Page 2 If further information is required, Thermo King Corporation should be consulted. Sale of product shown in the Manual is subject to Thermo King’s terms and conditions including, but not limited to, the Thermo King Limited Express Warranty. Such terms and conditions are available upon request.
Page 3 Specifications 1 Engine Disassembly 2 Inspection and Reconditioning 3 Engine Assembly 4 Lubrication System 5 Fuel System 6 Electrical 7 Run In 8...
Page 4: Table Of Contents
TK 2.44 & TK 3.66 Diesel Engine Specifications ....... . .
Page 5 Table of Contents (Continued) Fuel System ................83 Table of Contents.
Page 6: Specifications
TK 3.95 Diesel Engine Specifications ..18 Torque Values for TK 2.44 & TK 3.66 Engines ..23 Torque Values for TK 2.49 & TK 3.74 Engines ..24 Torque Values for TK 3.88 Engine .
Page 7: Tk 2.44 & Tk 3.66 Diesel Engine Specifications
TK 2.44 & TK 3.66 Diesel Engine Specifications The TK 2.44 is a two cylinder engine. The TK 3.66 is a three cylinder engine. Unless it is otherwise noted, the specifications for both of these engines are the same. General TK 2.44...
Page 8 TK 2.44 & TK 3.66 Diesel Engine Specifications (Rev 1/97) Valve Train (continued) Standard Dimensions Wear Limit Valve Seat Width Intake .045 in. (1.15 mm) .065 in. (1.65 mm) Exhaust .056 in. (1.41 mm) .075 in. (1.91 mm) Push Rod Length 4.488-4.528 in.
Page 9 TK 2.44 & TK 3.66 Diesel Engine Specifications (Rev 1/97) Piston, Piston Rings, and Wrist Pin (continued) Piston Ring Groove Width Top Ring Groove .0612-.0618 in .(1.555-1.570 mm) Middle Ring Groove .0598-.0604 in. (1.520-1.535 mm) Bottom Ring Groove .1382-.1388 in. (3.510-3.525 mm)
Page 10 TK 2.44 & TK 3.66 Diesel Engine Specifications (Rev 1/97) Crankshaft and Crankshaft Bearings (continued) Rod Bearing Inside Diameter Standard 1.4173-1.4190 in. (36.000-36.042 mm) 1.4201 in. (36.070 mm) Undersize 1.4075-1.4091 in. (35.750-35.792 mm) 1.4102 in. (35.820 mm) Rod Bearing Clearance .0008-.0028 in.
Page 11 TK 2.44 & TK 3.66 Diesel Engine Specifications (Rev 1/97) Starter No Load Test Voltage 11 volts Current 180 amps @ 11 volts Speed More than 3500 rpm @ 11 volts Commutator Outside Diameter 1.18 in. (30.0 mm) 1.14 in. (29.0 mm)
Page 12: Tk 2.49 & Tk 3.74 Diesel Engine Specifications
TK 2.49 & TK 3.74 Diesel Engine Specifications The TK 2.49 is a two cylinder engine. The TK 3.74 is a three cylinder engine. Unless it is otherwise noted, the specifications for both of these engines are the same. General TK 2.49 TK 3.74 Model...
Page 13 TK 2.49 & TK 3.74 Diesel Engine Specifications (Rev 1/97) Valve Train (continued) Standard Dimensions Wear Limit Valve Seat Width Intake .045 in. (1.15 mm) .065 in. (1.65 mm) Exhaust .056 in. (1.41 mm) .075 in. (1.91 mm) Push Rod Length 4.488-4.528 in.
Page 14 TK 2.49 & TK 3.74 Diesel Engine Specifications (Rev 1/97) Piston, Piston Rings, and Wrist Pin (continued) Piston Ring Groove Width Top Ring Groove .0610-.0618 in .(1.550-1.570 mm) Middle Ring Groove .0622-.0628 in. (1.580-1.595 mm) Bottom Ring Groove .1185-.1191 in. (3.010-3.025 mm) Piston Ring Width Top Ring .0579-.0587 in.
Page 15 TK 2.49 & TK 3.74 Diesel Engine Specifications (Rev 1/97) Crankshaft and Crankshaft Bearings (continued) Rod Bearing Inside Diameter Standard 1.4178-1.4185 in. (36.013-36.029 mm) 1.4197 in. (36.060 mm) Undersize 1.4080-1.4086 in. (35.763-35.779 mm) 1.4098 in. (35.810 mm) Rod Bearing Clearance .0013-.0023 in.
Page 16 TK 2.49 & TK 3.74 Diesel Engine Specifications (Rev 1/97) Starter No Load Test Voltage 11 volts Current 180 amps @ 11 volts Speed More than 3500 rpm @ 11 volts Commutator Outside Diameter 1.18 in. (30.0 mm) 1.14 in. (29.0 mm)
Page 17: Tk 3.88 Diesel Engine Specifications
TK 3.88 Diesel Engine Specifications General TK 3.88 Model 3TNA72 Type Four Stroke Cycle Water Cooled Number of Cylinders Bore 2.83 in. (72.0 mm) Stroke 2.83 in. (70.2 mm) Displacement 53.6 cu. in. (879 cc) Power Rating 15.2 hp (11.2 kW) Compression Ratio 22.3 to 1 Direction of Rotation...
Page 18 TK 3.88 Diesel Engine Specifications (Rev 1/97) Valve Train (continued) Standard Dimensions Wear Limit Valve Seat Width Intake 0.57 in. (1.44 mm) .078 in. (1.98 mm) Exhaust .070 in. (1.77 mm) .089 in. (2.27 mm) Push Rod Length 5.551-5.591 in. (141.00-142.00 mm) Rocker Arm Bushing Inside Diameter .4724-.4732 in.
Page 19 TK 3.88 Diesel Engine Specifications (Rev 1/97) Piston, Piston Rings, and Wrist Pin (continued) Piston Ring Groove Width Top Ring Groove .0616-.0622 in .(1.565-1.580 mm) Middle Ring Groove .0598-.0604 in. (1.520-1.535 mm) Bottom Ring Groove .1382-.1388 in. (3.510-3.525 mm) Piston Ring Width Top Ring .0579-.0587 in.
Page 20 TK 3.88 Diesel Engine Specifications (Rev 1/97) Crankshaft and Crankshaft Bearings (continued) Rod Bearing Inside Diameter Standard 1.5748-1.5765 in. (40.000-40.042 mm) 1.5776 in. (40.070 mm) Undersize 1.5650-1.5666 in. (39.750-39.792 mm) 1.5677 in. (39.820 mm) Rod Bearing Clearance .0008-.0028 in. (0.020-0.072 mm) .0059 in .(0.150 mm) End Play .0035-.0107 in.
Page 21 TK 3.88 Diesel Engine Specifications (Rev 1/97) Starter No Load Test Voltage 11 volts Current 180 amps @ 11 volts Speed More than 3500 rpm @ 11 volts Commutator Outside Diameter 1.18 in. (30.0 mm) 1.14 in. (29.0 mm)
Page 22: Tk 3.95 Diesel Engine Specifications
TK 3.95 Diesel Engine Specifications General TK 3.95 Model 3TNE72KC Type Four Stroke Cycle Water Cooled Number of Cylinders Bore 2.83 in. (72.0 mm) Stroke 3.07 in. (78.0 mm) Displacement 58.2 cu. in. (953 cc) Power Rating 16.8 hp (12.5 kW) Compression Ratio 22.9 to 1 Direction of Rotation...
Page 23 TK 3.95 Diesel Engine Specifications (Rev 1/97) Valve Train (continued) Standard Dimensions Wear Limit Valve Seat Width Intake 0.57 in. (1.44 mm) .078 in. (1.98 mm) Exhaust .070 in. (1.77 mm) .089 in. (2.27 mm) Push Rod Length 5.551-5.591 in. (141.00-142.00 mm) Rocker Arm Bushing Inside Diameter .4724-.4732 in.
Page 24 TK 3.95 Diesel Engine Specifications (Rev 1/97) Piston, Piston Rings, and Wrist Pin (continued) Piston Ring Groove Width Top Ring Groove .0610-.0618 in .(1.550-1.570 mm) Middle Ring Groove .0622-.0628 in. (1.580-1.595 mm) Bottom Ring Groove .1185-.1191 in. (3.010-3.025 mm) Piston Ring Width Top Ring .0579-.0587 in.
Page 25 TK 3.95 Diesel Engine Specifications (Rev 1/97) Crankshaft and Crankshaft Bearings (continued) Rod Bearing Inside Diameter Standard 1.5753-1.5759 in. (40.013-40.029 mm) 1.5772 in. (40.060 mm) Undersize 1.5655-1.5661 in. (39.763-39.779 mm) 1.5673 in. (39.810 mm) Rod Bearing Clearance .0013-.0023 in. (0.033-0.059 mm) .0059 in .(0.150 mm) End Play .0035-.0107 in.
Page 26 TK 3.95 Diesel Engine Specifications (Rev 1/97) Starter No Load Test Voltage 11 volts Current 180 amps @ 11 volts Speed More than 3500 rpm @ 11 volts Commutator Outside Diameter 1.18 in. (30.0 mm) 1.14 in. (29.0 mm)
Page 27: Torque Values For Tk 2.44 & Tk 3.66 Engines
Torque Values for TK 2.44 & TK 3.66 Engines Dia. x Pitch N•m ft-lb Description (mm) Camshaft Thrust Plate Mtg. Bolt 9.8-11.8 7.2-8.7 1.0-1.2 Connecting Rod Bolt 22.6-27.5 16.6-20.3 2.3-2.8 Crankshaft Pulley Bolt 12x1.25 83.4-93.2 61.5-68.7 8.5-9.5 Cylinder Head Mtg. Bolt 8x1.25...
Page 28: Torque Values For Tk 2.49 & Tk 3.74 Engines
Torque Values for TK 2.49 & TK 3.74 Engines Dia. x Pitch N•m ft-lb Description (mm) Camshaft Thrust Plate Mtg. Bolt 9.8-11.8 7.2-8.7 1.0-1.2 Connecting Rod Bolt 22.6-27.5 16.6-20.3 2.3-2.8 Crankshaft Pulley Bolt 12x1.25 83.4-93.2 61.5-68.7 8.5-9.5 Cylinder Head Mtg. Bolt 8x1.25 37.3-41.2 27.5-30.4...
Page 29: Torque Values For Tk 3.88 Engine
Torque Values for TK 3.88 Engine Dia. x Pitch N•m ft-lb Description (mm) Camshaft Thrust Plate Mtg. Bolt 9.8-11.8 7.2-8.7 1.0-1.2 Connecting Rod Bolt 22.6-27.5 16.6-20.3 2.3-2.8 Crankshaft Pulley Bolt 12x1.25 83.4-93.2 61.5-68.7 8.5-9.5 Cylinder Head Mtg. Bolt 9x1.25 58.8-63.7 43.4-47.0 6.0-6.5 Engine Lift Bracket Mtg.
Page 30: Torque Values For Tk 3.95 Engine
Torque Values for TK 3.95 Engine Dia. x Pitch N•m ft-lb Description (mm) Camshaft Thrust Plate Mtg. Bolt 9.8-11.8 7.2-8.7 1.0-1.2 Connecting Rod Bolt 22.6-27.5 16.6-20.3 2.3-2.8 Crankshaft Pulley Bolt 12x1.25 83.4-93.2 61.5-68.7 8.5-9.5 Cylinder Head Mtg. Bolt 9x1.25 58.8-63.7 43.4-47.0 6.0-6.5 Engine Lift Bracket Mtg.
Page 31 Engine Disassembly 2 Table of Contents ....27 Engine Disassembly ....29...
Page 32: Engine Disassembly
Engine Disassembly Before disassembling the engine, drain the engine oil and While disassembling the engine, note things such as the coolant, remove the following parts from the engine, and position of dowel pins and O-rings, and the existing timing remove the engine from the unit: marks and bearing cap marks.
Page 33: Engine Disassembly
Engine Disassembly (Rev 1/97) Crankcase Breather Hose Water Pump Fuel Injection Line Valve Cover Exhaust Manifold Starter Flywheel aea202 Oil Pan TK 3.88 Rear View...
Page 34 Engine Disassembly (Rev 1/97) Remove the exhaust manifold. Remove the fuel injection lines. Cover all the injection lines, fuel lines, and fittings with plastic covers or tape. The smallest amount of dirt can damage the fuel system. Remove the crankcase breather hose. Remove the fuel injection return lines.
Page 35 Engine Disassembly (Rev 1/97) 11. Remove the oil filter and the oil pressure control valve. 14. Remove the rocker arm assembly by removing the nuts On the TK 3.88 and TK 3.95 the oil pressure control and (and bolt on three cylinder engines) that mount the valve is attached to the oil filter adapter.
Page 36 Engine Disassembly (Rev 1/97) 17. Break each cylinder head bolt loose 1/4 to 1/2 turn in a 20. Remove the starter mounting flange. crisscross pattern starting at the ends. Then remove the NOTE: The bolts at the bottom of the starter mount- cylinder head bolts.
Page 37 Engine Disassembly (Rev 1/97) 24. Remove the timing gear cover. 25. Check the timing gear lash. If the gear lash is within specifications (refer to Specifications), the gears can probably be reused. If the gear lash is excessive, some or all of the gears must be replaced to meet the specifi- cations.
Page 38 Engine Disassembly (Rev 1/97) 28. Remove the mounting bolts from the camshaft thrust 31. Make sure the oil has been drained and remove the oil plate by turning the camshaft gear to access the bolts pan and the oil intake pipe. through the holes in the gear.
Page 39 Engine Disassembly (Rev 1/97) 32. Remove the timing gear housing and injection pump. 35. Remove the connecting rod caps. aea221 aea223 Timing Gear Housing and Injection Pump Removing Connecting Rod Caps 33. Remove the ring ridge from the top of each cylinder, if 36.
Page 40 Engine Disassembly (Rev 1/97) NOTE: The upper rear main bearing (flywheel end) has a thrust bearing on each side. Make sure to remove these two thrust bearings. aea225 Rear Main Bearing Cap 38. Carefully remove the crankshaft from the block. aea226 Upper Rear Main Bearing...
Page 41 Inspection and Reconditioning 3 Table of Contents ........39 Inspection and Reconditioning .
Page 42: Inspection And Reconditioning
Inspection and Reconditioning Cylinder Block NOTE: Refer to the Specifications Section for specific dimensions that are not given in this section. Inspect the cylinder block for cracks, damage, and dis- This section covers the cleaning, inspection, overhaul, and tortion. Use a straight edge and a feeler gauge to check assembly of individual engine components.
Page 43: Inspection And Reconditioning
Inspection and Reconditioning (Rev 1/97) aea228 aea230 Checking Block Distortion Check each cylinder for out of round, taper, pocketing, Cylinder Measuring Positions or any other damage that would require boring the cyl- If the cylinders must be bored, determine which over- inders.
Page 44 The bottom end of a cylinder sleeve has a slightly dimensions in the illustrations below. smaller outside diameter than the rest of the sleeve. aea231 TK 2.44, TK 2.49, TK 3.66, aea233 and TK 3.74 Pressing Tool Cylinder Sleeve Spray oil on the outside of the cylinder sleeve or on the inside of the cylinder bore in the block.
Page 45 Inspection and Reconditioning (Rev 1/97) Bore and hone each cylinder sleeve to obtain the Measure the middle and rear camshaft bearings. If the correct piston clearance. middle or rear camshaft bearings are larger than the wear limits (refer to Specifications), or if the surfaces Measure each piston.
Page 46 Inspection and Reconditioning (Rev 1/97) Measure the main bearing bores both vertically and 10. Measure each tappet bore in the block. If any of the tap- horizontally. If the main bearing bores are more than pet bores are larger than the wear limit (refer to Specifi- .001 in.
Page 47 Inspection and Reconditioning (Rev 1/97) Only the .010 in. (0.25 mm) undersize rod bearings are available. Refer to Specifications for the suggested out- side diameter of undersized rod journals. NOTE: The most accurate method of determining the outside diameter of the undersized rod journals is to install the rod caps with the undersized bearing inserts in place.
Page 48 Inspection and Reconditioning (Rev 1/97) Measure the outside diameter of each piston. This mea- surement should be taken perpendicular to the wrist pin at a specific distance, called “A”, above the bottom of the piston skirt. Refer to Specifications for the sug- gested values for distance “A”.
Page 49: Connecting Rods
Inspection and Reconditioning (Rev 1/97) Use a new set of piston rings and a feeler gauge to the wrist pin through the connecting rod bushing, but check the clearance between the rings and the ring the wrist pin should rotate freely. grooves.
Page 50 Inspection and Reconditioning (Rev 1/97) Measure the inside diameter of the connecting rod bear- Use a connecting rod alignment fixture to check each ings. If any of the connecting rod bearings are larger rod for twist and parallelism. The service limit for both than the wear limits (refer to Specifications) or show twist and parallelism is .003 in.
Page 51 Inspection and Reconditioning (Rev 1/97) Timing Gears Inspect the timing gears for chipped or excessively worn teeth, and for any cracks on or between the teeth. The gear lash should have been checked during the dis- assembly of the engine. If not, check the gear lash dur- ing the assembly of the engine.
Page 52: Cylinder Head
Inspection and Reconditioning (Rev 1/97) clearance again. If the clearance still exceeds the wear limit after replacing the thrust plate, replace the cam- shaft gear also. To remove the camshaft gear use a stan- dard gear puller or a hydraulic press. Install the camshaft gear with a hydraulic press.
Page 53: Disassembly
Inspection and Reconditioning (Rev 1/97) deck. The standard distortion is .002 in. (0.05 mm). The top of the valve spring seat) is correct. Refer to Specifi- wear limit is .006 in. (0.15 mm). Resurface or replace cations for the recommended valve guide projections. the head if the distortion exceeds the wear limit.
Page 54: Valve Depth
Inspection and Reconditioning (Rev 1/97) Valve Depth grinding the valve or valve seat, the valve, the valve seat or both may need replacement. If the valve depth is over the The valve depth is the distance between the cylinder head wear limit after grinding the valve or the valve seat, the deck and the valve.
Page 55: Valve Seat Replacement
Inspection and Reconditioning (Rev 1/97) After grinding the valves, check the valve margin. Replace any valve with a valve margin that is less than .039 in. (1.00 mm). NOTE: Valves with a valve margin that is not even after being ground are slightly bent. These valves should be replaced if the valve margin is less than .039 in.
Page 56: Valve Springs
Inspection and Reconditioning (Rev 1/97) After grinding the valve seats, install the valves in their Valve Springs respective valve seats and check the valve depth of Clean and inspect the valve springs. Replace valve each. Replace any valve that has been ground and now springs that are cracked, or significantly scratched or has a valve depth over the wear limit.
Page 57 Inspection and Reconditioning (Rev 1/97) Lightly oil the valve stem seals and place them on the valve guides. NOTE: New valve stem seals should always be used when assembling the cylinder head. Oil the valve stem and place the valves in their respec- tive valve seats.
Page 58: Valves
Inspection and Reconditioning (Rev 1/97) Place the valve in the valve seat and use a valve Remove the valve and wipe the lapping compound lapping tool to spin the valve against the valve seat off the valve seat and the valve face. The valve seat for a short time.
Page 59 Inspection and Reconditioning (Rev 1/97) Remove the rocker arms, the rocker arm supports, and Measure the inside diameter of each rocker arm bush- the springs from the rocker arm shaft. Keep these parts ing. If a rocker arm bushing is larger than the wear limit in order, to make sure they will be assembled correctly.
Page 60 Inspection and Reconditioning (Rev 1/97) Place each push rod on a completely flat surface and Measure the outside diameter of each tappet. Replace use a feeler gauge to check the how much the push rod any tappets that are smaller than the wear limit (refer to is bent.
Page 61: Oil Pressure Control Valve
Inspection and Reconditioning (Rev 1/97) aea282 aea280 Checking Clearance Between Checking Clearance Between Oil Pump Body and Outer Rotor Rotor Plate and Rotors Measure the outside diameter of the rotor 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 clear- ance.
Page 62 Inspection and Reconditioning (Rev 1/97) Check the water pump bearing. If the water pump shaft does not rotate smoothly, or if it is loose or wobbly, replace the water pump. Manifolds Inspect the manifolds for cracks, damage, or a build up of carbon.
Page 63 Engine Assembly Table of Contents ....63 Engine Assembly..... 65 Assembly Precautions .
Page 64: Engine Assembly
Engine Assembly Assembly Precautions NOTE: Refer to the Specifications section for specifica- tions not given in this section. After the components of the engine have been repaired, reconditioned, or replaced, the engine can bee assembled. It is very important to keep the engine as clean as possible while it is being assembled, because dirt is one of the major factors that contributes to the failure of rebuilt engines.
Page 65 Engine Assembly (Rev 1/97) aea290 Install Lower Main Bearings aea288 Install Upper Thrust Bearings Carefully lay the crankshaft in the upper main bearing inserts. aea291 Install Lower Thrust Bearings aea289 Install Crankshaft Place the new lower main bearing inserts in the main bearing caps.
Page 66 Engine Assembly (Rev 1/97) Place a piece of plastigauge on each main bearing jour- nal and install the main bearing caps in their proper positions. The cast arrows on the main bearing caps are labeled FW and should point to the rear (flywheel end) of the engine.
Page 67 Engine Assembly (Rev 1/97) 15. Before installing the piston rings, check the end gap of each ring. Place a ring in its respective cylinder. Level the ring in the cylinder with a piston and check the end gap with a feeler gauge. If the end gap is not correct (refer to Specifications), check to make sure that the cylinder bore is the correct size and that the ring is the correct size.
Page 68 Engine Assembly (Rev 1/97) 17. Place the oil ring expander in the bottom ring groove. 18. Place the oil ring in the bottom ring groove over the expander with the end gap of the oil ring positioned 180 degrees from the joint in the expander. 19.
Page 69 Engine Assembly (Rev 1/97) 28. Lubricate the rod journal and the rod bearings of each connecting rod with engine assembly compound or engine oil. Install and torque the rod caps. 29. After installing each piston assembly, turn the crank- shaft over several times. Check to see that the bearings move freely and that the pistons and rings slide through the cylinders easily and do not scratch the cylinder walls.
Page 70 Engine Assembly (Rev 1/97) 37. Install and tighten the camshaft thrust plate mounting 40. Place the thrust washer and the snap ring on the idler bolts. gear shaft. The sharp edge of the thrust washer and the snap ring should face away from the idler gear. aea306 Install Camshaft aea308...
Page 71 Engine Assembly (Rev 1/97) 43. Make sure the dowel pins are in place in the top of the block. aea312 Two Cylinder Head Bolt Torque Sequence aea310 Check Dowel Pins 44. Place a new head gasket on the block. Align the head gasket with the dowel pins and make sure the engine model inscription is facing up.
Page 72 Engine Assembly (Rev 1/97) 47. Install the push rods in their respective openings. Make 51. Torque the rocker arm mounting nuts (and bolt). Refer sure the push rods are seated properly in the tappets. to Specifications for the recommended torque. Lubricate the socket in the top end of each push rod 52.
Page 73 Engine Assembly (Rev 1/97) 54. Pressure check the engine’s lubrication system, if possi- cates that the oil clearance is too large, the wrong ble. A pressure check can point out problem areas in part has been used, or a component is damaged or the lubrication system, and it eliminates the possibility missing.
Page 74 Engine Assembly (Rev 1/97) (3) Install the oil pan mounting bolts. Make sure (4) Install the oil intake pipe. the rear end of the block and the oil pan are flush before tightening the mounting bolts. aea322 Install Oil Intake Pipe (5) Place a thin layer of sealant on the sealing sur- face of the oil pan cover and place the oil pan cover in position on the oil pan.
Page 75 Engine Assembly (Rev 1/97) 59. Replace the rear seal by pressing the old seal out of the 64. Place the starter mounting flange in position on the rear rear seal housing and pressing a new seal in. of the block and make sure to align the dowel pins. 60.
Page 76 Engine Assembly (Rev 1/97) 70. Place a thin layer of sealant on the sealing surface of the timing gear cover. 71. Place the timing gear housing in position and make sure to align the dowel pins. 72. Install and tighten the mounting bolts for the timing gear cover.
Page 77 Engine Assembly (Rev 1/97) 79. Install the intake manifold with a new gasket. 80. Install the fuel return lines. 81. Install the crankcase breather hose. 82. Install the fuel injection lines. 83. Install the exhaust manifold with a new gasket. 84.
Page 78 Lubrication System Table of Contents ....79 Lubrication System....81...
Page 79: Lubrication System
Lubrication System These engines all use a pressure lubrication system. A tro- Some of the oil supplied to the main bearings flows through choid type oil pump circulates the oil through the system to passages in the cylinder block to the camshaft bearings. lubricate the engine components.
Page 80 Fuel System Table of Contents ....83 Fuel System ..... . . 85 Bleeding Air From The Fuel System .
Page 81: Fuel System
Fuel System The fuel systems for these engines are basically the same. Injection Pump The major components of the fuel system are: Injection Nozzles Fuel Tank The fuel is drawn from the fuel tank, through the prefilter (if Prefilter (Optional) used), to the electric fuel pump.
Page 82: Bleeding Air From The Fuel System
The work should be done in a relatively clean area and the work should be completed in the shortest time possible. Thermo King recommends that any major injection pump or nozzle repairs be done by a qualified diesel injection service shop.
Page 83 Fuel System (Rev 1/97) Energize the electric fuel pump by turning the unit on. Tighten the air bleed screw when air bubbles are no longer present in the fuel flowing out of the air bleed screw. Loosen the injection lines at the injection nozzles. Crank the engine over with the starter until fuel appears at all of the injection nozzles.
Page 84 Fuel System (Rev 1/97) Adjust Plunger Clearance With the engine running in high speed, check the engine speed and adjust as necessary for that particular Remove the lead seal and the cap nut from the fuel unit. adjustment screw. With the engine running in high speed, turn the maxi- mum speed stop screw in (clockwise) until it touches the governor linkage.
Page 85 Fuel System (Rev 1/97) Check the plunger clearance with a feeler gauge. The Place the fuel limit screw assembly in the governor plunger clearance should be .016 in. (0.40 mm). Use housing. Make sure the lock nut is turned out toward the two plunger lock screws to adjust the plunger clear- the cap nut enough to allow adjustment.
Page 86 Fuel System (Rev 1/97) CAUTION: Do not push on the fuel control rack too Turn the fuel limit screw in or out to align the scribe hard or the governor spring will stretch and the ten- mark on the fuel control rack with the edge of the guide sioner lever will move away from the fuel limit screw.
Page 87: Fuel Injection Pump
Fuel System (Rev 1/97) 11. Recheck the alignment of the scribe mark and the edge Remove the nuts from the four studs on top of injection of the guide plate. pump. 12. Turn the unit off and connect 20 wire to the reset Center the fuel control rack and remove the injection switch.
Page 88 Fuel System (Rev 1/97) Remove the plunger guide, the plunger shims, the plunger spring, the plunger spring retainers, the fuel control pinion, and the plunger. NOTE: Make sure to keep the plunger shims with their respective plunger guides. aea347 Fuel Injection Pump Assembly aea346 Plunger and Associated Components Remove the fuel control rack.
Page 89: Major Component Inspection
Fuel System (Rev 1/97) Major Component Inspection Slowly tilt them up to an angle of approximately 60 degrees. The plunger should slide smoothly into NOTE: If a plunger assembly or a plunger guide assembly the plunger barrel. is replaced the injection pump must be recalibrated by a qualified diesel injection service shop.
Page 90: Plunger Guide Assembly
Fuel System (Rev 1/97) Replace the fuel control pinions if the gear teeth show excessive wear or damage. Assembly NOTE: The steps in this procedure that describe the com- ponents for an individual cylinder must be performed on the components of each cylinder. Place the plunger barrel seal in the injection pump body.
Page 91: Injection Pump Timing
Fuel System (Rev 1/97) 13. Install the plunger guide stopper by inserting it into the injection pump body and the slot in the side of the plunger guide. 14. Release the plunger guide. The plunger spring and the plunger guide stopper should now hold the plunger guide in place.
Page 92: Timing Injection Pump To Engine
Fuel System (Rev 1/97) especially if the injection pump has been repaired or CAUTION: Before turning the engine by hand, loosen all replaced recently. the injection lines at the injection nozzles to prevent the any possibility that the engine might fire. Timing Injection Pump To Engine Rotate the engine in the normal direction of rotation NOTE: The cylinders on these engines are numbered...
Page 93 Fuel System (Rev 1/97) number 1 cylinder should be lined up with the index NOTE: On the three cylinder engines the order for the fly- timing mark on the starter mounting plate. wheel timing marks is 1, 2, 3, but the firing order is 1,3,2. The reason for this is that the engine fires every 240 If the timing marks do not line up, timing shims must degrees of crankshaft rotation.
Page 94 Fuel System (Rev 1/97) CAUTION: Keep your hands away from the nozzle spray. The nozzle spray is at such high pressure that it can break the skin and penetrate into the underlying tissue. Such an injury is very painful and can lead to serious complica- tions such as blood poisoning.
Page 95 Fuel System (Rev 1/97) Repair Remove the nozzle valve and seat set from the nozzle nut and submerge them in diesel fuel. Make sure to Place the nozzle body in a vise that has aluminum jaws keep them together as a set. or jaw covers.
Page 96 Fuel System (Rev 1/97) Release the nozzle valve. The nozzle valve should slide into the nozzle seat by itself. Rotate the nozzle valve in the nozzle seat about 90 degrees at a time, and repeat this test four or five times.
Page 97: Electrical
Electrical Table of Contents ....101 Electrical ......103 Fuel Solenoid .
Page 98: Electrical
Electrical Glow Plugs The glow plugs heat the prechambers in the cylinder head. This helps the engine start easier in cold weather. The glow plugs can be tested with an ohmmeter. Each glow plug should have a resistance of 0.7 to 1.0 ohms. Replace glow plugs with a resistance that is out of this range.
Page 99 Electrical (Rev 1/97) Place the brush springs on the sides or the brush holders. Remove the positive brushes (the brushes con- nected to the stator) from the brush holders. Pull the negative brushes (the brushes 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.
Page 100: Major Component Inspection
Electrical (Rev 1/97) Remove what remains of the pinion assembly from the pinion housing. Remove the pinion assembly retainer, pinion shaft retainer, pinion clutch, and pinion shaft spring from the pinion shaft. Disassemble the starter solenoid. Remove the three screws from the cover and aea370 remove the cover from the starter solenoid.
Page 101 Electrical (Rev 1/97) Visually check the armature. Replace the armature if there is any sign of thrown solder, discolored windings, bubbled insulation, burned or damaged commutator bars, or damaged shafts. Place the armature in a lath and check the commu- tator and the core with a dial indicator.
Page 102: Gears And Bearings
Electrical (Rev 1/97) Turn the commutator or the core down if they resistance between each commutator bar and the exceed this limit. Also turn the commutator down armature core or shafts. Replace the armature if to remove any wear grooves made by the brushes. there is any continuity between the armature coils and the core.
Page 103: Starter Solenoid
Electrical (Rev 1/97) Check the overrunning clutch. Hold the pinion clutch. Place the pinion shaft in the pinion clutch and try to rotate the pinion shaft in both directions. The pinion shaft should rotate freely in one direc- tion and should not rotate in the other direction. Replace the pinion clutch if the pinion shaft does not rotate smoothly in the proper direction, or if it aea379...
Page 104: No Load Test
Electrical (Rev 1/97) Release the pinion gear and let it push the stop ring Install the two screws that fasten the brush ring over the snap ring. Make sure the snap ring is assembly to the commutator cover. seated in the groove in the stop ring. 11.
Page 105 Electrical (Rev 1/97) Connect the starter to a 12 volt battery as shown in the Test the hold-in coil. illustration. Energize the hold-in coil by placing a jumper When the switch is turned on, check the current, volt- between the 8D pin in the fuel solenoid connector age, and starter speed.
Page 106 Electrical (Rev 1/97) Place the O-ring in the groove in the end of the fuel injection pump. Make sure the O-ring is positioned cor- rectly during installation to avoid damage and leaks. Install the new fuel solenoid. Turn the unit off and make sure to connect the 20 wire to the reset switch.
Page 107: Run In Procedure
Run In Procedure Table of Contents ....113 Run In ......115 Compression Test .
Page 108: Run In
Mount the unit on a truck and run the unit in high speed Thermo King recommends an engine be run in on a dyna- heat with truck doors open for 2-10 hours.
Page 109 Run In (Rev 1/97) Adjust the valves if necessary by loosening the lock nut and turning the adjustment screw until the valve clear- ance is correct. aea381 Timing Marks CAUTION: Before turning the engine by hand, loosen all the injection lines at the injection nozzles to aea317 prevent the any possibility that the engine might fire.
Page 110: Three Cylinder Procedure
Run In (Rev 1/97) Three Cylinder Procedure first. Then rotate the engine past the number 2 cylin- der timing marks to the number 3 cylinder timing Remove the valve cover. marks and check the number 3 cylinder. Finally, Torque the cylinder head bolts to the proper torque. rotate the engine past the number 1 cylinder timing marks to the number 2 cylinder timing marks and NOTE: The cylinders on these engines are numbered...
Page 111 Run In (Rev 1/97) If the rocker arms and push rods are tight, the num- If the rocker arms and push rods are tight, the num- ber 1 cylinder is at top dead center of the exhaust ber 3 cylinder is at top dead center of the exhaust stroke.
Page 112 Run In (Rev 1/97) • A Schrader valve must be installed in the end of the Repeat this procedure on each cylinder. adapter that is facing the combustion chamber. Compare the final readings of all the cylinders. • The compression tester and connecting hose must have 10.

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