This document is an overhaul manual for Thermo King TK482 and TK486 diesel engines. It provides specifications, torque values, and step-by-step instructions for disassembling, inspecting, reconditioning, and reassembling the engines. The manual covers both Tier 1 and earlier engine models as well as Tier 2 models, detailing any differences between them. It aims to inform users and should not be considered a complete guide covering all scenarios, as further consultation with Thermo King may be required.

1. TK482 and TK486
TK 50136-2-OM (Rev. 2, 02/06)
Copyright©
1998 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in
U.S.A.
Overhaul Manual

2. 2
This manual is published for informational purposes only and the information so provided should
not be considered as all-inclusive or covering all contingencies. If further information is required,
Thermo King Corporation should be consulted.
Sale of product shown in this manual is subject to Thermo King’s terms and conditions
including, but not limited to, the Thermo King Limited Express Warranty. Such terms and
conditions are available upon request. Thermo King’s warranty will not apply to any
equipment which has been “so repaired or altered outside the manufacturer’s plants as,
in the manufacturer’s judgment, to effect its stability.”
No warranties, express or implied, including warranties of fitness for a particular
purpose or merchantability, or warranties arising from course of dealing or usage of
trade, are made regarding the information, recommendations, and descriptions
contained herein. Manufacturer is not responsible and will not be held liable in contract
or in tort (including negligence) for any special, indirect or consequential damages,
including injury or damage caused to vehicles, contents or persons, by reason of the
installation of any Thermo King product or its mechanical failure.

3. 3
Table of Contents
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TK482 & TK486 Diesel Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tier 1 and Earlier - TK482, TK482E, TK486, TK486E, and TK486EH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tier 2 - TK486V, TK486VB, and TK486VH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Exhaust Gas Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TK482, TK482E, TK486, TK486E, and TK486EH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TK486V, TK486VB, and TK486VH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Inspection and Reconditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Wrist Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Timing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Valve Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Valve Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Push Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Oil Pump for Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Oil Pump for Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Crankcase Breather System Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Crankcase Breather System Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Checking Crankcase Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Assembly Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Bleeding Air from the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Injection Pump Timing Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Attaching Injection Pump Gear to Flange on Tier 1 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Injection Pump Timing Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Injection Pump Removal and Installation (All Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Trochoid Feed Pump Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Trochoid Feed Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Trochoid Feed Pump O-Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Cold Start Device Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Checking Cold Start Device Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Cold Start Device Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

4. Table of Contents
4
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Fuel Return Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Fuel Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Fuel Transfer Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Fuel System Operation and Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Normal Fuel System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Static Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Static Air Leaks Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Solution for Static Air Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
FAQ (Frequently Asked Questions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Using Clear Fuel Lines To Diagnose Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Battery Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Cold Weather Battery Recommendation for Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
TK482/TK486 Starters Not Interchangeable with di2.2/se2.2 Starters . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Major Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Fuel Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Fuel Solenoid Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Run In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Dynamometer Run In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Run In Procedure without Dynamometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Compression Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Compression Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Special Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Checking Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Gear Case Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
Engine History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Engine History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Released . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Front Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Rear Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Flywheel Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
EPA Tier 1 Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
Oil Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
ELC Compatible Water Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
EMI 3000 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
Screw-In Oil Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
EPA Tier 2 Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
Engine History Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Engine Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
History of Engine Related Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Fuel Solenoid Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Alternator Mounting Brackets for Model 30 Trailer Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155

5. 5
List of Figures
Figure 1: Valve Guide Removal Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 2: Valve Guide Installation Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 3: Valve Stem Seal Installation Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 4: Connecting Rod Bushing Removal and Installation Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 5: Camshaft Bearing Removal Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 6: Front View of Early Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 7: Front View of Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 8: Remove Fuel Injection Lines Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 9: Remove Fuel Injection Lines Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 10: Remove Fuel Injection Nozzles Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 11: Remove Fuel Injection Nozzles Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 12: Remove Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 13: Disconnect Coolant Hoses on Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 14: Remove Valve Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 15: Remove Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 16: Remove Valve Stem Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 17: Remove Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 18: Remove Oil Filter and Oil Filter Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 19: Remove Oil Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 20: Remove Fuel Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 21: Remove Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 22: Remove Gear Case Cover and Sound Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 23: Check Timing Gear Lash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 24: Remove Fuel Injection Pump Gear Nut and Lock Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 25: Use Puller to Remove Fuel Injection Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 26: Single-Piece Fuel Injection Pump Gear Early Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 27: Three-Piece Fuel Injection Pump Gear Tier 1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 28: Three-Piece Fuel Injection Pump Gear Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 29: Tier 1 and Earlier Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 30: Typical Tier 1 and Earlier Index Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 31: Tier 2 Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 32: Typical Tier 2 Index Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 33: Remove Fuel Injection Pump Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 34: Remove Fuel Injection Pump Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 35: Remove Oil Pump Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 36: Remove Idler Gear and Idler Gear Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 37: Remove Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 38: Remove Bellhousing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 39: Rear Seal Removal Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 40: Remove Rear Seal Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 41: Remove Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 42: Remove Oil Pump Intake Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 43: Remove Camshaft Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 44: Remove Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 45: Remove Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 46: Remove Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 47: Remove Piston and Rod Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 48: Remove Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 49: Measuring Cylinder Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 50: Cylinder Measuring Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 51: Pressing Tool Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Figure 52: Cylinder Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Figure 53: Cylinder Sleeve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure 54: Measuring Front Camshaft Bearing Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure 55: Main Bearing Cap Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 56: Measuring Main Bearing Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 57: Checking Main Bearing Bore Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 58: Measuring Main Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

6. List of Figures
6
Figure 59: Measuring Rod Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Figure 60: Measuring Crankshaft Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Figure 61: Crankshaft Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Figure 62: Piston Measuring Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Figure 63: Measuring Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Figure 64: Checking Ring Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Figure 65: Measuring Wrist Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Figure 66: Measuring Rod Bearing or Bearing Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Figure 67: Measuring Connecting Rod Twist and Parallelism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Figure 68: Measuring Wrist Pin Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Figure 69: Measuring Idler Gear Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Figure 70: Measuring Idler Gear Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Figure 71: Measuring Camshaft Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Figure 72: Measuring Cam Lobes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Figure 73: Measuring Camshaft Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Figure 74: Checking Thrust Plate Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Figure 75: Checking Cylinder Head Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Figure 76: Cylinder Head Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Figure 77: Removing or Installing Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Figure 78: Valve Guide Projection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Figure 79: Valve Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Figure 80: Measuring Valve Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Figure 81: Measuring Valve Stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Figure 82: Valve Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Figure 83: Intake Valve Seat Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Figure 84: Exhaust Valve Seat Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Figure 85: Measuring Valve Seat Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Figure 86: Dimensions for Replacement Valve Seat Bores Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . .55
Figure 87: Dimensions for Replacement Valve Seat Bores Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Figure 88: Measuring Valve Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Figure 89: Checking Valve Spring Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Figure 90: Valve Spring Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Figure 91: Installing Valve Stem Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Figure 92: Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Figure 93: Lapping Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Figure 94: Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Figure 95: Measuring Rocker Arm Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Figure 96: Measuring Rocker Arm Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Figure 97: Checking Bend in Push Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Figure 98: Tappet Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Figure 99: Measuring Tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Figure 100: Oil Pump Assembly Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Figure 101: Checking Clearance Between Oil Pump Body and Outer Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Figure 102: Checking Clearance Between Inner Rotor and Outer Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Figure 103: Checking Clearance Between Rotor Plate and Rotors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Figure 104: Mark on Outer Rotor Faces Oil Pump Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Figure 105: Oil Pump Located in Gear Case Cover on Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Figure 106: Oil Pump Components Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Figure 107: Measure Inner Rotor to Crankshaft Gear Boss Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Figure 108: Oil Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Figure 109: Water Pump and Thermostat Assemblies Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . .64
Figure 110: Water Pump and Thermostat Assembly Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Figure 111: Crankcase Breather Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Figure 112: Crankcase Breather Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Figure 113: Magnehelic Gauge Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Figure 114: Measuring Crankcase Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Figure 115: Install Camshaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Figure 116: Install Upper Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Figure 117: Install Upper Thrust Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Figure 118: Install Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

7. List of Figures
7
Figure 119: Install Lower Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 120: Install Lower Thrust Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 121: Main Bearing Cap Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 122: Install Main Bearing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 123: Check Plastigauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 124: Check End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 125: Assemble Piston and Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Figure 126: Ring Placement Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Figure 127: Ring Placement Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Figure 128: Check Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Figure 129: Mark on Ring Faces Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Figure 130: Oil Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Figure 131: Ring Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Figure 132: Install Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Figure 133: Install Rod Cap and Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Figure 134: Check Plastigauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Figure 135: Front of Engine Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 136: Install Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 137: Install Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 138: Install Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 139: Install Camshaft Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 140: Install Oil Pump Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 141: Install Fuel Injection Pump Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 142: Install Fuel Injection Pump Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 143: Tier 1 and Earlier Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Figure 144: Typical Tier 1 and Earlier Index Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Figure 145: Tier 2 Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Figure 146: Typical Tier 2 Index Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Figure 147: Install Fuel Injection Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Figure 148: Install Idler Gear and Idler Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 149: Align Timing Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 150: Install Cylinder Head and Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 151: Cylinder Head Bolt Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 152: Install Valve Stem Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 153: Install Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 154: Adjust Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 155: Install Oil Filter Head and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Figure 156: Install Valve Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Figure 157: Install Oil Pump Intake Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Figure 158: Install Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Figure 159: Install Rear Seal Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Figure 160: Install Rear Seal with Tool P/N 204-952 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Figure 161: Install Bellhousing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Figure 162: Install Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Figure 163: Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Figure 164: Align Flat Sides of Crankshaft Gear with Flat Sides of Inner Rotor in Timing Gear Cover . . . . . . . 84
Figure 165: Install Gear Case Cover and Sound Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Figure 166: Install Front Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 167: Dowel Pin Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 168: Install Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 169: Install Oil Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 170: Install Fuel Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 171: Install Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 172: Connect Coolant Hoses on Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 173: Install Fuel Injection Nozzles Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Figure 174: Install Fuel Injection Nozzles Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Figure 175: Install Fuel Injection Lines Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Figure 176: Install Fuel Injection Lines Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Figure 177: Fuel Injection Line Connections on Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Figure 178: Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

8. List of Figures
8
Figure 179: Typical Fuel System for Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Figure 180: Typical Fuel System for Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Figure 181: Tier 1 and Earlier Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Figure 182: Tier 2 Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Figure 183: Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Figure 184: Top Dead Center One and Four . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Figure 185: Fuel Solenoid Connector Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Figure 186: Timing Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Figure 187: Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Figure 188: Correct Timing Mark Alignment for TK482 and TK486 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Figure 189: Correct Timing Mark Alignment for TK482E and TK468E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Figure 190: Correct Timing Mark Alignment for TK486EH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Figure 191: Three-Piece Fuel Injection Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Figure 192: Timing Mark on Injection Pump Gear with Transfer Pump Cam Installed . . . . . . . . . . . . . . . . . . .100
Figure 193: Timing Mark on Injection Pump Gear without Transfer Pump Cam Installed . . . . . . . . . . . . . . . . .100
Figure 194: Flange and Injection Pump Gear Alignment with Transfer Pump Cam Installed . . . . . . . . . . . . . .101
Figure 195: Flange and Injection Pump Gear Alignment without Transfer Pump Cam Installed . . . . . . . . . . .101
Figure 196: Timing Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Figure 197: Tier 2 Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Figure 198: Tier 2 Index Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Figure 199: Marking Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Figure 200: Place Injection Angle Sticker on Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Figure 201: Injection Angle Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Figure 202: Removing Injection Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Figure 203: Injection Angle Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Figure 204: Injection Angle Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Figure 205: Injection Pump Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Figure 206: Examples of Injection Pump Index Mark Alignment with Injection Angle Sticker . . . . . . . . . . . . . .104
Figure 207: Timing Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Figure 208: Align Flat Sides of Crankshaft Gear with Flat Sides of Inner Rotor in Timing Gear Cover . . . . . .104
Figure 209: Tier 1 and Earlier Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Figure 210: Typical Tier 1 and Earlier Index Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Figure 211: Tier 2 Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Figure 212: Typical Tier 2 Index Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Figure 213: Injection Pump Gear Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Figure 214: Trochoid Feed Pump Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Figure 215: Trochoid Feed Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Figure 216: Trochoid Feed Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Figure 217: Trochoid Feed Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Figure 218: Trochoid Feed Pump Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Figure 219: Cold Start Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Figure 220: Remove Engine Coolant Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Figure 221: Remove Cold Start Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Figure 222: Clean Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Figure 223: Testing Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Figure 224: Acceptable Spray Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Figure 225: Unacceptable Spray Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Figure 226: Injection Nozzle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Figure 227: Testing Nozzle Valve and Seat Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Figure 228: Fuel Return Line Replacement Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Figure 229: Fuel Return Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Figure 230: Outlet Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Figure 231: Inlet and Delivery Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Figure 232: Pressure Controlled Delivery Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Figure 233: Fuel Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Figure 234: Fuel System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Figure 235: Fuel Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Figure 236: Tier 1 and Earlier Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Figure 237: Tier 2 Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Figure 238: Tier 1 and Earlier Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123

9. List of Figures
9
Figure 239: Tier 2 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Figure 240: TK482/TK486 Starter (Tier 1 and Earlier Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Figure 241: di2.2/se2.2 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Figure 242: De-energized Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Figure 243: Energized Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Figure 244: Starter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Figure 245: Check Brush Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Figure 246: Measure Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Figure 247: Check Field Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Figure 248: Check Stator Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Figure 249: Check Armature Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Figure 250: Clean Up Commutator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Figure 251: Check Commutator Undercut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Figure 252: Check Armature Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Figure 253: Check Shunt Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Figure 254: Check Series Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Figure 255: Check Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Figure 256: Install Shift Lever and Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Figure 257: No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Figure 258: Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Figure 259: Fuel Solenoid Connector Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Figure 260: Fuel Solenoid Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Figure 261: Fuel Solenoid Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Figure 262: Simplified Schematic Diagram of Fuel Solenoid System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Figure 263: Main Wire Harness Connector Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Figure 264: Fuel Solenoid Connector Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Figure 265: Relay Socket Terminal Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Figure 266: Top Dead Center One and Four . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Figure 267: Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Figure 268: Adjusting Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Figure 269: Early Engine Shown Others Similar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Figure 270: Remove Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Figure 271: Remove Sound Shield and Gear Case Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Figure 272: Oil Pump Located in Gear Case Cover on Tier 2 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Figure 273: Remove Oil Pump Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Figure 274: Check Intake Pipe Gasket Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Figure 275: Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Figure 276: Align Flat Sides of Crankshaft Gear with Flat Sides of Inner Rotor in Timing Gear Cover . . . . . . 143
Figure 277: Dowel Pin Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Figure 278: Install Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Figure 279: Front Pulley and Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Figure 280: Front Pulley and Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Figure 281: Water Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Figure 282: Oil Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Figure 283: Retrofitting Low Mount ELC Compatible Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Figure 284: Oil Filter Heads and Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Figure 285: Oil Level Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Figure 286: Tier 1 (and Earlier) Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Figure 287: Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Figure 288: Typical Serial Number Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Figure 289: Serial Number Nameplate Location Tier 1 and Earlier Engines . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Figure 290: Serial Number Nameplate Location Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Figure 291: Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Figure 292: Early Style Fuel Solenoid Timer P/N 41-1533 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Figure 293: Late Style Fuel Solenoid Timer P/N 41-2191 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Figure 294: Alternator Mounting Brackets for High Mount Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Figure 295: Early Style Alternator Mounting Brackets for Low Mount Water Pump . . . . . . . . . . . . . . . . . . . . . 154
Figure 296: Late Style Alternator Mounting Brackets for Low Mount Water Pump . . . . . . . . . . . . . . . . . . . . . . 154

10. List of Figures
10

11. 11
TK482 & TK486 Diesel Engine Specifications
This manual contains information about the TK482 and TK486 engine families.
• The TK482 engine family includes the TK482 and TK482E.
• The TK486 engine family includes the TK486, TK486E, TK486EH, TK486V, TK486VB, and
TK486VH.
• The TK482 and TK486 were made before the requirement to comply with EPA regulations.
• The TK482E, TK486E, and TK486EH comply with EPA Tier 1 regulations.
• The TK486V, TK486VB (used in bus applications), and TK486VH comply with any EPA Tier 2
regulations.
• Tier 1 and earlier engines (TK482, TK486, TK482E, TK486E, and TK486EH) use an in-line injection
pump.
• Tier 2 engines (TK486V, TK486VB, and TK486VH) use a mono-plunger and distributor injection
pump.
See “Engine Model Identification” on page 152 for information about identifying the engine models. See
“Engine History” on page 147 more information about the engine models and changes.
NOTE: The number 1 cylinder is on the flywheel (rear) end of the engine.
Tier 1 and Earlier -
TK482, TK482E, TK486, TK486E, and TK486EH
Except where noted, the specifications for these engines are the same.
General
Type Four Stroke Cycle Water Cooled
Number of Cylinders 4
Cylinder Arrangement In-line Vertical, Number 1 on Flywheel End
Bore
TK482, and TK482E 3.23 in. (82.0 mm)
TK486, TK486E, and TK486EH 3.39 in. (86.0 mm)
Stroke 3.54 in. (90.0 mm)
Displacement
TK482, and TK482E 116 cu. in. (1.90 liters)
TK486, TK486E, and TK486EH 128 cu. in. (2.09 liters)
Power Rating
TK482, and TK482E 30.3 hp (22.6 kW) @ 2200 rpm
TK486, and TK486E 33.9 hp (25.3 kW) @ 2200 rpm
TK486EH 35.0 hp (26.1 kW) @ 2600 rpm
Compression Ratio 18.0 to 1
Direction of Rotation Counterclockwise (Viewed from Flywheel)
Firing Order 1-3-4-2 (Number 1 on Flywheel End)
Fuel Injection Timing
TK482 and TK486 12 ± 1 Degrees BTDC
TK482E and TK486E 10 ± 1 Degrees BTDC
TK486EH 11 ± 1 Degrees BTDC
Nozzle Injection Pressure 2,800-3,000 psi (19,600-20,600 kPa)

12. TK482 & TK486 Diesel Engine Specifications
12
General (Continued)
Oil Pressure 18.5 psi (127 kPa) Minimum @ 230 F (110 C) & 1600 rpm
45-57 psi (310-390 kPa) @ 230 F (110 C) & 2200 rpm
Engine Coolant Thermostat 180 F (82 C)
Valve Clearance (Static @ 70 F [21 C])
Intake 0.006-0.010 in. (0.15-0.25 mm)
Exhaust 0.006-0.010 in. (0.15-0.25 mm)
Valve Train Standard Dimensions Wear Limit
Valve Spring
Free Length 1.75 in. (44.5 mm) 1.67 in. (42.5 mm)
Inclination (Top to Bottom from
Vertical)
0-0.04 in. (0-1.1 mm) 0.04 in. (1.1 mm)
Valve Guide Inside Diameter
Intake 0.3154-0.3159 in. (8.010-8.025 mm) 0.3189 in. (8.100 mm)
Exhaust 0.3156-0.3161 in. (8.015-8.030 mm) 0.3189 in. (8.100 mm)
Valve Stem Outside Diameter
Intake 0.3132-0.3140 in. (7.955-7.975 mm) 0.3110 in. (7.900 mm)
Exhaust 0.3132-0.3138 in. (7.955-7.970 mm) 0.3110 in. (7.900 mm)
Valve Stem to Valve Guide Clearance
Intake 0.0014-0.0028 in. (0.035-0.070 mm) 0.0079 in. (0.200 mm)
Exhaust 0.0018-0.0030 in. (0.045-0.075 mm) 0.0079 in. (0.200 mm)
Valve Margin
Intake 0.0490-0.0569 in. (1.244-1.444 mm) 0.020 in. (0.50 mm)
Exhaust 0.0531-0.0610 in. (1.350-1.550 mm) 0.020 in. (0.50 mm)
Valve Depth (Cylinder Head Deck to
Valve)
Intake 0.0120-0.0199 in. (0.306-0.506 mm) 0.039 in. (1.00 mm)
Exhaust 0.0118-0.0197 in. (0.300-0.500 mm) 0.039 in. (1.00 mm)
Valve Guide Projection (Above Valve
Spring Seat in Cylinder Head)
Intake 0.591 in. (15.00 mm)
Exhaust 0.591 in. (15.00 mm)
Valve Angle
Intake 30 Degrees
Exhaust 45 Degrees
Valve Seat Angle
Intake 30 Degrees
Exhaust 45 Degrees
Valve Seat Width
Intake 0.042-0.049 in. (1.07-1.24 mm) 0.069 in. (1.74 mm)
Exhaust 0.049-0.057 in. (1.24-1.45 mm) 0.076 in. (1.94 mm)
Rocker Arm Bushing Inside Diameter 0.6299-0.6307 in. (16.000-16.020 mm) 0.6335 in. (16.090 mm)
Rocker Arm Shaft Outside Diameter 0.6286-0.6293 in. (15.966-15.984 mm) 0.6280 in. (15.950 mm)
Tier 1 and Earlier -
TK482, TK482E, TK486, TK486E, and TK486EH (Continued)

13. TK482 & TK486 Diesel Engine Specifications
13
Valve Train (Continued) Standard Dimensions Wear Limit
Rocker Arm Bushing to Rocker Arm
Shaft Clearance
0.0006-0.0021 in. (0.016-0.054 mm) 0.0055 in. (0.140 mm)
Tappet Outside Diameter 0.4715-0.4720 in. (11.975-11.990 mm) 0.4697 in. (11.930 mm)
Tappet Bore Inside Diameter 0.4724-0.4731 in. (12.000-12.018 mm) 0.4744 in. (12.050 mm)
Tappet To Tappet Bore Clearance 0.0004-0.0017 in. (0.010-0.043 mm) 0.0047 in. (0.120 mm)
Push Rod Bend 0-0.001 in. (0-0.03 mm) 0.001 in. (0.03 mm)
Camshaft
Cam Lobe Height 1.5211-1.5262 in. (38.635-38.765 mm) 1.5118 in. (38.400 mm)
Camshaft Journal Outside Diameter
Timing Gear End 1.7687-1.7697 in. (44.925-44.950 mm) 1.7657 in. (44.850 mm)
Middle 1.7681-1.7691 in. (44.910-44.935 mm) 1.7657 in. (44.850 mm)
Flywheel End 1.7687-1.7697 in. (44.925-44.950 mm) 1.7657 in. (44.850 mm)
Camshaft Bearing Inside Diameter
Timing Gear End Bearing Insert 1.7713-1.7738 in. (44.990-45.055 mm) 1.7756 in. (45.100 mm)
Middle Bearing (No Insert) 1.7717-1.7726 in. (45.000-45.025 mm) 1.7756 in. (45.100 mm)
Flywheel End Bearing (No Insert) 1.7717-1.7726 in. (45.000-45.025 mm) 1.7756 in. (45.100 mm)
Camshaft Journal to Camshaft Bearing
Clearance
Timing Gear End 0.0016-0.0051 in. (0.040-0.130 mm) 0.0079 in. (0.200 mm)
Middle 0.0026-0.0045 in. (0.065-0.115 mm) 0.0079 in. (0.200 mm)
Flywheel End 0.0020-0.0039 in. (0.050-0.100 mm) 0.0079 in. (0.200 mm)
Camshaft Deflection 0.001 in. (0.02 mm) 0.002 in. (0.05 mm)
Camshaft End Play 0.002-0.010 in. (0.05-0.25 mm) 0.016 in. (0.40 mm)
Piston, Piston Rings, and Wrist Pin
Piston Outside Diameter Measuring
Point (From Bottom of Piston
Perpendicular to Wrist Pin)
0.95 in. (24.0 mm)
Piston Outside Diameter
TK482 and TK482E
Standard 3.2260-3.2272 in. (81.940-81.970 mm) 3.2244 in. (81.900 mm)
1st Oversize 0.010 in. (0.25 mm) 3.2358-3.2370 in. (82.190-82.220 mm) 3.2343 in. (82.150 mm)
2nd Oversize 0.020 in. (0.50 mm) 3.2457-3.2469 in. (82.440-82.470 mm) 3.2441 in. (82.400 mm)
TK486, TK486E, and TK486EH
Standard 3.3835-3.3846 in. (85.940-85.970 mm) 3.3819 in. (85.900 mm)
1st Oversize 0.010 in. (0.25 mm) 3.3933-3.3945 in. (86.190-86.220 mm) 3.3917 in. (86.150 mm)
2nd Oversize 0.020 in. (0.50 mm) 3.4031-3.4043 in. (86.440-86.470 mm) 3.4016 in. (86.400 mm)
Piston to Cylinder Wall Clearance 0.0012-0.0035 in. (0.030-0.090 mm)
Piston Top Clearance (Between Top of
Piston at TDC and Combustion
Chamber with Cylinder Head
Installed)
0.026-0.033 in. (0.65-0.83 mm)
Tier 1 and Earlier -
TK482, TK482E, TK486, TK486E, and TK486EH (Continued)

14. TK482 & TK486 Diesel Engine Specifications
14
Piston, Piston Rings, and Wrist Pin
(Continued) Standard Dimensions Wear Limit
Piston Ring Groove Width
Top Ring Groove 0.0813-0.0819 in. (2.065-2.080 mm)
Middle Ring Groove 0.0801-0.0807 in. (2.035-2.050 mm)
Bottom Ring Groove 0.1581-0.1587 in. (4.015-4.030 mm)
Piston Ring Width
Top Ring 0.0776-0.0783 in. (1.970-1.990 mm)
Middle Ring
TK482 and TK482E 0.0776-0.0783 in. (1.970-1.990 mm)
TK486, TK486E, and TK486EH 0.0768-0.0776 in. (1.950-1.970 mm)
Bottom Ring 0.1563-0.1571 in. (3.970-3.990 mm)
Piston Ring to Ring Groove Clearance
Top 0.0030-0.0043 in. (0.075-0.110 mm) 0.0098 in. (0.250 mm)
Middle
TK482 and TK482E 0.0018-0.0031 in. (0.045-0.080 mm) 0.0098 in. (0.250 mm)
TK486, TK486E, and TK486EH 0.0026-0.0039 in. (0.065-0.100 mm) 0.0098 in. (0.250 mm)
Bottom 0.0010-0.0024 in. (0.025-0.060 mm) 0.0079 in. (0.200 mm)
Piston Ring End Gap
Top Ring 0.008-0.016 in. (0.20-0.40 mm) 0.059 in. (1.50 mm)
Middle Ring 0.008-0.016 in. (0.20-0.40 mm) 0.059 in. (1.50 mm)
Bottom Ring 0.008-0.016 in. (0.20-0.40 mm) 0.059 in. (1.50 mm)
Piston Wrist Pin Bore Inside Diameter 1.0236-1.0240 in. (26.000-26.009 mm) 1.0244 in. (26.020 mm)
Wrist Pin Outside Diameter 1.0231-1.0236 in. (25.987-26.000 mm) 1.0197 in. (25.900 mm)
Wrist Pin to Piston Wrist Pin Bore
Clearance
0-0.0009 in. (0-0.022 mm) 0.0047 in. (0.120 mm)
Connecting Rod
Wrist Pin Bushing Inside Diameter 1.0246-1.0251 in. (26.025-26.038 mm) 1.0276 in. (26.100 mm)
Wrist Pin Outside Diameter 1.0231-1.0236 in. (25.987-26.000 mm) 1.0197 in. (25.900 mm)
Wrist Pin to Wrist Pin Bushing
Clearance
0.0010-0.0020 in. (0.025-0.051 mm) 0.0079 in. (0.200 mm)
Large End Bore (Without Bearing) 2.0079-2.0083 in. (51.000-51.010 mm)
Rod Bearing Clearance 0.0015-0.0029 in. (0.038-0.074 mm) 0.0063 in. (0.160 mm)
Side Clearance (Crank to Rod) 0.008-0.016 in. (0.20-0.40 mm) 0.022 in. (0.55 mm)
Twist per 4 in. (100 mm) 0.001 in. (0.03 mm) 0.003 in. (0.08 mm)
Parallelism per 4 in. (100 mm) 0.001 in. (0.03 mm) 0.003 in. (0.08 mm)
Crankshaft and Crankshaft Bearings
Main Journal Outside Diameter
Standard 1.9666-1.9670 in. (49.952-49.962 mm) 1.9650 in. (49.910 mm)
Undersize 1.9568-1.9572 in. (49.702-49.712 mm) 1.9551 in. (49.660 mm)
Main Bearing Inside Diameter
Standard 1.9685-1.9693 in. (50.000-50.020 mm) 1.9709 in. (50.060 mm)
Undersize 1.9587-1.9594 in. (49.750-49.770 mm) 1.9610 in. (49.810 mm)
Main Bearing Clearance 0.0015-0.0027 in. (0.038-0.068 mm) 0.0059 in. (0.150 mm)
Tier 1 and Earlier -
TK482, TK482E, TK486, TK486E, and TK486EH (Continued)

15. TK482 & TK486 Diesel Engine Specifications
15
Crankshaft and Crankshaft Bearings
(Continued) Standard Dimensions Wear Limit
Main Bearing Bore Inside Diameter
(Without Bearing)
2.1260-2.1267 in. (54.000-54.019 mm)
Rod Journal Outside Diameter
Standard 1.8879-1.8883 in. (47.952-47.962 mm) 1.8862 in. (47.910 mm)
Undersize 1.8780-1.8784 in. (47.702-47.712 mm) 1.8764 in. (47.660 mm)
Rod Bearing Inside Diameter
Standard 1.8898-1.8908 in. (48.000-48.026 mm) 1.8925 in. (48.070 mm)
Undersize 1.8799-1.8809 in. (47.750-47.776 mm) 1.8827 in. (47.820 mm)
Rod Bearing Clearance 0.0015-0.0029 in. (0.038-0.074 mm) 0.0063 in. (0.160 mm)
End Play 0.0035-0.0107 in. (0.090-0.271 mm) 0.0130 in. (0.330 mm)
Deflection 0.0008 in. (0.020 mm)
Cylinder Block
Cylinder Inside Diameter
TK482 and TK482E
Standard 3.2283-3.2295 in. (82.000-82.030 mm) 3.2362 in. (82.200 mm)
1st Oversize 3.2382-3.2394 in. (82.250 -82.280 mm) 3.2461 in. (82.450 mm)
2nd Oversize 3.2480-3.2492 in. (82.500-82.530 mm) 3.2559 in. (82.700 mm)
TK486, TK486E, and TK486EH
Standard 3.3858-3.3870 in. (86.000-86.030 mm) 3.3937 in. (86.200 mm)
1st Oversize 3.3957-3.3969 in. (86.250-86.280 mm) 3.4035 in. (86.450 mm)
2nd Oversize 3.4055-3.4067 in. (86.500-86.530 mm) 3.4134 in. (86.700 mm)
Cylinder Roundness 0-0.0004 in. (0-0.010 mm) 0.0012 in. (0.030 mm)
Cylinder Taper (Cylindricity) 0-0.0004 in. (0-0.010 mm) 0.0012 in. (0.030 mm)
Deck Distortion 0.002 in. (0.05 mm)
Cylinder Head
Distortion 0-0.002 in. (0-0.05 mm) 0.006 in. (0.15 mm)
Timing Gears
Timing Gear Lash
Crankshaft Gear to Idler Gear 0.0028-0.0059 in. (0.070-0.150 mm) 0.0079 in. (0.200 mm)
Crankshaft Gear to Oil Pump Gear 0.0028-0.0059 in. (0.070-0.150 mm) 0.0079 in. (0.200 mm)
Idler Gear to Camshaft Gear 0.0028-0.0059 in. (0.070-0.150 mm) 0.0079 in. (0.200 mm)
Idler Gear to Fuel Injection Pump
Gear
0.0028-0.0059 in. (0.070-0.150 mm) 0.0079 in. (0.200 mm)
Idler Gear Bushing Inside Diameter 1.8110-1.8120 in. (46.000-46.025 mm) 1.8142 in. (46.080 mm)
Idler Gear Shaft Outside Diameter 1.8091-1.8100 in. (45.950-45.975 mm) 1.8083 in. (45.930 mm)
Idler Gear Shaft to Idler Gear Bushing
Clearance
0.0010-0.0030 in. (0.025-0.075 mm) 0.0059 in. (0.150 mm)
Tier 1 and Earlier -
TK482, TK482E, TK486, TK486E, and TK486EH (Continued)

16. TK482 & TK486 Diesel Engine Specifications
16
Oil Pump
Type Trochoid
Outer Rotor to Pump Body Clearance 0.0039-0.0063 in. (0.100-0.160 mm) 0.0098 in. (0.250 mm)
Inner Rotor Tip to Outer Rotor Lobe
Clearance
0.0059 in. (0.150 mm)
Rotor Plate to Rotor Clearance 0.0012-0.0035 in. (0.030-0.090 mm) 0.0059 in. (0.150 mm)
Rotor Shaft to Rotor Shaft Bore
Clearance
0.0005-0.0017 in. (0.013-0.043 mm) 0.0079 in. (0.200 mm)
Pressure Control Valve Setting 36-50 psi (245-343 kPa)
Starter Standard Dimensions Wear Limit
No Load Test
Voltage 11 volts
Current Maximum of 140 amps @ 11 volts
Speed Minimum of 3900 rpm @ 11 volts
Loaded Properties
Voltage 8.76 volts
Current 300 amps
Commutator Outside Diameter 1.44 in. (36.5 mm) 1.40 in. (35.5 mm)
Tier 1 and Earlier -
TK482, TK482E, TK486, TK486E, and TK486EH (Continued)

17. 17
Tier 2 - TK486V, TK486VB, and TK486VH
Except where noted, the specifications for these engines are the same.
General
Type Four Stroke Cycle Water Cooled
Number of Cylinders 4
Cylinder Arrangement In-line Vertical, Number 1 on Flywheel End
Bore 3.39 in. (86.0 mm)
Stroke 3.54 in. (90.0 mm)
Displacement 128 cu. in. (2.09 liters)
Power Rating
TK486V and TK486VB 33.9 hp (25.3 kW) @ 2200 rpm
TK486VH 35.0 hp (26.1 kW) @ 2600 rpm
Compression Ratio 19.1 to 1
Direction of Rotation Counterclockwise (Viewed from Flywheel)
Firing Order 1-3-4-2 (Number 1 on Flywheel End)
Fuel Injection Timing See “Injection Pump Timing Tier 2 Engines” on page 102.
Nozzle Injection Pressure 3,100-3,300 psi (21,600-22,600 kPa)
Oil Pressure 18.5 psi (127 kPa) Minimum @ 230 F (110 C) & 1600 rpm
45-57 psi (310-390 kPa) @ 230 F (110 C) & 2200 rpm
Engine Coolant Thermostat 160 F (71 C)
Valve Clearance (Static @ 70 F [21 C])
Intake 0.006-0.010 in. (0.15-0.25 mm)
Exhaust 0.006-0.010 in. (0.15-0.25 mm)
Valve Train Standard Dimensions Wear Limit
Valve Spring
Free Length 1.65 in. (42.0 mm) 1.63 in. (41.5 mm)
Inclination (Top to Bottom from
Vertical)
0-0.04 in. (0-1.4 mm) 0.06 in. (1.4 mm)
Valve Guide Inside Diameter
Intake 0.3154-0.3159 in. (8.010-8.025 mm) 0.3189 in. (8.100 mm)
Exhaust 0.3156-0.3161 in. (8.015-8.030 mm) 0.3189 in. (8.100 mm)
Valve Stem Outside Diameter
Intake 0.3132-0.3140 in. (7.955-7.975 mm) 0.3110 in. (7.900 mm)
Exhaust 0.3132-0.3138 in. (7.955-7.970 mm) 0.3110 in. (7.900 mm)
Valve Stem to Valve Guide Clearance
Intake 0.0014-0.0028 in. (0.035-0.070 mm) 0.0071 in. (0.180 mm)
Exhaust 0.0018-0.0030 in. (0.045-0.075 mm) 0.0071 in. (0.180 mm)
Valve Margin
Intake 0.053 in. (1.34 mm) 0.020 in. (0.50 mm)
Exhaust 0.057 in. (1.45 mm) 0.020 in. (0.50 mm)

18. TK482 & TK486 Diesel Engine Specifications
18
Valve Train (Continued) Standard Dimensions Wear Limit
Valve Depth (Cylinder Head Deck to
Valve)
Intake 0.012-0.020 in. (0.30-0.50 mm) 0.031 in. (0.80 mm)
Exhaust 0.012-0.020 in. (0.30-0.50 mm) 0.031 in. (0.80 mm)
Valve Guide Projection (Above Valve
Spring Seat in Cylinder Head)
Intake 0.579-0.591 in. (14.70-15.00 mm)
Exhaust 0.579-0.591 in. (14.70-15.00 mm)
Valve Angle
Intake 30 Degrees
Exhaust 45 Degrees
Valve Seat Angle
Intake 30 Degrees
Exhaust 45 Degrees
Valve Seat Width
Intake 0.042-0.049 in. (1.07-1.24 mm) 0.069 in. (1.74 mm)
Exhaust 0.049-0.057 in. (1.24-1.45 mm) 0.076 in. (1.94 mm)
Rocker Arm Bushing Inside Diameter 0.6299-0.6307 in. (16.000-16.020 mm) 0.6327 in. (16.070 mm)
Rocker Arm Shaft Outside Diameter 0.6286-0.6293 in. (15.966-15.984 mm) 0.6276 in. (15.940 mm)
Rocker Arm Bushing to Rocker Arm
Shaft Clearance
0.0006-0.0021 in. (0.016-0.054 mm) 0.0051 in. (0.130 mm)
Tappet Outside Diameter 0.4715-0.4720 in. (11.975-11.990 mm) 0.4707 in. (11.955 mm)
Tappet Bore Inside Diameter 0.4724-0.4734 in. (12.000-12.025 mm) 0.4742 in. (12.045 mm)
Tappet To Tappet Bore Clearance 0.0004-0.0020 in. (0.010-0.050 mm) 0.0035 in. (0.090 mm)
Push Rod Bend 0-0.001 in. (0-0.03 mm) 0.001 in. (0.03 mm)
Camshaft Standard Dimensions Wear Limit
Cam Lobe Height 1.5197-1.5276 in. (38.600-38.800 mm) 1.5098 in. (38.350 mm)
Camshaft Journal Outside Diameter
Timing Gear End 1.7687-1.7697 in. (44.925-44.950 mm) 1.7673 in. (44.890 mm)
Middle 1.7681-1.7691 in. (44.910-44.935 mm) 1.7667 in. (44.875 mm)
Flywheel End 1.7687-1.7697 in. (44.925-44.950 mm) 1.7673 in. (44.890 mm)
Camshaft Bearing Inside Diameter
Timing Gear End Bearing Insert 1.7713-1.7738 in. (44.990-45.055 mm) 1.7768 in. (45.130 mm)
Middle Bearing (No Insert) 1.7717-1.7726 in. (45.000-45.025 mm) 1.7756 in. (45.100 mm)
Flywheel End Bearing (No Insert) 1.7717-1.7726 in. (45.000-45.025 mm) 1.7756 in. (45.100 mm)
Camshaft Journal to Camshaft Bearing
Clearance
Timing Gear End 0.0016-0.0051 in. (0.040-0.130 mm) 0.0094 in. (0.240 mm)
Middle 0.0026-0.0045 in. (0.065-0.115 mm) 0.0089 in. (0.225 mm)
Flywheel End 0.0020-0.0039 in. (0.050-0.100 mm) 0.0082 in. (0.210 mm)
Camshaft Deflection 0.001 in. (0.02 mm) 0.002 in. (0.05 mm)
Camshaft End Play 0.002-0.008 in. (0.05-0.20 mm) 0.012 in. (0.30 mm)
Tier 2 - TK486V, TK486VB, and TK486VH (Continued)

19. TK482 & TK486 Diesel Engine Specifications
19
Piston, Piston Rings, and Wrist Pin Standard Dimensions Wear Limit
Piston Outside Diameter Measuring
Point (From Bottom of Piston
Perpendicular to Wrist Pin)
0.95 in. (24.0 mm)
Piston Outside Diameter
Standard 3.3835-3.3846 in. (85.940-85.970 mm) 3.3817 in. (85.895 mm)
1st Oversize 0.010 in. (0.25 mm) 3.3935-3.3941 in. (86.195-86.210 mm) 3.3917 in. (86.150 mm)
2nd Oversize 0.020 in. (0.50 mm) 3.4033-3.4039 in. (86.445-86.460 mm) 3.4016 in. (86.400 mm)
Piston to Cylinder Wall Clearance
Standard 0.0018-0.0030 in. (0.045-0.075 mm)
1st Oversize 0.010 in. (0.25 mm) 0.0016-0.0033 in. (0.040-0.085 mm)
2nd Oversize 0.020 in. (0.50 mm) 0.0016-0.0033 in. (0.040-0.085 mm)
Piston Top Clearance (Between Top of
Piston at TDC and Combustion
Chamber with Cylinder Head
Installed)
0.0262-0.0306 in. (0.666-0.778 mm)
Piston Ring Groove Width
Top Ring Groove 0.0813-0.0819 in. (2.065-2.080 mm)
Middle Ring Groove 0.0801-0.0807 in. (2.035-2.050 mm)
Bottom Ring Groove 0.1581-0.1587 in. (4.015-4.030 mm)
Piston Ring Width
Top Ring 0.0776-0.0783 in. (1.970-1.990 mm) 0.0768 in. (1.950 mm)
Middle Ring 0.0768-0.0776 in. (1.950-1.970 mm) 0.0760 in. (1.930 mm)
Bottom Ring 0.1563-0.1571 in. (3.970-3.990 mm) 0.1555 in. (3.950 mm)
Piston Ring to Ring Groove Clearance
Top 0.0030-0.0043 in. (0.075-0.110 mm) 0.0098 in. (0.250 mm)
Middle 0.0026-0.0039 in. (0.065-0.100 mm) 0.0098 in. (0.250 mm)
Bottom 0.0010-0.0024 in. (0.025-0.060 mm) 0.0079 in. (0.200 mm)
Piston Ring End Gap
Top Ring 0.008-0.016 in. (0.20-0.40 mm) 0.019 in. (0.49 mm)
Middle Ring 0.012-0.020 in. (0.30-0.50 mm) 0.023 in. (0.59 mm)
Bottom Ring 0.008-0.016 in. (0.20-0.40 mm) 0.019 in. (0.49 mm)
Piston Wrist Pin Bore Inside Diameter 1.0236-1.0240 in. (26.000-26.009 mm) 1.0252 in. (26.039 mm)
Wrist Pin Outside Diameter 1.0234-1.0236 in. (25.995-26.000 mm) 1.0222 in. (25.965 mm)
Wrist Pin to Piston Wrist Pin Bore
Clearance
0-0.0006 in. (0-0.014 mm) 0.0029 in. (0.074 mm)
Connecting Rod Standard Dimensions Wear Limit
Wrist Pin Bushing Inside Diameter 1.0246-1.0251 in. (26.025-26.038 mm) 1.0263 in. (26.068 mm)
Wrist Pin Outside Diameter 1.0234-1.0236 in. (25.995-26.000 mm) 1.0223 in. (25.967 mm)
Wrist Pin to Wrist Pin Bushing
Clearance
0.0010-0.0017 in. (0.025-0.043 mm) 0.0040 in. (0.101 mm)
Large End Bore (Without Bearing) 2.0079-2.0083 in. (51.000-51.010 mm)
Rod Bearing Clearance 0.0015-0.0029 in. (0.038-0.074 mm) 0.0059 in. (0.150 mm)
Side Clearance (Crank to Rod) 0.008-0.016 in. (0.20-0.40 mm) 0.022 in. (0.55 mm)
Twist per 4 in. (100 mm) 0.001 in. (0.03 mm) 0.003 in. (0.08 mm)
Parallelism per 4 in. (100 mm) 0.001 in. (0.03 mm) 0.003 in. (0.08 mm)
Tier 2 - TK486V, TK486VB, and TK486VH (Continued)

20. TK482 & TK486 Diesel Engine Specifications
20
Crankshaft and Crankshaft Bearings Standard Dimensions Wear Limit
Main Journal Outside Diameter
Standard 1.9666-1.9670 in. (49.952-49.962 mm) 1.9646 in. (49.902 mm)
Undersize 1.9568-1.9572 in. (49.702-49.712 mm) 1.9548 in. (49.652 mm)
Main Bearing Inside Diameter
Standard 1.9685-1.9693 in. (50.000-50.020 mm) 1.9705 in. (50.052 mm)
Undersize 1.9587-1.9594 in. (49.750-49.770 mm) 1.9607 in. (49.802 mm)
Main Bearing Clearance 0.0015-0.0027 in. (0.038-0.068 mm) 0.0059 in. (0.150 mm)
Main Bearing Bore Inside Diameter
(Without Bearing)
2.1260-2.1267 in. (54.000-54.019 mm)
Rod Journal Outside Diameter
Standard 1.8879-1.8883 in. (47.952-47.962 mm) 1.8859 in. (47.902 mm)
Undersize 1.8780-1.8784 in. (47.702-47.712 mm) 1.8761 in. (47.652 mm)
Rod Bearing Inside Diameter
Standard 1.8898-1.8908 in. (48.000-48.026 mm) 1.8918 in. (48.052 mm)
Undersize 1.8799-1.8809 in. (47.750-47.776 mm) 1.8820 in. (47.802 mm)
Rod Bearing Clearance 0.0015-0.0029 in. (0.038-0.074 mm) 0.0059 in. (0.150 mm)
End Play 0.0051-0.0091 in. (0.130-0.230 mm) 0.0110 in. (0.280 mm)
Deflection 0.0008 in. (0.020 mm)
Cylinder Block
Cylinder Inside Diameter
Standard 3.3858-3.3870 in. (86.000-86.030 mm) 3.3937 in. (86.200 mm)
1st Oversize 3.3957-3.3969 in. (86.250-86.280 mm) 3.4035 in. (86.450 mm)
2nd Oversize 3.4055-3.4067 in. (86.500-86.530 mm) 3.4134 in. (86.700 mm)
Cylinder Roundness 0-0.0004 in. (0-0.010 mm) 0.0012 in. (0.030 mm)
Cylinder Taper (Cylindricity) 0-0.0004 in. (0-0.010 mm) 0.0012 in. (0.030 mm)
Deck Distortion 0.002 in. (0.05 mm)
Cylinder Head Standard Dimensions Wear Limit
Distortion 0-0.002 in. (0-0.05 mm) 0.006 in. (0.15 mm)
Timing Gears
Timing Gear Lash
Crankshaft Gear to Idler Gear 0.0028-0.0059 in. (0.070-0.150 mm) 0.0067 in. (0.170 mm)
Idler Gear to Camshaft Gear 0.0028-0.0059 in. (0.070-0.150 mm) 0.0067 in. (0.170 mm)
Idler Gear to Fuel Injection Pump
Gear
0.0028-0.0059 in. (0.070-0.150 mm) 0.0067 in. (0.170 mm)
Idler Gear Bushing Inside Diameter 1.8110-1.8120 in. (46.000-46.025 mm) 1.8140 in. (46.075 mm)
Idler Gear Shaft Outside Diameter 1.8091-1.8100 in. (45.950-45.975 mm) 1.8071 in. (45.900 mm)
Idler Gear Shaft to Idler Gear Bushing
Clearance
0.0010-0.0030 in. (0.025-0.075 mm) 0.0069 in. (0.175 mm)
Tier 2 - TK486V, TK486VB, and TK486VH (Continued)

21. TK482 & TK486 Diesel Engine Specifications
21
Oil Pump
Type Trochoid
Outer Rotor to Gear Case Cover
Clearance
0.0047-0.0083 in. (0.120-0.210 mm) 0.0118 in. (0.300 mm)
Oil Pump Cover to Outer Rotor
Clearance
0.0008-0.0028 in. (0.020-0.070 mm) 0.0047 in. (0.120 mm)
Inner Rotor Inside Diameter 2.1043-2.1083 in. (53.450-53.550 mm)
Crankshaft Gear Boss Outside
Diameter
2.0886-2.0925 in. (53.050-53.150 mm)
Inner Rotor to Crankshaft Gear Boss
Clearance
0.0118-0.0197 in. (0.300-0.500 mm) 0.0236 in. (0.600 mm)
Inner Rotor Width Across Flat 1.9665-1.9705 in. (49.950-50.050 mm)
Crankshaft Gear Boss Width Across
Flat
1.9468-1.9587 in. (49.450-49.750 mm)
Inner Rotor to Crankshaft Gear Boss
Clearance Between Flats
0.0079-0.0236 in. (0.200-0.600 mm) 0.0276 in. (0.700 mm)
Pressure Control Valve Setting 43-57 psi (294-392 kPa)
Starter
No Load Test
Voltage 11 volts
Current Maximum of 130 amps @ 11 volts
Speed Minimum of 3900 rpm @ 11 volts
Loaded Properties
Voltage 8.5 volts
Current 400 amps
Commutator Outside Diameter 1.44 in. (36.5 mm) 1.40 in. (35.5 mm)
Tier 2 - TK486V, TK486VB, and TK486VH (Continued)

22. TK482 & TK486 Diesel Engine Specifications
22
Exhaust Gas Specifications
The following specifications are provided to help design a system to remove exhaust gas from a shop or garage.
Exhaust Gas Temperature at Muffler
Outlet
1450 rpm 340 F (171 C)
2200 rpm 450 F (232 C)
2600 rpm 450 F (232 C)
Exhaust Gas Flow Rate
1450 rpm 49 cubic feet/minute (1.4 cubic meters/minute)
2200 rpm 106 cubic feet/minute (3.0 cubic meters/minute)
2600 rpm 124 cubic feet/minute (3.5 cubic meters/minute)

23. Torque Values
23
Torque Values
TK482, TK482E, TK486, TK486E, and TK486EH
Description
Dia. x Pitch
(mm)
N•m ft-lb kgm
Connecting Rod Bolt 9x1.0 44.1-53.9 32.5-39.8 4.5-5.5
Crankshaft Pulley Bolt 14x1.5 112.8-122.6 83.2-90.4 11.5-12.5
Cylinder Head Mtg. Bolt 10x1.25 85.3-91.2 62.9-67.3 8.7-9.3
Flywheel Mtg. Bolt 10x1.25 83.4-88.3 61.5-65.1 8.5-9.0
Fuel Injection Line Nut 12x1.5 29.4-34.3 21.7-25.3 3.0-3.5
Fuel Injection Nozzle Mtg. Nut 6x1.0 6.9-8.8 5.1-6.5 0.7-0.9
Fuel Injection Nozzle Nut 39.2-44.1 28.9-32.5 4.0-4.5
Fuel Injection Pump Gear Mtg. Nut 12x1.75 58.8-68.6 43.4-50.6 6.0-7.0
Main Bearing Bolt 12x1.5 96.1-100.0 70.9-73.8 9.8-10.2
Rocker Arm Support Mtg. Bolt 8x1.25 22.6-28.4 16.6-21.0 2.3-2.9
Standard 6 mm Bolt and Nut 6x1.0 9.8-11.8 7.2-8.7 1.0-1.2
Standard 8 mm Bolt and Nut 8x1.25 22.6-28.4 16.6-21.0 2.3-2.9
Standard 10 mm Bolt and Nut 10x1.5 44.1-53.9 32.5-39.8 4.5-5.5
Standard 12 mm Bolt and Nut 12x1.75 78.5-98.1 57.9-72.3 8.0-10.0
NOTE: For standard bolts in aluminum parts use 80% of the specified torque.
TK486V, TK486VB, and TK486VH
Description
Dia. x Pitch
(mm)
N•m ft-lb kgm
Connecting Rod Bolt 9x1.0 44.1-49.0 32.5-36.2 4.5-5.0
Crankshaft Pulley Bolt 14x1.5 112.8-122.6 83.2-90.4 11.5-12.5
Cylinder Head Mtg. Bolt 10x1.25 85.3-91.2 62.9-67.3 8.7-9.3
Flywheel Mtg. Bolt 10x1.25 83.4-88.3 61.5-65.1 8.5-9.0
Fuel Injection Line Nut 12x1.5 29.4-34.3 21.7-25.3 3.0-3.5
Fuel Injection Nozzle Mtg. Bolt 8x1.25 24.4-28.4 18.0-21.0 2.5-2.9
Fuel Injection Nozzle Nut 39.2-44.1 28.9-32.5 4.0-4.5
Fuel Injection Pump Gear Mtg. Nut 14x1.5 78.5-88.3 57.9-65.1 8.0-9.0
Main Bearing Bolt 12x1.5 93.2-98.1 68.7-72.4 9.5-10.0
Oil Pump Cover Mtg. Screw 5.4-8.4 3.9-6.2 0.6-0.9
Rocker Arm Support Mtg. Bolt 8x1.25 22.6-28.4 16.6-21.0 2.3-2.9
Standard 6 mm Bolt and Nut 6x1.0 9.8-11.8 7.2-8.7 1.0-1.2
Standard 8 mm Bolt and Nut 8x1.25 22.6-28.4 16.6-21.0 2.3-2.9
Standard 10 mm Bolt and Nut 10x1.5 44.1-53.9 32.5-39.8 4.5-5.5
Standard 12 mm Bolt and Nut 12x1.75 78.5-98.1 57.9-72.3 8.0-10.0
NOTE: For standard bolts in aluminum parts use 80% of the specified torque.

24. Special Tools
24
Special Tools
The following special tools for all versions of TK482/486 engines are available from the Thermo King
Service Parts Department. Refer to the Tool Catalog (TK 5955).
The following drawings show dimensions for special tools that are to be made a locally. The tools are for
all versions of TK482/486 engines.
Description Part Number
Fuel Injection Nozzle Puller 204-902
Rear Seal Installation Tool 204-952
Rear Seal Remover 204-994
Injection Pump Remover 204-1011
Compression Test Adapter (For use with Compression Tester 204-542) 204-1056
Injection Pump Plunger Spring Tool (Tier 1 and Earlier Engines) 204-1083
Front Seal Installation Tool 204-1138
L1. 0.79 in. (20.0 mm)
L2. 2.95 in. (75.0 mm
d1. 0.30 in. (7.5 mm)
d2. 0.43 in. (11.0 mm)
Figure 1: Valve Guide Removal Tool
L1. 0.59 in. (15.0 mm)
L2. 2.56 in. (65.0 mm)
d1. 0.55 in. (14.0 mm)
d2. 0.79 in. (20.0 mm)
Figure 2: Valve Guide Installation Tool

25. Special Tools
25
L1. 0.74 in. (18.8 mm)
L2. 2.56 in. (65.0 mm)
L3. 0.16 in. (4.0 mm)
d1. 0.64 in. (16.2 mm)
d2. 0.87 in. (22.0 mm)
d3. 0.53 in. (13.5 mm)
Figure 3: Valve Stem Seal Installation Tool
L1. 0.79 in. (20.0 mm)
L2. 3.94 in. (100.0 mm)
d1. 1.02 in. (26.0 mm)
d2. 1.14 in. (29.0 mm)
Figure 4: Connecting Rod Bushing
Removal and Installation Tool
L1. 0.71 in. (18.0 mm)
L2. 2.76 in. (70.0 mm)
d1. 1.77 in. (45.0 mm)
d2. 1.89 in. (48.0 mm)
Figure 5: Camshaft Bearing Removal Tool

26. Special Tools
26

27. 27
Engine Disassembly
NOTE: Most of the illustrations in this manual
show the early engine with the in-line fuel
injection pump and the high mount water pump.
The other engines are similar and significant
differences are noted.
Before disassembling the engine, drain the engine
oil and coolant, disconnect the battery cables, and
remove the engine from the unit.
1. Lift Bracket 9. Oil Pan
2. Fuel Injection Line 10. Fuel Transfer Pump
3. Valve Cover 11. Oil Level Switch
4. Crankcase Breather Hose 12. Dipstick
5. Water Pump 13. Oil Filter
6. In-Line Fuel Injection Pump 14. Oil Line
7. Gear Case Cover 15. Starter
8. Crankshaft Pulley 16. Intake Manifold
Figure 6: Front View of Early Engine
15
14
11
4
2
1
8
9
3
1
16
13
12
AGA01
5
6
7
10

28. Engine Disassembly
28
1. Lift Bracket 10. Oil Level Switch
2. Fuel Injection Line 11. Dipstick
3. Crankcase Breather Hose 12. Oil Filter
4. Valve Cover 13. Trochoid Feed Pump
5. Water Pump 14. Mono-Plunger and Distributor Fuel Injection Pump
6. Gear Case Cover 15. Cold Start Device
7. Crankshaft Pulley 16. Starter
8. Oil Pan 17. Intake Manifold
9. Fuel Transfer Pump
Figure 7: Front View of Tier 2 Engine
16
15
10
42
1
7
8
3
1
17
12
11
5
6
9
13
14

29. Engine Disassembly
29
While disassembling the engine, note things such
as the position of dowel pins and O-rings, and the
existing timing marks and bearing cap marks.
Identical components in the valve train and the
crankshaft assembly should be kept in order or
marked. This prevents mixing up these
components and allows the components to be
placed in their original positions when the engine
is assembled.
1. Remove the exhaust manifold.
2. Remove the crankcase breather hose.
NOTE: The crankcase breather hose on Tier
1 and earlier engines is not interchangeable
with the crankcase breather hose on the Tier
2 engine. See “Crankcase Breather System
Tier 1 and Earlier Engines” on page 65 and
“Crankcase Breather System Tier 2 Engine”
on page 66 for more information.
3. Remove the fuel injection lines. Cover all the
injection lines, fuel lines, and fittings with
plastic covers or tape. The smallest amount of
dirt can damage the fuel system.
4. Remove the fuel return lines. Do not reuse the
fuel return lines if they are old style lines. See
“Fuel Return Line Replacement” on page 113.
5. Remove the intake manifold.
6. Remove the lift brackets from the cylinder
head.
1. Fuel Injection Lines
2. Fuel Return Lines
Figure 8: Remove Fuel Injection Lines
Tier 1 and Earlier Engines
2
1
AGA02
1. Fuel Injection Lines
2. Fuel Return Lines
Figure 9: Remove Fuel Injection Lines
Tier 2 Engines
2
1

30. Engine Disassembly
30
7. Remove the fuel injection nozzle mounting
nuts and retainers from Tier 1 and earlier
engines. Remove the fuel injection nozzle
mounting bolts and retainers from Tier 2
engines.
8. Remove the fuel injection nozzles. Use
injection nozzle puller P/N 204-902 if
necessary.
9. Remove the water pump.
NOTE: Tier 2 engines have two coolant
hoses that go from the water pump to a the
cold start device on the fuel injection pump.
Disconnect the hoses from the water pump
before removing it.
1. Retainer
2. Fuel Injection Nozzle
3. Nozzle Protector
4. Nozzle Gasket
Figure 10: Remove Fuel Injection Nozzles
Tier 1 and Earlier Engines
1. Retainer
2. Fuel Injection Nozzle
3. Nozzle Protector
4. Nozzle Gasket
Figure 11: Remove Fuel Injection Nozzles
Tier 2 Engines
1
2
3
4
1
2
3
4
1. High Mount Water Pump
2. Low Mount Water Pump
Figure 12: Remove Water Pump
1. Coolant Hoses
Figure 13: Disconnect Coolant Hoses on
Tier 2 Engines
2
1
1
1

31. Engine Disassembly
31
10. Remove the valve cover by removing the three
special cap nuts. Inspect the O-rings under
these cap nuts and replace the O-rings, if
necessary, during assembly.
NOTE: The valve cover on Tier 1 and earlier
engines is not interchangeable with the valve
cover on the Tier 2 engine. See “Crankcase
Breather System Tier 1 and Earlier Engines”
on page 65 and “Crankcase Breather System
Tier 2 Engine” on page 66 for more
information.
Figure 14: Remove Valve Cover
11. Remove the rocker arm assembly by removing
the bolts that mount the rocker arm supports.
Alternately loosen each bolt one turn at a time
to evenly release the spring pressure on the
rocker arm assembly.
Figure 15: Remove Rocker Arm Assembly
12. Remove the valve stem caps and keep them in
order.
Figure 16: Remove Valve Stem Caps
13. Remove the push rods and keep them in order
if they will be reused.
14. Break each cylinder head bolt loose 1/4 to 1/2
turn in a crisscross pattern starting at the ends.
Then remove the cylinder head bolts.
15. Remove the cylinder head from the cylinder
block.
Figure 17: Remove Cylinder Head
AGA05
AGA06
AGA07
AGA08

32. Engine Disassembly
32
16. Remove the oil filter and the oil filter head.
Figure 18: Remove Oil Filter and Oil Filter Head
17. Remove the oil line that goes from the
cylinder block to the fuel injection pump and
the gear case cover.
NOTE: On later model engines the oil line
stops at the fuel injection pump and does not
go to the gear case cover. The hole in the
gear case cover is plugged with a screw
(P/N 55-5768). Tier 2 engines do not have
the hole in the gear case cover and do not use
the plug screw.
Figure 19: Remove Oil Line
18. Remove the fuel transfer pump from the gear
case cover.
Figure 20: Remove Fuel Transfer Pump
19. Remove the front crankshaft bolt.
20. The end of the crankshaft is tapered. Remove
the crankshaft pulley by using a suitable
puller. Check the pulley for a crack in the area
near the dowel pin (see Figure 167 on page
85). A cracked pulley can leak oil and should
be replaced.
Figure 21: Remove Crankshaft Pulley
AGA09
AGA10
AGA11
AGA12

33. Engine Disassembly
33
21. Remove the gear case cover and sound shield.
NOTE: On Tier 2 engines the oil pump is
located in the gear case cover. The inner
rotor of the oil pump fits around the
crankshaft gear. See “Oil Pump for Tier 2
Engines” on page 62.
Figure 22: Remove Gear Case Cover
and Sound Shield
22. Check the timing gear lash. If the gear lash is
within specifications (refer to Specifications),
the gears can probably be reused. If the gear
lash is excessive, some or all of the gears must
be replaced to meet the specifications.
Figure 23: Check Timing Gear Lash
23. Note the timing marks on the timing gears.
The timing marks must be aligned when the
engine is assembled.
24. Remove the fuel injection pump gear nut and
lock washer.
Figure 24: Remove Fuel Injection Pump Gear
Nut and Lock Washer
25. The fuel injection pump shaft is tapered. The
fuel injection pump gear must be removed to
remove the fuel injection pump. Remove the
fuel injection pump gear by using a suitable
puller.
NOTE: See “Injection Pump Removal and
Installation (All Engines)” on page 105 for
information about removing the injection
pump without removing the crankshaft
pulley and gear case cover.
Figure 25: Use Puller to Remove
Fuel Injection Pump Gear
AGA13
AGA14

34. Engine Disassembly
34
NOTE: Early engines (before Tier 1) use a
single-piece fuel injection pump gear (see
Figure 26).
Tier 1 engines use a three-piece fuel
injection pump gear assembly (see Figure
27). Do not loosen or remove the four bolts
that fasten the injection pump gear to the
flange because that changes the timing. See
“Attaching Injection Pump Gear to Flange
on Tier 1 Engines” on page 100 if the
injection pump gear is detached from the
flange.
Tier 2 engines use a three-piece fuel
injection pump gear assembly (see Figure 28
on page 35). Do not loosen or remove the
four bolts that fasten the injection pump gear
to the flange because that changes the
timing. That will cause the engine to violate
EPA, CARB, or other emission control
regulations and require recertification.
1. Fuel Injection Pump
2. Key
3. Injection Pump Gear
4. Nut (Injection Pump Gear)
Figure 26: Single-Piece Fuel Injection Pump Gear
Early Engines
1
2
3
4
1. Fuel Injection Pump
2. Key
3. Flange
4. Injection Pump Gear
5. Transfer Pump Cam
6. Nut (Injection Pump Gear)
7. Do Not Remove Gear From Flange
Figure 27: Three-Piece Fuel Injection Pump Gear
Tier 1 Engine
1
2
3
4
5
6
7

35. Engine Disassembly
35
26. Note the alignment of the index marks on the
injection pump and the gear case. On Tier 1
and earlier engines, the index mark on the
injection pump is usually aligned with the
center (long) index mark on the gear case. On
Tier 2 engines, the index mark on the injection
pump is usually aligned with the single index
mark on the gear case. If not, mark it so the
injection pump can be returned to the same
position when it is reinstalled.
1. Fuel Injection Pump
2. Key
3. Flange
4. Injection Pump Gear
5. Transfer Pump Cam
6. Nut (Injection Pump Gear)
7. Do Not Remove Gear From Flange
Figure 28: Three-Piece Fuel Injection Pump Gear
Tier 2 Engine
1
2
3
4
5
6
7
1. Index Marks
Figure 29: Tier 1 and Earlier Index Mark Location
1. Index Mark on Injection Pump
2. Center Index Mark on Gear Case
Figure 30: Typical Tier 1 and Earlier
Index Mark Alignment
1. Index Marks
Figure 31: Tier 2 Index Mark Location
1
1 2
1

36. Engine Disassembly
36
27. Remove the fuel injection pump from the gear
case.
Figure 33: Remove Fuel Injection Pump
Tier 1 and Earlier Engines
Figure 34: Remove Fuel Injection Pump
Tier 2 Engines
28. Remove the oil pump from Tier 1 and earlier
engines. On Tier 2 engines the oil pump is
located in the gear case cover.
NOTE: See “Checking Oil Pump” on
page 141 for information about check and
changing the oil pump without pulling the
engine from the unit.
Figure 35: Remove Oil Pump
Tier 1 and Earlier Engines
29. Remove the two bolts from the idler gear
shaft.
30. Remove the idler gear and the idler gear shaft
from the cylinder block.
Figure 36: Remove Idler Gear and Idler Gear Shaft
1. Index Mark on Injection Pump
2. Index Mark on Gear Case
Figure 32: Typical Tier 2 Index Mark Alignment
1 2
AGA16
AGA17
AGA18