TROUBLESHOOT THE 6V53/6V53T DETROIT DIESEL ENGINE

INTRODUCTION
The 6V53T engine provides power for a variety of military equipment to include: cargo, personnel, recovery vehicles, selfpropelled mortars, flame throwers, missile carriers, and light armored vehicles. Specifically, the 6V53T engine powers the M113 family of vehicles (FOV).
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M113A3 FOV

M113A3

EQUIPMENT DESCRIPTION
6- CYLINDER , FUEL INJECTED V- TYPE, LIQUID COOLED 53- cu. in per cylinder (Total displacement 318.) T-Turbocharged
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EQUIPMENT DESCRIPTION (CONT.)

Numbering of the cylinders is one, two, and three from the front (accessory end) of the engine, on both banks. When determining position of a component on the engine (left or right), view the engine from the rear or flywheel. The firing order of this engine is: 1L, 3R, 3L, 2R, 2L, and 1R. As viewed from the front of the engine, this engine rotates clockwise.
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Right Front View

Left Rear View

COMPONENT LOCATIONS
A. Water Pump B. Valve Rocker Covers C. Engine Oil Cooler D. Exhaust Manifolds E. Liquid Level Gage Rod F. Thermostat & Housing Assembly
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F B E

COMPONENT LOCATIONS CONT.

G.

G. Transmission Oil Cooler

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COMPONENT LOCATIONS CONT.

H. Oil Filter I. Governor J. Oil Pan K. Starter L. Flywheel M. Fuel Strainer N. Fuel Filter O. Turbocharger
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K L J

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COMPONENT LOCATIONS CONT.

R

P. Fuel Pump Q. Blower R. Cylinder Heads

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ENGINE SYSTEMS
The diesel engine is an internal combustion power unit where the heat energy of fuel is converted into working energy inside the cylinder. In a diesel engine, air alone is compressed in the cylinder. After compression, a charge of fuel is sprayed into the cylinder where ignition is accomplished by the heat of compression.
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FUEL SYSTEM
The fuel pump draws fuel from the vehicle tank through the strainer and forces it through the filter. From the filter, fuel goes through the fuel inlet passage in the cylinder head and fuel tubes into the injectors. The fuel passes through a filter element within the injector to a chamber where it is metered, displaced, and atomized through the injector tip into the combustion chamber and excess fuel not injected cools the injector and returns to the tank.
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LUBRICATION SYSTEM
The gear type oil pump is bolted to the back of the lower front cover and is driven directly by the crankshaft. Lubricating oil is picked up from the oil pan by the pump. From the pump, it passes from the lower front cover through short gallery passages in the cylinder block to the oil filter adapter plate. From the adapter plate, oil flows through the oil filter, through the oil cooler, back through the lower front cover, and into the cylinder block oil galleries for distribution to the various engine 16 bearing.

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The water pump takes coolant from the radiator and circulates it through the oil cooler, cylinder block, and cylinder heads to the thermostat housing. During the warm-up period, the thermostat blocks the flow of coolant to the radiator(below 160 degree Fahrenheit). With the thermostat closed, the pump circulates the coolant through the bypass system to the cylinder block and cylinder head. As coolant reaches approximately 160 degrees Fahrenheit, the thermostat opens and the coolant then passes through the radiator for cooling.
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COOLING SYSTEM

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AIR INDUCTION
The blower forces air into the cylinder(called scavenging) and sweeps out the burned gases through the exhaust valve ports. This air also cools the internal engine parts, particularly the exhaust valves. The turbocharger forces additional pressurized air into the cylinders (called supercharging) to allow burning of more fuel for additional power.
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AIR INDUCTION

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COMBUSTION CYLINDER

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ELECTRICAL SYSTEM
The electrical system consists of: A. THE STARTER B. THE AIR BOX HEATER C. ALL RELATED WIRING
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GEAR TRAIN
The gear train consists of a crankshaft gear, idler gear, fuel pump drive gear, and two camshaft gears. Model 50635393 also has a hydraulic pump drive gear. The camshaft gears mesh with each other and run at the same speed as the crankshaft gear. The stamped timing marks on the face of the gears show proper timing.
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GOVERNOR
The limiting-speed, mechanical governor is mounted between the blower and flywheel housing. The governor holds the injector racks in the advanced fuel position for starting when the speed control lever is in the idle position. Immediately after starting, the governor moves the injector racks to control idle and maximum engine speed during operation.
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Throttle Lever Engine Stop

Buffer screw
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TWO STROKE(CYCLE) ENGINE

A two stroke engine completes one cycle (intake, compression, power, and exhaust) every time the piston goes up and down. Up being one stroke and down being the return stroke. The air intake and exhaust functions are accomplished during the compression and power strokes.
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SCAVENGING
The blower forces air into the cylinders and sweeps out the exhaust gases to supply the cylinder with fresh air for combustion. When the top of the piston moves down and uncovers the ports, air in the air box is forced through the ports. The air then flows towards the exhaust valves and produces a scavenging effect, leaving the cylinder full of fresh air when the piston returns and covers the ports.
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COMPRESSION
As the piston continues its upward stroke, it compresses the charge of fresh air. Just before the piston reaches its highest point, top dead center, the fuel injectors injects the required amount of fuel into the cylinder. The heat created during compression of the air ignites the fine spray immediately, and combustion continues until the fuel air mixture burns completely.
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The resulting pressure forces the piston downward on its power stroke. The exhaust valves open approximately halfway down allowing the burned gasses to escape into the exhaust manifold. Shortly thereafter, the downward moving piston uncovers the inlet ports sweeping the cylinder with fresh scavenging air. This entire cycle takes one revolution of the crankshaft or two strokes.
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POWER

EXHAUST
When the piston is halfway down, the exhaust valve open and most of the high pressure exhaust gases escape. Shortly thereafter, the piston drop below the inlet ports in the cylinder wall. Pressurized air is then forced through the cylinder. During this process, the remaining exhaust gases are removed (or scavenged) from the cylinder.
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INTAKE AIR

COMPRESSION

EXHAUST

POWER
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ENGINE ADJUSTMENT
The Intervals and Adjustment Sequence: a. Intervals following any engine repair, perform adjustments specified in Par 4-3.b. b. Adjustment sequence when performing adjustments on an engine in service, check various settings for possible changes from previous adjustments. However, if the cylinder head, governor, or fuel injectors have been removed or replaced, also check specific preliminary adjustments before starting engine.
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ADJUSTMENT SEQUENCE
The preliminary adjustments consist of the
first four steps in the following sequence. The remaining items complete the list of engine adjustments to be performed. 1. Exhaust valve clearance 2. Fuel injector timing adjustment 3. Governor gap adjustment 4. Fuel injector control tube adjustment
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ADJUSTMENT SEQUENCE CONT.

5. Throttle delay adjustment 6. Starting aid screw adjustment 7. Maximum no-load speed adjustment 8. Idle speed adjustment 9. Buffer screw adjustment
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EXHAUST VALVE CLEARANCE ADJUSTMENT

A. rotate crankshaft until injector follower is fully depressed on cylinder to be adjusted. B. .025-.027 cold & .023-.025 hot engine

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FUEL INJECTOR TIMING ADJUSTMENT

The fuel injector enables starting directly on diesel fuel and permits the use of a simple, open combustion chamber. High pressure fuel lines, airfuel mixing, or vaporizing devices are required.

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FUEL INJECTOR TIMING ADJUSTMENT CONT.

The fuel injector: 1. Creates the high fuel pressure required for efficient injection. 2. Meters and injects fuel in the exact amount required to handle the load on the engine. 3. Atomizes the fuel for mixing with the air in the cylinder. 4. Permits continuous fuel flow.
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FUEL INJECTOR TIMING ADJUSTMENT

A. Rotate crankshaft until exhaust valve stem are fully depressed on cylinder to be timed. B. 1.496 inch timing gage for model 5063-5392 & 5393. C. 1.460 inch timing gage for models 50635299, 5063-5395, 5063-5398, and 5063539F.
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GOVERNOR GAP ADJUSTMENT

A. Extend buffer screw 5/8, start engine and adjust idle to 500-600 RPM. B. Start and run engine 1100-1300 with differential lever and check gap between low-speed and high-speed plunger with a thickness gage .002-.004 inch.
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GOVERNOR GAP ADJUSTMENT

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INJECTOR CONTROL TUBE ADJUSTMENT

Purpose: It controls the amount of fuel injected into the cylinder. A. Adjust No. 3L or 3R injector control lever first to establish a guide for adjusting remaining injector control lever. B. Loosen and back out six adjusting screw. Remove opposite control lever clevis and cotter pin. Turn screw until slight movement is felt on speed control lever or roll up on injector control tube. 43

INJECTOR CONTROL TUBE ADJUSTMENT CONT.

ATTENTION:Once 3L and 3R injector control levers are adjusted, do not alter their settings. Make further adjustments only on remaining injector control rack levers.

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CONTROL TUBE ADJUSTMENT

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CONTROL TUBE ADJUSTMENT

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THROTTLE DELAY ADJUSTMENT

Purpose: It retards full fuel injection when the engine accelerates, reducing exhaust smoke and improving fuel economy. A. Fill delay with clean engine oil. Insert delay timing gage on 2R injector. B. Align delay piston flush with throttle delay cylinder.
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THROTTLE DELAY VALVE

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A. Hold starting aid screw and loosen locknut. Insert starting aid gage on 3R injector rack. Prevent gap adjusting screw from turning and adjust starting aid screw with a 0.345 inch gage.

STARTING AID SCREW ADJUSTMENT

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MAXIMUM NO-LOAD SPEED ADJUSTMENT

A. to adjust engine start with five 0.010 inch shims and 0.078 inch shims in governor spring pack. B. Back out buffer 5/8 inch and place control lever in FULL FUEL position. Maximum speed should be 2965 RPM.
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NOTE:Removing shims will decrease engine speed and adding shims will increase engine speed. Each 0.010 inch shim will change engine speed approximately 10 RPM.

MAXIMUM NO-LOAD SPED ADJUSTMENT CONT.

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IDLE SPEED ADJUSTMENT

A. Place speed control lever in idle position of 600-650 RPM. B. Adjust idle screw to obtain 15 RPM below recommended idle speed and stop engine.
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IDLE SPEED ADJUSTMENT

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BUFFER SCREW ADJUSTMENT

A. Start engine and place speed control lever in FULL FUEL and record maximum no-load speed. B. Do not increase engine idle speed more than 15 RPM with buffer screw. C. Place speed control lever in idle position and turn buffer screw until it contact differential lever as lightly as possible and eliminates engine roll.
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BUFFER SCREW ADJUSTMENT

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CHECK ON LEARNING
Q. What is the purpose of the fuel injector ? A. It meters, displaces and atomizes the fuel for the cylinders.

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CHECK ON LEARNING CONT.

Q. What purpose does the turbocharger serve? A. Provide pressurized air to the blower.
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CHECK ON LEARNING CONT.

Q. The electrical system consists of what components? A. The starter, air box heater, and assorted wiring.

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SUMMARY
In this lesson you were introduced to the 6V53/6V53T engine, its characteristics, component locations and tune-up procedures.
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