Documentos de Académico
Documentos de Profesional
Documentos de Cultura
July 2006
Systems Operation
Testing and Adjusting
2506-15 Industrial Engine
MGA (Engine)
MGB (Engine)
MGD (Engine)
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Table of Contents
Table of Contents
Index Section
Index ..................................................................... 56
23
23
24
24
25
26
26
27
28
31
32
34
35
35
Lubrication System
Engine Oil Pressure - Test ....................................
Excessive Bearing Wear - Inspect ........................
Excessive Engine Oil Consumption - Inspect .......
Increased Engine Oil Temperature - Inspect ........
37
39
39
40
Cooling System
Cooling System - Check (Overheating) ................
Cooling System - Inspect ......................................
Cooling System - Test ...........................................
Water Temperature Regulator - Test .....................
Water Pump - Test ................................................
41
42
43
45
46
Basic Engine
Piston Ring Groove - Inspect ................................
Connecting Rod Bearings - Inspect ......................
Main Bearings - Inspect ........................................
Cylinder Block - Inspect ........................................
Cylinder Liner Projection - Inspect ........................
Flywheel - Inspect .................................................
Flywheel Housing - Inspect ...................................
Vibration Damper - Check ....................................
47
47
47
47
48
50
51
53
Electrical System
Battery - Test ......................................................... 54
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Systems Operation Section
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General Information
The following model views show the 2506 Engine
features. Due to individual applications, your engine
may appear different from the illustrations.
g01288248
Illustration 1
Typical example
Left side view
(1) Front timing gear housing
(2) Fuel priming pump
(3) Electronic Control Module (ECM)
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Systems Operation Section
g01288247
Illustration 2
Typical example
Right side view
(8) Exhaust manifold
(9) Turbocharger
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Systems Operation Section
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i02589727
g01279775
Illustration 3
(1) Coolant temperature sensor
(2) Camshaft position sensor
(3) Inlet manifold pressure sensor
Controls
Outputs
An input component is one that sends an electrical
signal to the ECM. The signal that is sent varies in
one of the following ways:
Voltage
Frequency
Pulse width
The variation of the signal is in response to a change
in some specific system of the vehicle. The ECM
sees the input sensor signal as information about the
condition, environment, or operation of the vehicle.
Inputs
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Systems Operation Section
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Systems Operation Section
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i02550058
Fuel System
g01282152
Illustration 4
Fuel system schematic
(1)
(2)
(3)
(4)
(5)
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KENR6231
Fuel from the tank (6) flows to the fuel filter base.
The fuel filter base contains the primary fuel filter
and the secondary fuel filter. The fuel flows through
cored passages in the fuel filter base. The fuel
priming pump (4) is mounted on the fuel filter base.
The fuel priming pump is used in order to manually
pump the fuel into the fuel system after the system,
or parts of the system have been drained. The fuel
priming pump is used in order to refill the fuel system
after air has been introduced into the system. For
more information on priming the fuel system, refer
to Systems Operation, Testing and Adjusting, Fuel
System - Prime.
9
Systems Operation Section
The fuel exits the fuel gallery and returns to the fuel
filter base. A pressure regulating valve is located in
the fuel filter base. The pressure regulating valve
regulates the pressure for the fuel system. A sufficient
amount of back pressure is maintained in the system
in order to ensure a continuous availability of fuel to
the electronic unit injectors. The fuel flows from the
fuel filter base to the fuel cooler (5). The fuel flows
from the fuel cooler (5) back to the tank (6).
Illustration 5
g00451841
Electronic governor
(1) Signals to the electronic unit injectors
(2) Fuel injection control
(3) Fuel position
(4) Electronic governor
(5) Desired rpm
(6) Coolant temperature
(7) TC for No. 1 cylinder
(8) FRC fuel position
(9) Rated fuel position
(10) FCR maps
(11) Torque maps
(12) Engine speed/timing sensor
(13) Engine speed/timing signals interpreter
(14) Engine rpm
(15) Coolant temperature sensor
(16) Boost pressure sensor
(17) Boost pressure
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Systems Operation Section
Fuel Injection
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Illustration 6
g00291269
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Systems Operation Section
Illustration 7
g00984466
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Systems Operation Section
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i02550062
Illustration 9
Illustration 8
g01046036
Air cleaner
Turbocharger
Aftercooler
Cylinder head
Valves and valve system components
Piston and cylinder
Exhaust manifold
The turbocharger compressor wheel pulls inlet air
through the air cleaner and into the air inlet. The air
is compressed and this causes the air to become hot.
The air flows through aftercooler core (2) and the
temperature of the compressed air lowers. This helps
to provide increased horsepower output. Aftercooler
core (2) is a separate cooler core that is mounted in
front of the engine radiator. The engine fan causes
ambient air to move across both cores. This cools the
turbocharged inlet air and the engine coolant.
g00615497
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Systems Operation Section
Turbocharger
Illustration 10
g00291085
Illustration 11
Turbocharger
(1)
(2)
(3)
(4)
(5)
(6)
(7)
g01046041
Valve bridge
Rocker arm
Camshaft
Rotocoil
Valve spring
Valve guide
Valve
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Systems Operation Section
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Lubrication System
Illustration 12
g01033757
Oil pan
Oil pump
Oil cooler
Oil filter
Turbocharger oil lines
Oil passages for the cylinder block
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Systems Operation Section
Illustration 14
g00562383
g00562123
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Systems Operation Section
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g00431790
Illustration 15
Engine oil flow schematic
(1) Rocker arm shaft
(2) Oil passage to air compressor
(3) Camshaft bearing journals
(4) Oil passage to adjustable idler gear
Cooling System
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Systems Operation Section
Illustration 16
g01096647
Basic Engine
The coolant from the oil cooler (10) goes into the
cylinder block (9) through a bonnet and an elbow.
The coolant goes around the cylinder liners, through
the water directors and into the cylinder head.
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Systems Operation Section
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Camshaft
Crankshaft
The crankshaft converts the combustion force in the
cylinder into rotating torque. A vibration damper is
used at the front of the crankshaft in order to reduce
the torsional vibrations.
The crankshaft drives a group of gears (front gear
train) on the front of the engine. The front gear
train provides power for the following components:
camshaft, water pump, oil pump, fuel transfer
pump, and accessory items that are specific to the
application.
i02554889
Electrical System
Grounding Practices
Proper grounding for the machine electrical system
and engine electrical systems is necessary for
proper machine performance and reliability. Improper
grounding will result in uncontrolled electrical circuit
paths and unreliable electrical circuit paths.
Uncontrolled engine electrical circuit paths can result
in damage to main bearings, crankshaft bearing
journal surfaces, and aluminum components.
To ensure proper functioning of the vehicle and
engine electrical systems, an engine-to-frame ground
strap with a direct path to the negative battery post
must be used. This may be provided by way of a
starting motor ground, a frame to starting motor
ground, or a direct frame to engine ground.
An engine-to-frame ground strap must be used in
order to connect the grounding stud of the engine to
the frame of the vehicle and to the negative battery
post.
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Systems Operation Section
NOTICE
When boost starting an engine, the instructions in Operation and Maintenance Manual, Engine Starting
should be followed in order to properly start the engine.
This engine is equipped with a 24 volt starting system.
Only equal voltage for boost starting should be used.
The use of a higher voltage will damage the electrical
system.
The Electronic Control Module (ECM) must be disconnected at the J1/P1 and J2/P2 locations before
welding on the vehicle.
The engine has several input components which are
electronic. These components require an operating
voltage.
Illustration 17
g01028488
Typical example
Grounding Stud To Battery Ground (-)
Charging
Starting (If equipped)
Illustration 18
g01028479
Typical example
Alternate Grounding Stud To Battery Ground (-)
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Systems Operation Section
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Field winding
Stator windings
Six rectifying diodes
Regulator circuit components
The rotor assembly has many magnetic poles that
look like fingers with air space between each of the
opposite poles. The poles have residual magnetism.
The residual magnetism produces a small magnetic
field between the poles. As the rotor assembly
begins to turn between the field winding and the
stator windings, a small amount of alternating current
(AC) is produced. The AC current is produced in the
stator windings from the small magnetic field. The
AC current is changed to direct current (DC) when
the AC current passes through the diodes of the
rectifier bridge. The current is used for the following
applications:
Illustration 19
g00425518
Regulator
Roller bearing
Stator winding
Ball bearing
Rectifier bridge
Field winding
Rotor assembly
Fan
Illustration 20
g00317613
NOTICE
Never operate the alternator without the battery in the
circuit. Making or breaking an alternator connection
with heavy load on the circuit can cause damage to
the regulator.
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Illustration 21
21
Systems Operation Section
g00425521
Field
Solenoid
Clutch
Pinion
Commutator
Brush assembly
Armature
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Testing and Adjusting Section
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Required Tools
Tool
Part Number
Part Description
Qty
Table 2
Size of Belt
Width of Belt
5/8
Measure the tension of the belt that is farthest from the engine.
(1)
(2)
Width of Belt
3/8
Gauge Reading
Initial Belt Tension(1)
Measure the tension of the belt that is farthest from the engine.
(1)
(2)
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Testing and Adjusting Section
Fuel System
Relief valves
Check valves
i02550123
2. Check all fuel lines for fuel leakage. The fuel lines
must be free from restrictions and faulty bends.
Verify that the fuel return line is not collapsed.
3. Install a new fuel filter.
4. Cut the old filter open with a suitable filter cutter.
Inspect the filter for excess contamination.
Determine the source of the contamination. Make
the necessary repairs.
5. Service the primary fuel filter (if equipped).
6. Operate the hand priming pump (if equipped).
If excessive resistance is felt, inspect the fuel
pressure regulating valve. If uneven resistance
is felt, test for air in the fuel. Refer to Systems
Operation, Testing and Adjusting, Air in Fuel Test for more information.
7. Remove any air that may be in the fuel system.
Refer to Systems Operation, Testing and
Adjusting, Fuel System - Prime.
i02550146
Elbows
Illustration 22
g01096678
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Testing and Adjusting Section
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Required Tools
Tool
Part Number
Part Description
Qty
CH11149
Illustration 23
g01023138
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
Rocker arm
Adjusting screw
Locknut
CH11149 Injector Height Gauge
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Testing and Adjusting Section
i02551444
Required Tools
Tool
Part Number
CH11148
27610286
Part Description
Qty
Timing pin
Illustration 24
g01278981
Typical example
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Testing and Adjusting Section
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NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over disconnected fuel system component.
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27
Testing and Adjusting Section
g01282239
Typical example
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Testing and Adjusting Section
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i02551488
Table 6
Required Tools
Tool
Part Number
Part Description
Pressure Gauge
Illustration 26
Qty
1
g01288627
Illustration 27
g01097754
Timing marks
Camshaft gear
Adjustable idler gear
Idler gear
Cluster gear
Timing marks
Crankshaft gear
Oil pump gear
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Testing and Adjusting Section
Required Tools
Tool
Part Number
27610321
Camshaft Alignment
tool
21825617
Finger Clock
Part Description
Qty
g00294873
Typical example
Installation of the adjustable idler assembly
(A) Camshaft Alignment tool
(1) Nuts
(3) Bolt
Illustration 28
g00294872
Typical example
Loosen stub shaft assembly.
(1) Nuts
(2) Stub shaft
Illustration 30
g00294874
Typical example
Checking backlash
(B) Indicator assembly
(4) Camshaft gear
(5) Idler gear assembly
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Testing and Adjusting Section
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31
Testing and Adjusting Section
Required Tools
Tool
Part Number
Part Description
Differential Pressure
Gauge
Qty
1
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Testing and Adjusting Section
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g01293044
Illustration 31
Air inlet piping
(1) Air Cleaner
(3) Turbocharger
Turbocharger - Inspect
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Testing and Adjusting Section
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Testing and Adjusting Section
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Illustration 32
g00763164
Typical example
(1) Turbine Housing
(2) Turbine Wheel
(3) Turbocharger
Required Tools
Tool
Part Number
Part Description
Qty
Infrared Thermometer
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Testing and Adjusting Section
i02571687
Table 10
Do not come in contact with the fuel injector terminals while the engine is running.
Required Tools
Tool
Part
Number
Part Name
Pressure Gauge
Quantity
1
Inlet Valves
Exhaust Valves
Valve Lash
(Stopped
Engine)
0.38 0.08 mm
(0.015 0.003
inch)
0.76 0.08 mm
(0.030 0.003 inch)
TC
Compression
Stroke
1-2-4
1-3-5
TC Exhaust
Stroke(1)
3-5-6
2-4-6
Firing Order
(1)
(2)
1-5-3-6-2-4(2)
i02553372
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Testing and Adjusting Section
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g00935559
Illustration 33
Cylinder and valve location
(A) Exhaust valves
(B) Inlet valves
Compression
Stroke for No.
1 Piston
Inlet Valves
Exhaust Valves
Valve Lash
0.38 0.08 mm
(0.015 0.003
inch)
0.76 0.08 mm
(0.030 0.003
inch)
Cylinders
1-2-4
1-3-5
Compression
Stroke for No.6
Piston
Inlet Valves
Exhaust Valves
Valve Lash
0.38 0.08 mm
(0.015 0.003
inch)
0.76 0.08 mm
(0.030 0.003
inch)
Cylinders
3-5-6
2-4-6
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Testing and Adjusting Section
Lubrication System
i02571670
Illustration 34
g00977330
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
Table 14
Part
Number
Part Name
Pressure Gauge
Required Tools
Tool
Quantity
1
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Testing and Adjusting Section
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39
Testing and Adjusting Section
NOTICE
Perkins oil filters are manufactured to Perkins specifications. Use of an oil filter that is not recommended
by Perkins could result in severe damage to the engine bearings, crankshaft, etc., as a result of the larger
waste particles from unfiltered oil entering the engine
lubricating system. Only use oil filters recommended
by Perkins.
i02553373
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
Engine oil pressure will be high if the engine oil
bypass valves become stuck in the closed position
and the engine oil flow is restricted. Foreign matter
in the engine oil system could be the cause for the
restriction of the oil flow and the movement of the
engine oil bypass valves. If the engine oil bypass
valves are stuck in the closed position, remove
each bypass valve and clean each bypass valve in
order to correct this problem. You must also clean
each bypass valve bore. Install new engine oil
filters. New engine oil filters will prevent more debris
from causing this problem. For information on the
repair of the engine oil filter bypass valve, refer to
Disassembly and Assembly, Engine Oil Filter Base Disassemble.
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40
Testing and Adjusting Section
KENR6231
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41
Testing and Adjusting Section
Cooling System
i02553376
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42
Testing and Adjusting Section
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43
Testing and Adjusting Section
Illustration 35
g00921815
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Testing and Adjusting Section
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Seal
Table 15
Tool
Part Number
GE50031
Part Description
Pressurizing Pump
Qty
1
Required Tools
Illustration 36
g01096114
Filler cap
Tool
Part Number
GE50031
Part Description
Pressurizing Pump
Qty
1
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45
Testing and Adjusting Section
Illustration 37
Table 17
Typical example
(1) Water manifold assembly
Required Tools
Tool
Part Number
Part Description
Thermometer
g01096115
Qty
1
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Testing and Adjusting Section
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Required Tools
Tool
Part Number
GE50033
Part Description
Pressure Gauge
Illustration 38
Qty
1
g01033819
Typical example
(1)
(2)
(3)
(4)
(5)
Water outlet
Port
Temperature regulator housing
Water pump
Port
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47
Testing and Adjusting Section
Basic Engine
i02553382
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Testing and Adjusting Section
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i02553404
Required Tools
Tool
Part Number
Part Description
GE50005
Clamp bolt
GE50006
Clamp washer
GE50007
Fibre washer
GE50002
Cylinder liner
projection tool
Qty
Illustration 39
g01096458
Bolt
Washer
Washer
Spacer plate
Cylinder liner
Block
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49
Testing and Adjusting Section
Illustration 40
g00443044
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Testing and Adjusting Section
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i02553516
Flywheel - Inspect
Face Runout (Axial Eccentricity) of
the Flywheel
Table 21
Required Tools
Tool
Part Number
21825617
Part Description
Dial Indicator Group
Qty
1
Specifications
Liner Projection
0.025 to 0.152 mm
(0.0010 to 0.0060 inch)
Maximum Variation In
Each Liner
Maximum Average
Variation Between
Adjacent Liners
Maximum Variation
Between All Liners
Illustration 41
g00286049
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Testing and Adjusting Section
Tool
Part Number
21825617
Part Description
Dial Indicator Group
g00286058
Illustration 43
Required Tools
Qty
1
Required Tools
Illustration 42
g01278054
Tool
Part Number
21825617
Part Description
Dial Indicator Group
Qty
1
Illustration 44
g00285931
Typical example
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Testing and Adjusting Section
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Illustration 47
g00285932
Illustration 45
g00285932
Illustration 48
g00763974
Illustration 46
g00285934
Typical example
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Testing and Adjusting Section
i02553546
Illustration 50
(1)
(2)
(3)
(4)
g01287000
Adapter
Vibration damper
Bolts
Crankshaft pulley
g00286046
NOTICE
Inspect the viscous vibration damper for signs of leaking and for signs of damage to the case. Either of
these conditions can cause the weight to contact the
case. This contact can affect damper operation.
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Testing and Adjusting Section
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Electrical System
i02555153
Battery - Test
Most of the tests of the electrical system can be done
on the engine. The wiring insulation must be in good
condition. The wire and cable connections must be
clean, and both components must be tight.
Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operated. A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte through the battery outlets. Injury to personnel can be the result.
The battery circuit is an electrical load on the charging
unit. The load is variable because of the condition of
the charge in the battery.
Illustration 51
NOTICE
The charging unit will be damaged if the connections
between the battery and the charging unit are broken
while the battery is being charged. Damage occurs
because the load from the battery is lost and because
there is an increase in charging voltage. High voltage
will damage the charging unit, the regulator, and other
electrical components.
See Special Instruction, SEHS7633, Battery Test
Procedure for the correct procedures to use to
test the battery. This publication also contains the
specifications to use when you test the battery.
i02554905
g01012117
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Illustration 52
55
Testing and Adjusting Section
g00283566
i02554920
Keyswitch
Start relay
Starting motor solenoid
Starting motor
Trouble with the starting system could be caused
by the battery or by charging system problems. If
the battery is suspect, refer to Troubleshooting,
Battery. If the starting system is suspect, refer to
Troubleshooting, Engine Will Not Crank.
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Index Section
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Index
A
Air in Fuel - Test..................................................... 23
Air Inlet and Exhaust System .......................... 12, 31
Turbocharger ..................................................... 13
Valves And Valve Mechanism ............................ 13
Air Inlet and Exhaust System - Inspect.................. 31
Air Inlet Restriction............................................. 31
B
Basic Engine.................................................... 17, 47
Camshaft............................................................ 18
Crankshaft.......................................................... 18
Cylinder Block Assembly ................................... 17
Cylinder Head Assembly.................................... 18
Pistons, Rings And Connecting Rods ................ 18
Battery - Test ......................................................... 54
Belt Tension Chart ................................................. 22
C
Charging System - Test ......................................... 54
Test Tools For The Charging System................. 54
Connecting Rod Bearings - Inspect....................... 47
Cooling System ............................................... 16, 41
Cooling System - Check (Overheating) ................. 41
Cooling System - Inspect....................................... 42
Cooling System - Test............................................ 43
Checking the Filler Cap...................................... 44
Test For The Water Temperature Gauge ........... 45
Testing The Radiator And Cooling System For
Leaks................................................................ 44
Cylinder Block - Inspect......................................... 47
Cylinder Liner Projection - Inspect......................... 48
E
Electric Starting System - Test............................... 55
Electrical System ............................................. 18, 54
Charging System Components .......................... 19
Engine Electrical System ................................... 19
Grounding Practices .......................................... 18
Starting System Components ............................ 20
Electronic Control System Components.................. 6
Electronic Unit Injector - Adjust ............................. 24
Electronic Unit Injector - Test................................. 24
Engine Crankcase Pressure (Blowby) - Test ......... 35
Engine Oil Pressure - Test..................................... 37
Measuring Engine Oil Pressure ......................... 37
Reason for High Engine Oil Pressure ................ 39
Reasons for Low Engine Oil Pressure ............... 38
Engine Valve Lash - Inspect/Adjust ....................... 35
Valve Lash Adjustment ...................................... 36
Valve Lash Check .............................................. 35
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57
Index Section
M
Main Bearings - Inspect......................................... 47
P
Piston Ring Groove - Inspect.................................
Inspect the Clearance of the Piston Ring...........
Inspect the Piston and the Piston Rings ............
Inspect the Piston Ring End Gap.......................
47
47
47
47
S
Systems Operation Section ..................................... 4
T
Table of Contents..................................................... 3
Testing and Adjusting ............................................ 22
Testing and Adjusting Section ............................... 22
Turbocharger - Inspect .......................................... 32
Inspection of the Compressor and the Compressor
Housing ............................................................ 33
Inspection of the Turbine Wheel and the Turbine
Housing ............................................................ 33
V
Vibration Damper - Check ..................................... 53
W
Water Pump - Test................................................. 46
Water Temperature Regulator - Test ..................... 45
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58
Index Section
KENR6231
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59
Index Section
This document has been printed from SPI. Not for Resale
Printed in U.K.
This document has been printed from SPI. Not for Resale