Contents
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Page
Group 30—Cooling System Water Pump — Exploded View . . . . . . . . . . . . . . . 30-1 Remove Water Pump . . . . . . . . . . . . . . . . . . . . . . 30-1 Disassemble Water Pump . . . . . . . . . . . . . . . . . . . 30-2 Assemble Water Pump . . . . . . . . . . . . . . . . . . . . . 30-3 Install Water Pump . . . . . . . . . . . . . . . . . . . . . . . . 30-5 Inspect Thermostat . . . . . . . . . . . . . . . . . . . . . . . . 30-6 Cold Start Advance Switch . . . . . . . . . . . . . . . . . . 30-6 Cooling System Deaeration . . . . . . . . . . . . . . . . . . 30-7 Check Fan/Alternator Belt Tension . . . . . . . . . . . . 30-8 Install Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9 Coolant Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10 Radiator Exploded view (CD3209DF128) . . . . . . 30-12
Install DELPHI/LUCAS Fuel Injection Pump . . . . Remove Fuel Supply Pump (MICO in-Line Injection Pump) . . . . . . . . . . . . . . . . . . . . . . . . Test Fuel Supply Pump (MICO in-Line Injection Pump) . . . . . . . . . . . . . . . . . . . . . . . . Disassemble Fuel Supply Pump (MICO in-Line Injection Pump) . . . . . . . . . . . . . . . . . . Assemble Fuel Supply Pump (MICO in-Line Injection Pump) . . . . . . . . . . . . . . . . . . . . . . . . Install Fuel Supply Pump (MICO in-Line Injection Pump) . . . . . . . . . . . . . . . . . . . . . . . . Service Injection Pump Overflow Valve (MICO in-Line Injection Pump). . . . . . . . . . . . . Modification of JDG670A. . . . . . . . . . . . . . . . . . . Remove MICO in-Line Fuel Injection Pump. . . . . Repair MICO in-Line Fuel Injection Pump . . . . . . Install MICO in-Line Fuel Injection Pump. . . . . . . Dynamic Timing . . . . . . . . . . . . . . . . . . . . . . . . . Install Timing Sensor. . . . . . . . . . . . . . . . . . . . . . Install Magnetic Probe. . . . . . . . . . . . . . . . . . . . . Timing Sensor and Magnetic Probe Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . Check Fuel Injection Pump Timing . . . . . . . . . . . Fuel Injection Nozzle Identification . . . . . . . . . . . Remove Fuel Injection Nozzle . . . . . . . . . . . . . . . Clean Fuel Injection Nozzle. . . . . . . . . . . . . . . . . Fuel Injection Nozzle Test . . . . . . . . . . . . . . . . . . Fuel Injection Nozzle Disassembly . . . . . . . . . . . Adjust Fuel Injection Nozzle . . . . . . . . . . . . . . . . Install Fuel Injection Nozzle. . . . . . . . . . . . . . . . . Bleed Fuel System . . . . . . . . . . . . . . . . . . . . . . . Check Engine Speed on Rotary Fuel Injection Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check Engine Speed on MICO in-Line Fuel Injection Pump. . . . . . . . . . . . . . . . . . . . . . . . .
Group 35—Air Intake and Exhaust System Check Air Inlet Pipe . . . . . . . . . . . . . . . . . . . . . . . 35-1 Exhaust Manifold Inspection . . . . . . . . . . . . . . . . . 35-2 Remove Turbocharger. . . . . . . . . . . . . . . . . . . . . . 35-3 Turbocharger Cut-Away View (Borg-Warner/Schwitzer) . . . . . . . . . . . . . . . . . . 35-4 Check Radial Clearance . . . . . . . . . . . . . . . . . . . . 35-5 Check Axial Clearance . . . . . . . . . . . . . . . . . . . . . 35-6 Repair Turbocharger . . . . . . . . . . . . . . . . . . . . . . . 35-6 Prelube Turbocharger . . . . . . . . . . . . . . . . . . . . . . 35-6 Install Turbocharger . . . . . . . . . . . . . . . . . . . . . . . 35-7 Turbocharger Break-In . . . . . . . . . . . . . . . . . . . . . 35-9 Recommendations for Turbocharger Use . . . . . . . 35-9 Remove and Install Air Heater Glow Plug . . . . . . . 35-9 Air Filter Exploded View . . . . . . . . . . . . . . . . . . . 35-10 Group 40—Fuel System Replace Fuel Filter Element (Rotary Fuel Injection Pump) . . . . . . . . . . . . . . . . . . . . . . . . . 40-1 Replace Fuel Filter Assembly (Rotary Fuel Injection Pump) . . . . . . . . . . . . . . . . . . . . . . . . . 40-2 Replace Fuel Filter Assembly (MICO in-Line Injection Pump) . . . . . . . . . . . . . . . . . . . . . . . . . 40-3 Replace Fuel Filter Element (MICO in-Line Injection Pump) . . . . . . . . . . . . . . . . . . . . . . . . . 40-3 Replace Fuel Supply Pump (Rotary Fuel Injection Pump) . . . . . . . . . . . . . . . . . . . . . . . . . 40-4 Remove STANADYNE DB2 or DB4 Fuel Injection Pump. . . . . . . . . . . . . . . . . . . . . . . . . . 40-4 Repairs to STANADYNE Fuel Injection Pump . . . . 40-6 Replace Throttle Lever (STANADYNE) . . . . . . . . . 40-7 Aneroid Replacement (STANADYNE) . . . . . . . . . . 40-7 Aneroid Field Adjustment (STANADYNE) . . . . . . . 40-8 Aneroid Workshop Adjustment (STANADYNE) . . . 40-9 Install STANADYNE DB2 or DB4 Fuel Injection Pump. . . . . . . . . . . . . . . . . . . . . . . . . 40-10 Remove DELPHI/LUCAS Fuel Injection Pump . . 40-12 Repairs to DELPHI/LUCAS Fuel Injection Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-13 CTM125 (22MAR06)
40-14 40-16 40-16 40-17 40-18 40-18 40-19 40-19 40-20 40-21 40-22 40-24 40-25 40-26 40-27 40-27 40-31 40-32 40-33 40-34 40-37 40-38 40-39 40-41 40-44 40-45
Group 100—Engine Tune-Up Preliminary Engine Testing . . . . . . . . . . . . . . . . . 100-1 General Tune-Up Recommendations . . . . . . . . . 100-1 Group 105—Engine System - Operation Lubrication System . . . . . . . . . . . . . . . . . . . . . . . 105-1 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . 105-4 Group 110—Engine System - Diagnosis and Tests Diagnose Engine Malfunctions . . . . . . . . . . . . . . 110-1 Checking Engine Compression . . . . . . . . . . . . . . 110-4 Check Engine Oil Pressure . . . . . . . . . . . . . . . . . 110-5 Measure Engine Blow-By . . . . . . . . . . . . . . . . . . 110-5 Using Stanadyne “TIME-TRAC” as Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . 110-6 Continued on next page
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POWERTECH 2.9 L Diesel Engines 032306
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