Service Manual

Index
Page X-6
Torque Table................................................................................................V-111
Propeller Shaft ................................................................................................16-50
General Information......................................................................................16-50
Out of Water..................................................................................................16-50
Alignment..................................................................................................16-51
Preparatory Steps.........................................................................................16-50
Specifications................................................................................................16-52
Radiator .............................................................................................................8-72
General Information........................................................................................8-72
Initial Check....................................................................................................8-72
Radiator Hoses .................................................................................................8-73
Inspect for Reuse............................................................................................8-73
Radiator Pressure Cap .....................................................................................8-73
General Information........................................................................................8-73
Inspect for Reuse............................................................................................8-73
Radiator Shutter Assembly .............................................................................8-74
General Information........................................................................................8-74
Refrigerant Compressor ..................................................................................9-22
Finishing Steps...............................................................................................9-24
Inspect for Reuse............................................................................................9-23
Install...............................................................................................................9-23
Preparatory Steps...........................................................................................9-22
Remove...........................................................................................................9-23
Refrigerant Compressor Mounting Bracket ...................................................9-30
Clean and Inspect for Reuse..........................................................................9-31
Finishing Steps...............................................................................................9-32
Install...............................................................................................................9-31
Preparatory Steps...........................................................................................9-30
Remove...........................................................................................................9-30
REPTO ...............................................................................................................9-10
Clean and Inspect for Reuse..........................................................................9-14
Disassemble...................................................................................................9-15
Exploded View................................................................................................9-10
Finishing Steps...............................................................................................9-22
Install...............................................................................................................9-17
Preparatory Steps...........................................................................................9-11
Preparatory Steps...........................................................................................9-16
Remove...........................................................................................................9-11
Sea Water Pump ...............................................................................................8-83
Finishing Steps...............................................................................................8-90
Initial Check....................................................................................................8-83
Inspect for Reuse............................................................................................8-89
Install...............................................................................................................8-89
Preparatory Steps...........................................................................................8-88
Remove...........................................................................................................8-88
Repair.............................................................................................................8-84
Sea Water Pump Pulley .................................................................................8-125
Clean and Inspect for Reuse........................................................................8-126
Finishing Steps.............................................................................................8-127
Install.............................................................................................................8-126
Preparatory Steps.........................................................................................8-125
Remove.........................................................................................................8-125
Sea Water Pump Support ................................................................................8-90
Clean and Inspect for Reuse..........................................................................8-91
Finishing Steps...............................................................................................8-92
Install...............................................................................................................8-92
Preparatory Steps...........................................................................................8-90
Remove...........................................................................................................8-90
Sea Water Strainer .........................................................................................8-100
Assemble......................................................................................................8-103
Marine Applications..................................................................................8-103
Clean.............................................................................................................8-102
Marine Applications..................................................................................8-102
Disassemble.................................................................................................8-101
Marine Applications..................................................................................8-101
General Information......................................................................................8-100
Marine Applications..................................................................................8-100
Prime.............................................................................................................8-102
Marine Applications..................................................................................8-102
Sea Water System Diagnostics .....................................................................8-112
General Information......................................................................................8-112
Initial Check..................................................................................................8-113
Pressure Differential Test.............................................................................8-116
Pressure Test................................................................................................8-115
Temperature Differential Test.......................................................................8-118
Test...............................................................................................................8-114
Service Literature Ordering Location ...............................................................L-2
Contact Information...........................................................................................L-2
Service Tools ......................................................................................................5-1
Fuel System......................................................................................................5-1
Service Tools ......................................................................................................6-1
Injectors and Fuel Lines....................................................................................6-1
Service Tools ......................................................................................................7-1
Lubricating Oil System......................................................................................7-1
Service Tools ......................................................................................................8-1
Cooling System.................................................................................................8-1
Service Tools ....................................................................................................10-1
Air Intake System
............................................................................................10-1
Service Tools ....................................................................................................11-1
Exhaust System..............................................................................................11-1
Service Tools ....................................................................................................12-1
Compressed Air System.................................................................................12-1
Service Tools ....................................................................................................13-1
Electrical Equipment.......................................................................................13-1
Service Tools ....................................................................................................14-1
Engine Testing................................................................................................14-1
Service Tools ....................................................................................................16-1
Mounting Adaptations.....................................................................................16-1
Service Tools ....................................................................................................17-1
Miscellaneous.................................................................................................17-1
Stall Speed Test ................................................................................................5-35
Stall Speed Check..........................................................................................5-35
Stall Speed Checklist......................................................................................5-39
Time Speed Check.........................................................................................5-38
Starter Magnetic Switch .................................................................................13-19
Initial Check..................................................................................................13-19
Resistance Check.........................................................................................13-20
Voltage Check...............................................................................................13-20
Starter Solenoid ..............................................................................................13-21
Initial Check..................................................................................................13-21
Voltage Check...............................................................................................13-21
Starting Motor .................................................................................................13-23
Clean and Inspect for Reuse........................................................................13-25
Finishing Steps.............................................................................................13-27
Install.............................................................................................................13-26
Measure........................................................................................................13-26
Preparatory Steps.........................................................................................13-24
Remove.........................................................................................................13-25
Rotation Check.............................................................................................13-23
Straight Thread Plug ........................................................................................17-6
Clean and Inspect for Reuse..........................................................................17-6
General Information........................................................................................17-6
Install...............................................................................................................17-7
Remove...........................................................................................................17-6
Symbols ................................................................................................................i-3
General Information...........................................................................................i-3
Tap-Drill Chart - U.S. Customary and Metric ...............................................V-112
General Information......................................................................................V-112
Turbocharger ..................................................................................................10-42
Clean and Inspect for Reuse........................................................................10-50
Finishing Steps.............................................................................................10-53
Initial Check..................................................................................................10-42
Install.............................................................................................................10-51
Leak Test......................................................................................................10-45
Preparatory Steps.........................................................................................10-47
Prime.............................................................................................................10-53
Remove.........................................................................................................10-49
Turbocharger Compressor Outlet Connection ............................................10-81
Clean and Inspect for Reuse........................................................................10-82
Finishing Steps.............................................................................................10-83
General Information......................................................................................10-81
Install.............................................................................................................10-82
Preparatory Steps.........................................................................................10-81
Remove.........................................................................................................10-82
Turbocharger Coolant Hoses ........................................................................10-54
Finishing Steps.............................................................................................10-57
Inspect .........................................................................................................10-55
Install.............................................................................................................10-56
Preparatory Steps.........................................................................................10-54
Remove.........................................................................................................10-55
Turbocharger Oil Drain Line ..........................................................................10-57
Clean and Inspect for Reuse........................................................................10-58
Initial Check..................................................................................................10-57
Install.............................................................................................................10-58
Remove.........................................................................................................10-57
Turbocharger Oil Supply Line .......................................................................10-59
Initial Check..................................................................................................10-59
Inspect for Reuse..........................................................................................10-60
Install.............................................................................................................10-60
Remove.........................................................................................................10-59
Turbocharger Wastegate Actuator ...............................................................10-60
Initial Check..................................................................................................10-60
Install.............................................................................................................10-63
Leak Test......................................................................................................10-62
Remove.........................................................................................................10-61
Turbocharger Wastegate Valve Body ...........................................................10-65
Maintenance Check......................................................................................10-65
Variable Geometry Turbo Actuator ...............................................................10-76
Finishing Steps.............................................................................................10-77
Install.............................................................................................................10-76
Preparatory Steps.........................................................................................10-76
Remove.........................................................................................................10-76
Water Inlet Connection ..................................................................................8-103
Clean and Inspect for Reuse........................................................................8-106