wsm 03-CR-E4 Manuals

Manuals and User Guides for wsm 03-CR-E4. We have 1 wsm 03-CR-E4 manual available for free PDF download: Workshop Manual

wsm 03-CR-E4 Workshop Manual

wsm 03-CR-E4 Workshop Manual (315 pages)

DIESEL ENGINE

Brand: wsm | Category: Engine | Size: 70 MB

Table of Contents

Table of Contents

5
- Safety
  19
- Safety First
  20
- Preparing for Emergencies
  20
- Working Precautions
  20
- Working Cautions
  21
- Starting Machine Safely
  22
- Preventing Fires
  22
- Avoiding Hot Exhaust
  23
- Cleaning Exhaust Filter
  23
- Avoiding High Pressure Fluid
  23
- Preventing Acid Burns
  23
- General
  26
- General Working Precautions
  27
- Tightening Bolts and Nuts
  27
- Applying Thread-Locking Fluid
  27
- Installing Circlips
  27
- Handling Liquid Gasket
  28
- Replacing O-Rings
  28
- Replacing Oil Seals
  28
- Handling Wire Harness
  29
- Handling the Battery
  29
- Handling Fuses
  30
- Handling Connectors
  31
- Wiring Color
  32
- Dispose Fluids Correctly
  32
- General Machine Information
  33
- Engine Identification
  33
- Engine Model Name and Engine Serial Number
  33
- E4B Engine
  34
- Part Number and Serial Number (DPF)
  35
- Muffler Full Assembly Identification
  35
- Cylinder Number
  35
- Specifications
  36
- Specification for D1803-CR-E4, TE4
  36
- Specification for V2403-CR-E4, TE4
  37
- Specification for D1803-CR-TIE4, V2403-CR-TIE4
  38
- Specification for V2403-CR-TE4BG
  39
- Specification for D1803-CR-TIE4BG, V2403-CR-TIE4BG
  40
- Performance Curves
  41
- Performance Curve for D1803-CR-E4
  41
- Performance Curve for D1803-CR-TE4
  42
- Performance Curve for D1803-CR-TIE4
  43
- Performance Curve for V2403-CR-E4
  44
- Performance Curve for V2403-CR-TE4
  45
- Performance Curve for V2403-CR-TIE4
  46
- Dimensions
  47
- Wiring Diagram
  48
- Engine Intermediate Harness (Engine Side Harness)
  48
- Injector Intermediate Harness (Engine Side Harness)
  50
- Engine ECU Intermediate Harness (OEM Side Harness)
  51
- System Wiring Diagram for D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4, V2403-CR-TE4BG
  56
- System Wiring Diagram for D1803-CR-TIE4, D1803-CR-TIE4BG, V2403-CR-TIE4, V2403-CR- TIE4BG
  58
- Special Tools
  61
- Diesel Engine Compression Tester
  61
- Compression Tester Adapter K
  62
- Oil Pressure Tester
  63
- Valve Guide Replacing Tool
  63
- Bushing Replacing Tools
  63
- Flywheel Stopper
  64
- Auxiliary Socket for Fixing Crankshaft Sleeve
  65
- Injection Top Correction Jig
  66
- Bearing Case Cover Oil Seal Replacing Tool
  68
- Maintenance
  71
Maintenance Check List

72
- Daily 50 Hrs
  73
- Every 1500 Hrs
  73
- Every 250 Hrs
  73
- Every 250 Hrs Every 400 Hrs
  73
- Every 3000 Hrs 1 Year
  73
- Hrs
  73
- Initial
  73
- Inspection Item
  73
- Check and Maintenance
  76
- Checking Engine Oil Level
  76
- Daily Check Points
  76
- Checking Coolant Level
  77
- Checking Fuel Level
  77
- Changing Engine Oil
  78
- Check Points of Initial 50 Hours
  78
- Checking Fan Belt
  78
- Bands
  79
- Check Point of Every 50 Hours
  79
- Checking Fuel Hoses and Clamp
  79
- Checking Fuel Hoses and Clamp Bands
  79
- Replacing Oil Filter Cartridge
  79
- Check Points of Every 250 Hours
  80
- Checking and Draining Water Sepa- Rator (Type 1)
  80
- Checking and Draining Water Separator (Type 1)
  80
- Cleaning Air Cleaner Primary Element
  80
- Adjusting Fan Belt Tension
  81
- Checking Radiator Hose and Clamp Bands
  81
- Changing Engine Oil
  82
- Checking Intake Air Line
  82
- Replacing Fuel Filter Cartridge
  83
- Replacing Oil Filter Cartridge
  83
- (Type2)
  84
- Cleaning Water Jacket and Radiator Interior
  84
- Cleaning Water Separator (Type 1)
  84
- Replacing Water Separator Filter
  84
- Replacing Water Separator Filter (Type 2)
  84
- Replacing Fan Belt
  86
- Check Point of Every 1000 Hours
  87
- Checking Valve Clearance
  87
- Check Points of Every 1500 Hours
  88
- Checking Injector (with Diagmas- Ter)
  88
- Checking Injector (with Diagmaster)
  88
- Checking EGR Cooler
  89
- Check Points of Every 3000 Hours
  90
- Checking Positive Crankcase Venti- Lation (PCV) Valve
  90
- Checking Positive Crankcase Ventilation (PCV) Valve
  90
- Checking Turbocharger
  90
- Replacing Oil Separator Element
  90
- Cleaning DPF
  91
- Judging Reuse of DPF Filter Comp before Cleaning (Service Dealer)
  93
- Judging Reuse of DPF Filter Comp after Cleaning (Cleaning Contractor)
  94
- Checking EGR System (with Diag- Master)
  95
- Checking EGR System (with Diagmaster)
  95
- Check Points of Every 1 Year
  96
- Checking DPF Differential Pressure Pipes and Hoses
  96
- Replacing Air Cleaner Element
  96
- Checking EGR Piping
  97
- Checking Intake Air Line
  97
- Check Points of Every 2 Years
  98
- Checking Exhaust Manifold
  98
- Replacing Fan Belt
  98
- Replacing Oil Separator Rubber Hose
  98
- Replacing Water Separator Filter (Type 2)
  98
- Changing Radiator Coolant
  99
- Replacing EGR Cooler Hose
  99
- Replacing Intake Hose (after Air Flow Sensor) and Intercooler Hose
  99
- Replacing Lubricant Hose
  99
- Replacing Rubber Hose of Differential Pressure Sensor
  99
- Replacing Water Hose
  99
- Replacing Radiator Hose and Clamp Bands
  101
- Replacing Fuel Hose and Clamps
  102
- Replacing Intake Air Line
  102
- Engine
  104
- Feature of Combustion (E-CDIS)
  105
- Flow of Combustion (E-CDIS)
  105
- General (Introduction)
  105
- Mechanism
  105
- Structure of Combustion (Center Direct Injection System (E-CDIS))
  105
- Control of Combustion (E-CDIS)
  106
- Engine Body
  107
- Structure of Engine Body
  107
- Crankcase
  108
- Cylinder Head
  108
- Feature of Engine Body
  108
- Function of Crankcase
  108
- Function of Cylinder Head
  108
- Outline of Crankcase
  108
- Outline of Cylinder Head
  108
- Specification of Crankcase
  108
- Structure of Crankcase
  108
- Structure of Cylinder Head
  108
- Breather
  109
- Cylinder Head Cover
  109
- Function of Breather
  109
- Function of Cylinder Head Cover
  109
- Oil Separator
  109
- Outline of Breather
  109
- Outline of Cylinder Head Cover
  109
- Outline of Oil Separator
  109
- Structure of Breather
  109
- Structure of Cylinder Head Cover
  109
- Function of Oil Separator
  110
- Function of Piston
  110
- Outline of Piston
  110
- Piston
  110
- Specification of Piston
  110
- Structure of Oil Separator
  110
- Structure of Piston
  110
- Connecting Rod
  111
- Function of Piston Ring
  111
- Outline of Connecting Rod
  111
- Outline of Piston Ring
  111
- Piston Ring
  111
- Specification of Piston Ring
  111
- Structure of Connecting Rod
  111
- Structure of Piston Ring
  111
- Crankshaft
  112
- Function of Connecting Rod
  112
- Function of Crankshaft
  112
- Function of Main Bearing Case
  112
- Main Bearing Case
  112
- Outline of Crankshaft
  112
- Outline of Main Bearing Case
  112
- Specification of Crankshaft
  112
- Structure of Crankshaft
  112
- Structure of Main Bearing Case
  112
- Flywheel
  113
- Function of Flywheel
  113
- Function of Rocker Arm Assembly
  113
- Outline of Flywheel
  113
- Outline of Rocker Arm Assembly
  113
- Rocker Arm Assembly
  113
- Specification of Flywheel
  113
- Structure of Flywheel
  113
- Structure of Rocker Arm Assembly
  113
- Camshaft
  114
- Function of Camshaft
  114
- Function of Valve
  114
- Outline of Camshaft
  114
- Outline of Valve
  114
- Specification of Camshaft
  114
- Specification of Valve
  114
- Structure of Camshaft
  114
- Structure of Valve
  114
- Valve
  114
- Function of Tappet
  115
- Outline of Push Rod
  115
- Outline of Tappet
  115
- Push Rod
  115
- Structure of Push Rod
  115
- Structure of Tappet
  115
- Tappet
  115
- Function of Push Rod
  116
- Function of Timing Gears
  116
- Outline of Timing Gears
  116
- Structure of Timing Gears
  116
- Timing Gears
  116
- Fuel System
  117
- Structure of Common Rail System (CRS) Engine
  117
- Feature of Common Rail System (CRS) Engine
  118
- Flow of Common Rail System (CRS) Engine
  119
- Control of Common Rail System (CRS) Engine
  121
- Fuel Tank
  121
- Function of Fuel Tank
  121
- Outline of Fuel Tank
  121
- Outline of Water Separator
  121
- Specification of Fuel Tank
  121
- Structure of Fuel Tank
  121
- Structure of Water Separator (Type1)
  121
- Structure of Water Separator (Type2)
  121
- Water Separator
  121
- Electromagnetic Fuel Feed Pump
  122
- Function of Electromagnetic Fuel Feed Pump
  122
- Function of Water Separator
  122
- Outline of Electromagnetic Fuel Feed Pump
  122
- Specification of Electromagnetic Fuel Feed Pump
  122
- Specification of Water Separator (Type2)
  122
- Structure of Electromagnetic Fuel Feed Pump
  122
- Fuel Feed Pump
  123
- Function of Fuel Feed Pump
  123
- Outline of Fuel Feed Pump
  123
- Specification of Fuel Feed Pump
  123
- Structure of Fuel Feed Pump
  123
- Fuel Filter
  124
- Function of Fuel Filter
  124
- Outline of Fuel Filter
  124
- Outline of Supply Pump
  124
- Specification of Fuel Filter
  124
- Structure of Fuel Filter
  124
- Structure of Supply Pump
  124
- Supply Pump
  124
- Function of Supply Pump
  125
- Specification of Supply Pump
  127
- Function of Injection Pipe
  128
- Function of Rail Assembly
  128
- Injection Pipe
  128
- Outline of Injection Pipe
  128
- Outline of Rail Assembly
  128
- Rail Assembly
  128
- Structure of Injection Pipe
  128
- Structure of Rail Assembly
  128
- Specification of Rail Assembly
  129
- Injector
  130
- Outline of Injector
  130
- Structure of Injector
  130
- Function of Injector
  131
- Check Valve
  133
- Function of Check Valve
  133
- Function of Overflow Pipe
  133
- Outline of Check Valve
  133
- Outline of Overflow Pipe
  133
- Overflow Pipe
  133
- Specification of Check Valve
  133
- Specification of Injector
  133
- Structure of Check Valve
  133
- Structure of Overflow Pipe
  133
- Engine ECU
  134
- Function of Engine ECU
  134
- Function of Fuel Cooler
  134
- Outline of Engine ECU
  134
- Specification of Engine ECU
  134
- Structure of Engine ECU
  134
- Structure of Fuel Cooler
  134
- Crankshaft Position Sensor
  135
- Function of Crankshaft Position Sensor
  135
- Outline of Crankshaft Position Sensor
  135
- Specification of Crankshaft Position Sensor
  135
- Structure of Crankshaft Position Sensor
  135
- Camshaft Position Sensor
  136
- Function of Camshaft Position Sensor
  136
- Outline of Camshaft Position Sensor
  136
- Specification of Camshaft Position Sensor
  136
- Structure of Camshaft Position Sensor
  136
- Coolant Temperature Sensor
  137
- Function of Coolant Temperature Sensor
  137
- Outline of Coolant Temperature Sensor
  137
- Structure of Coolant Temperature Sensor
  137
- Atmosphere Pressure Sensor
  138
- Boost Pressure Sensor
  138
- Function of Atmosphere Pressure Sensor
  138
- Function of Boost Pressure Sensor
  138
- Outline of Atmosphere Pressure Sensor
  138
- Outline of Boost Pressure Sensor
  138
- Specification of Boost Pressure Sensor
  138
- Structure of Atmosphere Pressure Sensor
  138
- Structure of Boost Pressure Sensor
  138
- Fuel Camshaft
  139
- Function of Fuel Camshaft
  139
- Outline of Fuel Camshaft
  139
- Structure of Fuel Camshaft
  139
- Intake and Exhaust System
  140
- Structure of Intake and Exhaust System
  140
- Feature of Intake and Exhaust System
  141
- Flow of Intake and Exhaust System
  142
- Air Cleaner
  144
- Control of Intake and Exhaust System
  144
- Function of Air Cleaner
  144
- Function of Pre-Cleaner
  144
- Outline of Air Cleaner
  144
- Outline of Pre-Cleaner
  144
- Pre-Cleaner
  144
- Specification of Pre-Cleaner
  144
- Structure of Air Cleaner
  144
- Structure of Pre-Cleaner
  144
- Function of Intercooler
  145
- Function of Turbocharger
  145
- Intercooler
  145
- Outline of Intercooler
  145
- Specification of Intercooler
  145
- Specification of Turbocharger
  145
- Structure of Intercooler
  145
- Structure of Turbocharger
  145
- Exhaust Manifold
  146
- Function of Glow Plug
  146
- Function of Intake Manifold
  146
- Glow Plug
  146
- Intake Manifold
  146
- Outline of Glow Plug
  146
- Outline of Intake Manifold
  146
- Specification of Glow Plug
  146
- Structure of Glow Plug
  146
- Structure of Intake Manifold
  146
- Function of Exhaust Manifold
  147
- Exhaust Gas Recirculation (EGR) System
  148
- Structure of EGR System
  148
- Feature of EGR System
  149
- Flow of EGR System
  150
- Control of EGR System
  151
- EGR Cooler
  151
- EGR Valve
  151
- Function of EGR Cooler
  151
- Outline of EGR Cooler
  151
- Outline of EGR Valve
  151
- Specification of EGR Cooler
  151
- Structure of EGR Cooler
  151
- Structure of EGR Valve
  152
- Function of EGR Valve
  154
- Function of Reed Valve
  154
- Outline of Reed Valve
  154
- Reed Valve
  154
- Specification of EGR Valve
  154
- Structure of Reed Valve
  154
- Lubricating System
  155
- Structure of Lubricating System
  155
- Feature of Lubricating System
  156
- Flow of Lubricating System
  157
- Function of Oil Pan
  159
- Function of Oil Strainer
  159
- Oil Pan
  159
- Oil Strainer
  159
- Outline of Oil Pan
  159
- Outline of Oil Strainer
  159
- Specification of Oil Pan
  159
- Specification of Oil Strainer
  159
- Structure of Oil Pan
  159
- Structure of Oil Strainer
  159
- Function of Oil Pump
  160
- Oil Pump
  160
- Outline of Oil Pump
  160
- Outline of Relief Valve
  160
- Relief Valve
  160
- Specification of Oil Pump
  160
- Structure of Oil Pump
  160
- Structure of Relief Valve
  160
- Function of Oil Filter
  161
- Function of Relief Valve
  161
- Oil Filter
  161
- Outline of Oil Filter
  161
- Specification of Oil Filter
  161
- Structure of Oil Filter
  161
- Function of Oil Cooler
  162
- Oil Cooler
  162
- Oil Pressure Switch
  162
- Outline of Oil Cooler
  162
- Outline of Oil Pressure Switch
  162
- Specification of Oil Cooler
  162
- Structure of Oil Cooler
  162
- Structure of Oil Pressure Switch
  162
- Function of Oil Pressure Switch
  163
- Specification of Oil Pressure Switch
  163
- Cooling System
  164
- Structure of Cooling System
  164
- Control of Cooling System (Bottom By-Pass System)
  165
- Feature of Cooling System
  165
- Flow of Cooling System (Bottom By-Pass System)
  165
- Function of Thermostat
  166
- Function of Water Pump
  166
- Outline of Thermostat
  166
- Outline of Water Pump
  166
- Structure of Thermostat
  166
- Structure of Water Pump
  166
- Thermostat
  166
- Water Pump
  166
- Function of Radiator
  167
- Outline of Radiator
  167
- Radiator
  167
- Specification of Radiator
  167
- Specification of Thermostat
  167
- Structure of Radiator
  167
- Cooling Fan
  168
- Function of Cooling Fan
  168
- Function of Radiator Cap
  168
- Outline of Cooling Fan
  168
- Outline of Radiator Cap
  168
- Radiator Cap
  168
- Specification of Radiator Cap
  168
- Structure of Cooling Fan
  168
- Structure of Radiator Cap
  168
- Fan Belt
  169
- Function of Fan Belt
  169
- Function of Reserve Tank
  169
- Outline of Fan Belt
  169
- Outline of Reserve Tank
  169
- Reserve Tank
  169
- Specification of Cooling Fan
  169
- Structure of Fan Belt
  169
- Structure of Reserve Tank
  169
- Electrical System
  170
- Structure of Electrical System
  170
- Feature of Electrical System
  171
- Flow of Electrical System
  172
- Battery
  174
- Control of Electrical System
  174
- Function of Battery
  174
- Key Switch
  174
- Outline of Battery
  174
- Outline of Key Switch
  174
- Specification of Battery
  174
- Structure of Battery
  174
- Structure of Key Switch
  174
- Function of Key Switch
  175
- Function of Starter (Planetary Gear Reduction Type)
  175
- Outline of Starter (Planetary Gear Reduction Type)
  175
- Specification of Key Switch
  175
- Starter (Planetary Gear Reduction Type)
  175
- Structure of Starter (Planetary Gear Reduction Type)
  175
- Alternator
  176
- Function of Alternator
  176
- Outline of Alternator
  176
- Specification of Starter (Planetary Gear Reduction Type)
  176
- Structure of Alternator
  176
- Specification of Alternator
  178
- Aftertreatment System
  179
- Feature of Diesel Particulate Filter (DPF) System
  179
- Flow of Diesel Particulate Filter (DPF) System
  179
- Structure of Diesel Particulate Filter (DPF) System
  179
- Control of Diesel Particulate Filter (DPF) System
  180
- Feature of Diesel Oxidation Catalyst (DOC) System
  182
- Flow of Diesel Oxidation Catalyst (DOC) System
  182
- Structure of Diesel Oxidation Catalyst (DOC) System
  182
- Diesel Oxidation Catalyst (DOC)
  183
- Diesel Particulate Filter (DPF)
  183
- Function of Diesel Oxidation Catalyst (DOC)
  183
- Outline of Diesel Oxidation Catalyst (DOC)
  183
- Outline of Diesel Particulate Filter (DPF)
  183
- Structure of Diesel Oxidation Catalyst (DOC)
  183
- Structure of Diesel Particulate Filter (DPF)
  183
- Air Flow Sensor
  184
- Function of Air Flow Sensor
  184
- Function of Diesel Particulate Filter (DPF)
  184
- Outline of Air Flow Sensor
  184
- Structure of Air Flow Sensor
  184
- Exhaust Gas Temperature Sensor
  185
- Outline of Exhaust Gas Temperature Sensor
  185
- Specification of Air Flow Sensor
  185
- Structure of Exhaust Gas Temperature Sensor
  185
- Function of Exhaust Gas Temperature Sensor
  186
- Specification of Exhaust Gas Temperature Sensor
  186
- Differential Pressure Sensor
  187
- Function of Differential Pressure Sensor
  187
- Outline of Differential Pressure Sensor
  187
- Specification of Differential Pressure Sensor
  187
- Structure of Differential Pressure Sensor
  187
- Function of Intake Throttle Valve
  188
- Intake Throttle Valve
  188
- Outline of Intake Throttle Valve
  188
- Specification of Intake Throttle Valve
  188
- Structure of Intake Throttle Valve
  188
- Servicing
  191
- Troubleshooting
  191
- Troubleshooting for 03 Series Engine
  191
- Service Specifications
  195
- Service Specifications for Engine
  195
- Tightening Torques
  200
- Tightening Torques of Screws, Bolts and Nuts for General Use
  200
- Tightening Torques of Screws, Bolts and Nuts for Special Use
  200
- Adjusting Valve Clearance
  202
- Checking and Adjusting
  202
- Checking Compression Pressure of Cylinder
  202
- Checking Engine Oil Pressure
  203
- Checking Fan Belt Damage and Wear
  204
- Checking Fan Belt Tension
  204
- Checking Opening Temperature of Thermostat Valve
  205
- Checking Radiator Water Leakage
  205
- Checking Battery Specific Gravity
  206
- Checking Battery Voltage
  206
- Checking Starter Motor
  207
- Checking Magnetic Switch of Starter
  208
- Checking Alternator on Unit
  209
- Checking Magnetic Switch Continuity
  209
- Checking Air Leakage of Turbocharger Compressor Side
  210
- Checking Exhaust Gas Leakage of Turbocharger Turbine Side
  210
- Checking Glow Plug Continuity
  210
- Checking Injector
  211
- Checking Radial Clearance of Turbocharger
  211
- Checking Suction Control Valve (SCV)
  211
- Checking Boost Pressure Sensor
  212
- Checking Rail Pressure Sensor
  212
- Checking Camshaft Position Sensor
  213
- Checking Coolant Temperature Sensor
  213
- Checking Crankshaft Position Sensor
  213
- Checking Air Flow Sensor
  214
- Checking EGR System
  214
- Checking Exhaust Gas Temperature Sensor
  215
- Selecting Cylinder Head Gasket
  215
- Measuring Angular Deviation between Crankshaft T.D.C. and Crankshaft Position Sensor Detected T.D.C
  216
- Adjusting Air Gap between Crankshaft Position Sensor and Flywheel
  218
- Adjusting Air Gap between Camshaft Position Sensor and Pulsar Gear
  219
- Disassembling
  219
- Draining Coolant
  219
- Draining Engine Oil
  219
- Removing CRS Intermediate Harness
  220
- Removing External Components
  220
- Removing Muffler Full Assembly
  221
- Disassembling DPF Assembly
  222
- Removing EGR Cooler
  223
- Removing Turbocharger
  223
- Removing Common Rail
  224
- Removing EGR Valve
  224
- Removing Intake Throttle Valve
  224
- Removing Sensors
  225
- Removing Cylinder Head Cover
  226
- Removing Glow Plug
  226
- Removing Injector
  226
- Removing Cylinder Head
  227
- Removing Rocker Arm Assembly
  227
- Removing Tappet
  228
- Removing Valve
  228
- Removing Suction Control Valve (SCV)
  229
- Removing Supply Pump
  229
- Removing Thermostat Assembly
  229
- Removing Fan Drive Pulley
  230
- Removing Oil Cooler
  230
- Removing Water Pump
  230
- Removing Crankshaft Oil Slinger
  231
- Removing Gear Case Cover
  231
- Removing Idle Gear
  231
- Removing Camshaft with Cam Gear
  232
- Removing Fuel Camshaft Assembly
  232
- Removing Oil Pump
  232
- Removing Crank Gear
  233
- Removing Oil Pan and Oil Strainer
  233
- Disassembling Piston Assembly
  234
- Removing Piston
  234
- Removing Piston Ring
  234
- Removing Flywheel
  235
- Removing Flywheel Housing
  235
- Removing Bearing Case Cover
  236
- Removing Crankshaft (for 3 Cylinders)
  236
- Disassembling Alternator
  238
- Disassembling Starter
  238
- Removing Main Bearing Case
  238
- Assembling
  239
- Assembling Alternator
  239
- Assembling Starter
  241
- Installing Main Bearing Case
  242
- Installing Crankshaft (for 3 Cylinders)
  243
- Installing Crankshaft (for 4 Cylinders)
  243
- Installing Bearing Case Cover
  244
- Installing Flywheel
  244
- Installing Flywheel Housing
  244
- Assembling Piston Assembly
  245
- Installing Piston
  246
- Installing Piston Ring
  246
- Installing Oil Strainer and Oil Pan
  248
- Installing Camshaft with Cam Gear
  249
- Installing Crank Gear
  249
- Installing Oil Pump
  249
- Installing Fuel Camshaft with Supply Pump Gear
  250
- Installing Idle Gear
  250
- Installing Crankshaft Oil Slinger
  251
- Installing Fan Drive Pulley
  251
- Installing Gear Case Cover
  251
- Installing Oil Cooler
  252
- Installing Water Pump
  252
- Installing Suction Control Valve (SCV)
  253
- Installing Supply Pump
  253
- Installing Cylinder Head
  254
- Installing Tappet
  254
- Installing Thermostat Assembly
  254
- Installing Valve
  254
- Installing Injector
  256
- Installing Rocker Arm Assembly
  256
- Installing Glow Plug
  257
- Installing Cylinder Head Cover
  258
- Installing Sensors
  258
- Installing Common Rail
  259
- Installing EGR Valve
  260
- Installing Intake Throttle Valve
  260
- Installing Turbocharger Assembly
  260
- Assembling DPF Assembly
  261
- Installing EGR Cooler
  261
- Installing Muffler Full Assembly
  262
- Installing CRS Intermediate Harness
  264
- Installing External Components
  266
- Checking Cylinder Head Top Clearance
  267
- Filling Coolant
  267
- Filling Engine Oil
  267
- Servicing
  267
- Checking Cylinder Head Flaw
  268
- Checking Cylinder Head Surface Flatness
  268
- Adjusting Valve Lapping
  269
- Checking Valve Recessing
  269
- Checking Clearance between Valve Stem and Valve Guide
  270
- Replacing Valve Guide
  270
- Adjusting Valve Angle
  271
- Adjusting Valve Seat
  271
- Checking Free Length of Valve Spring
  272
- Checking Tilt of Valve Spring
  272
- Checking Oil Clearance between Rocker Arm and Rocker Arm Shaft
  273
- Checking Set Load of Valve Spring
  273
- Checking Oil Clearance between Tappet and Tappet Guide Bore
  274
- Checking Push Rod Alignment
  274
- Checking Timing Gear Backlash
  274
- Checking Side Clearance of Camshaft
  275
- Checking Side Clearance of Idle Gear
  275
- Checking Camshaft Alignment
  276
- Replacing Idle Gear Bushing
  276
- Checking Cam Height
  277
- Checking Oil Clearance between Camshaft Journal and Crankcase Bore
  277
- Checking Oil Clearance between Idle Gear Shaft and Idle Gear Bushing
  278
- Checking Oil Clearance between Piston Pin and Small End Bushing
  278
- Checking Piston Pin Bore I.D
  278
- Replacing Small End Bushing
  279
- Checking Connecting Rod Alignment
  280
- Checking Piston Ring Gap
  280
- Checking Clearance between Piston Ring and Ring Groove
  281
- Checking Side Clearance of Crankshaft
  282
- Checking Crankshaft Alignment
  283
- Checking Oil Clearance between Crankpin and Crankpin Bearing
  284
- Checking Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1
  284
- Replacing Crankshaft Sleeve
  285
- Checking Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2
  286
- Replacing Crankshaft Bearing 1
  286
- Replacing Bearing Case Cover Oil Seal
  287
- Adjusting Cylinder Correction (over Size)
  288
- Checking Cylinder Wear
  288
- Checking Clearance between Inner Rotor and Outer Rotor
  289
- Checking Clearance between Outer Rotor and Pump Body
  289
- Checking Clearance between Rotor and Cover
  290
- Checking Commutator and Mica of Starter
  290
- Checking Armature Coil of Starter
  292
- Checking Brush Holder of Starter
  292
- Checking Brush Wear of Starter
  292
- Checking Field Coil of Starter
  293
- Checking Bearing of Alternator
  294
- Checking Rotor of Alternator
  294
- Checking Slip Ring of Alternator
  294
- Checking Stator of Alternator
  294
- Checking Brush Wear of Alternator
  295
- Checking Rectifier
  295
- Checking IC Regulator
  296
- Replacing Injector
  296

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