also crack where it
the end of the crankshaft and against the  contacts the
the dowel pin. This can
can cause the
seal.  front seal to leak oil. Check
Check the pulley for
 cracks if the front seal
seal leaks. Replace
Replace the
d. Place
Place the
the mounti
mounting
ng bolt
bolt and
and washer
washer for
for the
the
 dowel pin if it is damaged.
damaged.
crankshaft pulley through the front seal
installation tool and into the crankshaft.
1 2
e. Tight
Tighten
en the
the bolt
bolt unti
untill the
the front
front seal
seal
installation tool stops against the end of
the crankshaft. This installs the front seal
to the proper depth.
f. Remove
Remove the bolt
bolt and
and the front
front seal
seal
installation tool.
g. Coat
Coat the lip
lip of the
the front
front seal
seal with
with engi
engine
ne
oil.

1. Dowel Pin
2. Mati
Mating
ng Ho
Hole
le in Cran
Cranks
ksha
haft
ft Pull
Pulley
ey
Figure 167:
167: Dowel Pin
Pin Alignment
Alignment

1
2

1. Front Seal
2. Front
Front Sea
Seall Inst
Instal
alla
lati
tion
on Too
Tooll P/N
P/N 204-
204-1
1138
138
Figure 166:
166: Install
Install Front Seal
Seal

AGA124

Figure 168: Install

Install Crankshaft
Crankshaft Pulley

85
Engine Assembly

75. Install the oil line that goes from the cylinder 77. Install the water pump with a new O-ring, a
block to the fuel injection pump and the gear new thermostat, and new gaskets.
case cover.
 NOTE: On later model engines
engines the oil line 1
 stops at the fuel injection pump and
and does not
not
 go to the gear case
case cover.
cover. The hole in the
 gear case cover
cover is plugged with
with a screw
(P/N 55-5768). Tier
Tier 2 engines
engines do not have
 the hole
hole in the gear
gear case
case cover
cover and do not use
 the plug screw.
screw. 2

1. High Moun
ount Wate
ater Pump
2. Low Mo
Mount Wa
Water Pu
Pump
Figure 171: Install
Install Water
Water Pump

 NOTE: Tier
Tier 2 engines have
have two coolant
 hoses that go from
from the water pump to a the
 cold start device
device on the fuel injection pump.
Connect the hoses to the water pump and the
AGA125
 fuel injection pump
pump after installing the water
Figure 169:
169: Install
Install Oil Line
Line  pump.
76. Install the fuel transfer
transfer pump in the gear case
case
cover.
1

1. Coolant Hoses
Figure 172: Connect
Connect Coolant Hoses
Hoses
on Tier
ier 2 Engi
Engine
nes
s

AGA126

Figure 170: Install

Install Fuel Transfer
Transfer Pump

86
 Engine Assembly

78. Place a nozzle

nozzle gasket and a nozzle protector
protector in
each opening for the fuel injection nozzles.
Install the nozzle gasket first, then install the
nozzle protector. The nozzle protector is
shaped like a cup, and the bottom of the cup
should face down.
1 81. Install
2
3 Line Replacement”
4
79. Install the fuel injection nozzles.
80. Install the fuel injection
injection nozzle retainers and
mounting nuts or bolts. Torque the mounting
nuts to 5.1 to 6.5 ft-lb (6.9 to 8.8 N•m) on
Tier 1 and earlier engines.
engines. Torque
Torque the
mounting bolts to 18.0 to 21.0 ft-lb (24.4 to
28.4 N•m)
N•m) on Tier 2 engines.
engines.
Install the lift brackets.
brackets.
82. Install the intake manifold with a new gasket.
83. Install
Install the fuel return lines.
lines. See “Fuel Return
Replacement” on page 113.
84. Install
Install the fuel injection
injection lines. Figure 177 on
page 88 shows
88 shows the injection line connections
for Tier 2 engines.

1. Retainer
2. Fuel
uel Inje
njection No
Nozzle
3. Nozzle Protector
4. Nozzle Gasket 2

Figure 173: Install

Install Fuel Injection
Injection Nozzles
Tier
Tier 1 and
and Earli
Earlier
er Engi
Engine
nes
s

3
4

AGA02

1. Fuel Injection Lines

2 Fuel Return Lines
Figure 175: Install
Install Fuel Injection
Injection Lines
Tier
Tier 1 and Earl
Earlier
ier Engi
Engines
nes

1. Retainer
2. Fuel
uel Inje
njection No
Nozzle
3. Nozzle Protector
4. Nozzle Gasket
Figure 174: Install
Install Fuel Injection
Injection Nozzles
Tier
Tier 2 Engi
Engine
nes
s

87
Engine Assembly

85. Install the crankcase

crankcase breather
breather hose. Clean
Clean the
restrictor in the crankcase breather hose on
Tier 1 and earlier engines to make sure it is not
2
1 blocked.
86. Install the exhaust manifold
manifold with a new
gasket.
87. Install
Install the starter
starter.

1. Fuel Injection Lines

2. Fuel Re
Return Li
Lines
Figure 176: Install
Install Fuel Injection
Injection Lines
Tier
Tier 2 Engi
Engine
ness

1 3 4

1. For
For IInj
njec
ecti
tion
on Line
Line to Nu
Numbe
mberr One
One Cyli
Cylind
nder
er
2. For
For Inj
Injec
ecti
tion
on Line
Line to Nu
Numb
mber
er Two Cyli
Cylinde
nderr
3. For
For Inj
Injec
ecti
tion
on Line
Line to Nu
Numbe
mberr Thre
Three
e Cyl
Cylind
inder
er
4. For
For Inj
Injec
ecti
tion
on Line
Line to Nu
Numb
mber
er Four
Four Cyl
Cylin
inde
derr
Figure 177: Fuel Injection
Injection Line Connections
Connections
on Tier
ier 2 Engi
Engine
nes
s

88
Lubrication System

The TK482 and TK486 engine families use a
pressure lubrication system. A trochoid type oil
pump circulates the oil through the system to
lubricate the engine components. The oil pump
contains a pressure control valve that limits the oil
pressure to 45 to 57 psi (310 to 390 kPa).
On Tier
Tier 1 and earlier
earlier engines the oil pump is
driven by the crankshaft gear, and is attached to
the lower part of the
t he gear case.
On Tier 2 engines the oil pump is driven by the
the boss on the crankshaft gear, and is located in
the gear case cover.
The oil is picked up by a screened inlet near the
bottom of the oil pan. The inlet is positioned far
enough from the bottom of the pan to avoid
picking up any of the residue that tends to settle
on the bottom of the pan. The oil then passes
through the intake pipe to the oil pump.

AGA129

1. Oil Pan 11. Fuel Transfer Pump

2. Oil Inlet Pipe (Strainer) 12 . Camshaft Bearing
3. Oil Pump 13. Valve Rocker Arm Shaft
4. Pressure Control Valve 14 . Valve Rocker Arm
5. Bypass Valve 15 . Tappet and Cam Faces
6. Bypass Oil Filter 16 . Crankshaft Journals—Main Bearings
7. Full Flow Oil Filter 17 . Crank Pins—Rod Bearings
8. Cylinde
nder Bo
Body and
and Main Oi
Oil Ga
Gallery 18. Fue
Fuel In
Injection Pump Ge
Gear
9. Idler Gear Shaft 19. Fuel Injection Pump
10.
10. Timing
ming Gea
Gearr Face
Faces
s
Figure 178:
178: Lubrication
Lubrication System
System

89
Lubrication System

The oil pump forces a large volume of high Some of the oil supplied to thet he camshaft bearings
pressure oil through an oil gallery to thet he dual flows through passages in the cylinder block, the
element (full flow/bypass) oil filter. Dirt and other cylinder head, and the rocker arm supports to the
particles are trapped in the filter element as the oil rocker arm shaft. The rocker arm shaft supplies oil
passes through the oil filter. If the filter element to the rocker arm bushings and the rocker arms.
becomes clogged, a bypass valve built in the oil Some oil squirts out of holes in the rocker arms to
filter head allows the oil to bypass the filter lubricate the valve stem caps and the valve stems.
element. This keeps the engine components from The oil that is pumped up to the rocker arm
being starved for oil if the filter element is assembly flows back down through the push rod
clogged. openings and lubricates the tappets and the cam
lobes as it returns to the oil pan.
After passing through the oil filter, the oil enters
the main oil gallery. Oil passages connected to the The oil that flows to the fuel injection pump
main oil gallery supply oil to the idler gear shaft, returns to the oil pan after lubricating the injection
the camshaft bearings, and the main bearings. An pump components.
external oil line is connected to the main oil
Oil pressure is affected by oil temperature, oil
gallery and the fuel injection pump. On early
viscosity,
viscosity, and engine speed. Low oil pressure can
Tier 1 and earlier engines
engines the external oil
oil line also
usually be traced to the lack of oil, diluted oil, a
connects to the gear case cover. The external oil
faulty oil pressure control valve, loose
line supplies oil to the fuel injection pump. On
connections in the lubrication system, or worn
early Tier
Tier 1 and earlier
earlier engines the external oil
bearings. Low oil pressure is not normally caused
line also supplies oil to the fuel injection pump
by a faulty oil pump. Use the flow chart on the
gear.
following page to help diagnose low oil pressure.
Oil from the idler gear shaft lubricates the idler
gear bushing, the idler gear, the other timing
gears, and the fuel transfer pump before returning
to the oil pan. On early
early Tier 1 and earlier engines
oil is also delivered to the fuel injection pump
gear, the timing gears, and the fuel transfer pump
through the external oil line connected to the top
of the gear case cover.
Some of the oil supplied to the main bearings
flows through passages in the crankshaft to the
connecting rod bearings. This oil is thrown around
the bottom end of the engine as it flows out of the
bearings while the crankshaft rotates. Some of this
oil lubricates the cylinder walls. Some of this oil
lands in the holes on the top of the connecting
rods and lubricates the wrist pins and the
connecting rod bushings. The oil eventually
returns to the oil pan.

90
 Lubrication System

Low Oil Pressure Flow Chart

Oil Pressure Low

Check Oil Level

Oil Level Low Oil Level OK or High

Add Oil Oil May Be Diluted

Check Oil Pressure Change Oil and Filter
Check Oil Pressure

Oil Pressure OK Oil Pressure Low Oil Pressure OK

Install Known Good Oil Pressure Gauge

Check Oil Pressure

Oil Pressure OK Oil Pressure Low

Remove Oil Pump (Access the oil pump by removing the

crankshaft pulley, the sound shield and the gear case cover.
See “Checking
“Checking Oil Pump”
Pump” on page
page 141
141.)
.) Check Oil Pump Tolerances
Check Oil Pressure Control Valve for Broken Spring or Sticking Piston

Reinstall Oil Pump

Check Oil Pressure

Oil Pressure OK Oil Pressure Low

Pull Engine
Remove Oil Pan
Check Inlet Screen, Intake Pipe,
and Intake Pipe Gasket or O-Ring
Pressure Check Engine for Internal Leaks

91
Lubrication System

92
Fuel System

Description The most common cause of problems in the fuel

system is contamination. The fuel must be clean
The major components of the fuel system are: and the fuel tank must be kept free of
• Fuel Tank   contaminants. The fuel filter/water separator must
be changed regularly. The prefilter should be
• Inle
Inlett Strai
traine
nerr (Pre
(Prefi
filt
lter
er)) cleaned when the fuel filter is changed. Any time
• Priming Pump the fuel system is opened, all possible precautions
must be taken to keep dirt from entering the
• Fuel Transfer
fer Pump system. All fuel lines must be capped when
• Fuel
Fuel Fil
Filte
ter/
r/W
Water
ater Sep
Separ
arat
ator
or disconnected. The work should be done in a
relatively clean area and the work should be
• Fuel In
Injection
ion Pump completed in the shortest time possible.
• Troch
rochoi
oid
d Feed
Feed Pum
Pump
p (Tie
(Tierr 2 Eng
Engin
inee Only
Only)) Thermo King recommends that any major
• Injec
jection No
Nozzles. injection pump or nozzle repairs be done by a
qualified diesel injection service shop. The
The priming pump is used to manually draw fuel investment in equipment and facilities tot o service
from the tank up to the fuel transfer pump if the these components is quite high. Therefore, this
unit should run out of fuel. equipment is not found in most repair shops.
The fuel is drawn from the fuel tank through the The following procedures can be performed under
prefilter by the fuel transfer
tr ansfer pump. The fuel field conditions:
transfer pump forces the fuel through the fuel
filter/water separator to the injection pump. The • Blee
Bleedi
ding
ng air
air from
from the
the fuel
fuel sys
syste
tem
m
injection pump forces the fuel, at a very high • Main
Mainten
tenan
ance
ce of
of the
the fuel
fuel tan
tank
k and
and fuel
fuel filt
filter
er
pressure, through the injection nozzles. The system
injection nozzles atomize the fuel as it is injected
directly into the combustion chambers. • Prim
Primin
ing
g pum
pump
p rep
repai
airr or
or rep
repla
lace
ceme
ment
nt

Tier 1 and earlier engines use an in-line injection • Fuel

Fuel tra
trans
nsfe
ferr pump
pump rep
repai
airr or rep
repla
lace
ceme
ment
nt
pump. Tier 2 engines use a mono-plunger and • Inje
Inject
ctio
ion
n lin
linee repl
replac
acem
emen
entt
distributor injection pump.
• Engi
Engine
ne spee
speed
d adju
adjust
stme
ment
ntss
Injection pump leakage, injection nozzle
overflow,
overflow, and excess fuel from
f rom the fuel filter • Inje
Injecction
tion pump
ump timi
timin
ng
assembly return to the fuel tank through the return • Inject
Injection
ion nozzle
nozzle testin
testing,
g, adjust
adjustmen
ment,
t, and
lines. minor repair
The injection pump and the fuel transfer pump are • Troch
rochoi
oid
d feed
feed pum
pump
p repl
replac
acem
emen
entt (Tie
(Tierr 2
relatively trouble free and if properly maintained engine only).
will usually not require major service or repair
between engine overhauls.

93
Fuel System

4
5

1. Relief
Relief Val
Valve
ve (Ke
(Keep
eps
s air
air from
from ent
enter
erin
ing
g fuel
fuel
5. Fuel Transfer Pump
system when engine is not running.)
2. Filter Head 6. Inlet Strainer (Prefilter)
3. In-line Injection Pump 7. Priming Pump
4. Bleed Screw 8. Fuel Filter/Water Separator
Figure 179: Typical Fuel System for Tier 1 and Earlier Engines

94
 Fuel System

1 2

8 5

1. Relief
Relief Val
Valve
ve (Kee
(Keeps
ps air
air from
from enter
enterin
ing
g fue
fuell
5. Trochoid Feed Pump
system when engine is not running.)
2. Filter Head 6. Fuel Transfer Pump
3. Bleed Screw 7. Priming Pump
4. Mono
Mono-p
-plu
lung
nger
er and
and Dis
Distr
trib
ibut
utor
or Inje
Inject
ctio
ion
n Pum
Pump
p 8. Fuel
Fuel Filt
Filter
er/W
/Wat
ater
er Sep
Separat
arator
or
Figure 180: Typical Fuel System
System for Tier 2 Engines

95
Fuel System

Bleeding Air from the Fuel 1

System
Air usually gets into the fuel system when the
engine runs out of fuel or if repairs are made to
the fuel system.
 NOTE: Be sure to keep
keep the vent in the fuel tank
 open. If the vent
vent becomes clogged,
clogged, a partial
vacuum develops in the fuel tank. This increases
 the chance that air will enter the fuel system.
system.
Use the following procedure to bleed air out of the
fuel system.
1. Loosen
Loosen the
the bleed
bleed screw
screw on the
the Tier
Tier 1 injection
injection 2
pump about two turns. Loosen the bleed screw 1. Bleed Screw 2. Priming Pump
on the Tier 2 injection pump about one turn.
Figure 182:
182: Tier 2 Injection
Injection Pump
Pump
1
2. Unscre
Unscrew
w the primi
priming
ng pump
pump hand
handlele and
and
manually prime the fuel system until air
bubbles are no longer visible in the fuel
coming out of the bleed screw.
3. Tighten
ighten the
the air bleed
bleed scre
screw
w and scre
screw
w the
priming pump handle back in.
4. Loosen
Loosen the injection
injection lines at the injection
injection
nozzles.
5. Crank
Crank the engine
engine over
over with
with the
the starter
starter until
fuel appears at all of the injection
i njection nozzles.
2 6. Tighten
ighten the inject
injection
ion lines.
lines.
1. Bleed Screw 2. Priming Pump 7. Start
Start the engine
engine and
and observe
observe the engine
engine run for
for
Figure 181: Tier 1 and Earlier
Earlier Injection Pump
Pump a few minutes. If the engine fails to
t o start, or
starts but stops in a few minutes, repeat the
procedure.

96
 Fuel System

Injection Pump Timing Tier 1 3. Remove

Remove the
the injectio
injection
n line
line for
for the
the number
number one
and Earlier Engines cylinder from the delivery valve on the
injection pump and from the injection nozzle.
This timing procedure requires fuel pressure at the
injection pump inlet. This can be accomplished by  NOTE: The number one cylinder is the
pumping the priming pump by hand, or by using  cylinder at the flywheel
flywheel end of the engine.
an electric fuel pump to supply fuel to
t o the fuel  NOTE: Do not remove
remove the delivery valve
valve
pump inlet.  spring to check the timing. OM636 and C201
C201
engines must have the delivery valve spring
1. If the engine
engine is in the
the unit,
unit, make
make sure
sure the
the unit
unit
 removed for injection
injection pump timing. TK482
is turned off.
 and TK486 engines
engines DO NOT!
2. Remov
Removee the roun
round
d cover
cover (plug
(plug)) from
from the
4. Remove
Remove the rocke
rockerr arm
arm cove
coverr.
timing mark access hole on the front of the
bell housing. The index marks on either side 5. Place
Place the
the engine
engine at
at top dead
dead cent
center
er of the
the
of this hole and the timing marks on the compression stroke for the number one
flywheel are used to check the injection pump cylinder.
cylinder. Refer to steps a through d.
timing.
a. Rotate
Rotate the
the engin
enginee in the
the normal
normal dire
directi
ction
on
of rotation (clockwise viewed from the
1 water pump end) until the 1-4 timing
t iming mark
on the flywheel lines up with the index
mark in the timing mark access hole.

1 2

AEA701

2 1. Index Mark
2. Top De
Dead
ad Ce
Cent
nter
er Ma
Mark
rk for
for 1 and
and 4
AGA01
Figure 184: Top Dead Center One and Four
1. Numb
Number
er One
One Cyl
Cylin
inde
derr Inj
Injec
ecti
tion
on Line
Line
b. Check
Check the
the rocker
rocker arms
arms on
on the numb
number
er one
one
2. Timing Mar
Mark
k Ac
Access
ess Ho
Hole
cylinder to see if they are loose.
l oose.
Figure 183:
183: Component
Component Location
Location
c. If the
the rocke
rockerr arms
arms are loose
loose the
the engin
enginee is at
at
CAUTION: Loosen all of the injection top dead center of the compression stroke
lines at the injection nozzles to prevent the for the number one cylinder.
 possibility of the engine firing while it is
d. If the rocker
rocker arms
arms are
are tight
tight the engi
engine
ne is at
at
 being rotated.
top dead center of the exhaust stroke for
the number one cylinder. Rotate the engine
360 degrees to place the engine at top dead
center of the compression stroke for the
number one cylinder.

97
Fuel System

6. Discon
Disconnec
nectt the 8S
8S wire
wire from
from the starte
starterr Tier 1 engines (TK482E, TK486E, and
solenoid to prevent the engine from cranking TK486EH) have an additional injection timing
when the unit is turned On. mark at 10 degrees BTDC. The 10 degree
BTDC timing mark is a horizontal line
7. Energize
Energize the fuel
fuel solen
solenoid.
oid. If the engine
engine is in
stamped on the flywheel approximately 1.0 in.
the unit, turn the unit On. Use the Service Test
Test
(25 mm) before the top dead center
center mark. The
Mode to energize the fuel solenoid if the unit
TK482E and TK486E are timed at 10 degrees
has a microprocessor.
BTDC (see Figure 189 on page 9999).
). The
If the engine is not in
i n the unit, use jumper TK486EH is timed at 11 degrees BTDC (see
wires to energize the fuel solenoid at the three Figure 190 on page 99
99).
).
pin connector.
connector. Place a jumper between the
black wire (CH - pin C) and ground (–). Place
1 2
a jumper between the red wire (8D - pin A)
and 12 Vdc (+). Momentarily place a jumper
between the white wire (8DP - pin B) and 12
Vdc (+).

CAUTION: Do not leave the jumper on

 the white wire (8PD
(8PD - pin B) for more
more than
3
 a few seconds or
or the fuel solenoid will be
 damaged.

1. Index Mark
2. 12 De
Degr
gree
ee BTDC
BTDC Timin
iming
g Mar
Mark
k
3. 10 Deg
Degre
ree
e BTD
BTDCC Tim
Timin
ing
g Mark
Mark
(Tier 1 Engines Only)
AEA633
Figure 186: Timing Mark
Mark Alignment
Alignment
1. Red (8D) 9. Pump
Pump the primi
priming
ng pump
pump by hand
hand a few
few times
times,,
2. White (8DP) or energize the electric fuel pump if an electric
3. Black (CH) fuel pump is being used.
Figure 185: Fuel Solenoid
Solenoid 10. Use a clean
clean towel to wipe the fuel from the top
Connecto
Connectorr Pin Identif
Identificat
ication
ion end of the delivery valve holder.
8. Rotate
Rotate the engine
engine backwa
backwards
rds
1
(counterclockwise viewed from the water
pump end) until the injection timing mark or
marks are positioned in the bottom of the
timing mark access hole (see Figure 186).
186).
Early engines (TK482 and TK486) have one
injection timing mark at 12 degrees BTDC
(before top dead center). The 12 degree BTDC
timing mark is a horizontal line
l ine stamped on
the flywheel approximately 1.2 in. (30 mm)
before the top dead center mark. The TK482
and TK486 are timed at 12 degrees BTDC AEA759
(see Figure 188 on page 9999).
).
1. Delivery Va
Valve Ho
Holder
Figure 187: Injection
Injection Pump
Pump

98
 Fuel System

11. Slowly turn the engine in the normal direction

direction c. On TK48
TK486EH
6EH engine
enginess the
the index
index mark
mark
of rotation until you see the fuel rise in the end should align with the midpoint between
of the delivery valve holder.
holder. Stop as soon as the two timing marks on the flywheel.
f lywheel.
you see the fuel rise slowly.
12. Check position
position of the timing marks. 1
2
a. On TK482
TK482 and TK486
TK486 engine
enginess the
the
injection timing mark on the flywheel
should be aligned with the index mark on
the side of the timing mark access hole.
3

1 2

1. Index Mark
2. 12 De
Degr
gree
ee BTDC
BTDC Timing
ming Ma
Mark
rk
3. 10 De
Degr
gree
ee BTDC
BTDC Timing
ming Ma
Mark
rk
Figure 190: Correct Timing Mark Alignment
Alignment
for TK486
TK486EH
EH
AEA703
13. Repeat
Repeat steps
steps 8 through 12 to
12 to recheck the
1. Index Mark timing.
2. Injection Ma
Mark 14. If the timing is off by more than 1 degree
degree (0.1
Figure 188: Correct Timing
Timing Mark Alignment
Alignment in. [2.5 mm]), loosen the mounting nuts on the
for TK482
TK482 and TK486
TK486 studs that fasten the injection pump to the
engine and rotate the injection pump to change
b. On TK48
TK482E2E and
and TK468E
TK468E engi
engines
nes the 10
10 the timing.
degree BTDC timing mark on the flywheel
should be aligned with the index mark on a. Pull
Pull the top of the
the injec
injectio
tion
n pump
pump away
away
the side of the timing mark access hole. from the engine to advance the timing.
b. Push
Push the top
top of the inje
injecti
ction
on pump
pump towar
toward
d
1 2 the engine to retard the timing.
15. Tighten the injection pump mounting nuts and
and
recheck the timing. Repeat steps 8 through 15
until the timing is correct.
3 16. Install the cover
cover in the timing mark access
hole, install the injection line for the
t he number
one cylinder, tighten the other injection lines,
li nes,
and reconnect the 8S wire to the starter
solenoid when finished with the procedure.

1. Index Mark
2. 12 Degre
egree
e BTDC
BTDC Timin
iming
g Mar
Mark
k
3. 10 Degre
egree
e BTDC
BTDC Timin
iming
g Mar
Mark
k
Figure 189: Correct Timing
Timing Mark Alignment
Alignment
for TK482E and TK468E
TK468E

99
Fuel System

Attaching Injection Pump Gear 1. Find

Find the timin
timing g mark
mark on the
the inject
injection
ion pump
pump
to Flange on Tier 1 Engines gear.
gear. The timing mark is the letter “B”
stamped between two teeth near the edge of
Tier 1 engines have a three-piece injection pump the gear.
gear. It is also marked with a dab of white
gear.
gear. The injection pump gear should not be paint. Remove the transfer pump cam if you
removed from the flange because that changes the are not sure where the timing mark is.i s.
timing. However, if the injection pump gear was
removed from the flange, use the following
procedure to assemble them correctly.

2 1
3
4 1. Dab of White Paint
5 Figure 192: Timing Mark
Mark on Injection Pump
Pump Gear
with Transfer Pump Cam Installed
1
6

1. Fuel In
Injection Pu
Pump
2. Key
3. Flange
4. Injection Pu
Pump Ge
Gear
5. Transfer Pump Cam
6. Nutt (Inj
Nu (Injec
ecti
tion
on Pump
Pump Gear
Gear Asse
Assemb
mbly
ly))
7. Do No
Nott Rem
Remov
ove
e Gea
Gearr Fro
From
m Fla
Flang
nge
e
Figure 191: Three-Piece
Three-Piece Fuel
Fuel Injection
Injection Pump
Pump Gear
1

1. Letter “B”
Figure 193: Timing Mark
Mark on Injection Pump
Pump Gear
without Transfer Pump Cam Installed

100
 Fuel System

2. Place the injection

injection pump gear on the
the flange
flange so 4. Instal
Installl the injec
injection
tion pump
pump gear
gear mount
mounting
ing
the timing mark on the injection pump gear is screws and torque them to 25 ft-lb (34
( 34 N•m).
approximately 180 degrees from the keyway
5. Instal
Installl the tran
transfe
sferr pump
pump cam
cam if it was
was
in the flange.
removed.
3. Center
Center the slots in the flange
flange in the large
large holes
6. Install
Install the
the injectio
injection
n pump
pump gear assembly
assembly on
in the injection pump gear. The slotted
the fuel injection pump. Torque
Torque the mounting
adjustment is used to enable the factory to
nut to 43.4 to 50.6 ft-lb
ft-l b (58.8 to 68.6 N•m).
adjust the timing more rapidly during
The timing marks on the timing gears must be
assembly.
assembly. If the flange and gear are
aligned as shown below with the Number 1
disassembled, the slot is centered in the hole
Cylinder at TDC (Top
(Top Dead Center) of the
and the injection pump must be flow timed.
compression stroke. It helps to install the idler
gear last when aligning the timing marks.
2
1 3

1 2

5
3 4

1. Keyway in Flange AGA110

2. Slot
Slot in
in Flan
Flange
ge Cen
Cente
tere
red
d in Ho
Hole
le in
in Gear
Gear**
1. Fuel Inj
Injec
ecttion Pu
Pump Ge
Gear
3. Dab of White Paint
2. Idler Gear
Figure 194: Flange and Injection
Injection Pump Gear
Gear
3. Camshaft Gear
Alignment with Transfer Pump Cam Installed
4. Crankshaft Gear
5. Oil Pump Gear
2 Figure 196:
196: Timing Mark
Mark Alignment
Alignment

7. Flow
Flow time
time the
the fuel
fuel injec
injection
tion pump.
pump. See
1
“Injection Pump Timing Tier 1 and Earlier
Engines” on page 97.

1. Keyway in Flange
2. Slot
Slot in
in Flan
Flange
ge Cen
Cente
tere
red
d in Ho
Hole
le in
in Gear
Gear**
3. Letter “B”
Figure 195: Flange and Injection
Injection Pump Gear
Alignment without Transfer Pump Cam Installed

101
Fuel System

Injection Pump Timing Tier 2

2
Engines
1
Use this timing procedure when installing a new
injection pump on a Tier 2 engine. It is not 3
necessary to use this timing procedure when
removing and reinstalling the original injection
pump. In that case, align the index marks on the
1. Inde
Index
x Mar
Mark
k on
on Inj
Injec
ecti
tion
on Pump
Pump
injection pump and the gear case as they were
before removing the injection pump. 2. Exis
Existi
ting
ng Inde
Index
x Mar
Mark
k on Gear
Gear Ca
Case
se
3. Make
Make Ne
New
w Mar
Mark
k on
on Gea
Gearr Cas
Case
e If
If Nee
Neede
ded
d
1. Before
Before removin
removingg the
the old
old injectio
injection
n pump,
pump, note
Figure 199:
199: Marking Gear
Gear Case
Case
the alignment of the index marks on the
injection pump and the gear case. The index 2. Clean
Clean the
the area
area with brake
brake clea
cleaner
ner or
or
mark on the injection pump is usually aligned something similar. Place an injection angle
with the index mark on the gear case. If not, sticker on the gear case so the center line on
make a mark on gear case in line with the the sticker is aligned with the index mark on
index mark on the injection pump (see Figure the injection pump. An injection angle sticker
199).
199). is provided with the new injection pump.

1 2

1. Inde
Index
x Mar
Mark
k on
on Inj
Injec
ecti
tion
on Pump
Pump
1
2. Inje
Inject
ctio
ion
n Angl
Angle
e Stick
ticker
er
1. Index Marks Figure 200:
200: Place Injection
Injection
Figure 197:
197: Tier 2 Index
Index Mark Location
Location Angl
Angle
e Stick
ticker
er on Gear
Gear Ca
Casese

0.5 Degrees
1

1 2 1. –1.0 Degrees Mark

2. Cente
enterr Lin
Line
e (0
(0 Deg
Degre
rees
es Ma
Mark
rk))
1. Inde
Index
x Mar
Mark
k on
on Inj
Injec
ecti
tion
on Pum
ump
p
3. + 1. 0 D
De
egrees Ma
Mark
2. Index Mark on Gear
ear Case
Figure 201: Injection
Injection Angle Sticker
Sticker
Figure 198: Tier 2 Index
Index Mark Alignment
Alignment

102
 Fuel System

3. Remov
Removee the old
old injec
injectio
tion
n pump.
pump. Use
Use the
1
injection pump gear tool P/N 204-1011 to
remove the injection pump gear without
removing the timing gear cover (see “Injection
Pump Removal and Installation (All
Engines)”
Engines)” on
on page 105).
105).
 NOTE: Remove the injection
injection pump gear by by
 removing the nutnut and lock washer that
 secure the injection
injection pump gear assembly
assembly to
 the injection pump shaft. The injection
injection pump
 gear assembly
assembly is made of three pieces;
pieces; the
 flange, the gear,
gear, and the transfer
transfer pump cam.
 Do not loosen or remove the four bolts
bolts that
 fasten the gear to the flange because
because that 1. Injec
njecti
tio
on Angl
ngle Mark
 changes the timing.
timing. Figure 203: Injection
Injection Angle Mark Location
Location
1

1
2

1
1
1

1. Injec
njecti
tio
on Angl
ngle Mark
1. Do Not
Not Loo
Loose
sen
n or Re
Remo
move
ve The
These
se Fou
Fourr Bolt
Bolts
s
Figure 204:
204: Injection
Injection Angle Mark
Mark
2. Remo
Remove
ve Nut and
and Loc
Lock
k Was
Washe
herr
Figure 202: Removing
Removing Injection
Injection Pump Gear  NOTE: If you cannot
cannot read the injection angle
angle
 mark, contact
contact Yanmar
Yanmar (e-mail both Koichi
Koichi
4. Record
Record the
the injectio
injection
n angle
angle marked
marked on the old Sawada at koichi_sawada@yanmar
koichi_sawada@yanmar.co.jp.co.jp and
injection pump (see the following  Hisashi Hamada at
photographs). The injection angle mark is  hisashi_hamada@yanmar
 hisashi_hamada@yanmar.co.jp)
.co.jp) with the
located on the side of the pump facing the injection pump serial number or the engine
engine. The injection angle mark on the pump  serial number
number and they will provide
provide the injection
does not use a decimal point. Add a decimal  angle. The injection pump serial number is
point before the last digit of the injection located on the bottom of the sticker on the
angle mark to get the injection angle. The injection pump.
injection angle mark in the following
photographs is 67. That equals an injection
angle of 6.7 degrees.
1
 Examples
Injection An
Angle Ma
Mark Injection An
Angle
67 6.7 Degrees
85 8.5 Degrees

1. Inje
Inject
ctio
ion
n Pum
Pump
p Ser
Seriial Nu
Numb
mber
er
Figure 205: Injection
Injection Pump Serial Number Location
Location

103
Fuel System

5. Record
Record the
the injectio
injection
n angle
angle marked
marked on the
the side
side
1 3
of the new injection pump.
2
6. Calculate
Calculate the injection
injection angle differenc
differencee by
by
subtracting the injection angle of the old
injection pump from the injection angle of the
new injection pump.

Examples
Injection Angle of New
8.5 6.1
Injection Pump (Degrees)
 – Injection Angle of Old 4
 – 6.7 – 6.7
Injection Pump (Degrees)
= Injection
Injection Angle Differen
Difference
ce
= +1
+ 1.8 = –0
– 0.6 1. Fuel
Fuel Inje
Inject
ctio
ion
n Pum
ump
p Gear
Gear
(Degrees)
2. Idler Gear
7. Instal
Installl the new
new injec
injectio
tion
n pump
pump on the
the gear
gear 3. Camshaft Gear
case and position it so the index mark on the 4. Crankshaft Gear
injection pump is aligned with the
t he mark equal
Figure 207: Timing Mark
Mark Alignment
Alignment
to the injection angle difference on the
injection angle sticker (see the following  NOTE: The oil pump is located in the timing
examples). Tighten the injection pump  gear cover on Tier 2 engines. The inner
inner rotor of
mounting nuts when the index mark is aligned  the oil pump fits around
around the crankshaft
crankshaft gear.
gear.
as necessary with the injection angle sticker.
sticker.  Make sure that the flat sides of the inner rotor
 are aligned with the flat sides
sides on the crankshaft
crankshaft
 gear when installing
installing the timing gear cover
cover..
1
1
2
5
3
4

6
1. Inje
Inject
ctio
ion
n Pum
Pump
p Ind
Index
ex Mark
Mark at
at –0.
–0.6
6 Deg
Degree
rees
s
2. Injec
Injecti
tion
on Pump
Pump Inde
Index
x Mar
Mark
k at
at +1.
+1.8
8 Deg
Degree
rees
s
Figure 206: Examples
Examples of Injection Pump
Pump Index
Mark Alignment
Alignment with Injection
Injection Angle Sticker
Sticker
1. Crankshaft Gear
8. Install
Install the injection
injection pump gear,
gear, lock
lock washer
washer,, 2. Oil Pump Cover
and nut. Torque
Torque the nut to 58 to 65 ft-lb (78
( 78 to 3. Outer Rotor
88 N•m). 4. Inner Rotor
 NOTE: If the timing gear cover was removed
removed to 5. Timing Gear Cover
 remove the injection
injection pump gear,
gear, make sure thethe 6. Flat Si
Sides on
on In
Inner
ner Ro
Rotor
 timing marks on the timing gears
gears are aligned
aligned as 7. Flat
Flat Side
Side on Cran
Cranks
ksha
hafft Gea
Gearr
 shown below. It helps to install the idler gear last
last
Figure 208: Align Flat Sides of Crankshaft
Crankshaft Gear
when aligning the timing marks. with Flat Sides of Inner Rotor in Timing Gear Cover

104
 Fuel System

Injection Pump Removal and

Installation (All Engines)
Removal
The injection pump gear will not fit through the
gear housing when removing the injection pump,
the gear must be removed from the pump. Using
tool P/N 204-1011, it will not be necessary to
remove the belts, fuel transfer pump, crankshaft
pulley, or gear case cover. See Figure 213 on page
106.
106. 1 2

1. Note
Note the alig
alignme
nment
nt of the
the index
index marks
marks on
on the 1. Inde
Index
x Mar
Mark
k on
on Inj
Injec
ecti
tion
on Pum
ump
p
injection pump and the gear case. On the 2. Cent
Center
er Inde
Index
x Mar
Mark
k on
on Gea
Gearr Cas
Case
e
Tier 1 engine, the index mark
mark on the injection
injection
Figure 210: Typical Tier
Tier 1 and Earlier
pump is usually aligned with the center (long) Index
Index Ma
Mark
rk Align
Alignmen
mentt
index mark on the gear case. On the Tier 2
engine, the index mark on the injection pump
is usually aligned with the single index mark
on the gear case. If not, mark it so the
injection pump can be returned to the same
position when it is reinstalled.

1. Index Marks
Figure 211:
211: Tier 2 Index Mark Location
Location

1. Index Marks
Figure 209: Tier 1 and Earlier
Earlier Index Mark Location
Location

1 2

1. Inde
Index
x Mar
Mark
k on
on Inj
Injec
ecti
tion
on Pum
ump
p
2. Index Mark on
on Gear Case
Figure 212: Typical Tier
Tier 2 Index Mark Alignment

105
Fuel System

2. Remove
Remove the the starte
starterr for cleara
clearanc
nce,
e, remove
remove 5. Align the threaded
threaded holes in the
the injectio
injection
n pump
pump
throttle linkage, fuel lines, harness and gear with the two holes in the tool plate by
mounting hardware from the injection pump. rotating the engine crankshaft. Attach the gear
to the tool plate with the screws provided with
3. Remove
Remove the
the cover
cover plat
platee from
from the gear
gear case
case
the tool plate.
cover.
cover. Remove the nut and lock washer which
secure the gear to the injection pump shaft. 6. Thread
Thread the
the long
long screw
screw supplied
supplied with the tool
Use a shop rag to prevent the lock washer or plate into the small end of the
t he adapter,
adapter, also
nut from falling into the gear case. supplied with the tool plate. Insert the adapter
into the tool plate and rotate it to provide a
 NOTE: On Tier
Tier 1 and Tier
Tier 2 engines the
solid position to force the injection pump shaft
injection pump gear assembly is made of
from the gear. Caution should be taken to
 three pieces; the flange, the gear,
gear, and the
align the screw over the center of the injection
 transfer pump
pump cam. Do not loosen or remove
pump shaft.
 the four bolts that fasten
fasten the gear to the
 flange because that
that changes the timing. 7. Remove
Remove thethe screw
screw and adapter
adapter leavi
leaving
ng the
the tool
tool
plate in place. This holds the gear in proper
4. Use the hard
hardwar
waree from
from the cove
coverr plate
plate to
tooth alignment until the injection pump is
attach the tool plate (with the
t he marked side
reinstalled.
pointing up and out) to the gear case cover.
cover.

4
2

9 8 7

1. Tier 1 and Earlier Injection Pump 6. Adapter

2. Tier 2 Injection Pump 7. Tool Long Screw
3. Gear Case 8. Tool Short Screw
4. Cover Plate 9. Tool Plate
5. Cover Plate Bolt
Figure 213: Injection
Injection Pump Gear Tool
Tool

106
 Fuel System

Installation
1
1. Positio
Positionn the inje
injecti
ction
on pump
pump shaft
shaft into
into the
injection pump gear, rotating the shaft to mate
the key with the keyway in the gear. Take care
to make sure the key mates with the keyway.
2. Secure
Secure the
the injec
injectio
tion
n pump
pump to the gear
gear case
case
2
with previously removed hardware. Make sure
to align the index marks on the injection pump
and the gear case like they were in step
tep 1 of
“Removal”
“Removal” on on page 105.
105.
 NOTE: If a different injection
injection pump is being 1. Troch
Trochoid
oid Feed Pump
Pump Outl
Outlet
et Pressu
Pressure
re Port
Port
installed, see the appropriate injection pump 2. Troch
rochoi
oid
d Fee
Feed
d Pum
Pump
p
 timing procedure to set the timing.
Figure 214: Trochoid
Trochoid Feed Pump
Pump Location
3. Remov
Removee hardwa
hardware
re holdin
holding
g the gear
gear to the
the tool
If the seal in the trochoid feed pump fails, it could
plate, then remove the tool plate.
allow some fuel to leak into the engine oil. A
4. Secure
Secure the
the gear
gear to the
the injecti
injection
on pump
pump shaft
shaft faulty injection nozzle or fuel transfer pump can
with the lock washer and nut. Use a shop rag, also dilute the engine oil with fuel. Replace the
as before, to prevent the lock washer or nut trochoid feed pump if the engine oil is being
from falling into the gear case. Torque the nut diluted with fuel and a faulty injection nozzle or
to 43 to 51 ft-lb
ft-l b (59 to 69 N•m) on the Tier 1 fuel transfer pump is not the cause. See “Trochoid
or earlier engines, or 58 to 65 ft-lb (78 to Feed Pump Replacement” on page 107.
88 N•m) on the TierTier 2 engines.
engines.
If oil leaks from between the trochoid feed pump
5. Fasten
Fasten cove
coverr plate
plate to gear
gear cas
casee cover
cover and
and and the injection pump, replace the O-rings
reinstall all components removed previously between the trochoid feed pump and the injection
to facilitate injection pump removal. pump. If fuel leaks from the trochoid
t rochoid feed pump,
replace all the O-rings. See “Trochoid Feed Pump
Trochoid Feed Pump Tier 2 O-Ring Replacement” on page 108.
Engines
Trochoid Feed Pump Replacement
The Tier 2 engine has a trochoid feed pump on the
1. Remove
Remove the
the four
four hex
hex head
head screws
screws that
that attach
attach
fuel injection pump. The trochoid feed pump
the trochoid feed pump to the injection pump.
supplies fuel to the injection pump at a pressure of
Do not remove the two Allen head screws.
65 to 87 psi (450 to 600 kPa). Check the outlet
pressure of the trochoid feed pump by removing
the plug and attaching a pressure gauge to the port
shown below.
below. The plug has M12x1.25 threads.
You will have to
t o make an adaptor to
t o attach a
pressure gauge. Replace the trochoid feed pump if
the outlet pressure is below 59 psi (410 kPa) or
above 94 psi (650 kPa).

1 2 1

1. Alle
Allen
n Head
Head Scr
Screw
ews
s (Do
(Do Not
Not Remov
Remove)
e)
2. Hex He
Head Screw
rews
Figure 215: Trochoid
Trochoid Feed Pump
Pump Removal

107
Fuel System

2. Remove
Remove the troc
trochoi
hoid
d feed
feed pump
pump from
from the
the Trochoid Feed Pump O-Ring
injection pump. Replacement
 NOTE: The gear on on the trochoid feed pump 1. Remove
Remove the
the two
two Allen
Allen head
head screws
screws that attach
attach
is lubricated with engine oil. Some engine oil the trochoid feed pump cover to the trochoid
 might leak out of the injection pump when feed pump body. It is not necessary to remove
 the trochoid feed pump
pump is removed. The the Allen head screws if you are not replacing
 trochoid feed pump
pump does not need to be timed the O-ring between the trochoid feed pump
when it is installed.Clean the area on the cover and the trochoid feed pump body.
injection pump from which the trochoid feed
2. Remove
Remove the
the four
four hex head
head screw
screwss that
that attach
attach
 pump was removed.
removed.
the trochoid feed pump to the injection pump.
3. Place
Place new
new O-rings
O-rings on
on the new
new troch
trochoid
oid feed
feed
pump and make sure it is clean.

1 2 1
1
1 1. Alle
Allen
n Hea
Head
d Scr
Screw
ews
s
2. Hex Hea
Head
d Sc
Screw
rews
1. O-Rings Figure 217: Trochoid
Trochoid Feed Pump Removal
Removal
Figure 216: Trochoid
Trochoid Feed Pump
Pump
3. Remove
Remove the
the trocho
trochoid
id feed
feed pump
pump cover
cover from
from
4. Place
Place the
the new
new trocho
trochoid
id feed
feed pump
pump on the the trochoid feed pump body and remove the
injection pump. trochoid feed pump body from the injection
pump.
5. Install
Install and
and tighten
tighten four hex head screws
screws that
that
attach the trochoid feed pump to the injection  NOTE: The gear on the trochoid feed pump
pump. Torque the hex head screws to 6 to is lubricated with engine oil. Some engine oil
7 ft-lb (8
(8 to 10
10 N•m).
N•m).  might leak out of the injection pump when
 the trochoid feed pump is removed. The
 NOTE: The hex head
head screws
screws have
have sealant
sealant on
 trochoid feed pump
pump does not need to be timed
 the threads. The screws can be
be reused once,
once,
when it is installed.Clean the area on the
 but must be replaced
replaced if removed a second
second
injection pump from which the trochoid feed
 time.
 pump was removed.
removed.
4. Place
Place a new O-ring for the
the trochoid
trochoid feed pump
cover on the trochoid feed pump body and
make sure it is clean.

108
 Fuel System

5. Place
Place the
the trochoi
trochoidd feed
feed pump
pump cover
cover on the
the Cold Start Device Tier 2
trochoid feed pump body and install the two Engines
Allen head screws. Torque the Allen head
screws
screws to 6 to 7 ft-lb (8 to 10 N•m).
N•m). The Tier 2 engine has a cold start device located
on the fuel injection pump. The cold start device
 NOTE: The Allen head
head screws have
have sealant has a plunger that retracts at engine coolant
 on the threads. The screws can
can be reused temperature
temperaturess below
below 41 F (5 C) to advanc
advancee the
 once, but must be replaced if removed
removed a injection timing approximately 2 degrees. The
 second time. plunger controls the position of a piston in the
injection pump to change the timing. The plunger
is extended and the injection timing is normal at
engine
engine coolant
coolant tempera
temperatures
tures above
above 41 F (5 C).
Check the operation of the cold start device if it is
difficult to start the engine in cold weather.
weather.
 NOTE: Do not pull the plunger
plunger out of a cold
 start device because that will damage
damage it.
4

3
2
1

5
1
1. Alle
Allen
n Head
ead Screw
crew 1. Plung
lunger
er (Ext
(Exten
ende
ded)
d)
2. Troch
rochoi
oid
d Fee
Feed
d Pum
Pump
p Cov
Cover
er
Figure 219: Cold Start
Start Device
Device
3. O-rings
4. Troch
rochoi
oid
d Fee
Feed
d Pum
Pump
p Bod
Body
y Checking Cold Start Device
5. Hex Head Screw
rew Operation
Figure 218: Trochoid
Trochoid Feed Pump Components
Components Use the following procedure to check the
6. Place
Place the
the new O-rin
O-rings
gs on the
the trocho
trochoid
id feed
feed operation of the cold start device. The engine
pump and make sure it is clean. coolant
coolant tempera
temperature
ture must
must be below
below 32 F (0 C) to
start the procedure.
7. Place
Place the
the trochoi
trochoid
d feed
feed pump
pump on the
the injec
injection
tion
pump. 1. Check
Check the
the coolant
coolant temperature
temperature to make
make sure
sure it
is bel
below
ow 32 F (0 C).
C).
8. Install
Install and
and tighten
tighten four hex head screws
screws that
that
attach the trochoid feed pump to the injection 2. Start
Start the engine,
engine, then
then check
check the engine
engine rpm.
pump. Torque the hex head screws to 6 to The engine rpm should be approximately 100
7 ft-lb (8 to 10 N•m). rpm higher than normal (see Specifications in
unit Maintenance Manual).
 NOTE: The hex head
head screws
screws have
have sealant
sealant on
 the threads. The screws can be reused once,
once,
 but must be replaced
replaced if removed a second
 time.

109
Fuel System

3. Let the
the engi
engine
ne run
run to warm
warm up
up and
and check
check the
coolant temperature and engine rpm. When
the coolant temperature rises above 41
41 F
(5 C), the engine rpm should drop
drop back to 1
normal. Replace the cold start device if the
engine rpm does not drop approximately 100
rpm when the engine warms up.
2

Cold Start Device Replacement

1. Drai
Drain
n the
the engi
engine
ne coo
coola
lant
nt..
2. Remove
Remove the banjo bolt that fastens
fastens the
the engine
engine
coolant fitting to the cold start device. Use a
backup wrench on the cold start device if 1. Cold
Cold Start
art Dev
Devic
ice
e
necessary.
2. Inje
Inject
ctio
ion
nPPum
ump
p Fit
Fitti
ting
ng
Figure 221: Remove Cold
Cold Start
Start Device
1
4. Make
Make sure
sure the pist
piston
on insid
insidee the injec
injectio
tion
n
2 pump fitting is clean.

3
1

1. Banjo Bo
Bolt
2. Engi
Engine
ne Co
Cool
olan
antt Fit
Fitti
ting
ng
3. Cool
Coolant
ant Ho
Hose
ses
s to Col
Cold
d Sta
Start
rt Dev
Devic
ice
e
1. Piston
Figure 220: Remove Engine
Engine Coolant Fitting
Fitting
Figure 222: Clean Piston
3. Remove
Remove the cold
cold star
startt device
device from
from the
the
5. Instal
Installl the new
new cold
cold start
start devic
devicee with a new
new
injection pump fitting. Use a backup wrench
O-ring in the injection pump fitting. Torque
on the injection pump fitting if necessary.
necessary.
the cold start device to 22 to 26 ft-lb (30 to
35 N•m)
N•m)..
6. Install
Install the coolant
coolant fitting
fitting and banjo bolt on the
the
cold start device. Torque the banjo bolt to 16
to 18 ft-lb (22 to 25 N•m).
7. Refill
Refill the
the engine
engine cool
cooling
ing syst
system
em and
and make
make
sure to bleed the air from the cooling system.

110
 Fuel System

Fuel Injection Nozzles b. Each

Each hole
hole in the
the nozzl
nozzlee shoul
should
d form
form a
straight conical spray pattern. The spray
The fuel injection nozzles for Tier 1 and earlier patterns should be uniform and separated
engines are not interchangeable with the fuel by an angle of approximately 150 degrees.
injection nozzles for the Tier 2 engine. The testing
and repair procedures are the same except for the
different opening pressures.

Testing
1. Attach
Attach the
the injectio
injection
n nozzle
nozzle to a nozzle
nozzle tester
tester
(P/N 204-290).
 NOTE: Use only testing fluid or clean
 filtered diesel fuel to test
test injection nozzles.

CAUTION: Keep your hands away from

 the nozzle spray.
spray. The nozzle spray is at AEA698

 such high pressure

pressure that it can break
break the Figure 224: Acceptable
Acceptable Spray Pattern
Pattern
 skin and penetrate
penetrate into the underlying
 tissue. Such an injury is very painful and
and
 can lead to serious
serious complications such
such as
 blood poisoning.

AGA131

Figure 225: Unacceptable

Unacceptable Spray
Spray Pattern

3. Open the press

pressure
ure gauge
gauge valve and check
check the
opening pressure by pushing the hand lever
completely down several times.
a. The inject
injection
ion nozzle
nozzle should
should make
make a
buzzing sound.
b. The open
opening
ing pres
pressur
suree should
should be
be 2,800
2,800 to
3,000 psi (19,600 to 20,600 kPa) for Tier 1
and earlier engines, or 3,100 to 3,300 psi
AGA130 (21,600 to 22,600 kPa) for Tier 2 engines.
c. Adjust
Adjust the
the openi
opening
ng press
pressure
ure by
by changi
changing
ng
the size or number of adjustment shims
Figure 223: Testing Injection
Injection Nozzles
above the spring. See the repair procedure
2. Close the pressu
pressure
re gauge
gauge valve
valve and
and push
push the on page
page 112.
12.
hand lever completely down several times.
a. The inje
injecti
ction
on nozzl
nozzlee should
should make
make a shri
shrill
ll
whistling or buzzing noise.

111
111
Fuel System

4. Leave
Leave the
the pressur
pressuree gauge
gauge valve
valve open
open and
and
check to see if the injection nozzle drips.
Slowly press on the hand lever to bring the
pressure up to 300 psi (2068 kPa) below the
opening pressure of the injection nozzle.
Maintain this pressure for at least 5 seconds. 1
Fuel should not drip from injection nozzle in
less than 5 seconds.
5. Repair
Repair the
the injecti
injection
on nozzl
nozzlee if it fails
fails any
any of
these tests or if fuel leaks out of the return 2
tube during the tests.

Repair
3
1. Clamp
Clamp the
the nozzl
nozzlee body
body in a vise
vise with
with the
nozzle nut up. Use a vise that has aluminum 4
 jaws or jaw covers. 5

2. Loosen
Loosen and remove
remove the nozzle
nozzle nut.
nut. 6

3. Remove
Remove the nozzle
nozzle valve
valve and
and seat
seat set
set from
from the 7
nozzle nut and submerge them in diesel fuel.
Make sure to keep them together as a set. 8
4. Remove
Remove the nozz
nozzle
le body
body from
from the
the vise.
vise.
5. Remove
Remove the spacer
spacer,, pins,
pins, spring
spring seat, spring,
spring,
and adjustment shim(s) from the nozzle 9
holder.
AGA132
6. Inspect
Inspect the spacer
spacer.. Replac
Replacee the spacer
spacer if any
wear or damage is evident. 1. Nozzle Body
2. Adjustment Shims
7. Inspect
Inspect the spring.
spring. Replac
Replacee the spring
spring if it
it is
3. Spring
bent, scratched, or rusted.
4. Spring Seat
8. Use a nozz
nozzle
le clea
cleanin
ning
g tool
tool kit to clea
clean
n the 5. Pin
nozzle valve and seat set.
6. Spacer
a. Clean
Clean the
the carb
carbon
on off
off the
the outsi
outside
de of
of the 7. Nozzle Valve
nozzle seat with a cloth and solvent. 8. Nozzle Seat
b. Clean
Clean the
the inside
inside of
of the nozz
nozzle
le with
with the
the 9. Nozzle Nut
cleaning tools and solvent. Figure 226: Injection
Injection Nozzle Assembly
Assembly
c. Thorou
Thoroughl
ghlyy rinse
rinse the nozzl
nozzlee seat
seat and valve
valve 9. Test the
the nozz
nozzle
le valve
valve and
and seat
seat set.
set.
with cleaning spray and submerge them
separately in diesel fuel. a. Place
Place the
the nozzl
nozzlee valve
valve in
in the nozzl
nozzlee seat
seat
while holding the nozzle seat in a vertical
position.
b. Pull
Pull the noz
nozzle
zle valv
valvee about
about one
one third
third of the
the
way out of the nozzle seat.

112
 Fuel System

Fuel Return Line Replacement

In November of 2003 the fuel return lines
li nes (hoses)
on TK486E and TK486EH engines were
upgraded with a new hose material featuring a
Viton inner liner. Viton is highly resistant to the
additives that are currently used in diesel fuel
systems. Units built after unit serial number
AGA133
103XXXXXXX use fuel return lines that contain
the new material. The new fuel return lines start at
Figure 227: Testing Nozzle Valve
Valve and Seat Set engine serial number L77626 for the TK486E,
and L78616 for the TK486EH. The new fuel
c. Relea
Release
se the
the nozzle
nozzle valv
valve.
e. The
The nozzle
nozzle valv
valvee return lines look similar to those used previously,
should slide into the nozzle seat by itself. so identification must be done by unit or engine
d. Rotate
Rotate the
the nozzl
nozzlee valve
valve in the
the nozzle
nozzle seat
seat serial number. Units built before the serial number
about 90 degrees at a time, and repeat this above use the original hose material, units built
test four or five times. after that number contain Viton. Thermo King
recommends that fuel return lines
l ines be changed
e. Replac
Replacee the nozz
nozzle
le valve
valve and
and seat
seat set
set if the
the every 10,000 engine operating hours in all units
nozzle valve does not slide smoothly into equipped with the new Viton-lined hoses. Units
the nozzle seat. built before that date should have their fuel return
 NOTE: A new nozzle
nozzle valve and seat
seat set lines changed at 5,000 engine operating hours.
 should be thoroughly
thoroughly cleaned and tested
Fuel Return Line
 before being installed.
installed.
Replacement TK482/486 Engine Units
10. Clamp the nozzle
nozzle body in a vise with the Interval
nozzle nut end up. 5,000 Hours Original lines on units built before
October 2003
11. Place the adjustment
adjustment shim(s) in the nozzle
nozzle 10,000 Hours Lines on units built before
body.
body. If the opening pressure needs to be October 2003 that have had kit
adjusted, change the shims as required. Add P/N 10-368 installed
shims or replace the present shim with a larger 10,000 Hours All units built in October 2003
one to increase the opening pressure. Remove and later
shims or replace the present shim with a
smaller one to decrease the opening pressure. The return line kit (P/N 10-368) contains new
return lines, clamps, an end cap, and a decal like
12. Place the spring,
spring, spring seat,
seat, and pins
pins in the the one shown below. This decal is was added to
nozzle body. production units in January of 2005. The decal is
13. Place the spacer
spacer over the pins and check the located near the unit serial plate. The date and
alignment. engine hours must be entered on the decal when
the fuel return lines are changed.
14. Place the nozzle valve
valve and seat set
set on the pins
and check the alignment.
15. Install the nozzle
nozzle nut and torque it to 29
29 to
33 ft-lb (39
(39 to 44
44 N•m).
N•m).
16. Test the injection nozzle
nozzle and adjust the Figure 228: Fuel Return
Return Line Replacement
Replacement Decal
opening pressure as necessary.

113
Fuel System

Use the following procedure to replace the fuel Fuel Transfer Pump
return lines and end cap.
1. Remove
Remove the clamps,
clamps, the
the end
end cap,
cap, the
the short
short fuel
fuel Fuel Transfer Pump Operation
return lines between the injection nozzles, and The fuel transfer pump is driven by a cam on the
the long fuel return line from the injection fuel injection pump gear. The cam actuates the
nozzle to the banjo fitting on the
t he injection piston through the tappet assembly and push rod.
pump. Fuel is forced through the outlet check valve to
the area behind the piston when the cam moves
1
towards the piston and compresses the spring. The
3 inlet check valve closes to prevent fuel from
2
flowing back through the inlet.

2
3

4 1

3
3

5 4

3
1. Piston 3. Outlet Check Valve
1. End Cap 4. Short Fuel Return Lines 2. Cam 4. Inlet Check Valve
2. Larger Clamp 5. Long Fuel Return Lines Figure 230: Outlet Stroke
3. Smaller Cl
Clamps
The spring pushes the piston towards the cam
Figure 229: Fuel Return Line
Line Replacement
Replacement when the cam moves away from the piston. This
2. Discar
Discardd the old
old clamp
clamps,
s, end
end cap,
cap, and fuel
fuel draws fuel through the inlet check valve and
return lines. forces fuel out of the outlet. The outlet check
valve closes to prevent fuel from flowing back
3. Install
Install the
the end
end cap
cap and
and clamp.
clamp. Note that the behind the piston.
end cap has a larger OD than the other hoses
and requires the larger clamp.
2
4. Install
Install the
the fuel
fuel return
return lines and clamps.
clamps. ItIt may
be necessary to adjust the banjo fitting
fitt ing slightly
to obtain the straightest routing for the long 1
return line.
5. Be sure
sure all
all the fittings
fittings are
are tight
tight and check
check for 3
leaks.
6. Write
Write the
the date
date and
and engine
engine hours on the
the decal.
decal. 4

AGA136

1. Piston 3. Outlet Check Valve

2. Cam 4. Inlet Check Valve
Figure 231: Inlet and Delivery
Delivery Stroke
Stroke

114
 Fuel System

When the fuel pressure at the outlet is

i s more than Testing
approximately 7 psi (48 kPa), it stops the spring
1. Instal
Installl the fuel
fuel tran
transfe
sferr pump
pump if it was
was
from pushing the piston back toward the cam.
removed for inspection.
This prevents fuel from being forced out of the
t he
outlet. When the pressure drops, operation 2. Disconnec
Disconnectt the fuel solenoid
solenoid wire connector
connector..
resumes. This limits the outlet fuel pressure to
3. Disconnec
Disconnectt the inlet and outlet
outlet fuel
fuel lines
lines from
from
approximately 7 psi (48 kPa).
the fuel transfer pump.

2 4. Attach
Attach a fuel
fuel hose about
about 6 feet
feet (2
(2 meters)
meters) long
to the inlet fitting on the fuel transfer pump.
5. Position
Position a container
container of diesel
diesel fuel about
about 3 feet
1 (1 meter) below the level of the fuel transfer
pump, and place the end of the inlet hose in
3 the diesel fuel.
6. Attach
Attach a fuel
fuel hose
hose to the
the outlet
outlet fittin
fitting
g on the
the
fuel transfer pump and place the end of this
4 hose in a bucket or can.
AGA137
7. Turn
Turn the engine
engine over
over with
with the starter
starter. The fuel
transfer pump should pump fuel out of the
1. Piston 3. Outlet Check Valve outlet within 60 revolutions of the engine, and
2. Cam 4. Inlet Check Valve there should be a good flow of solid fuel
coming out of the pump. Repair or replace the
Figure 232: Pressure Controlled
Controlled Delivery
Delivery Stroke
fuel transfer pump if more than
t han 120
revolutions of the engine are required to pump
Inspection fuel through the pump.

Refer to Figure 233 on page 116.

116. You can also use a compound gauge to check a
fuel transfer pump.
1. Remov
Removee and insp
inspec
ectt the check
check valv
valves
es and
and
check valve springs. Replace any that are 1. Install
Install a block off fitting on the
the fuel
fuel transfer
transfer
worn or damaged and reassemble the check pump inlet with a compound gauge attached.
valves. Crank the engine and check the gauge reading.
The compound gauge should show vacuum of
2. Remov
Removee the trans
transfer
fer pump
pump from
from the
the gear
gear case
case at least a 10 in. (-34 kPa).
cover.
2. Install
Install a block off fitting on the
the fuel
fuel transfer
transfer
3. Carefu
Carefully
lly remov
removee the retai
retainer
ner.. It is under
under pump outlet with a compound gauge attached.
spring pressure. Crank the engine and check the gauge reading.
4. Remove
Remove and inspect
inspect the
the spring
spring and
and piston.
piston. The compound gauge should show a pressure
Replace the spring if it is worn or damaged. of at least 7 psi (48 kPa).
Replace the transfer pump if the piston or 3. If either
either of
of these
these pressu
pressure
re checks
checks is incorre
incorrect,
ct,
pump body is damaged or worn. the problem is usually caused by one of the
5. Reassemb
Reassemble
le the
the piston
piston,, spring,
spring, and retainer
retainer.. check valves.

6. Press
Press on the tappet
tappet and release
release it. Repeat
Repeat this
this a
few times. Check to see that the tappet moves
in and out of the pump body smoothly without
sticking or binding. Replace the transfer pump
if the tappet sticks or binds.

115
Fuel System

4 5

3
2

2 3 AGA134
8

9
10

1. Priming Pump 6. Pump Body

2. Check Valve Spring 7. Push Rod
3. Check Valve 8. Piston
4. Inlet Strainer (P
(Prefilter) 9. Spring
5. Tappet Assembly 10. Retainer
Figure 233: Fuel Transfer
Transfer Pump
Pump

116
 Fuel System

10

8
11

6
7

12

3
2

1. Fuel Tank 7. Fuel Injection Pump

2. Supply from Fu
Fuel Tank to Fu
Fuel Transfer Pu
Pump 8. Fuel Injection Nozzle
3. Fuel Transfer Pump 9. Return from Injection Nozzles to Injection Pump
4. Suppl
upply
y ffro
rom
m Fue
Fuell Tra
Trans
nsfe
ferr Pum
Pump
p to
to Fue
Fuell Fil
Filte
terr 10.
10. Retu
Return
rn from
from Inj
Injecti
ection
on Pump
Pump to Fuel
Fuel Filt
Filter
er
5. Fuel Filter Assembly 11. Relief Valve
6. Suppl
upply
y fro
from
m Fue
Fuell Fil
Filte
terr to
to Fue
Fuell Inj
Injec
ecti
tion
on Pum
ump
p 12.
12. Retur
eturn
n fro
from
m Fue
Fuell Fil
Filte
terr to
to Fue
Fuell Tan
Tank
k
Figure 234:
234: Fuel System
System Diagram
Diagram

117
Fuel System

Fuel System Operation and If either of these pressure checks is incorrect, the
Diagnosis problem is usually caused by one of the check
valves.
The following section discusses some
characteristics of the fuel system and some things You can also check the transfer pump by cranking
to consider when troubleshooting the fuel system. the engine with the outlet line placed in a bucket
or can. There should be a good flow of solid fuel
Normal Fuel System Operation coming out of the pump when the engine is
cranked.
The transfer pump creates a vacuum in the supply
line and the atmospheric pressure in the tank Fuel Filter Assembly
pushes the fuel up the pickup tube and into the
3/8 in. plastic fuel supply line and
and on to the
the unit in The fuel filter assembly removes air, removes
the front of the trailer. It may travel directly to the water, and filters the fuel. There are four openings
transfer pump, or in later units, to fittings located on the filter housing; the inlet for fuel from the
at the bottom of the unit. These bulkhead fittings transfer pump, the outlet for clean fuel tot o the
were added so that the routing of fuel lines was injection pump, the inlet for fuel returning from
done at the factory and would be standardized on the injection pump and nozzles, and the outlet that
all units. The pressure in the pickup line should returns air, water, and excess fuel to the fuel tank.
always be negative when the engine is running. It 3
will be negative or at atmospheric pressure when 5 7
the engine is off. 2
4
Fuel Transfer Pump
1
The piston in the fuel transfer pump is driven by a
cam located on the front of the injection
i njection pump
gear.
gear. A return
r eturn spring pushes the piston back out
against the cam. There are two check valves. One
is the inlet valve and the other is the outlet valve.
See “Fuel Transfer
Transfer Pump Operation” on on page 114
for a detailed description of the operation.
The important thing to remember is that iti t is not a
positive displacement pump and the outlet
pressure is limited to approximately 7 psi
(48 kPa). It is not
not the cam pushing
pushing on the
the piston,
but the spring pushing the piston back against the
cam that forces fuel out of the transfer pump.
You can use a compound gauge to check
che ck a transfer
pump.
6
• Instal
Installl a block
block off
off fitti
fitting
ng on the transf
transfer
er pump
pump
1. Inle
Inlett from
from Trans
ransffer Pump
Pump
inlet with a compound gauge attached. Crank
the engine and check the gauge reading.
r eading. The 2. Outlet
tlet to Inj
Injec
ecttion Pump
compound gauge should show vacuum of at 3. Inlet
Inlet for Re
Retu
turn
rn from
from Inj
Injec
ecti
tion
on Pump
Pump and
least a 10 in. (-34 kPa). Nozzles
4. Outl
Outlet
et for
for Re
Retu
turn
rn to Fuel
Fuel Tank
ank
• Instal
Installl a block
block off
off fitti
fitting
ng on the transf
transfer
er pump
pump
5. Air Outlet Hole
outlet with a compound gauge attached. Crank
the engine and check the gauge reading.
r eading. The 6. Water
ater Pic
Pickup
kup Tube
ube Inle
Inlett
compound gauge should show a pressure of at 7. Water
ater Outl
Outlet
et (Ble
(Bleed
ed)) Hol
Hole
e
least 7 psi (48 kPa). Figure 235:
235: Fuel Filter
Filter Assembly
Assembly

118
 Fuel System

First, the air is removed. As the fuel is pushed in
to the filter assembly, any air in the fuel rises to
the top. There is a small outlet hole drilled in the
top of the assembly that allows air out into the
return fuel passage where it returns to the fuel
f uel
tank with the return fuel. There is a limit to the
amount of air that can flow through the outlet
hole, and eventually the engine will stop if enough
air passes through the filter assembly to the
injection pump. The small bleed hole also causes
a small drop in fuel pressure as it bleeds off air
and fuel. Under normal conditions there is plenty
of extra flow and the small reduction of flow (and
pressure) isn't significant.
Next, the water is removed. The filter media
contains a coating that attracts water. It is called
coalescing media. The water builds up on the
coalescing media and forms drops that fall to the
bottom of the filter can. The Thermo King filter
has a patented system to remove the water that
collects at the bottom of the filter. The filter has a
long rubber tube that extends almost to the
bottom. The tube is sealed to the small metal pipe
that protrudes down through the filter spud. The
pipe is screwed into the filter housing. There is a
small (0.030 in.) bleed hole drilled from the
passage the pipe is screwed into up into the return
fuel passage in the filter head. The water is pushed
up the rubber tube, through the pipe and bleed
hole into the return fuel passage because
because the
pressure in the return fuel passage is lower than
the pressure in the filter. This also causes a small
drop in fuel pressure as it bleeds off water and
fuel.
The second thing to be aware of is that the
pressure drop is proportional to the amount of dirt
the filter has trapped in the media. If there is a lot
of dirt, there is a lot of restriction, and more of a
pressure drop. As the dirt builds up, the outlet
pressure keeps dropping, and eventually the
engine dies. The outlet pressure from the fuel
filter is a good measurement of how clogged the
filter is.
Injection Pump
Tier 1 and Earlier Engines
On Tier 1 and earlier engines, the clean fuel enters
the injection pump at the fitting farthest from the
gear end of the pump. It then travels
tr avels in the pump
gallery and provides fuel to each plunger.
plunger. The
transfer pump provides more fuel than the engine
needs so a return outlet port is
i s provided at the gear
end of the pump. Yanmar found that a problem
called cavitation could occur in the pump gallery
if the internal pressure in the pump falls below
5 psi (34 kPa). Cavitation can damage
damage the
plungers. To prevent cavitation, Yanmar put a
5-psi (34-kPa) relief valve in the injection pump
return outlet on units built before 1999. The relief
valve will not open until the fuel
f uel pressure rises
above 5 psi (34 kPa). That protects the injection
pump. Unfortunately, it can also cause some
problems that are discussed later in this section.
1
2

As the air and water are being removed, fuel is

also being forced through the filter media. The
fuel is now free of air, water,
water, and dirt. It then
travels to the injection pump. However, there are
still some things to consider.
The first is that there will be a pressure drop
through the filter media and the outlet pressure to
the injection pump is a few psi (or kPa) less than
the outlet pressure from the transfer pump.

1. Inle
Inlett from
from Trans
ransfe
ferr Pum
ump
p
2. Retu
Return
rn Out
Outle
lett to Fue
Fuell Filt
Filter
er Ass
Assem
embl
bly
y
Figure 236: Tier 1 and Earlier
Earlier Injection Pump
Pump

119
Fuel System

Tier 2 Engines takes the return fuel from the injection pump and
injection nozzles and transfers it to the return fuel
On Tier 2 engines, the clean fuel enters the
outlet in the filter head. The air and water bleed
injection pump at the fitting on the side of the
ports also empty into this passage so this
pump farthest from the engine. The injection
combines all the fuel, air, and water returning to
pump on the Tier 2 engine has a trochoid feed
the fuel tank. The long length of the 1/4 in. return
pump that supplies fuel to the pump gallery at a
line going back to the fuel tank acts as a natural
pressure of 65 to 87 psi (450 to 600 kPa). The Tier
restriction and usually holds a pressure of 3 to
2 injection pump has only one plunger called a
5 psi (21 to 34 kPa) in the return system. You
You will
mono-plunger. The mono-plunger and a
usually see a pressure of about 5 psi (34 kPa) in
distributor head are used instead of individual
the return line between the fuel injection pump
plungers. This design is less likely
l ikely to experience
and the fuel filter head. As long
l ong as the engine is
cavitation. The return outlet is located on side of
running this system functions well, however,
however,
the injection pump nearest the engine and does
when the engine is shut off some things can
not have a relief valve.
happen that can cause the engine to be hard
2 starting.
1
Static Pressures
When the engine is shut off the return fuel that is
in the return line wants to
t o drain back down into
the tank. To do that the drain-back fuel would
need to be replaced with air pulled into the system
or fuel pulled from the system. When the engine
stops there is positive pressure in the fuel system.
This pressure closes the inlet check valve in the
transfer pump. As long as the pressure in the
system stays positive, the inlet check valve stays
closed. The fuel in the supply line also tries toto
1. Inle
Inlett from
from Trans
ransfe
ferr Pump
Pump drain back and it helps keep the inlet check valve
2. Retu
Return
rn Out
Outle
lett to Fue
Fuell Filt
Filter
er Ass
Assem
embl
bly
y
closed. If there is no air and there is no fuel to
replace the drain-back fuel, a vacuum starts to
Figure 237: Tier 2 Injection
Injection Pump
Pump
form in the system. The air and water bleed holes
in the filter head connect the pressure (supply
Return System (All Engines)
side) of the system to the return side of the
t he system
There are three sources of return fuel that goes so when the vacuum occurs, it occurs throughout
back to the fuel tank: the whole system, right to the inlet check valve in
the transfer pump. If there are no air leaks in the
• Exce
Excess
ss fuel
fuel from
from the
the inje
inject
ctio
ion
n pum
pump.
p.
system, it will stay like this until the engine is
• Fuel
Fuel tha
thatt leak
leakss from
from the
the inj
injec
ectio
tion
n nozz
nozzle
les.
s. started again. There is no air so the engine starts
easily.
• Fuel
Fuel tha
thatt is bled
bled thr
throu
ough
gh the
the air
air and
and wat
water
er
bleed ports in the filter housing.
The excess fuel from the injection pump and the
leakage fuel from the injection nozzles are
combined at a fitting on the outlet of the injection
pump. This is located after the relief valve in the
early units. The combined return fuel from the
injection pump and injection nozzles travels
through a return line to the return passage in fuel
filter head. The return passage in the filter head

120
 Fuel System

Static Air Leaks Tier 1 and Earlier This relief valve has been installed on production
Engines units since 1999 and many units have been
retrofitted with kit P/N 10-342.
There are two places where air can leak into the
t he
static fuel system: This solution provides a positive way to keep
5 psi (34 kPa) in the injection pump when the
• One
One is the
the thro
throug
ugh
h the
the plu
plung
nger
erss in the
the
engine is running to answer Yanmar's
injection pump. It leaks from the pump
requirement, and prevents a vacuum from forming
camshaft and lifter area around the plungers
in the fuel system when the engine is off.
and into the fuel galley in the pump. Over the
years the plunger clearances have been  NOTE: YouYou must remove the original Yanmar
Yanmar
reduced to try to prevent air leaks.  relief valve from the injection pump when
installing kit P/N 10-342. If not, it will take a
• The
The oth
other
er is anyw
anywhe
here
re else
else..
 pressure of at
at least 10 psi (69 kPa)
kPa) to overcome
If air is leaking through the plungers the engine  the relief valves. This will make it much harder
harder
will not start, not even try to fire because the air is  to prime the system
system with the hand pump.
in the injection pump.
FAQ (Frequently Asked
A sked Questions)
If the air is getting in anywhere else, it will end up
in the fuel filter and the engine will start, run for a If the unit is leaking
l eaking air when it’s off, why
few seconds, and then die. In this case you may doesn't it leak fuel when it runs?
see an Alarm Code 63 on a unit with
wit h a
It is probably a matter of time and size. Most of
microprocessor.
the hard starting problems caused by air take a
long engine off period, usually days or weeks,
Solution for Static Air Leaks indicating they are extremely small. It could be
Understanding the problem helped find a solution. that the fuel boils off a warm engine before it is
The vacuum cannot be stopped from forming in even seen.
return line. The air leakage at the injection
i njection pump
Why can't I find the leaks when I pressurize
plungers can be minimized, but not stopped. The
the fuel system?
solution was to stop the vacuum from forming in
the whole system by moving the 5-psi (34-kPa) Again, it is time and size. If
I f you pressurize the
relief valve from the outlet of the injection pump fuel tank, do not go over 5 to 10 psi (34 to 69
to the return fuel outlet in the fuel filter head. kPa). Never pressurize a fuel system without a
relief valve in the supply regulator set at 10 psi
 NOTE: Even though it is often often called a check
check
[69 kPa] maximum. A leak that pulls in 50 cc of
valve, it functions as a relief valve, not a check
air in a week (enough to affect starting) is going to
valve. A check valve would close when return
take hours or days to show under pressure.
 fuel tried to go to the tank. This
This functions a 5-psi
(34-kPa) relief valve. When the return fuel How can I check the
t he fuel return relief valve?
 pressure reaches
reaches 3 to 5 psi
psi (21 to 34 kPa), the
Probably the quickest way is to replace it. If that
 spring in the relief valve
valve allows the piston to
fixes it, then that was the problem. If not, it means
 retract, which allows the return fuel to flow back
it is something else, or you have another faulty
 to the fuel tank. When
When the engine stops,
stops, the
relief valve.
 spring pushes the piston closed and and traps a
 positive pressure
pressure in the fuel system. The relief The only sure way of checking a relief valve is to
valve is not always a perfect seal, but as the take a clear hose at least 8 ft (2.4 m) long and
 pressure side drops from leakage,
leakage, the spring immerse it in water or fuel. Make sure the hose
 pushes the piston closed tighter.
tighter. By the time the fills completely with liquid. Keep the hose
 pressure reaches
reaches zero, the piston is usually immersed and insert the outlet end of the valve
 completely sealed. into the hose. Slowly raise the valve out of the
liquid with the hose following it. The liquid
should not drop out of the hose. Raise the valve
8 ft (2.4 m) in the air and keep
keep the other end
end of the

121
Fuel System

hose in the container of liquid. Fasten the valve at Using Clear Fuel Lines To Diagnose
the 8 ft (2.4 m) level. Watch
Watch it to see how long it Problems
holds fluid. It should hold for an hour or more.
To use clear fuel
f uel lines most effectively use the
t he
That why it is probably quicker to replace relief
following lines and gauges.
valve if there is a problem.
1. Remove
Remove thethe suppl
supply
y line
line from the
the fuel
fuel tank
tank at
How do I know if air is leaking through the
the transfer pump. Add on about two or three t hree
injection pump plungers?
feet of clear line and attach it to the inlet of the
If the engine does not fire at all, it is probably air transfer pump. This allows you to se if the fuel
leaking through the injection pump plungers. If drops down after the engine stops. If it does,
the engine starts, runs a little, and then and dies, either the transfer pump inlet check valve is
the air is in the fuel filter and the leak is not working, or air is being pulled in at the
somewhere other than the injection pump. Use banjo fitting. You do not normally need a
clear fuel lines to confirm the problem if it is not gauge at this point. This line is usually in a
obvious. vacuum when the engine is off or running.
What can I do if air is leaking through the 2. Instal
Installl a clear
clear line
line from
from the trans
transfer
fer pump
pump
injection pump plungers? outlet to the fuel filter
filt er.. It should have a
compound gauge in the middle of it. This line
Newer injection pumps, built in 2000 or later,
allows you to see air coming from the tank
rarely leak through the plungers. The best thing to
fittings, supply line, or transfer pump fittings.
do is to make sure the relief valve is functioning
The gauge shows the outlet pressure of
so the system will not go into a vacuum when the
transfer pump.
engine is not running.
3. Install
Install a clear line from the fuel
fuel filter
filter outlet
outlet to
What if there
t here is air coming from somewhere
the injection pump. A compound gauge is
else and I just cannot find it?
optional. This line allows you to see fuel
f uel come
The best thing to do is to make sure the relief from the fuel filter to the injection pump when
valve is functioning so the system will not go into the engine starts. If a gauge is used it should
a vacuum when the engine is not running. The show a pressure a couple psi (or kPa) lower
system usually does not leak air if it does not go than the fuel filter inlet pressure because of
into a vacuum. Occasionally,
Occasionally, changing the whole drop from the filter.
filter head has stopped an air leak. It may have
4. Install
Install a clear line from the return outlet
outlet of the
been porosity in the fuel filter head casting, or it
injection pump to the fuel filter head. A gauge
may have been a fitting. That would be a last
is optional. This line allows you to see air that
resort. Pressurizing the system for 24 hours, if
comes from the pump when the engine starts.
possible, may show a small leak. Use clear fuel
The gauge should show the 3 to 5 psi (21 to
lines fuel lines and pressure gauges to diagnose
34 kPa) of return line back pressure.
pressure.
problems that are difficult to find.
5. You can
can also
also add a foot
foot or two
two of clear
clear line
line to
Why doesn't other diesel-powered equipment
the return line right after the relief valve. A
have air leakage problems when they are off?
gauge is optional. About the only thing to see
Refrigeration units on trailers are one of the few in this line is that if the relief valve leaks, you
pieces of equipment that mount the fuel tank so will see the air form as the return fuel drops to
far below the engine. the fuel tank. A gauge would show the
vacuum form and then disappear as the fuel
system allows air in.
By observing the formation and travel of air and
the gauge pressures, along with some basic
knowledge of the fuel system, you should be able
to diagnose and repair most problems.

122
Electrical

Battery Cables
Units with Tier 2 engines typically use 0-gauge
battery cables to ensure reliable starting in
extremely cold weather. Units with Tier 1 and
earlier engines typically use 2-gauge negative
battery cables and 4-gauge positive battery cables.
Make sure to use the
t he 0-gauge battery cables when
replacing the battery cables for a Tier 2 engine.
Refer to the unit Parts Manual for
f or the correct part
numbers. Do not use the 0-gauge battery cables on
Tier 1 and earlier engines because the battery
cables are sized to match the starter performance.
Figure 238: Tier 1 and Earlier
Earlier Starter
Starter
Cold Weather Battery
Recommendation for Tier 2
Engines
Thermo King recommends that units with Tier 2
engines be equipped with a 950 CCA (cold
cranking amp) battery for operation at
temperatures below -15 F (-26 C).

Starter
The Tier 1 and earlier engines and Tier 2 engines
use different starters. The Tier 2 engine has a
more powerful starter to ensure reliable starting in
extremely cold weather. Identify the starters by
looking at the through bolts. The Tier 2 starter has 1
external through bolts, but the Tier 1 starter does
1. Extern
ernal Thro
hrough Bolt
not.
Figure 239:
239: Tier 2 Starter
Starter
Other than the through bolts, the basic design is
the same. Therefore, except where noted, the
t he
service procedures are the same.
Do not try to put a Tier
Tier 1 starter on a Tier
Tier 2
engine. The Tier 1 starter does not fit on the Tier 2
engine because it is too long. The Tier 2 starter
does fit on the Tier 1 engine. The Tier 2 starter
requires heavier battery cables (see “Battery
Cables” above).
Cables” above).

123
Electrical

TK482/TK486 Starters Not

Interchangeable with di2.2/se2.2
Starters
The starters for Yanmar TK482/TK486 engines
are not interchangeable with starters for Isuzu
di2.2/se2.2 engines. Although the starters will fit,
the diameter of the pinion gear is different:
• Star
Starte
ters
rs for
for TK4
TK482
82/T
/TK4
K486
86 eng
engin
ines
es hav
havee a
1.38 in. (35.1 mm) diameter pinion gear.
• Starte
Starters
rs for
for di2.
di2.2/s
2/se2
e2.2
.2 engi
engines
nes have
have a 1.25
1.25 in.
in.
(31.8 mm) diameter pinion gear.
If the wrong starter is installed, the pinion will not
mesh properly with the ring gear on the flywheel,
fl ywheel,
resulting in failure of both the
t he ring gear and the
starter.

1. Pini
Pinion
on Gea
Gearr Diam
Diamet
eter
er 1.2
1.25
5 in.
in. (31.
(31.8
8 mm)
mm)
Figure 241: di2.2/se2.2
di2.2/se2.2 Starter
Starter

1. Pini
Pinion
on Gea
Gearr Diam
Diamet
eter
er 1.3
1.38
8 in.
in. (35.
(35.1
1 mm)
mm)
Figure 240: TK482/TK486
TK482/TK486 Starter
Starter
(Tie
(Tierr 1 and
and Earl
Earlie
ierr Show
Shown)
n)

124
 Electrical

Description
The major components of the starter are the starter 2
motor, the starter solenoid, and the pinion 1
assembly.
assembly. The starter motor turns the pinion
pini on
assembly with a small gear on the end of the 3
armature. 4
5
2
1

3
4 AGA138
7 6
5

1. Heavy Du
Duty Co
Contacts
2. Starter Solenoid
3. Shift Lever
4. Pinion Assembly
AGA139
7 6 5. Pinion Gear
6. Ring Gear

1. Heavy Du
Duty Co
Contacts 7. Starter Motor

2. Starter Solenoid Figure 243: Energized

Energized Starter
Starter

3. Shift Lever
Disassembly
4. Pinion Assembly
5. Pinion Gear 1. Disconnec
Disconnectt the stator
stator lead
lead from
from the M terminal
terminal
on the starter solenoid.
6. Ring Gear
7. Starter Motor 2. Remove
Remove the two
two 4x10
4x10 mm
mm screws
screws from
from the
Figure 242: De-energized
De-energized Starter
Starter
rear cover. These screws fasten the brush
holder assembly to the rear
r ear cover.
When the starter solenoid is energized, it
energizes the starter motor through a set of heavy 3. Remove
Remove the
the two
two through
through bolt
boltss from the
the rear
rear
duty contacts. When the starter solenoid is cover and remove the rear cover from the
energized, it also pulls the shift lever.
lever. This extends starter motor.
motor.
the pinion gear to engage the ring gear on the t he 4. Place the brush springs
springs on
on the
the sides
sides of the
the
engine’s
engine’s flywheel. The pinion assembly includes brush holders.
an overrunning clutch that allows the pinion gear
to turn freely if the engine is turning faster than 5. Remove
Remove the
the positi
positive
ve brushes
brushes (the brushes
brushes
the starter while the starter is energized. connected to the stator) from the brush
holders.

125
Electrical

10

11
8
7 12
6 13
5
4 14

15

3
2 16
1 17

18

19

20

AGA140 21

1. Pinion Shaft 12 . Shims

2. 5x16 mm Screw 13 . Plunger
3. Pinion Assembly Retainer 14 . Shift Lever Spring
4. Clutch 15 . Shift Lever
5. Pinion Return Spring 16. 4x10 mm Screw
6. Stop Ring 17. Through Bolt
7. Snap Ring 18 . Rear Cover
8. 6x35 mm Bolt 19 . Brush Ring
9. Gear Housing 20. Stator
10 . Dust Cover 21 . Armature
11. Start
tarter
er Sole
Soleno
noid
id
Figure 244:
244: Starter
Starter Assembly
Assembly

126
 Electrical

6. Pull
Pull the negat
negative
ive brus
brushe
hess (the brus
brushes
hes
connected to the brush holder assembly) part
way out of the brush holders and place the
brush springs on top of the brush holders
against the sides of brushes. This is called the
locked position and it holds the brushes in
place off the commutator.
7. Remov
Removee the brus
brush
h holder
holder asse
assembl
mbly
y from
from the
AEA370
commutator.
8. Remove
Remove the
the armatur
armaturee and
and stator
stator from the gear
housing.
9. Remove
Remove the
the armat
armature
ure from
from the
the stator
stator.. Figure 245:
245: Check Brush
Brush Holders
Holders
10. Remove the two 6x35 mm bolts that fasten the
starter solenoid to the gear housing.
11. Remove the starter solenoid, shims, shift lever
spring, shift lever, and dust cover from the
gear housing.
12. Remove the three 5x16 mm screws from the
pinion assembly retainer and remove the
pinion assembly from the gear housing.
AEA371

Major Component Inspection

Starter Motor
Figure 246: Measure Brushes
1. Check
Check the
the brus
brush
h ring
ring asse
assembl
mbly
y.
c. Check
Check the
the brus
brushh sprin
springs.
gs. Replac
Replacee the
the
a. Check
Check the brush
brush holde
holders
rs with an
brush springs if they are discolored,
ohmmeter.
ohmmeter. The positive brush holders
deformed, or if the spring tension is less
should have infinite resistance to the brush
than 7.1 lb (3.2 kg). The spring tension
ring plate. The negative brush holders
should be checked with the brush ring
should have continuity to the brush ring
assembly installed on the commutator.
commutator.
plate.
b. Check
Check the
the brushe
brushes.
s. Repla
Replace
ce the
the brushe
brushess if
they are chipped or cracked, or measure
less than 0.4
0.4 in. (9 mm) on the short
short side.
Replace the brushes as a set, or replace the
brush ring assembly.

127
Electrical

2. Chec
Check
k the
the sta
stato
torr. 3. Chec
Check
k the
the arma
armatu
ture
re..
a. Check
Check the
the field
field coil
coil with
with an ohmm
ohmmeteeterr. a. To check
check the
the beari
bearings
ngs,, turn
turn them
them by hand.
hand.
There should be continuity between the Replace the bearings if they are rough or
stator lead and both positive brushes. seem loose.
Replace the stator if there is no continuity
b. Visually
isually check
check the armature.
armature. Replace
Replace the
or high resistance in the field coil.
armature if there is any sign of thrown
solder, discolored windings, bubbled
insulation, burned or damaged
commutator bars, damaged shafts, or a
damaged gear.
c. Place
Place the
the armatu
armature
re in a lath
lath and check
check the
the
commutator and the core with a dial
indicator.
indicator. The distortion, run out, or out of
round should not exceed 0.008 in.
(0.2
(0.20
0 mm).
mm).

1 2
AEA373

Figure 247:
247: Check Field
Field Coil
Coil

b. Check
Check the
the stat
stator
or insu
insulat
lation
ion with
with an
ohmmeter set on the Rx1000 scale. There AGA141
should be infinite resistance between the
stator lead and the stator frame. Replace
the stator if there is any continuity 1. Commutator
between the stator lead and the stator 2. Core
frame. Figure 249: Check Armature
Armature Distortion
Distortion

d. Turn
Turn the
the commu
commutattator
or or the
the core
core down
down if
they exceed this limit. Also turn the
commutator down to remove any wear
grooves made by the brushes.
e. Replac
Replacee the armatu
armature
re if the
the comm
commutautator
tor
has an outside diameter that is less than
1.40 in. (35.5 mm) after being turned
t urned
down.
f. If the
the commu
commutat
tator
or is only
only dirty
dirty,, clean
clean it up
up
with 500-600 grit sandpaper.
sandpaper.

AEA373

Figure 248: Check Stator

Stator Insulation
Insulation

128
 Electrical

h. Check
Check the
the armatu
armature
re coils
coils with
with a grow
growler
ler
and an ammeter. Place the ammeter leads
on each pair of commutator bars that are
directly opposite each other. The ammeter
will show no current in an open coil and
lower than normal current in a shorted
coil. Replace the armature if any of the
coils are defective.
i. Check
Check the armatu
armature
re insula
insulatio
tion
n with
with an
ohmmeter set on the Rx1000 scale. There
should be infinite resistance between each
commutator bar and the armature core or
AEA375
shafts. Replace the armature if there is any
continuity between the armature coils and
the core.
Figure 250:
250: Clean Up Commuta
Commutator
tor

g. After turning
turning down
down the commutator
commutator,, check
check
the undercut of the mica. The standard
undercut is 0.02 to 0.03 in. (0.5 to
0.8 mm). Cut the undercu
undercutt down to the
proper depth if it is
i s less than 0.01 in.
(0.2
(0.2 mm).
mm).

1
AEA377

Figure 252: Check Armature

Armature Insulation
Insulation

Pinion Assembly
1. Inspect
Inspect each
each part of the
the pinion
pinion assembly
assembly and
3
replace any part that shows significant wear or
damage. Push the stop ring off the snap ring
and remove the snap ring from the end of the
pinion shaft to disassemble the pinion
assembly.
AGA142
2. Check
Check the overru
overrunni
nning
ng clutch
clutch..
1. Correct
a. Hold
Hold the
the pinio
pinion
n clutc
clutch
h assem
assembly
bly..
2. 0.02
0.02 to 0.03
0.03 in.
in. (0.
(0.5
5 to
to 0.8
0.8 mm
mm))
3. Incorrect b. Place
Place the
the pinion
pinion shaf
shaftt in the pinio
pinion
n clutch
clutch
and try to rotate the pinion shaft in both
Figure 251: Check Commutator
Commutator Undercut
Undercut
directions.

129
Electrical

c. The pinion
pinion shaf
shaftt should
should rota
rotate
te freel
freely
y in 3. Push the plunger
plunger in
in and
and check
check the continuity
continuity
one direction and should not rotate in the between the B terminal and the M terminal on
other direction. the starter solenoid. Replace the starter
solenoid if there is no continuity or high
d. Replac
Replacee the
the pinion
pinion clut
clutch
ch if the
the pini
pinion
on
resistance.
shaft does not rotate smoothly in the
proper direction, or if it rotates in both
directions.

Starter Solenoid
1. Check
Check the
the continu
continuity
ity betwee
betweenn the
the S terminal
terminal
and the chassis on the starter solenoid.
Replace the starter solenoid if there is no
continuity or high resistance.
r esistance.

AGA145

Figure 255: Check Contact

Contacts
s

Assembly
1. Place the pinion
pinion assemb
assembly
ly in the gear housing
housing
AGA143 and install the three 5x16 mm screws.
2. Place the shims and the shift
shift lever
lever spring over
Figure 253:
253: Check Shunt
Shunt Coil
Coil
the plunger in the starter solenoid.
3. Place
Place the
the shift
shift lever
lever in the
the hole
hole in the end
end of
2. Check
Check the
the continu
continuity
ity betwee
betweenn the
the S terminal
terminal
the plunger, and place the shift lever spring in
and the M terminal on the starter solenoid.
the notch in the
t he shift lever.
Replace the starter solenoid if there is no
continuity or high resistance.
r esistance.

AGA146

Figure 256: Install

Install Shift Lever and Spring
Spring
AGA144

Figure 254:
254: Check Series
Series Coil
Coil

130
 Electrical

4. Place
Place the asse
assembl
mbled
ed starte
starterr solenoi
solenoid
d (with
2 3
shift lever) and the dust cover in the gear
housing.
1
5. Fasten
Fasten the
the starter
starter soleno
solenoid
id to the gear housing
housing
with the two 6x35 mm bolts.
6. Place
Place the
the arma
armatur
turee in the
the stat
stator
or..
4
7. Place
Place the
the armatur
armaturee and
and the
the stator
stator in the
the gear
gear
housing. Make sure the armature bearing is
seated in the gear housing.
8. Make
Make sure
sure the nega
negativ
tivee brushe
brushess are in
in the 5
locked position and place the brush ring on the
commutator. AGA147

9. Place
Place the
the positiv
positivee brushe
brushess in the brus
brush
h
holders.
10. Move the brushes
brushes and the brush holders
holders to 1. Battery 4. Tachometer
their normal positions. Make sure that the 2. Ammeter 5. Voltmeter
brushes move freely in the brush holders and 3. Switch
that the brush springs hold the brushes against Figure 257:
257: No Load Test
Test
the commutator.
11. Place the rear
rear cover in position on the
the Air Heater
armature and stator. Make sure the armature
The air heater is mounted on the open end of the
bearing is seated in the rear cover.
intake manifold. It heats the intake air to help the
12. Install
Install the two through
through bolts.
bolts. engine start in cold weather.
weather.
13. Install the two 4x10 mm screws
screws that fasten the
brush holder assembly to the rear cover.
1
14. Connect the stator lead to the M terminal on
the starter solenoid.

No Load Test
CAUTION: Do not run the starter without
 a load for more than 30 seconds.
seconds.
AEA693

1. Clamp
Clamp the starte
starterr in a vise
vise..
1. M6 Terminal
2. Conne
Connect
ct the star
starter
ter to a 12
12 volt
volt batter
battery
y as
Figure 258: Air Heater
shown in the illustration.
Check the resistance of the air heater with an
3. When
When the switch
switch is
is turned
turned on, chec
check
k the ohmmeter between the M6 terminal on the front
current, voltage, and starter speed. The of the air heater and the screw on the back of the
standard values are: 140 amps, 11 volts, and air heater (or the air heater case). The resistance
3900
3900 rpm.
rpm. should be 0.14 ± 0.02 ohms.

131
Electrical

Check the current draw of the air heater with a make a definite click when the pull-in coil is
clamp-on ammeter at the H1 wire near the M6 energized and should click again when the
terminal on the front of the
t he air heater. During pull-in coil is de-energized.
de-energized.
preheat the current draw should be approximately
 NOTE: The pull-in coil will draw
draw 35 to 45
70 amps.
 amps so do not leave the jumper
jumper connected
connected to
The air heater is defective if the resistance is more  the white wire (8DP - pin
pin B) for more than a
than 0.2 ohms and the current draw is less than 60  few seconds.
amps, or if the current draw is more than 100
a. If the
the pull-i
pull-in
n coil
coil does
does ener
energiz
gize,
e, go
go to
amps.
step 3.
b. If the pull-in coil does not energ
energize,
ize, check
check
Fuel Solenoid
the resistance of the pull-in coil by placing
See “Fuel Solenoi
Solenoid”
d” on page 153 for
153 for information an ohmmeter between the white wire
about the different versions of the fuel solenoid. (8DP - pin B) and the black wire (CH - pin
When the fuel solenoid is energized, it places the C) in the fuel solenoid connector. The
fuel rack in the on position. This allows fuel
f uel to resistance of the pull-in coil should be 0.2
flow in the fuel injection
i njection pump. The fuel solenoid to 0.3 ohms. If the resistance of the pull-in
has two coils, the pull-in coil and the hold-in coil. coil is not in this range, replace the fuel
The pull-in coil must be momentarily energized to solenoid.
place the fuel rack in the on position. The 3. Test
est the
the hol
hold-
d-in
in coil.
coil.
energized hold-in coil can then hold the fuel rack
in the on position. Use the following procedure to a. Energ
Energize
ize the
the hold
hold-in
-in coil
coil by
by placin
placing
ga
test the fuel solenoid.  jumper between the red wire (8D - pin A)
in the fuel solenoid connector and the
 NOTE: On some unitsunits the 8D circuit goes
goes positive battery terminal.
 through the HPCO (high pressure cutout
 switch). Check for an intermittent contact
contact in the b. Momen
Momentari
tarily
ly ener
energiz
gizee the pull-i
pull-in
n coil by
by
 HPCO if the engine starts,
starts, but then stops
stops placing a jumper between the white wire
 because the fuel
fuel solenoid de-energizes,
de-energizes, and the (8DP - pin B) in the fuel solenoid
 fuel solenoid passes
passes the following tests.
tests. connector and the positive battery
terminal. The fuel solenoid should make a
1. Place
Place a jumpe
jumperr wire betw
between
een the
the black
black wire
wire definite click when the pull-in coil isis
(CH - pin C) in the fuel solenoid connector energized, but should not click when the
and a good chassis ground. pull-in coil is de-energized.
c. De-ene
De-energrgize
ize the
the hold-
hold-in
in coil
coil by remov
removing
ing
the jumper from the white wire (8DP - pin
B) and the positive battery terminal. The
fuel solenoid should make a definite click
when the hold-in coil is de-energized.
AEA633
d. If the
the hold-
hold-in
in coil
coil does
does not
not funct
function
ion
properly,
properly, check the resistance of the
1. Red (8D) hold-in coil by placing an ohmmeter
2. White (8DP) between the red wire (8D - pin A) and the
3. Black (CH) black wire (CH - pin C) in the fuel
Figure 259: Fuel Solenoid
Solenoid solenoid connector.
connector. The resistance
r esistance of the
Connecto
Connectorr Pin Identif
Identificat
ication
ion hold-in coil should be 24 to 29 ohms. If
the resistance of the hold-in coil is not in
2. Test the
the pull-in
pull-in coil
coil by
by momenta
momentarily
rily placin
placing
ga
this range, replace the fuel solenoid.
 jumper between the white
white wire (8DP - pin B)
in the fuel solenoid connector and the positive
battery terminal. The fuel solenoid should

132
 Electrical

Fuel Solenoid Replacement Fuel Solenoid Timer

This procedure assumes the engine is mounted in Some units use a fuel solenoid timer to
the unit. If the engine is not in the unit, use jumper momentarily energize the pull-in coil in the fuel
wires to energize the fuel solenoid at the three pin solenoid. (This function is built into the relay or
connector.
connector. Place a jumper between the black wire interface boards on later controllers such as the
(CH - pin C) and ground (–). Place a jumper µ P-VI and SR-2.) The fuel solenoid timer consists
between the red wire (8D - pin A) and 12 Vdc (+). of a small PC board that contains some electrical
Momentarily place a jumper between the white components, a four-pin wire connector,
connector, and one
wire (8DP - pin B) and 12 Vdc (+). removable relay.
relay. The relay is called the fuel
solenoid relay.
relay. The fuel solenoid timer
ti mer is typically
1. Disconnec
Disconnectt the
the fuel
fuel solenoid
solenoid wire connector
connector
mounted inside the control box. There are two
and remove the old fuel solenoid.
styles of fuel solenoid timers (see “Fuel Solenoid
2. Connect
Connect the fuel solenoid
solenoid wire connector
connector to Timer”
Timer” on page 153).
153). Both styles function the
the new fuel solenoid. same and are interchangeable.
3. If necess
necessary
ary,, disable
disable the
the engine
engine reset
reset switch
switch or 1 2
the CYCLE-SENTRY
CYCLE-SENTRY system on units so
equipped.
4. Turn
Turn the
the unit
unit on to energ
energize
ize the
the fuel
fuel solenoid.
solenoid.
Use the Service Test Mode to energize the fuel
solenoid if the unit has a microprocessor.
 NOTE: The fuel solenoid
solenoid must be energized
energized
when it is being installed. If not, the plunger
 and the linkage
linkage may not line up correctly
correctly and
 the fuel solenoid will not function
function properly.
properly.
AGA337
5. Place
Place the
the O-ring
O-ring in
in the groove
groove in the
the end
end of
the fuel injection pump. Make sure the O-ring 1. Four-Pin Co
Connector
is positioned correctly during installation to 2. Fuel
Fuel Sole
Soleno
noid
id Re
Rela
lay
y (FS
(FSR
R)
avoid damage and leaks.
Figure 261:
261: Fuel Solenoid
Solenoid Timer
Timer
6. Instal
Installl the
the new
new fuel
fuel sole
solenoi
noid.
d.
Fuel Solenoid Timer Operation
7. Turn
Turn the
the unit
unit off
off and make sure to enable
enable any
disabled systems. The fuel solenoid hold-in coil is connected to the
8D circuit. The fuel solenoid relay coil is also
connected to the 8D circuit and it is grounded
through the fuel solenoid timer. The fuel solenoid
pull-in coil is connected to the 2A circuit through
the normally open contacts of the fuel solenoid
relay when the fuel solenoid relay is energized.
When the 8D circuit is energized, it supplies
power to the fuel solenoid hold-in coil and to the
fuel solenoid relay coil. The hold-in coil is
AEA635
energized and remains energized as long as there
is power on 8D. The fuel solenoid relay is
1. Fuel Solenoid energized momentarily by the fuel solenoid timer
2. O-ring when the 8D circuit is first
fir st energized. After
3. Groo
Groov
ve in
in Fue
Fuell Inj
Injec
ecti
tion
on Pum
ump
p
approximately 2.5 seconds, the fuel solenoid timer
de-energizes
de-energizes the fuel solenoid relay by opening
Figure 260: Fuel Solenoid
Solenoid Components
Components the circuit to ground.

133
Electrical

During the time the fuel solenoid relay is 2. Turn

Turn the
the unit
unit on to energ
energize
ize the
the fuel
fuel solenoid
solenoid
momentarily energized, the fuel solenoid pull-in circuits. If the unit has a microprocessor
mi croprocessor,, use
coil is energized by the 2A circuit through the the microprocessor keypad to enter the t he Relay
normally open contacts of the fuel solenoid relay Board Test Mode. Energize the fuel solenoid
and the 8DP circuit. circuits by energizing the run relay [RUNR]
with the Relay Board Test Mode.
When power is removed from the 8D circuit the t he
fuel solenoid hold-in coil is de-energized, and the 3. Check
Check the
the voltag
voltagee on the
the 8D circui
circuitt (pin A)
A) in
fuel solenoid resets. the main wire harness connector for the fuel
solenoid. Refer to the following illustrations
1 to identify the pins in the wire connectors.
a. If batte
battery
ry volta
voltage
ge is not pres
present
ent on
on the 8D
2 circuit, check the 8D circuit and the
related circuits and components for a fault.
b. If batte
battery
ry volta
voltage
ge is prese
present
nt on the
the 8D
8D
circuit, go to step 4.

AGA310 AEA704

5 4 Figure 263:
263: Main Wire
Wire Harness
Harness
Connect
Connector
or Pin Identifi
Identificati
cation
on
1. Fuel
Fuel Sole
Soleno
noid
id Re
Rela
lay
y Cont
Contac
actts
2. Fuel
Fuel Sol
Solenoi
enoid
d Pul
Pull-
l-In
In Coil
oil
3. Fuel
Fuel Sol
Solenoi
enoid
d Hol
Hold-
d-In
In Co
Coiil
4. Fuel So
Solenoid Ti
Timer
5. Fuel
uel So
Solenoid
oid Re
Relay Co
Coil
Figure 262: Simplified
Simplified Schematic
Schematic Diagram
of Fuel Solenoi
Solenoidd System
System
AEA633

Troubleshooting the Fuel Solenoid Timer 1. Red (8D)

System 2. White (8DP)
 NOTE: The fuel solenoid
solenoid pull-in coil will 3. Black (CH)
 require 35 to 45
45 amps to turn on the fuel. The Figure 264: Fuel Solenoid
Solenoid
unit’s
unit’s battery must be in good condition. If the Connect
Connector
or Pin Identifi
Identificati
cation
on
 battery has enough
enough power to crank
crank the engine
4. Check
Check the
the CH circu
circuit
it (pin
(pin C) in the
the main
main wire
wire
 over,
 over, it has enough power
power to energize
energize the fuel
harness connector for continuity to a good
 solenoid pull-in coil.
chassis ground.
If you suspect that the engine does not run
a. If there
there is
is no cont
continu
inuity
ity betw
between
een the CH
CH
because the fuel solenoid is not operating
circuit and a good chassis ground, check
correctly,
correctly, use the following procedure:
the CH wire for an open circuit.
1. Disconnec
Disconnectt the
the fuel
fuel soleno
solenoid
id wire
wire connector
connector
b. If there
there is
is conti
continui
nuity
ty betwe
between
en the
the CH
from the main wire harness.
circuit in the main wire harness at the
t he fuel
solenoid wire connector and a good
chassis ground, go to step 5.

134
 Electrical

5. Place
Place a jumpe
jumperr wire betw
between
een the
the black
black wire
wire c. De-ene
De-energi
rgize
ze the
the hold-i
hold-in
n coil
coil by remov
removing
ing
(CH—pin C) in the fuel solenoid connector the jumper from the red wire (8D—pin A)
and a good chassis ground. and the positive battery terminal. The fuel
solenoid should make a definite click
6. Test the
the pull-in
pull-in coil by momenta
momentarily
rily placin
placing
ga
when the hold-in coil is de-energized.
 jumper between the white wire (8DP—pin B)
in the fuel solenoid connector and the positive d. If the
the hold-
hold-in
in coil
coil doe
doess not
not functi
function
on
battery terminal. The fuel solenoid should properly, check the resistance of the
make a definite click when the pull-in coil is hold-in coil by placing an ohmmeter
energized and should click again when the between the red wire (8D—pin A) and the
pull-in coil is de-energized.
de-energized. black wire (CH—pin C) in the fuelf uel
solenoid connector.
connector. The resistance of the
 NOTE: The pull-in coil will draw
draw 35 to 45
hold-in coil should be 24 to 29 ohms. If
 amps so do not leave
leave the jumper connected
connected to
the resistance of the hold-in coil is not in
 the white wire (8DP—pin B) for more
more than a
this range, replace the fuel solenoid.
 few seconds.
e. If the hold-
hold-in
in coil
coil does
does functio
function
n properl
properly
y,
a. If the pull
pull-in
-in coil
coil does
does not ener
energiz
gize,
e, check
check
go to step 8.
the resistance of the pull-in coil by placing
an ohmmeter between the white wire 8. Reconnec
Reconnectt the fuel solenoid
solenoid conne
connector
ctor and the
(8DP—pin B) and the black wire (CH— main wire harness connector.
connector.
pin C) in the fuel solenoid connector. The
9. Remove
Remove the fuel solenoid
solenoid relay
relay from its
its socket
socket
resistance of the pull-in coil should be 0.2
and make sure the unit is turned on, and is in
to 0.3 ohms. If the resistance of the pull-in
the Relay Board Test
Test Mode [RUNR] if it has a
coil is not in this range, replace the fuel
microprocessor.
solenoid.
 NOTE: If the pull-in coil fails, make
make sure to 10. Check the voltage on the 8D circuit at the 86
 replace the fuel solenoid
solenoid relay with relay terminal in the fuel solenoid relay socket.
 P/N 41-893. This particular
particular relay is needed
needed Refer to the following illustration to identify
 for the high current
current flow through the hold-in the terminals in the relay socket.
 coil. a. If batte
battery
ry volta
voltage
ge is not pres
presen
entt on the
the 8D
b. If the
the pull-in
pull-in coil
coil does
does ener
energiz
gize,
e, go
go to circuit, check the 8D circuit and the
step 7. related circuits and components for a fault
(minimum voltage is 10 volts).
7. Test
est the
the hol
hold-
d-in
in coi
coil.
l.
b. If batte
battery
ry volta
voltage
ge is presen
presentt on the
the 8D
a. Energ
Energize
ize the
the hold
hold-in
-in coil
coil by
by placin
placing
ga circuit, go to step 11.
11.
 jumper between the redred wire (8D—pin A)
in the fuel solenoid connector and the 1 2
positive battery terminal.
b. Moment
Momentariarily
ly ener
energiz
gizee the pull-i
pull-in
n coil by
by
placing a jumper between the white wire
(8DP—pin B) in the fuel solenoid
connector and the positive battery
4 3
terminal. The fuel solenoid should make a
definite click when the pull-in coil isis 1. 30 Termi
ermina
nal—
l—2A
2A Circ
Circui
uitt
energized, but should not click when the 2. 86 Terminal
nal—8D Wire
pull-in coil is de-energized.
de-energized.
3. 87 Te
Termina
minall—8DP Wi
Wire
4. 85 Termi
ermina
nall to
to Cap
Capac
acit
itor
or and
and Dio
Diode
de
Figure 265: Relay Socket Terminal
Terminal Identification
Identification

135
Electrical

11. Check the voltage on the 2A circuit at the 30

terminal in the fuel solenoid relay socket.
a. If volta
voltage
ge is not pres
present
ent on
on the 2A circu
circuit,
it,
check the 2A circuit for an open or a short.
b. If batte
battery
ry volta
voltage
ge is presen
presentt on the
the 2A
circuit, go to step 12.
12.
12. Test the relay.
relay.
a. Use a jumpe
jumperr to conn
connect
ect the 86 term
termina
inall
on the relay to the positive battery
terminal.
b. Use anothe
anotherr jumper
jumper to
to connec
connectt the 85
85
terminal on the relay to a CH circuit.
c. If the
the relay
relay does
does not
not ener
energiz
gize,
e, it
it is
defective. Replace the relay.
d. If the
the relay
relay does
does energ
energize
ize,, the timer
timer is
defective. Replace the fuel solenoid timer
PC board.
13. Turn the unit Off after completing the test
procedure.

136
Run In

The run in of a rebuilt engine will often determine

CAUTION: DO NOT run a newly rebuilt
the oil consumption, power output, and other
engine without a load for a long period of
variables during the service life of the engine. It is
 time. This can cause
cause the engine’s
engine’s oil
important to run in a rebuilt engine properly.
properly. How
 consumption to be higher than normal.
normal.
an engine will be run in is determined by the type
of equipment and the time that is available. 2. Mount the engine
engine in a unit and run the
the unit
unit on
on
Thermo King recommends an engine be run in on high speed heat for 2 hours. Occasionally
a dynamometer if possible. place the unit in low speed heat to vary the
compression pressures and engine
Dynamometer Run In temperatures.
Procedure 3. Mount
Mount the
the unit
unit on a truc
truck
k and
and run the
the unit
unit in
in
high speed heat with truck doors open for 2 to
1. Pressurize
Pressurize the lubrication
lubrication system
system of the engine
engine
10 hours.
with an oil pressure tank if the
t he engine has
been stored for any length of time. This
prevents a dry start. Valve Clearance Adjustment
2. Start
Start the
the engine
engine and
and run
run it at 1450
1450 rpm
rpm with a 1. Remove
Remove the rocke
rockerr arm
arm cove
coverr.
load that is 6 to 8% of the engine’s rated 2. Remove
Remove the
the round
round cove
coverr (plug)
(plug) from
from the
the
output for a short time. timing mark access hole on the front of the
3. Run the
the engin
enginee at 1450
1450 rpm
rpm with
with a load
load that
that is bell housing.
15% of the engine’s
engine’s rated output for 15
CAUTION: Loosen all of the injection
minutes.
lines at the injection nozzles to prevent the
4. Run the
the engin
enginee at 2200
2200 rpm
rpm with
with a load
load that
that is  possibility of the engine
engine firing while it is
22 to 25% of the engine’s rated output for 30  being rotated.
rotated.
minutes.
3. Place
Place the
the engine
engine at
at top dead
dead cent
center
er of the
the
5. Run the
the engin
enginee at 1450
1450 rpm
rpm with
with a load
load that
that is compression stroke for the number one
15% of the engine’s
engine’s rated output for 30 cylinder.
cylinder. The number 1 cylinder is on the
minutes. flywheel (rear) end of the engine.
6. Run the
the engin
enginee at 2200
2200 rpm
rpm with
with a load
load that
that is a. Rotate
Rotate the
the engi
engine
ne in the norm
normal
al direc
directio
tion
n
30 to 35% of the engine’s rated output for 10 of rotation (clockwise viewed from the
minutes. water pump end) until the 1-4 timing
ti ming mark
on the flywheel lines up with the index
7. If time
time permit
permits,
s, addit
addition
ional
al run
run in time
time is
mark in the timing mark access hole.
desirable. Vary the speed and load in ranges
between 1450 to 2200 rpm and 10 to 25% of 1 2
the engine’s rated output.

Run In Procedure without

Dynamometer
1. Run the engin
enginee on a test
test stand
stand with no load
load for
for
approximately 15 minutes in both low speed
(1450 rpm) and high speed (2200 rpm). Check
the engine for abnormal noises, coolant, fuel, AEA701
or oil leaks.
1. Index Mark
2. Top De
Dead
ad Ce
Cent
nter
er Ma
Mark
rk for
for 1 and
and 4
Figure 266: Top Dead Center One and Four
Four

137
Run In

b. Check
Check the
the rocker
rocker arms
arms on
on the numb
number
er one
one 5. Adjust
Adjust the valves
valves if necessary
necessary by loose
loosening
ning
cylinder to see if they are loose. the lock nut and turning the adjustment screw
until the valve clearance is correct.
c. If the
the rocker
rocker arms
arms are
are loose
loose,, the engi
engine
ne is
at top dead center of the compression 1
stroke for the number one cylinder.
2
d. If the
the rocker
rocker arms
arms are
are tight,
tight, the
the engi
engine
ne is at
at
top dead center of the exhaust stroke for
the number one cylinder. Rotate the engine
360 degrees to place the engine at top dead
center of the compression stroke for the
number one cylinder.
AGA148

4. Use a feeler
feeler gaug
gaugee to chec
checkk the valve
valve
clearance on both valves for the number one 1. Adjustment Screw
cylinder, the intake valve for the number two 2. Lock Nut
cylinder, and the exhaust valve for the number Figure 267:
267: Valve Clearance
Clearance
three cylinder. The valve clearance for both
the intake valves and tthe
he exhaust valves 6. Hold
Hold the adju
adjustm
stment
ent scre
screw
w in place
place and
should be 0.006 to 0.010 in. (0.15 to tighten the lock nut.
0.25
0.25 mm).
mm).
 NOTE: Check to make sure that the valve
 stem cap is in good condition and is
 positioned squarely
squarely on the top of the valve
valve
 stem. Replace the valve stem cap if it shows
 significant wear.
wear.

AGA114

Figure 268: Adjusting

Adjusting Valves
Valves

Valve Adjustments and Cylinder Configurations

Rear Front
Flywheel End Pulley End
Cylinder No. 1 2 3 4
Valve arrangement E I E I E I E I
Piston in No. 1 cylinder is at
TDC on compression stroke
Piston in No. 4 cylinder is at
TDC on compression stroke

138
 Run In

7. Rechec
Recheck
k the
the valv
valvee clea
clearan
rance
ce..  NOTE: The compression
compression should be tested
tested
when the engine is near the normal
8. Rotate
Rotate the
the engine
engine one full turn (360 degrees)
degrees)
 operating temperature.
temperature. If it is not possible
possible to
in the normal direction of rotation (clockwise
 run the engine, follow the rest of this
viewed from the water pump end), and align
 procedure. The
The compression pressures will will
the 1-4 timing mark on the
t he flywheel with the
 be approximately 10 percent lower than those
index mark in the timing mark access hole.
 on a warm engine.
This is top dead center of the compression
stroke for the number four cylinder. 2. Discon
Disconnec
nectt the wires
wires from
from the fuel
fuel solenoi
solenoidd
and loosen the injection lines at the injection
9. Check
Check and
and adjust
adjust the exhaust
exhaust valve
valve for
for the
nozzles.
number two cylinder, the intake valve for the
number three cylinder, and both valves for the CAUTION: The fuel solenoid must be
number four cylinder.  disconnected and
and the injection lines must
must
10. Replace the rocker
rocker arm cover,
cover, the cover for  be loosened
loosened to prevent the injection of fuel
the timing mark access hole, and tighten the into the cylinders during the test. If a
fuel injection lines when finished.  cylinder fires during the test, the resulting
resulting
 pressure will destroy
destroy the test equipment.
equipment.
The manufacturer of the test equipment
Compression Test  disclaims all responsibility
responsibility for damage or
injury resulting from a cylinder firing
Compression Test Equipment  during the test.
A TK482/486 adapter (P/N 204-1056) is now
3. Remove
Remove all
all of the
the fuel
fuel injecti
injection
on nozzl
nozzles.
es.
available for compression tester (P/N 204-542).
4. Disco
Disconne
nnect
ct the air clean
cleaner
er..
An adapter can be fabricated, but it must meet the
following guidelines. If not, the compression 5. Connect
Connect the
the compres
compression
sion tester
tester (P/N
(P/N 204-542
204-542))
readings will not be accurate. to a cylinder with the TK482/486 adapter (P/N
204-1056).
Combustion chambers in diesel engines are
relatively small, and the compression ratios are 6. Turn
Turn the engi
engine
ne over
over with
with the star
starter
ter and
and
relatively high. Therefore, to obtain accurate and observe the pressure gauge. Stop cranking the
consistent compression readings: engine when the pressure stabilizes.

• The
The adap
adapteterr used
used to
to conn
connec
ectt a comp
compre
ress
ssio
ion
n 7. Note the final reading,
reading, release
release the pressure,
pressure,
tester to an engine must closely approximate and disconnect the tester.
tester.
the size and shape of the part being replaced.
8. Repeat
Repeat this
this procedure
procedure on each cylinder
cylinder..
• A Schr
Schrade
aderr valv
valvee must
must be instal
installed
led in the end
end
9. Compar
Comparee the fina
finall readin
readings
gs of all
all the
the
of the adapter that is facing the combustion
cylinders.
chamber.
10. An engine in good condition will have a
• The compre
compressi
ssion
on tester
tester and connec
connectin
ting
g hose
hose
minimum compression pressure of
must have a small internal volume.
approximately 400 psi (2758 kPa) at cranking
speed (250 rpm) using the Thermo King
Compression Test Procedure compression tester (P/N 204-542) and the
1. Run the
the engin
enginee until
until it reach
reaches
es the
the normal
normal TK482/486 adapter (P/N 204-1056).
operating temperature and then stop the
11. Because the compression pressures will vary
vary
engine.
depending on what kind of equipment is used,
the most important factor is the variation
between cylinders. The variation between
cylinders should not exceed 10 percent.

139
Run In

140
Special Procedures

Checking Oil Pump 5. Remove

Remove the sound
sound shield
shield and
and gear
gear case
case cover
cover..

Use the following procedure to check the oil

pump without removing the engine from the unit.
1. Remo
Remove
ve the
the bel
belts
ts..
2. Remov
Removee the
the fuel
fuel transf
transfer
er pump.
pump.
3. Early engines
engines have
have an oil
oil line
line connec
connected
ted to
to the
gear case cover. Disconnect
Disconnect the oil line from
the gear case cover or remove it from the
engine.

Figure 271:
271: Remove Sound
Sound Shield
Shield
and
and Gear
Gear Ca
Case
se Cove
Coverr

 NOTE: On TierTier 2 engines the oil

oil pump is
located in the gear case cover.

1
2
5
3
4

2
AGA01

1. Oil
Oil Li
Line (Ear
(Early
ly Engi
Engine
nes
s Onl
Only)
y)
2. Transfer Pump
Figure 269: Early Engine
Engine Shown Others Similar
Similar
1. Crankshaft Gear 4. Inner Rotor
4. Remov
Removee the
the crank
cranksha
shaft
ft pulle
pulley
y. 2. Oil Pump Cover 5. Gear Case Cover
3. Outer Rotor
Figure 272:
272: Oil Pump Located
Located in Gear Case Cover
Cover
on Tier 2 Engines

Figure 270: Remove Crankshaf

Crankshaftt Pulley

141
Special Procedures

6. Remove
Remove the
the oil
oil pump
pump from
from Tier
Tier 1 and
and earlie
earlierr  NOTE: On Tier
Tier 1 and earlier
earlier engines you
engines.  can sometimes
sometimes see if the intake
intake pipe gasket
gasket is
 out of place by using
using a light to look between
between
 the gear case and the engine block below
where the oil pump mounts.

1. Look Th
Through H
He
ere
Figure 273:
273: Remove OilOil Pump Figure 274: Check Intake
Intake Pipe Gasket
Gasket
Tier
Tier 1 and
and Earl
Earlie
ierr Engi
Engine
nes
s Tier
Tier 1 and
and Earl
Earlie
ierr Engi
Engine
nes
s

7. Insp
Inspec
ectt the
the oil
oil pump
pump.. See
See “Oil Pump for Tier 1 8. Instal
Installl the oil
oil pump
pump on
on Tier
Tier 1 and
and earlie
earlierr
and Earlier
Earlier Engines”
Engines” on page
page 61,
61, or “Oil engines.
Pump for Tier
Tier 2 Engines” on page 62.
62. Replace
the oil pump if it is defective. If the oil pump 9. Coat
Coat the lip
lip of the
the front
front seal
seal with engi
engine
ne oil.
oil.
is not defective, pull the engine and remove 10. Place new O-rings (Tier
(Tier 2 engines only) in the
the oil pan. Check the inlet screen, the intake gear case.
pipe, the intake pipe gasket or o-ring, and
pressure check engine for internal leaks.  NOTE: Tier
Tier 1 and earlier engines
engines do not use
use
 these O-rings.

1. Dowel Pins
2. O-Ri
O-Ring
ngs
s (Tie
(Tierr 2 Engi
Engine
nes
s Only
Only))
Figure 275: Gear Case

142
 Special Procedures

11. Place a thin layer of sealant

sealant on the sealing
sealing 16. Install the crankshaft
crankshaft pulley and
and align it with
surface of the gear case cover. the dowel pin in the crankshaft gear. Torque
the mounting bolt to 83.2 to 90.4 ft-lb
f t-lb (112.8
12. Place the gear
gear case cover
cover in position and make
to 122.6 N•m).
sure to align the dowel pins.
 NOTE: Make sure to alignalign the dowel pin
 NOTE: The oil pump is located in the timing
with the mating hole in the crankshaft pulley.
 gear cover
cover on
on Tier
Tier 2 engines. The inner rotor
 If not, the pulley will not pull
pull down on the
 of the oil pump fits around
around the crankshaft
crankshaft
 tapered end of the crankshaft
crankshaft and will be
 gear.
 gear. Make sure that the flat sides of the
loose. The pulley can also crack where it
inner rotor are aligned with the flat sides on
 contacts the
the dowel pin. This can
can cause the
 the crankshaft
crankshaft gear when installing
installing the
 front seal to leak oil. Check
Check the pulley for
 timing gear cover.
cover.
 cracks if the front seal
seal leaks. Replace
Replace the
1  dowel pin if it is damaged.
damaged.
2
5
3
1 2
4

1. Crankshaft Gear
2. Oil Pump Cover
3. Outer Rotor
4. Inner Rotor 1. Dowel Pin

5. Timing Gear Cover 2. Mati

Mating
ng Ho
Hole
le in Cran
Cranks
ksha
haft
ft Pull
Pulley
ey

6. Flat
Flat Side
Sides
s on Inne
Innerr Rotor
otor Figure 277:
277: Dowel Pin
Pin Alignment
Alignment
7. Flat
Flat Side
Side on Crank
ranksh
shaf
aftt Gea
Gearr
Figure 276: Align Flat Sides
Sides of Crankshaft Gear
with Flat Sides of Inner Rotor in Timing Gear Cover

13. Install and tighten

tighten the gear
gear case cover
cover
mounting bolts that are covered by the sound
shield.
14. If the sponge on the back of the sound
sound shield
is damaged, replace it before installing the
sound shield.
15. Place the sound
sound shield in position and
and install
and tighten the mounting bolts.

AGA124

Figure 278: Install

Install Crankshaft
Crankshaft Pulley

143
Special Procedures

17. On early engines,

engines, attach or install the oil line 16. Remove the oil pump from Tier 1 and earlier
that goes from the cylinder block to the
t he fuel engines. On Tier 2 engines the oil pump is
injection pump to the gear case cover. located in the gear case cover (see
( see page
page 36).
36).
18. Install
Install the fuel transfer
transfer pump. 17. Remove the two bolts from the idler gear
gear shaft
(see page
page 36).
36).
19. Install
Install and tighten the belts.
belts.
18. Remove the idler gear and
and the idler gear
gear shaft
Gear Case Replacement from the cylinder block (se
( seee page
page 36).
36).

The following outlines the procedure to replace a 19. Turn the engine upside down to make the
broken gear case. See the Engine Disassembly tappets move off the camshaft and to prevent
Chapter and the Engine Assembly Chapter for the tappets from interfering with the removal
r emoval
details about removing and installing the of the camshaft.
components. 20. Remove the mounting bolts from the camshaft
1. Remove
Remove the engine
engine from
from the
the unit
unit.. thrust plate by turning the camshaft gear to
access the bolts through the holes in the gear
2. Remo
Remove
ve the
the val
valve
ve cove
coverr (see
(see page
page 31).
31). (see page
page 38).
38).
3. Remove
Remove the rocker
rocker arm assem
assembly
bly ( see 21. Carefully remove
remove the camshaft
camshaft to avoid
page
page 31).
31). scratching or marring the camshaft bearings.
4. Remove
Remove the valve
valve stem
stem caps
caps ( see
see page
page 31).
31). The engine must be upside down to prevent
the tappets from interfering with the removal
r emoval
5. Remo
Remove
ve the
the pus
push
h rod
rodss (see
(see page
page 31).
31). of the camshaft (see
( see page
page 39).
39).
6. Remove
Remove the oil
oil line
line that
that goes
goes from
from the
the  NOTE: Make sure to keep the engine upside
cylinder block to the fuel injection pump and  down until the camshaft
camshaft is reinstalled. The
the gear case cover (see
( see page
page 32).
32).  tappets will
will fall out of the block if the engine
engine
7. Remove
Remove the
the fuel
fuel transf
transfer
er pump
pump from
from the gear
gear is turned right side up after the camshaft is
case cover (see
(see page
page 32).
32).  removed.

8. Remove
Remove the front
front cranks
crankshaf
haftt bolt
bolt (see
(see 22. Remove the lower part of the oil pan (see
(see
page
page 32).
32). page
page 38).
38).

9. Remove
Remove thethe crank
cranksh
shaft
aft pulle
pulley
y by using
using a 23. Remove the four bolts that fasten
fasten the upper
upper
suitable puller (se
(seee page
page 32).
32). part of the oil pan to the gear case.

10. Remove the gear case

case cover and sound
sound shield 24. Remove the gear case. Also remove the two
(see
see page
page 33).
33). O-rings from the oil passages between the
gear case and the cylinder block on Tier 1 and
11. Note the timing marks
marks on the timing gears. earlier engines (see
(see page
page 39).
39).
The timing marks must be aligned when the
engine is assembled. 25. Clean all gasket
gasket and sealing
sealing surfaces.
surfaces.

12. Remove the fuel injection pump gear nut and

and 26. Place new O-rings (Tier 1 and earlier engines
lock washer (se
(seee page
page 33).
33). only) on the front of the
t he engine block and
make sure the dowel pins are in place ( see
13. Remove the fuel injection pump gear by using page
page 75).
75).
a suitable puller (see
(see page
page 33).
33).
 NOTE: Tier 2 engines do not
not use these
14. Note the alignment
alignment of the index
index marks on the O-rings.
injection pump and the gear case (see
( see
27. Place a thin layer of silicone sealant on the
page
page 35).
35).
back and the bottom sealing surfaces of the
15. Remove the fuel injection pump from the gear gear case (see
( see page
page 75).
75).
case (see
(see page
page 36).
36).

144
 Special Procedures

28. Install the gear

gear case. Make sure to align the 42. Place new O-rings (Tier
(Tier 2 engines only)
only) in the
dowel pins and tighten the mounting bolts (see
( see gear case (se
( seee page
page 84).
84).
page
page 75).
75).
 NOTE: Tier
Tier 1 and earlier engines do not use
29. Install and tighten the four
four bolts that fasten the  these O-rings.
upper part of the oil pan to the gear case.
43. Place a thin layer of sealant
sealant on the sealing
30. Place a thin layer of sealant
sealant on the sealing
sealing surface of the gear case cover.
cover.
surface of the lower part of the oil pan.
44. Place the gear
gear case cover
cover in position and make
31. Install
Install the lower part
part of the oil pan (see
(see sure to align the dowel pins (see
( see page
page 84).
84).
page
page 81).
81).  NOTE: The oil pump is located
located in the timing
32. Lubricate the camshaft
camshaft bearing, journals, and  gear cover
cover on Tier 2 engines.
engines. The inner rotor
rotor
lobes with engine assembly compound or  of the oil pump fits around
around the crankshaft
crankshaft
engine oil.  gear.
 gear. Make sure that
that the flat sides of the
inner rotor are aligned with the flat sides on
33. Carefully install the camshaft
camshaft to avoid
avoid  the crankshaft
crankshaft gear when installing
installing the
damaging the camshaft bearings (see
( see  timing gear cover.
cover.
page
page 75).
75).
45. Install and tighten the gear case
case cover
34. Install and tighten the camshaft thrust plate mounting bolts that are covered by the sound
mounting bolts (see
(see page
page 76).
76). shield (see
(see page
page 84).
84).
35. On Tier
Tier 1 and earlier engines, install the oil 46. If the sponge on the back of the sound
sound shield
pump with a new gasket and tighten the is damaged, replace it before installing the
mounting bolts. On Tier 2 engines the oil sound shield.
pump is located in the gear case cover and is
installed with the gear case cover (see
( see 47. Place the sound
sound shield in position and
and install
page
page 76).
76). and tighten the mounting bolts (see
( see page
page 84).
84).

36. Install a new O-ring for the fuel

fuel injection 48. Install the crankshaft
crankshaft pulley and
and align it with
pump in the gear case. the dowel pin in the crankshaft gear. Torque
the mounting bolt to 83.2 to 90.4 ft-lb
f t-lb (112.8
37. Install the fuel injection pump, align
align the index to 122.6 N•m) (see
(see page
page 85).
85).
marks as they were when the fuel injection
pump was removed, and tighten the mounting 49. Install the oil line that goes from the cylinder
nuts (se
(seee page
page 76).
76). block to the fuel injection pump and the gear
case cover (see
(see page
page 86).
86).
38. Install the fuel injection pump gear, lock
washer,
washer, and mounting nut. Make sure the key 50. Install the fuel transfer
transfer pump in the gear case
case
is aligned properly. Torque the mounting nut cover (se
(seee page
page 86).
86).
to 43.4 to 50.6 ft-lb (58.8
( 58.8 to 68.6 N•m) on 51. Place the valve stem
stem caps on the valve
valve stems
Tier 1 and earlier
earlier engines, or 57.9 to 65.1
65.1 ft-lb (see page
page 79).
79).
(78.5 to 88.3 N•m) on Tier 2 engines (see( see
page
page 77).
77). 52. Install the push
push rods in their respective
respective
openings. Make sure the push rods are seated
39. Install the idler gear
gear and the idler shaft and properly in the tappets. Lubricate the socket in
align the timing marks (se
( seee page
page 78).
78). the top end of each push rod with engine oil
40. Install and tighten the idler shaft mounting (see page
page 79).
79).
bolts (see
(see page
page 78).
78). 53. Place the rocker
rocker arm assembly
assembly in position.
41. Coat the lip of the front seal with engine oil. Make sure all the valve adjustment screws are
loose and have been backed out a few turns
(see page
page 79).
79).

145
Special Procedures

54. Install the rocker arm mounting bolts.

bolts.
Alternately turn each bolt one turn at a time to
evenly apply the valve spring pressure to the
rocker arm assembly. Make sure the valve
adjustment screws all seat properly in the
sockets on the ends of the push rods while the
rocker arm assembly is being tightened (see
( see
page
page 79).
79).
55. Torque the rocker arm mounting
mounting bolts to 16.6
to 21.0 ft-lb (22.6
(22.6 to 28.4 N•m).
N•m).
56. Adjust both the intake and the
the exhaust valves.
valves.
See “Valve Clearance Adjustment” on
page
page 137
137.
57. Install the valve cover with a new gasket and
put new O-rings on the special cap nuts ( see
page
page 81).
81).
58. Install
Install the engine
engine in the unit.

146
Engine History

Engine History Rear Seal

The following describe changes made to the
TK482 and TK486 families of engines.
Released
When the TK482 and TK486 engines were
released, the serial numbers for both engines
started at K00101.
Front Pulley
The rear seal was changed from a radial seal
(P/N 33-2759) to an axial
axial seal (P/N 33-2974).
TK482 engines start using the axial seal at serial
number K00203. TK486 engines start using the
axial seal at serial number K00152.
Special tools are required to remove and install
the axial seal. See page 37 for
37 for information about
removing the rear seal. See page 82 for
82 for
information about installing the rear seal.

The front pulley was changed. The inside

diameter of the pilot hole for
f or the pulley spacer
was changed
changed from 2.83 in. (72 mm) to 2.40 in. 1
(61 mm). Both the TK482
TK482 and TK486 engines
start using the front pulley with a pilot hole
diameter of 2.40 in. at serial number K00202.
The early front pulley with a pilot hole diameter
2
of 2.83 in. uses pulley spacer P/N 11-8710.
3
The late front pulley with a pilot hole diameter of
2.40 in. uses pulley spacer P/N 11-8902.
The pulley spacer is typically used on Model 30
trailer units that attach a fan belt pulley to the
front pulley.

1
2
4
3
5

1. Flywheel Housing
2. Rear Seal
3. Rear Seal Housing
4. Axia
Axiall Rear
Rear Sea
Seall Inst
Instal
alla
lati
tion
on Too
Tooll P/N
P/N 204-
204-952
952
5. Axia
Axiall Rea
Rearr Sea
Seall Rem
Remov
oval
al Tool
ool P/N
P/N 204
204-9
-994
94
Figure 280: Front Pulley
Pulley and Spacer
Spacer
1. Front Pulley
2. Pulley Spacer Flywheel Housing
3. Fan Belt Pulley
The flywheel housing (bellhousing) was changed
Figure 279: Front Pulley
Pulley and Spacer
Spacer to be universally compatible. The positions of the
threaded holes for the engine mounting and
snubber brackets were changed slightly. TK482
engines start using the universal flywheel housing
at serial number K00203. TK486 engines start
using the universal flywheel housing at serial
number K00409.

147
Engine History

Water Pump  NOTE: Later the engines

engines were changed
changed to
 comply with EPA
EPA Tier 2 regulations. See “EPA
The water pump was changed from a high mount
Tier 2 Compliance” on page 150 .
water pump to a low mount water pump. TK482
engines start using the low mount water pump at
serial number K00250. TK486 engines start using
Oil Line
the low mount water pump at serial number The long oil line (P/N 11-8668)
11-8668) that goes from the
K02406. block to the injection pump and on to the t he gear
case cover was changed to a short oil line
1 2 (P/N 11-8992).
11-8992). The short
short oil line only goes from
the block to the injection pump. The opening in
gear case cover is plugged with a screw
(P/N 55-8441). TK482E engines
engines start using the
short oil line at serial number A00261.
TK486E/EH engines start using the short oil line
at serial number L00261.

3
1
1. High
High Mo
Moun
untt Wat
Water
er Pump
Pump P/N
P/N 11-
11-94
9451
51
2. Low
Low Mou
Mount
nt Water
ater Pump
Pump P/N
P/N 11-
11-94
9499
99 2
Figure 281:
281: Water
Water Pumps
Pumps

EPA
EPA Tier 1 Compliance
The engines were changed to comply with EPA
Tier 1 regulations. The injection pumps were
changed and the injection timing was changed.
The EPA Tier 1 compliant engines are called the
TK482E, TK486E, and TK486EH (2600 rpm high
speed). The TK482E has a new serial number
range that starts at A00101. The TK486E and
TK486EH have a new serial number range that
starts at L00101.
L00101 . The EPA
EPA compliant engines
engi nes have
two injection timing marks on the flywheel. One
is at 10 degrees BTDC (before top dead center),
and the other is at 12 degrees BTDC. See
“Injection Pump Timing Tier 1 and Earlier 1. Long
Long Oil
Oil Line
Line P/N
P/N 11-86
1-8668
68
Engines”
Engines” onon page
page 97 for
97 for more information. See 2. Shor
Shortt Oil
Oil Line
Line P/N
P/N 11-89
1-8992
92
the following table for injection pump part 3. Plug Sc
Screw
rew P/
P/N 55
55-844
8441
numbers and the timing specifications.
Figure 282: Oil Lines
Initial Injection
Engine Serial Pump
Injection Timing ELC Compatible Water Pumps
Degrees BTDC
Number P/N The low mount water pump (P/N 11-9499) was
TK482 K00101 101-296 12 changed to be compatible with ELC (Extended
TK486 K00101 101-297 12 Life Coolant). TK482E engines start using the
TK482E A00101 101-322 10 ELC compatible water pump at serial number
TK486E L0 0 1 01 101-321 10 A05679. TK486E/EH engines start using the ELC
compatible water pump at serial number L16553.
TK486EH L 0 01 0 1 101-331 11

148
 Engine History

An ELC compatible high mount water pump
(P/N 11-9451)
11-9451) is available, but no engines
engines were
made with ELC compatible high mount water
pumps.
A unit can be retrofitted with ELC by flushing the
cooling system with hot water until all traces of
the precious coolant are gone and then filling the
cooling system with ELC. The water pump must
also be replaced on engines that are not equipped
with an ELC compatible water pump. Replace the
water pump and water pump gasket on engines
with a high mount water pump. Replace the parts
listed in Figure 283 (below)
283 (below) on engines with a low
mount water pump.
1
EMI 3000 Oil Filter
The oil filter (P/N 11-7382)
11-7382) and oil filter head
head
(P/N 11-8962) were changed to an EMI 3000 oil
filter (P/N 11-9182)
11-9182) and EMI 3000
3000 oil filter head
head
(P/N 11-9354).
11-9354). TK482E engines
engines start using
using the
EMI 3000 oil filter and filter head at serial
number A08750. TK486E/EH engines start using
the EMI 3000 oil filter and filter head at serial
number L32014.
An engine can be retrofitted to EMI 3000 by
replacing the oil filter head and oil filter with the
EMI 3000 oil filter head and EMI 3000 oil filter.
Use EMI 3000 Oil Filter Kit P/N 90-336. Engine
oil of API classification CI-4 (ACEA rating E3 in
Europe) or better is also required to allow 3000
hour oil change intervals.

1 3

2
4

1. Join
Jointt Gask
Gasket
et P/N
P/N 33-3
33-309
097
7
1. Oil
Oil Fil
Filte
terr Hea
Head
d P/N
P/N 11-89
1-8962
62
2. Joint
oint O-R
O-Ring
ing P/N 33-3
33-309
098
8
2. Oil Fi
Filter P/
P/N 11
11-7382
382
3. Water Pump P/
P/N 11
11-94
-9499
3. EMI
EMI 30
3000
00 Oil
Oil Fil
Filte
terr Hea
Head
d P/N
P/N 11-93
1-9354
54
4. Water
ater Pum
ump
p Gas
Gaske
kett P/N
P/N 33-3
33-309
096
6
4. EMI
EMI 300
3000
0OOil
il Filt
Filter
er P/N
P/N 11-
11-91
9182
82
Figure 283:
283: Retrofitting
Retrofitting Low Mount
Mount
Figure 284:
284: Oil Filter Heads
Heads and Oil Filters
ELC Compatible
Compatible Water
Water Pump

149
Engine History

Screw-In Oil Level Switch • Oil

Oil Pump
Pump – Oil
Oil pump
pump isis moun
mounte
tedd in the
the fron
frontt
gear case cover and is driven by the crankshaft
The oil level switch was changed from a push-in
oil level switch to a screw-in oil level switch. • Fron
Frontt Gear
Gear Cas
Casee Cove
Coverr – Oil
Oil pum
pump
p is moun
mounte
ted
d
TK482E engines start using the screw-in oil level in the front gear case cover
switch at serial number A15446. TK486E and
• Piston
Pistonss – Have
Have a differ
different
ent profile
profile and contai
contain
n
TK486E engines start using the screw-in oil level
steel inserts for the top ring
switch at serial number L49456.
• Pist
Piston
on Rin
Rings
gs – Hav
Havee diff
differ
eren
entt dime
dimens
nsio
ions
ns
• Valve
alve Cove
Coverr – Has
Has a new
new des
desig
ign
n
• Start
Starter
er – Has
Has higher
higher torque
torque,, but
but is smal
smaller
ler in
size than the Tier 1 and earlier starter
• Water
ater Pum
Pump p – Has
Has extra
extra ports
ports to pro
provi
vide
de
coolant to the cold start device
1 2
• Engi
Engine
ne Coo
Coola
lant
nt The
Therm
rmos
osta
tatt - Open
Openss at 160
160 F
(71 C)
• 950
950 CCA
CCA batt
batter
ery
y requ
requir
ired
ed for
for –15
–15 F (–26
(–26 C)
C)
ambient or below starting.
The most noticeable difference between a Tier 1
(and earlier) engine and a Tier 2 engine is the fuel
1. Push
Push-I
-In
n Oil
Oil Leve
Levell Swi
Switc
tch
h P/N
P/N 41-4
41-402
02 injection pump (see the following photographs).
2. Scre
Screw-
w-In
In Oil
Oil Lev
Level
el Swi
Switc
tch
h P/N
P/N 41-4
41-447
470
0
The Tier 1 and earlier engines use an in-line
injection pump. The Tier 2 engines use a
Figure 285:
285: Oil Level
Level Switches
Switches
mono-plunger and distributor injection pump. The
mono-plunger and distributor injection pump uses
EPA
EPA Tier 2 Compliance a higher injection pressure than the in-line
The engines were changed to comply with EPA injection pump. The higher injection
i njection pressure
Tier 2 regulations. The EPA Tier 2 compliant atomizes the fuel more efficiently,
efficiently, which reduces
engines are called the TK482V, TK486VB (Bus), the emissions.
and TK486VH (2600 rpm high speed). The
TK486V has a new serial number range that starts
at V00151. The TK486VH have a new serial
number range that starts at V00153.
The Tier 2 engines share many common parts 1
with the earlier engines, however the following
major parts are new on the Tier 2 engines:
• Cylind
Cylinderer Head
Head Assemb
Assemblyly – Compre
Compressi
ssion
on ratio
ratio
is slightly higher and the injection nozzles are
at a different angle
• Inject
Injection
ion Nozzle
Nozzless – Inject
Injection
ion nozzle
nozzless have
have a
higher popping pressure and use a different
mounting system
• Inje
Inject
ctio
ion
n Pump
Pump – Inj
Injec
ecti
tion
on pum
pump
p is a rot
rotar
ary
y
head design 1. In-L
n-Line In
Injection Pump

• Troch
Trochoid
oid Feed
Feed Pump
Pump – Rais
Raiseses the pressu
pressure
re of
of Figure 286:
286: Tier 1 (and Earlier)
Earlier) Engine
Engine
the fuel before it enters the
t he injection pump

150
 Engine History

1. Mono-
Mono-Pl
Plung
unger
er and Dist
Distri
ribut
butor
or Inje
Inject
ctio
ion
n Pum
Pump
p
Figure 287:
287: Tier 2 Engine

Engine History Chart

Engine Model and Serial Number for Start of Change
Change
TK482 TK482E TK486 TK486E TK486EH TK486V TK486VB TK486VH
Released K 00 1 0 1 K00101
Small Front Pulley K 00 2 0 2 K00152
Axial Rear Seal K 00 2 0 3 K00202
Universal Flywheel
K 00 2 0 3 K00409
Housing
Low Mount Water Pump K 00 2 5 0 K02406
EPA
EPA Tier 1 Compliant A 00 1 0 1 L0 0 1 0 1 L 0 0 10 1
Short Oil Line A 00 2 6 1 L0 0 2 6 1 L 0 0 26 1
ELC Water Pump A 05 6 7 9 L1 6 5 5 3 L 1 6 55 3
EMI 3000 Oil Filter A 08 7 5 0 L3 2 0 1 4 L 3 2 01 4
Screw In Oil Level
A 15 4 4 6 L4 9 4 5 6 L 4 9 45 6
Switch
EPA
EPA Tier 2 Compliant V00151 V00152 V 0 0 15 3

Injection Pump P/N 101-296 101-322 101-297 101-321 101-331 101-355 101-353 101-354
Injection Timing
12 10 12 10 11 NA NA NA
Degrees BTDC

151
Engine History

Engine Model Identification

1
The engine model is listed above the serial
number on the serial number nameplate. The
serial number nameplate is located on the side of
the valve cover on Tier 1 and earlier engines. The
serial number nameplate is located on the top of
the valve cover on Tier 2 engines.

1. Seri
Serial
al Nu
Numb
mber
er Nam
amep
epllate
ate
1. Engine Model Figure 290: Serial Number
Number Nameplate Location
Location
Figure 288: Typical Serial Number
Number Nameplate Tier
Tier 2 Engi
Engine
ne

1. Seri
erial Num
umbe
berr Na
Name
mepl
plat
ate
e
Figure 289: Serial Number
Number Nameplate Location
Location
Tier 1 and Earlier Engines

152
 Engine History

History of Engine Related Fuel Solenoid Timer

Components
Fuel Solenoid
The first fuel solenoid (P/N 41-1386) has a gray
plastic sleeve on its wires. It was replaced in a
campaign so it is seldom seen in the field.
fi eld.
The second fuel solenoid (P/N 41-3291) has a
clear plastic sleeve on its wires and the part
number is stamped on its metal housing. It was
changed to the third fuel solenoid to improve
reliability.
Some units use a fuel solenoid timer to
momentarily energize the pull-in coil in the fuel
solenoid. The fuel solenoid timer was changed in
June of 1997 to improve its reliability. The early
style fuel solenoid timer (P/N 41-1533) used a
large capacitor for the timing circuit. The late
style fuel solenoid timer (P/N 41-2191) used a
small capacitor and a transistor for the timing
timi ng
circuit. Both styles function the same and are
interchangeable.
1

The third fuel solenoid (P/N 41-4306) has a

brown plastic sleeve on its wires and the part
number is stamped on its metal housing. TK482E
engines start using the third fuel solenoid at serial
number A12790. TK486E/EH engines start using
the third fuel solenoid at serial number L45560.
The fourth fuel solenoid (P/N 41-6383) has a blue
plastic sleeve on its wires and the part number is
stamped on its metal housing. The hole in i n the end
of the solenoid has been enlarged to 0.455 in.
(11.56 mm). Tier 2 engines start using the fourth
fuel solenoid at serial number V01034.
1. Capacitor
The latest version replaces all earlier versions. Figure 292: Early Style
Style Fuel Solenoid Timer
Timer
P/N 41-1533
41-1533

1
1 2

1. Plastic Sleeve AGA337

• Gray = First
First Version
ersion P/N 41-1386
41-1386
1. Capacitor
• Clear
Clear = Seco
Second
nd Vers
Version
ion P/N 41-3291
41-3291
2. Transistor
• Brown
Brown = Third
Third Version
ersion P/N 41-4306
41-4306
Figure 293: Late Style
Style Fuel Solenoid
Solenoid Timer
• Blue
Blue = Fourt
Fourth
h Versi
Version
on P
P/N
/N 41-6
41-6383
383 P/N 41-2191
41-2191
2. 0.455 in. (11.56 mm) Hole
P/N 41-6383 Only
Figure 291: Fuel Solenoid
Solenoid

153
Engine History

Alternator Mounting Brackets for
Model 30 Trailer Units
The alternator mounting brackets used on some
Model 30 trailer units were changed in March of
1998 when the high mount water pump was
changed to a low mount water pump.
The alternator mounting brackets used on some
Model 30 trailer units with low mount water
pumps were changed to improve reliability. The
secondary alternator bracket is not used with the
late style alternator brackets. Refer to the unit
Parts Manual for more specific information.
2
1

1. Alternator
tor Bracket
Figure 294: Alternator
Alternator Mounting Brackets
Brackets
for
for High
High Moun
Mountt Water
ater Pump
Pump 2. Alte
Altern
rnat
ator
or Adju
Adjust
stin
ing
g Brac
Bracke
kett
3. Seco
Second
ndar
ary
y Alte
Altern
rnat
ator
or Brac
Bracke
kett
Figure 295: Early Style
Style Alternator Mounting
Mounting
Brackets for Low Mount Water Pump

1 2

1. Alternat
nator Brac
racket
2. Alte
Altern
rnat
ator
or Adju
Adjust
stin
ing
g Brac
Bracke
kett
Figure 296: Late Style Alternator
Alternator Mounting
Mounting
Brackets for Low Mount Water Pump

154
Index
A F
air heater, 131 fuel filter assembly, 118
alternator mounting brackets, 154 fuel injection nozzle
installation, 87
B repair, 112
battery cables, 123 testing, 111
battery, cold weather recommendation for tier 2 engine, fuel injection pump see injection pump 
123 fuel return line replacement, 113
bleeding air from fuel system, 96 fuel solenoid
history, 153
C replacement, 133
camshaft testing, 132
inspection and measurement, 50 fuel solenoid timer, 133
installation, 75 history, 153
specifications, 13, 18 operation, 133
camshaft bearing troubleshooting, 134
installation, 69 fuel system, 93
measurement, 43 air leaks, static, 121
cold start device, 109 bleeding air from, 96
checking operation, 109 description, 93
replacement, 110 FAQ (frequently asked questions), 121
compression test, 139 normal operation, 118
connecting rod operation and diagnosis, 118
inspection and measurement, 48 return system, 120
specifications, 14 solution for static air leaks, 121
connecting rod bearing static pressures, 120
installation, 73, 74 using clear fuel lines to diagnose problems, 122
crankcase breather system fuel transfer pump, 114
Tier 1 and earlier engines, 65 inspection, 115
Tier 2 engine, 66 operation, 114
crankcase pressure, checking, 67 testing, 115
crankshaft
inspection and measurement, 45 G
specifications, 14, 20 gear case replacement, 144
crankshaft bearings general specifications, 11, 17
specifications, 14, 20
cylinder I
boring, 41, 43 idler gear bushing, measurement, 49
measurement, 41 idler gear shaft, measurement, 49
sleeve installation, 42 idler gear, installation, 78
cylinder block injection nozzle see fuel injection nozzle 
inspection and measurement, 41 injection pump
specifications, 15, 20 installation, 76
cylinder head removal and installation, 105
assembly, 56 timing, Tier 1 and earlier engines, 97
disassembly, 51 timing, Tier 2 engines, 102
inspection and measurement, 51
installation, 78 L
specifications, 15, 20 low oil pressure, diagnosis, 90, 91
cylinder head bolts, torque sequence, 79 lubrication system, 89
pressure check, 80
E
engine M
assembly, 69 main bearing bores
disassembly, 27 checking alignment, 44
history, 147 measurement, 44
model identification, 152 main bearing, installation, 69
exhaust gas specifications, 22 manifolds, inspection and measurement, 65

155
Index

O timing gear lash, checking, 33

oil pan, installation, 81 timing gears
oil pressure, low, diagnosis, 90, 91 inspection and measurement, 49
oil pump specifications, 15, 20
inspection and measurement, 61 timing, 78
Tier 1 and earlier engines, 61 timing marks, 78
Tier 2 engine, 62 torque values, 23
installation, Tier 1 and earlier engines, 76 trochoid feed pump, 107
specifications, 16, 21 o-ring replacement, 108
replacement, 107
P
piston V
inspection and measurement, 46 valve clearance, adjustment, 137
installation, 72 valve depth, 52
specifications, 13, 19 measurement, 53
piston rings valve guide
installation, 72 measurement, 52
measurement, 47 replacement, 52
specifications, 13, 19 valve seat
push rod, inspection and measurement, 60 grinding, 54
inspection, 54
R replacing, 55
rear seal width measurement, 54
installation, 82 valve spring, inspection and measurement, 56
removal, 37 valve train specifications, 12, 17
rear seal housing, installation, 82 valves
rocker arm assembly grinding, 53
inspection, 58 inspection and measurement, 53
installation, 79 valve margin, measurement, 53
rocker arm bushing, measurement, 59
rocker arm shaft, measurement, 59 W
rod, connecting see connecting rod  water pump, inspection, 64
rod, push see push rod  wrist pin
run in, 137 inspection and measurement, 47
dynamometer run in procedure, 137 specifications, 13, 19
procedure without dynamometer, 137 wrist pin bushing, replacement, 49

S
special tools, 24
specifications, 11
exhaust gas, 22
Tier 1 and Earlier - TK482, TK482E, TK486,
TK486E, and TK486EH, 11
Tier 2 - TK486V, TK486VB, and TK486VH, 17
starter, 123
assembly, 130
description, 125
disassembly, 125
motor inspection, 127
no load test, 131
pinion assembly, inspection, 129
solenoid, inspection, 130
specifications, 16, 21

T
tappet
inspection and measurement, 60
installation, 75
tappet bores, measurement, 44

156