Engine

All Description and Operation

• Cleanliness and Care
• Drive Belt System Description
• Engine Component Description
• Lubrication Description
• New Product Information
• Replacing Engine Gaskets
• Separating Parts
• Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant

All Special Tools and Equipment

• Special Tools

All Visual Identification

• Disassembled Views
• Engine Identification

Cleaning, Inspection, and Adjustment

• Camshaft and Bearings Cleaning and Inspection
• Crankshaft and Bearing Cleaning and Inspection
• Crankshaft Balancer Cleaning and Inspection
• Cylinder Head Cleaning and Inspection
• Engine Block Cleaning and Inspection
• Engine Coolant Thermostat Housing Cleaning and Inspection
• Engine Flywheel Cleaning and Inspection
• Engine Flywheel Housing Cleaning and Inspection
• Engine Front Cover Cleaning and Inspection
• Exhaust Gas Recirculation Valve Cooler Cleaning and Inspection
• Exhaust Manifold Cleaning and Inspection
• Exhaust Outlet Cleaning and Inspection
• Exhaust Pipe Cleaning and Inspection
• Fuel Injection Pump Cleaning and Inspection
• Intake Manifold Cleaning and Inspection
• Lower Oil Pan Cleaning and Inspection
• Oil Filter Adapter and Oil Cooler Assembly Cleaning and Inspection
• Oil Pump Cleaning and Inspection
• Piston Oil Cooling Nozzle Cleaning and Inspection
• Piston, Connecting Rod, and Bearing Cleaning and Inspection
• Turbocharger Cleaning and Inspection
• Upper Oil Pan Cleaning and Inspection
• Vacuum Pump Cleaning and Inspection
• Valve Clearance Adjustment
• Valve Lifters Cleaning and Inspection
• Valve Rocker Arm and Shaft Cleaning and Inspection
• Valve Rocker Arm Cover Cleaning and Inspection - Lower
• Valve Rocker Arm Cover Cleaning and Inspection - Upper
• Water Pump Cleaning and Inspection

Diagnostic Procedures

• Base Engine Misfire with Abnormal Internal Lower Engine Noises
• Base Engine Misfire with Abnormal Valve Train Noise
• Base Engine Misfire with Coolant Consumption
• Base Engine Misfire with Excessive Oil Consumption
• Base Engine Misfire without Internal Engine Noises
• Coolant in Combustion Chamber
• Coolant in Engine Oil
• Crankcase Ventilation System Inspection/Diagnosis
• Cylinder Leakage Test
• Diagnostic Starting Point - Engine Mechanical
• Drive Belt Tensioner Diagnosis
• Engine Compression Test
• Engine Noise on Start-Up, but Only Lasting a Few Seconds
• Engine Noise Under Load
• Engine Will Not Crank - Crankshaft Will Not Rotate
• Fuel in Engine Oil
• Lower Engine Noise, Regardless of Engine Speed
• Symptoms - Engine Mechanical
• Turbocharger Hissing Noise
• Turbocharger Lack of Oil Supply
• Turbocharger Oil Leak From Compressor Seal
• Turbocharger Oil Leak From Turbine Seal
• Turbocharger Whine Noise
• Upper Engine Noise, Regardless of Engine Speed

Disassembly, Overhaul, Repair, and Assembly

• Camshaft Installation
• Camshaft Removal
• Cooling Fan Pulley Installation
• Cooling Fan Pulley Removal
• Crankshaft and Bearing Installation
• Crankshaft and Bearing Removal
• Crankshaft Front Oil Seal Installation
• Crankshaft Front Oil Seal Removal
• Crankshaft Rear Oil Seal Installation
• Crankshaft Rear Oil Seal Removal
• Cylinder Head Assemble
• Cylinder Head Disassemble
• Cylinder Head Gasket Selection
• Cylinder Head Installation - Left Side
• Cylinder Head Installation - Right Side
• Cylinder Head Removal - Left Side
• Cylinder Head Removal - Right Side
• Draining Fluids and Oil Filter Removal
• Engine Coolant Thermostat Housing Installation
• Engine Coolant Thermostat Housing Removal
• Engine Flywheel Housing Installation
• Engine Flywheel Housing Removal
• Engine Flywheel Installation
• Engine Flywheel Removal
• Engine Front Cover Installation
• Engine Front Cover Removal
• Engine Mounting to Stand
• Engine Prelubing
• Engine Removal from Stand
• Exhaust Manifold Installation - Left Side
• Exhaust Manifold Installation - Right Side
• Exhaust Manifold Removal - Left Side
• Exhaust Manifold Removal - Right Side
• Exhaust Outlet Installation
• Exhaust Outlet Removal
• Exhaust Pipe Installation - Left Side
• Exhaust Pipe Installation - Right Side
• Exhaust Pipe Removal - Left Side
• Exhaust Pipe Removal - Right Side
• Fuel Filter Assembly Installation
• Fuel Filter Assembly Removal
• Fuel Injection Control Module Harness Assembly Installation
• Fuel Injection Control Module Harness Assembly Removal
• Fuel Injection Pump Installation
• Fuel Injection Pump Removal
• Fuel Injector Control Module Installation
• Fuel Injector Control Module Removal
• Fuel Injector Installation
• Fuel Injector Removal
• Fuel Injector Sleeve Installation
• Fuel Injector Sleeve Removal
• Fuel Line Torquing
• Fuel Pipes and Fuel Rail Installation
• Fuel Pipes and Fuel Rail Removal
• Generator and Drive Belt Tensioner Bracket Installation
• Generator and Drive Belt Tensioner Bracket Removal
• Glow Plug Controller and Glow Plugs Installation
• Glow Plug Controller and Glow Plugs Removal
• Intake Manifold Installation - Left Side
• Intake Manifold Installation - Right Side
• Intake Manifold Removal - Left Side
• Intake Manifold Removal - Right Side
• Intake Manifold Tube Installation
• Intake Manifold Tube Removal
• Lower Oil Pan Installation
• Lower Oil Pan Removal
• Oil Filter Adapter and Oil Cooler Assembly Installation
• Oil Filter Adapter and Oil Cooler Assembly Removal
• Oil Pump Installation
• Oil Pump Suction Pipe and Screen Assembly Installation
• Oil Pump Suction Pipe and Screen Assembly Removal
• Piston and Connecting Rod Assemble
• Piston and Connecting Rod Disassemble
• Piston Oil Cooling Nozzle Installation
• Piston Oil Cooling Nozzle Removal
• Piston, Connecting Rod, and Bearing Installation
• Piston, Connecting Rod, and Bearing Removal
• Power Steering Pump Mounting Bracket Installation
• Power Steering Pump Mounting Bracket Removal
• Service Prior to Assembly
• Thread Repair
• Turbocharger Installation
• Turbocharger Removal
• Upper Oil Pan Installation
• Upper Oil Pan Removal
• Valve and Seat Grinding
• Valve Lifter Installation
• Valve Lifter Removal
• Valve Rocker Arm Cover Installation - Lower Left Side
• Valve Rocker Arm Cover Installation - Lower Right Side
• Valve Rocker Arm Cover Installation - Upper Left Side
• Valve Rocker Arm Cover Installation - Upper Right Side
• Valve Rocker Arm Cover Removal - Lower Left Side
• Valve Rocker Arm Cover Removal - Lower Right Side
• Valve Rocker Arm Cover Removal - Upper Left Side
• Valve Rocker Arm Cover Removal - Upper Right Side
• Valve Rocker Arm, Shaft, and Push Rod Installation
• Valve Rocker Arm, Shaft, and Push Rod Removal
• Water Pump Installation
• Water Pump Removal

Electrical/Electronic Specifications

• Engine Mechanical Specifications

General Diagnostic Information

• Drive Belt Chirping Diagnosis
• Drive Belt Excessive Wear Diagnosis
• Drive Belt Falls Off Diagnosis
• Drive Belt Rumbling Diagnosis
• Drive Belt Squeal Diagnosis
• Drive Belt Vibration Diagnosis
• Drive Belt Whine Diagnosis
• Oil Consumption Diagnosis
• Oil Leak Diagnosis
• Oil Pressure Diagnosis and Testing

General Information

• Tools and Equipment

Mechanical Specifications

• Connecting Rod Bearings Selection Specifications
• Crankshaft Bearing Selection Specifications
• Cylinder Head Gasket Selection Specifications
• Fastener Tightening Specifications
• Valve Clearance Adjustment Specifications

Other Specifications

• Adhesives, Fluids, Lubricants, and Sealers
• Thread Repair Specifications

Removal, Installation, and Replacement

• Air Conditioning (A/C) Compressor and Power Steering Pump Bracket Replacement
• Camshaft Position Sensor Exciter Ring Replacement
• Camshaft Replacement
• Charged Air Cooler Hoses/Pipes Replacement
• Charged Air Cooler Replacement
• Crankshaft Balancer Installation
• Crankshaft Balancer Removal
• Crankshaft Balancer Replacement
• Crankshaft Front Oil Seal Replacement
• Crankshaft Rear Oil Seal Replacement
• Crankshaft Reluctor and Oil Pump Drive Gear Replacement
• Cylinder Head Replacement - Left Side
• Cylinder Head Replacement - Right Side
• Drive Belt Idler Pulley Replacement
• Drive Belt Replacement
• Drive Belt Tensioner Replacement
• Engine Flywheel Housing Replacement
• Engine Flywheel Replacement - Automatic Transmission
• Engine Flywheel Replacement - Manual Transmission
• Engine Front Cover Replacement
• Engine Mount Inspection
• Engine Mount Replacement - Left Side
• Engine Mount Replacement - Right Side
• Engine Oil and Oil Filter Replacement
• Engine Oil Level Sensor and/or Switch Replacement
• Engine Oil Pressure Sensor and/or Switch Replacement
• Engine Replacement
• Fuel Injector Nozzle Tube Sleeve Replacement
• Intake Manifold Replacement - Left Side
• Intake Manifold Replacement - Right Side
• Intake Manifold Tube Replacement
• Lower Oil Pan Replacement
• Oil Filler Tube Replacement
• Oil Filter Adapter and Oil Cooler Assembly Replacement
• Oil Level Indicator Tube Replacement
• Oil Pump Removal
• Oil Pump Replacement
• Positive Crankcase Ventilation Hose/Pipe/Tube Replacement
• Positive Crankcase Ventilation Valve Replacement
• Starter Installation
• Starter Removal
• Turbocharger Oil Feed Pipe Replacement
• Turbocharger Replacement
• Upper Oil Pan Replacement
• Valve Clearance Adjustment
• Valve Lifter Replacement
• Valve Rocker Arm Cover Replacement - Lower Left Side
• Valve Rocker Arm Cover Replacement - Lower Right Side
• Valve Rocker Arm Cover Replacement - Upper Left Side
• Valve Rocker Arm Cover Replacement - Upper Right Side
• Valve Rocker Arm, Shaft, and Push Rod Replacement
• Valve Stem Oil Seal and Valve Spring Replacement