Service Manual
Index
Page X-5
Fuel System ......................................................................................................V-98
Specifications.................................................................................................V-98
General Cleaning Instructions .........................................................................i-12
Abrasive Pads and Abrasive Paper.................................................................i-12
Definition of Clean............................................................................................i-12
Fuel System.....................................................................................................i-15
Gasket Surfaces...............................................................................................i-13
Plastic Bead Cleaning......................................................................................i-14
Solvent and Acid Cleaning...............................................................................i-13
Steam Cleaning................................................................................................i-14
General Engine .................................................................................................V-96
Specifications.................................................................................................V-96
General Repair Instructions .............................................................................i-10
General Information.........................................................................................i-10
Welding on a Vehicle with an Electronic Controlled Fuel System....................i-11
General Safety Instructions ................................................................................i-8
Important Safety Notice......................................................................................i-8
Heat Exchanger ................................................................................................8-81
Clean and Inspect for Reuse..........................................................................8-82
Finishing Steps...............................................................................................8-83
Install...............................................................................................................8-82
Preparatory Steps...........................................................................................8-81
Remove...........................................................................................................8-81
How to Use the Manual .......................................................................................i-2
General Information...........................................................................................i-2
Hydraulic Pump Drive ........................................................................................9-6
Clean and Inspect for Reuse............................................................................9-7
Finishing Steps.................................................................................................9-9
Install.................................................................................................................9-8
Preparatory Steps.............................................................................................9-6
Remove.............................................................................................................9-6
Idler Pulley Mounting Bracket .........................................................................9-34
Clean and Inspect for Reuse..........................................................................9-35
Finishing Steps...............................................................................................9-36
Install...............................................................................................................9-35
Preparatory Steps...........................................................................................9-34
Remove...........................................................................................................9-34
Idler Pulley Sea Water Pump ...........................................................................9-32
Clean and Inspect for Reuse..........................................................................9-33
Finishing Steps...............................................................................................9-34
Install...............................................................................................................9-34
Preparatory Steps...........................................................................................9-32
Remove...........................................................................................................9-33
Illustrations ..........................................................................................................i-7
General Information...........................................................................................i-7
Injector ..............................................................................................................6-68
Clean and Inspect for Reuse..........................................................................6-77
Finishing Steps...............................................................................................6-81
General Information........................................................................................6-68
Initial Check....................................................................................................6-74
Install...............................................................................................................6-78
Preparatory Steps...........................................................................................6-76
Remove...........................................................................................................6-77
Setup...............................................................................................................6-69
Test.................................................................................................................6-75
Injector Supply Lines (High Pressure) ...........................................................6-83
Finishing Steps...............................................................................................6-85
General Information........................................................................................6-83
Initial Check....................................................................................................6-84
Inspect for Reuse............................................................................................6-84
Install...............................................................................................................6-85
Remove...........................................................................................................6-84
Boost Pressure ...............................................................................................10-66
Measure........................................................................................................10-66
Keel Cooler .....................................................................................................8-109
General Information......................................................................................8-109
Pressure Differential Test.............................................................................8-110
Temperature Differential Test.......................................................................8-110
Key Switch ......................................................................................................13-29
Voltage Check...............................................................................................13-29
Lubricating Oil and Filter Analysis .................................................................7-49
Inspect............................................................................................................7-49
Lubricating Oil Contamination ........................................................................7-44
General Information........................................................................................7-44
Lubricating Oil Cooler ........................................................................................7-5
Clean and Inspect for Reuse............................................................................7-8
Finishing Steps...............................................................................................7-10
General Information..........................................................................................7-5
Install.................................................................................................................7-9
Leak Test..........................................................................................................7-9
Preparatory Steps.............................................................................................7-5
Remove.............................................................................................................7-7
Lubricating Oil Dipstick ...................................................................................7-11
Calibrate..........................................................................................................7-11
Lubricating Oil Dipstick Tube .........................................................................7-12
Finishing Steps...............................................................................................7-13
Install...............................................................................................................7-13
Preparatory Steps
...........................................................................................7-12
Remove...........................................................................................................7-12
Lubricating Oil Filter (Spin-On) .......................................................................7-13
Finishing Steps...............................................................................................7-14
Install...............................................................................................................7-14
Remove...........................................................................................................7-13
Lubricating Oil Filter Head (Remote Mounted) ..............................................7-15
Assemble........................................................................................................7-16
Disassemble...................................................................................................7-16
Finishing Steps...............................................................................................7-17
Inspect for Reuse............................................................................................7-16
Install...............................................................................................................7-17
Preparatory Steps...........................................................................................7-15
Remove...........................................................................................................7-15
Lubricating Oil Filter Head Adapter ................................................................7-18
Clean and Inspect for Reuse..........................................................................7-18
Finishing Steps...............................................................................................7-20
Install...............................................................................................................7-19
Preparatory Steps...........................................................................................7-18
Remove...........................................................................................................7-18
Lubricating Oil Leaks .......................................................................................7-20
Initial Check....................................................................................................7-20
Lubricating Oil Lines ........................................................................................7-51
Inspect for Reuse............................................................................................7-51
Install...............................................................................................................7-52
Remove...........................................................................................................7-51
Lubricating Oil Pan ..........................................................................................7-21
Clean and Inspect for Reuse..........................................................................7-23
Finishing Steps...............................................................................................7-27
Install...............................................................................................................7-24
Preparatory Steps...........................................................................................7-21
Remove...........................................................................................................7-22
Lubricating Oil Pressure Regulator (Main Rifle) ...........................................7-27
Clean...............................................................................................................7-28
Finishing Steps...............................................................................................7-29
Inspect for Reuse............................................................................................7-28
Install...............................................................................................................7-29
Preparatory Steps...........................................................................................7-27
Remove...........................................................................................................7-27
Lubricating Oil Pressure Sensor, OEM ..........................................................7-49
Install...............................................................................................................7-49
Remove...........................................................................................................7-49
Lubricating Oil Pump .......................................................................................7-30
Clean and Inspect for Reuse..........................................................................7-32
Finishing Steps...............................................................................................7-35
Initial Check....................................................................................................7-31
Install...............................................................................................................7-34
Measure..........................................................................................................7-33
Preparatory Steps...........................................................................................7-30
Remove...........................................................................................................7-31
Lubricating Oil Suction Tube (Block-Mounted) .............................................7-37
Clean and Inspect for Reuse..........................................................................7-38
Finishing Steps...............................................................................................7-39
Install...............................................................................................................7-38
Preparatory Steps...........................................................................................7-37
Remove...........................................................................................................7-38
Lubricating Oil System ....................................................................................7-40
Drain...............................................................................................................7-41
Fill...................................................................................................................7-42
Measure..........................................................................................................7-40
Lubricating Oil System ....................................................................................V-99
Specifications.................................................................................................V-99
Marine Gear Oil Cooler ....................................................................................8-66
Assemble........................................................................................................8-70
Disassemble...................................................................................................8-68
Finishing Steps...............................................................................................8-71
Flush...............................................................................................................8-66
Inspect for Reuse............................................................................................8-68
Install...............................................................................................................8-71
Preparatory Steps...........................................................................................8-67
Remove...........................................................................................................8-68
Marine Vibration Isolator ...............................................................................16-53
Finishing Steps.............................................................................................16-57
General Information......................................................................................16-53
Initial Check..................................................................................................16-53
Inspect for Reuse..........................................................................................16-56
Install.............................................................................................................16-57
Preparatory Steps.........................................................................................16-55
Remove.........................................................................................................16-56
Newton-Meter to Foot-Pound Conversions .................................................V-110
Conversion Chart..........................................................................................V-110
Pipe Plug ...........................................................................................................17-4
Clean...............................................................................................................17-5
Inspect for Reuse............................................................................................17-5
Install...............................................................................................................17-5
Remove...........................................................................................................17-4
Pipe Plug Torque Values ...............................................................................V-111