Service Manual Comment Forms Rear of Manual

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KJ MAINTENANCE SCHEDULES 0 1,MAINTENANCE SCHEDULES. TABLE OF CONTENTS,MAINTENANCE SCHEDULES FOR ALL,MARKETS EXCEPT U S CANADA and. DESCRIPTION DIESEL ENGINES 1, MAINTENANCE SCHEDULES Check the windshield washer solvent and add if. FOR ALL MARKETS EXCEPT,U S CANADA and MEXICO Once a Month. Check the tire pressure and look for unusual,DESCRIPTION DIESEL ENGINES wear or damage.
Maintenance Schedule Information not included in Inspect the battery and clean and tighten the. this section is located in the appropriate Owner s terminals as required. Manual Check the fluid levels of coolant reservoir brake. There are two maintenance schedules that show master cylinder power steering and transmission. the required service for your vehicle and add as needed. First is Schedule B It is for vehicles that are Check all lights and all other electrical items for. operated under the conditions that are listed below correct operation. and at the beginning of the schedule,At Each Oil Change. Extensive engine idling,Change the engine oil filter. Driving in dusty conditions,Inspect the exhaust system. More than 50 of your driving is at sustained,Inspect the brake hoses. high speeds during hot weather above 32 C 90 F,Check the manual transmission fluid level if.
Trailer towing,Taxi police or delivery service commercial ser. Check the coolant level hoses and clamps,Inspect engine accessory drive belts Replace as. NOTE Most vehicles are operated under the condi necessary. tions listed for Schedule B Inspect for the presence of water in the fuel fil. ter water separator unit, Second is Schedule A It is for vehicles that are Rotate the tires. not operated under any of the conditions listed under. Schedule 9B9 Schedule B, Use the schedule that best describes your driving Follow schedule B if you usually operate your. conditions Where time and mileage are listed follow vehicle under one or more of the following conditions. the interval that occurs first Extensive engine idling. Driving in dusty conditions, CAUTION Failure to perform the required mainte More than 50 of your driving is at sustained.
nance items may result in damage to the vehicle high speeds during hot weather above 32 C 90 F. Trailer towing,Taxi police or delivery service commercial ser. At Each Stop for Fuel vice,Check the engine oil level about 5 minutes after. a fully warmed engine is shut off Checking the oil. level while the vehicle is on level ground will, improve the accuracy of the oil level reading Add oil. only when the level is at or below the ADD or MIN,0 2 MAINTENANCE SCHEDULES KJ. MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U S CANADA and MEXICO Continued. Kilometers 10 000 km 20 000 km 30 000 km 40 000 km 50 000 km. Change the engine oil and engine oil filter X X X X X. Inspect the ball joints X X X X X,Inspect engine accessory drive belt X X X X.
Replace engine accessory drive belt X,Inspect the engine air filter element X X X. Replace as necessary,Replace the engine air filter element X X. Replace the engine timing belt X,Inspect idler pulleys and timing belt X. Replace fuel filter water separator unit X X,Inspect the brake linings X X X X X. Drain and refill the front and rear axle fluid X X. Drain and refill automatic transmission fluid X,and replace transmission main sump filter.
Kilometers 60 000 km 70 000 km 80 000 km 90 000 km 100 000 km. Change the engine oil and engine oil filter X X X X X. Inspect the ball joints X X X X X,Inspect engine accessory drive belt X X X X X. Replace engine accessory drive belt X,Inspect the engine air filter element X X. Replace as necessary,Replace the engine air filter element X X X. Inspect idler pulleys and timing belt X,Replace the engine timing belt X. Inspect the brake linings X X X X X, Drain and refill the front and rear axle fluid X X X.
Replace the fuel filter water separator unit X X X. Drain and refill the transfer case fluid X,Drain and refill the automatic transmission X. fluid and replace transmission main sump,KJ MAINTENANCE SCHEDULES 0 3. MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U S CANADA and MEXICO Continued. Kilometers 110 000 km 120 000 km 130 000 km 140 000 km 150 000 km 160 000 km. Change the engine oil and X X X X X X,engine oil filter. Inspect the ball joints X X X X X X,Inspect the engine air filter X X X. element Replace as,Replace the engine air filter X X X.
Inspect engine accessory X X X X X,drive belt,Replace engine accessory X. drive belt,Inspect the idler pulleys and X,timing belt tensioner. Replace the engine timing X,Inspect the brake linings X X X X X X. Drain and refill the front and X X X,rear axle fluid. Replace the fuel filter water X X X,separator unit.
Flush and replace the engine X,Drain and refill automatic X. transmission fluid and replace,transmission filter s. Inspection and service should also be performed,anytime a malfunction is observed or suspected. Retain all receipts, Replace if there is superficial wear bearing clear. ance or evident grease leak,0 4 MAINTENANCE SCHEDULES KJ.
MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U S CANADA and MEXICO Continued. Schedule A, Kilometers 20 000 km 40 000 km 60 000 km 80 000 km 100 000 km. Change the engine oil and engine oil X X X X X,Inspect the ball joints X X X X X. Inspect the brake linings X X,Inspect the engine air filter element X X X. Replace as necessary,Replace the engine air filter element X X. Inspect the engine accessory drive belt X X X X X,Replace the engine accessory drive X.
Replace the fuel filter water separator X X X X X,Inspect idler pulleys and timing belt X. Replace the engine timing belt X,Inspect the transfer case fluid X. Kilometers 120 000 km 140 000 km 160 000 km 180 000 km. Change the engine oil and engine oil filter X X X X. Inspect the ball joints X X X X,Inspect the brake linings X X. Inspect the engine accessory drive belt X X X X,Inspect the engine air filter element Replace X X. as necessary,Replace the engine air filter element X X.
Replace the fuel filter water separator unit X X X X. Flush and replace the engine coolant X,Inspect the transfer case fluid X. Drain and refill the transfer case fluid X,Drain and refill automatic transmission fluid X. and replace transmission filter s, Inspection and service should also be performed WARNING You can be badly injured working on or. anytime a malfunction is observed or suspected around a motor vehicle Do only that service work. Retain all receipts for which you have the knowledge and the right. Replace if there is superficial wear bearing clear equipment If you have any doubt about your ability. ance or evident grease leak to perform a service job take your vehicle to a. competent mechanic,KJ COOLING 2 5L 2 8L TURBO DIESEL 7 1. COOLING 2 5L 2 8L TURBO DIESEL,TABLE OF CONTENTS, COOLING 2 5L 2 8L TURBO DIESEL STANDARD PROCEDURE COOLING.
DESCRIPTION COOLING SYSTEM 1 SYSTEM REVERSE FLUSHING 7. DIAGNOSIS AND TESTING CLEANING 8,DIAGNOSIS AND TESTING COOLING INSPECTION 8. SYSTEM FLOW CHECK 1 SPECIFICATIONS, DIAGNOSIS AND TESTING COOLING SPECIFICATIONS COOLING SYSTEM. SYSTEM AERATION 1 CAPACITY 8, DIAGNOSIS AND TESTING COOLING SPECIFICATIONS TORQUE 8. SYSTEM LEAK TEST 2 ACCESSORY DRIVE 9,DIAGNOSIS AND TESTING ON BOARD ENGINE 16. DIAGNOSTICS OBD 2,DIAGNOSIS AND TESTING COOLING,COOLING 2 5L 2 8L TURBO DIAGNOSIS AND TESTING.
DIESEL DIAGNOSIS AND TESTING COOLING SYSTEM,DESCRIPTION COOLING SYSTEM FLOW CHECK. The cooling system regulates engine operating tem To determine whether coolant is flowing through. perature It allows the engine to reach normal oper the cooling system use the following procedures. ating temperature as quickly as possible maintains 1 If engine is cold idle engine until normal oper. normal operating temperature and prevents over ating temperature is reached Then feel the upper. heating radiator hose If it is hot coolant is circulating. The cooling system also provides a means of heat,WARNING DO NOT REMOVE THE COOLING SYS. ing the passenger compartment The cooling system,TEM PRESSURE CAP WITH THE SYSTEM HOT AND. is pressurized and uses a centrifugal water pump to. UNDER PRESSURE BECAUSE SERIOUS BURNS, circulate coolant throughout the system A separate. FROM COOLANT CAN OCCUR,and remotely mounted pressurized coolant tank.
using a pressure vent cap is used 2 Remove pressure vent cap when engine is cold. idle engine until thermostat opens you should, COOLING SYSTEM COMPONENTS observe coolant flow while looking down in the cool. The cooling system consists of ant recovery pressure container Once flow is. Charge Air Cooler detected install the pressure vent cap. Electric Cooling Fans, A aluminum core radiator with plastic side DIAGNOSIS AND TESTING COOLING SYSTEM. A separate pressurized coolant tank AERATION, A pressure vent cap on the coolant tank Low coolant level in a cross flow radiator will. Fan shroud equalize in both tanks with engine off With engine. Thermostat at running and at operating temperature the high. Coolant pressure inlet tank runs full and the low pressure. Low coolant warning lamp outlet tank drops resulting in cooling system aera. Coolant temperature gauge tion Aeration will draw air into the water pump. Water pump resulting in the following, Hoses and hose clamps High reading shown on the temperature gauge. Loss of coolant flow through the heater core,Corrosion in the cooling system.
7 2 COOLING 2 5L 2 8L TURBO DIESEL KJ,COOLING 2 5L 2 8L TURBO DIESEL Continued. Water pump seal may run dry increasing the If there are no external leaks after the gauge dial. risk of premature seal failure shows a drop in pressure detach the tester Start. Combustion gas leaks into the coolant can also engine and run until the thermostat opens allowing. cause aeration the coolant to expand Reattach the cooling system. tester If the needle on the dial fluctuates it indicates. DIAGNOSIS AND TESTING COOLING SYSTEM a combustion leak usually a head gasket leak. WARNING WITH TOOL IN PLACE PRESSURE WILL, WARNING THE WARNING WORDS DO NOT OPEN BUILD UP RAPIDLY EXCESSIVE PRESSURE BUILT. HOT ON THE RADIATOR PRESSURE CAP IS A UP BY CONTINUOUS ENGINE OPERATION MUST. SAFETY PRECAUTION WHEN HOT PRESSURE BE RELEASED TO A SAFE PRESSURE POINT. BUILDS UP IN COOLING SYSTEM TO PREVENT NEVER PERMIT PRESSURE TO EXCEED 138 kPa. SCALDING OR INJURY THE RADIATOR CAP 20 psi,SHOULD NOT BE REMOVED WHILE THE SYSTEM. If the needle on the dial does not fluctuate raise. IS HOT OR UNDER PRESSURE,the engine rpm a few times If an abnormal amount. With engine not running remove pressure vent cap of coolant or steam emits from the tailpipe it may. from the coolant recovery pressure container and indicate a coolant leak caused by a faulty head gas. wipe the filler neck sealing seat clean The coolant ket cracked engine block or cracked cylinder head. level in the recovery pressure container should be There may be internal leaks that can be deter. full mined by removing the oil dipstick If water globules. Attach the Cooling System Tester 7700 or equiva appear intermixed with the oil it will indicate an. lent to the radiator as shown in Fig 1 and apply internal leak in the engine If there is an internal. 104 kPa 15 psi pressure If the pressure drops more leak the engine must be disassembled for repair. than 13 8 kPa 2 psi in 2 minutes inspect all points. for external leaks DIAGNOSIS AND TESTING ON BOARD, All radiator and heater hoses should be shaken DIAGNOSTICS OBD.
while at 104 kPa 15 psi since some leaks occur only. while driving due to engine movement COOLING SYSTEM RELATED DIAGNOSTICS. The Engine Control Module ECM has been pro,grammed to monitor certain cooling system compo. nents If the problem is sensed in a monitored circuit. often enough to indicated an actual problem a DTC,is stored The DTC will be stored in the ECM mem. ory for eventual display to the service technician. Refer to 25 EMISSIONS CONTROL DESCRIP,ACCESSING DIAGNOSTIC TROUBLE CODES. To read DTC s and to obtain cooling system data,Refer to 25 EMISSIONS CONTROL DESCRIP. ERASING TROUBLE CODES,After the problem has been repaired use the.
DRBIIIt scan tool to erase a DTC Refer to the,appropriate Powertrain Diagnostic Procedures ser. vice information for operation of the DRBIIIt scan. Fig 1 PRESSURE TESTING COOLING SYSTEM,1 COOLANT PRESSURE TESTER. 2 COOLANT RECOVERY PRESSURE CONTAINER,KJ COOLING 2 5L 2 8L TURBO DIESEL 7 3. COOLING 2 5L 2 8L TURBO DIESEL Continued, DIAGNOSIS AND TESTING COOLING SYSTEM Engine adjustments incorrect timing. Establish what driving conditions caused the com Slipping engine accessory drive belt. plaint Abnormal loads on the cooling system such as Brakes possibly dragging. the following may be the cause Changed parts incorrect water pump. 1 PROLONGED IDLE VERY HIGH AMBIENT Reconditioned radiator or cooling system refill. TEMPERATURE SLIGHT TAIL WIND AT IDLE ing possibly under filled or air trapped in system. SLOW TRAFFIC TRAFFIC JAMS HIGH SPEED, NOTE If investigation reveals none of the previous.
OR STEEP GRADES,items as a cause for an engine overheating com. Idle with A C off when temperature gauge is at, plaint refer to following Cooling System Diagnosis. GROUP TAB LOCATOR 0 Maintenance Schedules 7 Cooling 2 5L 2 8L Diesel 8E Electronic Control Modules 8F Engine Systems 8I Ignition Control 9 Engine 11 Exhaust System and Turbocharger 14 Fuel System 21 Automatic Transmission 545RFE 25 Emissions Control 2 5L 2 8L Turbo Diesel Service Manual Comment Forms Rear of Manual

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