Table of Contents
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Part ONE
POWER PLANT
Chapter
General Engine Overhaul, Inspection, and Repair
Section
Page
1
2
3
4
5
6
7
8
9
Trouble Shooting ................................................................... .
5
8
10
15
15
21
23
27
31
32
Tune-Up .......................................................................... .
Engine Removal and Installation ....................................................... .
Intake and Exhaust Manifolds ......................................................... .
Rocker Mechanism, Cylinder Heads, Valves, Valve Lash Adjustment, and Valve Timing ......... .
Timing Chain and Sprockets, Timing Gears, and Camshaft .................................. .
Flywheel, Crankshaft, and Main Bearings ............................................... .
Cylinder Block, Pistons, Piston Rings, and Connecting Rods and Bearings ................... .
Oil Pan and Oil Pump ............................................................... .
10
Exhaust System ..................................................................... .
Trouble shooting; tune-up; the cleaning, inspection,
and repair of component parts; and overhaul instructions
are covered in this chapter.
The cleaning, inspection, repair, and overhaul instruc-
tions apply only after the parts have been removed
from the engine, or in the case of a complete overhaul
after the engine has been disassembled.
To completely disassemble or assemble an engine, fol-
low all the removal or installation procedures contained
in the applicable engine chapter.
If
it is only desired to
remove and install an individual part, refer to the ap-
plicable section.
1. TROUBLE SHOOTING
Trouble shooting is the application of a definite pro-
cedure, in a logical sequence, to locate and eliminate
the cause of trouble in a particular system or unit. When
trouble shooting, first look for the obvious causes of
trouble, such as; an empty gas tank, a wet or cold engine,
loose or disconnected wiring, or any other item that may
cause a temporary defect.
The various factors that affect power plant operation
are outlined in this section.
a. Engine.
Poor engine performance can be attributed to the
engine or to forces on the truck that tend to retard its
motion.
For example, dragging
brakes can cause
the engine to work harder which will result in poor
performance.
Engine performance depends on proper fuel distribu-
tion, correctly timed ignition, normal and uniform com-
pression, and an unobstructed flow of exhaust gases.
Engine troubles, their causes, and remedies are dis-
cussed under appropriate headings.
(1) ENGINE WILL NOT CRANK.
If the starter
does not turn the engine over, or turns it over too slowly
5
to start, the most probable causes are a defective battery
or starter. Perform the following checks in the order
listed, until the trouble is located.
(a) CHECK THE BATIERY. Try the horn or lights. If
they do not operate properly, test the battery. Recharge
or replace the battery as necessary.
(b) CHECK THE BA TIERY CABLES. Check for loose
or corroded connections at the starter, starter relay, bat-
tery, and ground. Clean, tighten, or replace them as
necessary.
(c) CHECK THE STARTER RELAY CIRCUIT. The starter
relay contact surfaces seldom become so badly burned
that they will prevent the starter from cranking the en-
gine. However, other wiring may be at fault. Repair as
necessary. Refer to Part Three "Electrical and Acces-
sories."
( d) CHECK THE STARTER OR STARTER DRIVE. If the
above components are not at fault, the trouble is proba-
bly in the starter or starter drive. If the starter is run-
ning, but not engaging the flywheel, remove the starter
and make the necessary repairs to the starter drive. In
rare cases, the starter drive may lock up with the fly-
wheel. This can be corrected by loosening the starter
and releasing the starter drive. If the starter does not
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