INTRODUCTION

GENERAL

This section has the descriptions and repair proce-

dures for the engine and fuel system. Removal, disas-
sembly, assembly and installation procedures, checks
and adjustments and specifications are included. A
troubleshooting table is at the end of the section.

DESCRIPTION

The Perkins TV8.540 and TV8.640 are vee-eight die-

sel engines with fuel injection and a turbocharger. The
turbine in the turbocharger is driven directly by the
exhaust gases from the engine. The turbine in turn,
drives the impeller. Rotation of the impeller pushes air
into the intake manifolds. The turbocharger increases
engine torque and horsepower.

The engine firing order and serial number location

are shown in Figure 1.

FIGURE 1. FIRING ORDER AND SERIAL

NUMBER LOCATION

CYLINDER HEAD AND VALVE MECHANISM

CYLINDER HEAD F. If necessary, remove the fuel filter assembly and the
hoses for the breather.
Removal
G. Remove the intake and exhaust manifolds.
A. Disconnect the battery connections at the battery.
H. Remove the fuel injectors.
B. Drain the cooling system.
J. Remove the rocker arm covers. Remove the rocker
C. Remove the fuel lines to the fuel injectors. Put iden- arm assemblies and push rods. Make sure the valve
tification tags on the lines for correct installation. Put stem caps stay on the valve stems when the rocker
caps on the open ports. Disconnect the fuel line(s) arms are removed. Remove the valve stem caps.
and wire(s) at the thermostart element(s).
K. Remove the capscrews and nuts for the cylinder
D. Disconnect the hose for the water outlet. Discon- head in the reverse order of the tightening sequence.
nect the wire at the water temperature sender. (See Figure 4.)

E. Disconect the water hoses at the air compressor. L. Remove the cylinder head.
 FIGURE 2. CYLINDER HEAD

FIGURE 4. TIGHTENING SEQUENCE FOR

CYLINDER HEAD

Repairs

Use a straight edge to measure the clearance on the

face of the cylinder head. The maximum clearance
across the width of the cylinder head is 0.10 mm
FIGURE 3. OIL LINE FOR ROCKER SHAFT (0.004 in). The maximum clearance along the length
of the cylinder head is 0.20 mm (0.008 in).
The surface of the cylinder head can be machined to a C. Install the cylinder head. Lubricate the threads of
maximum of 0.38 mm (0.015 in). (See Figure 5). On the studs and capscrews. See Figure 6 for the correct
the TV8.540 the nozzle of the fuel injector must not location of the studs and capscrews. Tighten the nuts
extend more than 4.60 mm (0.181 in) beyond the cyl- and capscrews to 210 N.m (155 lbf ft) in the sequence
inder head. On the TV8.640 the nozzle of the fuel shown in Figure 4.
injector must not extend more than 3.63 mm (0.143
in) beyond the cylinder head. (Do not use washers to D. Install the push rods. Install the rocker arm assem-
change the position of the fuel injectors.) The height of bly. Make sure the valve stem caps are on the valve
the cylinder head must not be less than 100.84 mm stems. Tighten the screws and nuts for the rocker arms
(3.970 in). to 49 N. m (36lbf ft). Adjust the valve clearance as
specified in Checks and Adjustments.
NOTE: If the surface of the cylinder head has been
machined, it can be necessary to install new valve seat E. Install the rocker arm covers.
inserts. See Valve Seat Inserts for more information.
F. Install the intake and exhaust manifolds. Do not use
a sealant on the gaskets.

G. Connect the water hoses. If necessary, install the

fuel filter assembly and breather hoses. Connect wire
to water temperature sender.

H. Install the fuel injectors with new washers. Tighten

the nuts to 16 N. m ( 12 lbf ft). Install the fuel lines for
the fuel injectors. Make sure each fuel line is in the
correct position. Do not bend the fuel lines during in-
stallation. Connect fuel line(s) and wire(s) at the
thermostart element(s).

I. Remove air from the fuel system as described in

Checks and Adjustments.
FIGURE 5. CYLINDER HEAD DIMENSIONS J. Fill the cooling system.
Installation
K. Run the engine until operating temperature (at least
A. Clean the surface of the cylinder head. Clean the 77° C /170° F ) is reached. Check the torque on the
oil passages. nuts and capscrews for the cylinder head and tighten
as necessary.
B. Install a new gasket for the cylinder head. Make
sure the word TOP is at the top. Do not use a sealant. VALVE MECHANISM

Valve Guides

The maximum clearance between the valve stem and

the valve guide is 0.13 mm (0.005 in). If the clear-
ances are not within specifications, install new valve
guides. Install valve guides to dimensions shown in
Figure 7.

FIGURE 6. INSTALLING THE CYLINDER

HEAD
 Valves, TV8.640

When the valves are removed, make sure they have

identification marks. Use an approved service pro-
cedure when grinding the valves. The correct valve
angle is 30° for intake valves and 45° for exhaust valves.
The valves heads are below the surrface of the cylin-
der head. When new, the intake valves are 1.30-1.70
mm (0.051-0.067 in) below the surface. After grind-
ing, the valves must not be more than 2.59 mm (0.
102 in) below the head. When new, the exhaust valves
are 1.04-1.45 mm (0.041-0.057 below the surface
of the head. in). After grinding the valves must not be
more than 2.46 mm (0.097 in) below the head. (See
Figure 8.) When installing the valves, lubricate the valve
stems with oil.

FIGURE 7. VALVE GUIDE INSTALLATION Valve Springs

The springs used on the intake and exhaust valves are

Valves, TV8.540 the same. Check the condition of the springs as shown
in Figure 9. When installing the inner valve springs, the
When the valves are removed, make sure they have ends with the coils close together fit toward the cylin-
identification marks. Use an approved service pro- der head.
cedure when grinding the valves. The correct valve
angle is 45°. The valves extend above the surface of
the cylinder head. When new, the intake valves ex-
tend .07-1.32 mm (0.042-0.052 in) above the sur-
face. After grinding, the valves must extend at least
0.03 mm (0.001 in) or more. When new, the exhaust
valves extend 1.24-1.50 mm (0.049-0.059 in). After
grinding the valves must extend at least 0.23 mm (0.009
in). (See Figure 8.) When installing the valves, lubri-
cate the valve stems with oil.

FIGURE 9. VALVE SPRINGS

Valve Seat Inserts (See Figure 10)

FIGURE 8. VALVE INSTALLATION The intake and exhaust valves use valve seat inserts
that are pressed into the cylinder head. The inserts are
held in position by rolling the metal at the edge of the
insert. The valve seat inserts can be replaced only
once. Replace the inserts as follows:
A. If there is a letter “R” (TUB.540 only) next to the
insert, the surface of the cylinder head must be ma-
chined. When the cylinder head has been machined,
the new valve seat inserts must also be machined. The
inserts must not extend above the surface of the cylin-
der head.
FIGURE 10. VALVE SEAT INSERTS
B. If the surface of the cylinder head has not been
machined, the metal around the edge of the insert must
be removed. When removing this metal, do not ex-
ceed the diameter of the insert or the depth of the
chamfer on the insert 0.38-0.51mm (0.015-0.020 in).
C. Remove the valve seat insert from the cylinder head.
D. Clean the area for the insert and the new insert.
Make sure the bore for the insert is within the specifi-
cations shown in Figure 10.
E. Put the new insert in liquid nitrogen until the fast
boiling stops.
WARNING
Do not touch the valve seat insert with your
hands during or after freezing.
F. Press the insert into the bore in the cylinder head.
Make sure the insert touches the bottom of the bore.
G. Roll the metal around the edge of the insert. If the
metal cannot be rolled, use a punch to make marks at
four equal points around the insert.
Rocker Arm Assembly
DISASSEMBLY (See Figure 11)
A. Remove the capscrew that holds the bracket to the
shaft.
B. Remove the clips from the ends of the shaft.
C. Remove the rocker arms, washers and brackets
from the shaft.
D. If necessary, remove the bushing(s) from the rocker
arm(s).
ASSEMBLY (See Figure 11)
A. Make sure the oil passages in the shaft and rocker
arms are clean. If necessary, install the bushing(s) in
the rocker arm(s) as shown in Figure 11. Assemble
the clips, washers, brackets and rocker arms on the
shaft.
 FIGURE 11. ROCKER ARM ASSEMBLY
LUBRICATION SYSTEM
OIL PUMP
Removal
A. Drain the engine oil.
B. Remove the oil sump.
C. Remove the capscrews that hold the oil pump to
the cylinder block. Remove the oil pump.
Disassembly (See Figure 12)
A. Use a puller to remove the drive gear.
B. Remove the cover from the oil pump housing. Re- other.
move the drive shaft and gear and the driven gears.
Do not remove the gear from the drive shaft.
Inspection
Clean all parts and check for damage. Check the clear-
ance between the gears and the oil pump housing.
The maximum clearance is 0.25 mm (0.010 in). Check
the clearance between the drive gear and driven gears.
The maximum clearance is 0.10 mm (0.004 in). Check
the clearance between the end of the housing and the
end of the gears. The maximum clearance is 0.25 mm
(0.010 in).
Assembly (See Figure 12)
A. If the drive gear was removed, a new shaft and
drive gear must be installed. Install the shaft in the hous-
ing, then press the drive gear on the shaft. Press the
gear until it is even with the end of the shaft.
B. Install the driven gears with the shoulders at the
top. Make sure the oil holes are aligned with each
C. Install the cover with a new gasket. Install the
strainer and fittings.
Installation
A. Fill the oil pump with clean engine oil.
 mm (0.003 in) clearance between the teeth of the drive
gear and the idler gear.

C. Connect the strainer pipe to the oil pump. Install

the oil sump.

IDLER GEAR FOR THE OIL PUMP

Removal

A. Remove the timing gear case.

B. Remove the thrust plate, gear and hub.

Installation (See Figure 13)

A. Make sure the center hole in the hub has a plug at

the front.

B. Align oil holes in cylinder block and hub. Install

hub, gear and thrust plate. Tighten the capscrews to
23-26 N.m (17-19 1bf ft).

C. Measure the clearance between the thrust plate

and gear. The maximum clearance is 0.76 mm (0.030
in).

FIGURE 12. OIL PUMP D. Measure the clearance between the teeth of the
idler gear and the oil pump and crankshaft gears. There
must be at least 0.08 mm (0.003 in) clearance.

RELIEF VALVE FOR

B. Install the oil pump, making sure the drive gear and OILPRESSURE
idler gear are aligned. Check that there is at least 0.08
The relief valve for oil pressure is set to release pres-

FIGURE 13. IDLER GEAR FOR THE OIL PUMP

sure at 393-448 kPa (57-65 psi). The relief valve is Disassembly (See Figure 14)
installed at the bottom of the cylinder block. When
installing the relief valve, be sure to use a new gasket A. Put identification marks on the housing and the end
and O-rings. with the coolant connections.

RELIEF VALVE FOR COLD OIL, B. Remove the screws that hold the tube assembly in
TV8.640 the housing.

The relief valve for cold oil ure is set to release pres- C. Pull tube assembly from the housing. Remove O-
sure at 1240 kPa (180 psi). The relief valve is installed rings.
next to the suction strainer. There is no gasket be-
Assembly (See Figure 14)
tween the relief valve and the oil pump.
A. Lubricate the new O-rings and install O-rings and
OIL COOLER tube assembly in the housing.
Removal (See Figure 14) B. Install screws to hold the tube assembly to the hous-
ing.
A. Drain the cooling system for the engine. Remove
the drain plug from the oil cooler and drain the oil cooler. Tests

B. Disconnect the coolant lines at the oil cooler. A. To test the oil chamber of the oil cooler, fill the
coolant chamber with water. Put the oil cooler in wa-
C. Remove the oil cooler from the oil sump. ter. Add air pressure (415 kPa/60 psi) to the oil cham-
ber. Check for leakage.

B. Replace the tube assembly if leakage occurs.

FIGURE 14. OIL COOLER

Installation

A. Use new gaskets and O-rings when installing the

oil cooler.

B. Connect the hoses for the coolant. Fill the cooling

system.

C. Run the engine and check for leaks.

CONTROL VALVE FOR THE

PISTON COOLING JETS
This valve is installed at the top of the cylinder block
at the flywheel end of the engine. When the oil pres-
sure in the main oil gallery reaches 276 kPa (40 psi),
this valve opens to let oil flow through a secondary oil
gallery. From the secondary oil gallery, oil flows to the
piston cooling jets.

The control valve can be removed after removing the

turbocharger bracket and the top cover for the cylin-
der block. Check the parts for wear or damage. When
installing the control valve, tighten it to 20 N.m (15 lbf
ft). Install the top cover for the cylinder block and the
turbocharger bracket.

PISTON COOLING JETS

Removal

Remove the pistons and connecting rods to remove

the cooling jets. Remove the capscrew from the cool-
ing jet.

Installation

A. Install the cooling jet in the cylinder block. Tighten

the capscrew to 12 N.m (9 lbf ft). Make sure the oil
passages are aligned.

B. Check the alignment of the cooling jets as follows:

FIGURE 15. ALIGNMENT OF THE PISTON
1. Install a piece of 1.75 mm (0.069 in) rod into the COOLING JETS
nozzle of the cooling jet. The rod must extend above
the top of the face of the crankcase.

2. The correct nozzle position is shown in Figure 15.

Make sure the rod comes to an end at the mark made
by the measurements.
 TIMING GEARS AND CAMSHAFT

TIMING GEAR CASE A. Rotate engine until the Number 1 piston is at TDC
(compression stroke) as described in Timing.
Removal
B. Remove timing gear case.
A. Remove the crankshaft pulley.
C. Remove the capscrews from the camshaft gear.
B. Remove the water pump. Remove the camshaft gear.

Installation
C. Drain oil from oil sump and remove oil sump.
A. Check that the dowel in the camshaft is towards
D. Remove capscrews that hold the timing gear case
the center of the gear for the air compressor. If the
to the cylinder block. Remove both halves of the tim-
camshaft needs to be rotated, remove the rocker arm
ing gear case.
covers and loosen the rocker arm assemblies.
Installation
B. Remove the timing plug for the fuel injection pump.
Rotate the gear for the air compressor until the timing
A. Install a new oil seal in the timing gear case. The lip
with the spring must be toward the inside of the case. mark is aligned. Also make sure the two teeth with
Press the seal until it is 9.65-10.2 mm (0.38-0.40 in) marks are toward the camshaft.
below the front surface of the case.
C. Remove the idler gear for the camshaft.
B. Install new gaskets. Make sure the dowels are in
position. D. Rotate the camshaft until the tooth with a mark is
toward the center of the hub of the camshaft idler gear.
C. Install both halves of the timing gear case.
E. Install the camshaft gear. Make sure the marks on
the teeth are aligned.
D. Install the crankshaft pulley and the water pump.
F. Tighten the capscrews for the camshaft to 54 N.m
CAMSHAFT GEAR (40 1bf ft).
Removal

FIGURE 17. INSTALLATION OF THE

FIGURE 16. CAMSHAFT GEAR
CAMSHAFT GEAR
G. Install the camshaft idler gear. Align the marks on Installation
the camshaft idler gear with the teeth of the camshaft
and crankshaft gears. Install the retainer and the nuts A. Lubricate camshaft and bearings. Install the cam-
for the idler gear. Tighten the nuts to 41 N.m (30lbf ft). shaft in the cylinder block.
Check that the clearance between the teeth of the gears
is at least 0.08 mm (0.003 in). (See Figure 17.) B. Install the thrust plate for the camshaft. Tighten the
capscrews to 16 N.m (12 lbf ft).
H. Install the rocker arm assemblies.
C. Install the camshaft gear. Check the movement of
I. Install timing gear cover. the camshaft gear as shown in Figure 19. Maximum
movement is 0.51 mm (0.020 in). Replace the retainer
J. Check engine and fuel injection timing as described (see Figure 16) if movement exceeds the dimensions.
in Timing.

CAMSHAFT
Removal

A. Rotate the engine until the Number 1 piston is at

TDC (compression stroke) as described in Timing.

B. Remove the rocker arm assemblies and the push

rods.
FIGURE 19. INSTALLATION OF
C. Remove the timing gear case. THE CAMSHAFT GEAR
D. On the TV8.540, install the cam follower and
D. Remove the camshaft gear. blocks. Make sure the oil passages for the blocks are
clean. Tighten the capscrews for the blocks to 79 N.m
E. Remove the fuel filter assembly, air compressor, (58 lbf ft).
fuel injection pump and bracket for the turbocharger.
E. Install the cover on the cylinder block. Install the air
F. Remove the cover on top mf the cylinder block. compressor, fuel injection pump and fuel filter assem-
bly.
G. Hold the cam followers in the up position (use a
rubber band). On the TV8.540, the the cam followers
F. Install the timing gear case.
and blocks can be removed (see Figure 18).

H. Remove the camshaft. G. Install the push rods and rocker arm assemblies.
Install the rocker arm covers and fuel lines.

H. Check the timing at the engine and fuel injection

pump.

CAMSHAFT IDLER GEAR

Removal

A. Rotate the engine until the Number 1 piston is at

TDC (compression stroke) as described in Timing.
FIGURE 18. CAM FOLLOWERS, TV8.540
B. Remove the timing gear case.
 FIGURE 20. CAMSHAFT IDLER GEAR

C. Remove the capscrews, retainer, idler gear, hub aligned with the marks on the other gears. Tighten the
and thrust plate. capscrews to 41 N.m (30 lbf ft).

Installation B. Check that the clearance between the teeth of the

gears is at least 0.08 mm (0.003 in).
A. Install the thrust plate, hub, idler gear, retainer and
capscrews. Make sure the marks on the teeth are C. Check the clearance between the idler gear and
the retainer. Maximum clearance is 0.89 mm (0.035
in).
CRANKSHAFT

REMOVAL
NOTE: The thrust washers for the crankshaft can be
replaced without removing the crankshaft.

A. Remove the flywheel and flywheel housing.

B. Remove the cylinder heads.

C. Remove the crankshaft pulley. Do not use a pullr to

remove the pulley. Remoe the two capscrews and
thrust block. Loosen the lock rings by hitting the pul-
ley with a block of wood (see Figure 21).

D. Remove timing gear case. Remove the camshaft

idler gear.

E. Remove the housing for the rear oil seal.

F. Remove the pistons and connecting rods. FIGURE 21. REMOVAL OF CRANKSHAFT
PULLEY
G. Turn the engine over. Remove the capscrews from
the sides of the main bearing caps. Remove the other
capscrews from the main bearing caps. Remove the
bearing caps. Remove the crankshaft and thrust wash-
ers.
be heat treated (nitrided) after any machine work. If
the balance weights were removed, tighten the
capscrews to 115 N.m (85 lbf ft) on TV8.540 en-
gines and 163 N.m (120 lbf ft) on TV8.640 engines.
(See Figure 22.)

REPAIR INSTALLATION
The crankshaft can be machined. The limits are 0.25 A. If necessary, install the crankshaft gear and key
mm (0.010 in), 0.51 mm (0.020 in) and 0.76 mm using Loctite 601. Make sure the timing mark is at the
(0.030 in) under the standard size. The crankshaft must front of the crankshaft and the gear is against the Num-
ber 1 bearing location.

FIGURE 22. CRANKSHAFT BALANCE FIGURE 23. THRUST WASHERS

FIGURE 24. BEARING CAP LOCATIONS

B. Make sure the oil passages in the crankshaft and the main bearing caps to 136 N.m (100 lbf ft). On the
cylinder block are clean. TV8.640 engines, tighten the capscrews in the side of
the main bearing caps as follows:
C. Install the main bearings with the grooves in the
cylinder block. Lubricate the bearings and install the Front and rear capscrews (½ in U.N.F), 150 N.m
crankshaft. (110 lbf ft) Inner capscrews (9/16 U.N.F.), 2 l 7 N. m
( 160 lbf ft)
D. Install the thrust washers (see Figure 23). Install
the main bearings in the bearing caps, then install the
bearing caps. Make sure the bearing caps are in the
correct locations. (See Figure 24).

E. Lubricate and install the capscrews for the main

bearing caps. The two short capscrews are for the
rear main bearing cap. Tighten the capscrews for the
main bearing caps to 285 N.m (210 lbf ft). On the
TV8.540 engine, tighten the capscrews in the side of

FIGURE 25. CHECKING THE FIGURE 26. INSTALLING THE REAR SEAL
CRANKSHAFT

FIGURE 27. REAR SEAL BLOCK

 F. Check the movement of the crankshaft (see Figure
25). The maximum movement of the crankshaft is 0.51
mm (0.020 in). The movement is controlled by the
thrust washers on the center main bearing cap.

G. Install the pistons and connecting rods.

H. Install the housing and oil seal at the rear of the

crankshaft. The seal can be installed in different posi-
tions as shown in Figure 26. Lubricate the seal and
crankshaft flange.

I. Install the rear seal block and rubber seals (see Fig-
ure 27). Use a straight edge at the surface of the cylin-
der block. Make sure the rear seal block and cylinder
block are even.

J. Install the oil pump, relief valve and oil sump.

K. Install the camshaft idler gear. Install the timing gear

case.

L. Install the crankshaft pulley and key. Install the in-

ner ring and outer ring. Install second inner ring and
second outer ring. Make sure the slots in the rings are
not aligned. Install the thrust block and O-ring. Tighten
the capscrews in stages to 88 N.m (65 1bf ft).

M. Install the cylinder heads.

N. Install the flywheel housing and the flywheel.

FIGURE 28. CRANKSHAFT PULLEY

PISTONS AND CONNECTING RODS

REMOVAL E. Remove the piston rings from the piston. Remove

the piston pin. If necessary, heat the piston in water
A. Remove the cylinder head. (40°-50°C/100°-l20°F) to remove the piston pin.

B. Remove the oil sump. REPAIRS

C. Remove the carbon from the top of the cylinder A. Check the alignment of the connecting rod as shown
liner. in Figure 29.

D. Remove the capscrews from the cap for the con-

necting rod. Remove the piston and connecting rod
through the top of the cylinder liner. Make sure the
connecting rod does not hit the piston cooling jet.
 B. If a new bushing for the piston pin is installed, make
sure the oil holes are aligned. Use a tool to get the
inside dimensions of the bushing as shown in Specifi-
cations.

C. Check the clearance of the piston rings in the

grooves of the pistons. See Specifications for the cor-
rect clearance.

D. Check the clearance between the ends of the rings

as shown in Figure 31. See Specifications for the cor-
rect clearance.

FIGURE 31. INSTALLING THE PISTON RINGS

INSTALLATION

FIGURE 29. PISTON AND CONNECTING ROD A. Install the piston on the connecting rod in the direc-
tion shown in Figure 32. If necessary, heat the piston
in water 40°-50°C/ l00°-l20°F) to install the piston
pin. Install the clips for the piston pin.

FIGURE 30. ALIGNM ENT OF THE

CONNECTING ROD
FIGURE 32. PISTON AND CON NECTING ROD
B. Install the piston rings on the piston. When install-
ing the spring for the oil control ring, make sure the
ends of the spring are completely engaged. Install the
oil control ring so that the ends of the ring are opposite
from the ends of the spring.

C. Lubricate the piston, piston rings and bearings with

oil. Put the pistons in the correct bores. On the
TV8.540 engine, the chambers for the valves are to-
ward the center of the engine.

D. Push the piston into the bore making sure the con-
necting rod does not hit the piston coiling jet.

E. Install the bearing cap (see Figure 33). Make sure

the bearing cap is installed in the correct location. Tighten
the capscrews to 142 N.m (105 lbf ft).

F. Put the piston at TDC. On the TV8.540 engine,

check that the top of the piston is 0.00-0.216 mm
(0.00-0.0085 in below the surface of the cylinder
block. See Figure 34. On the TV8.640 engines, check
that the top of the piston is 0.04-0.25 mm (0.0015-
0.010 in) above the surface of the cylinder block. See
Figure 34.

FIGURE 33. INSTALLATION OF FIGURE 34. CHECKING THE HEIGHT OF THE

BEARING CAPS PISTON
 CYLINDER LINERS
REMOVAL AND INSTALLATION
A. The cylinder liner must be pulled from the top of
the cylinder block as shown in Figure 35.

B. When installing a liner, make sure the cylinder block

and liner are clean. Lubricate the outside of the liner
with clean engine oil.

C. Use a puller to pull the liner into position. When

completely installed, the liner on the TV8.540 engine
will extend 0.53-0.69 mm (0.021-0.027 in) above the
surface of the cylinder block. The flange of the liner
can be from 0.05 mm (0.002 in) below to 0.10 mm
(0.004 in) above the cylinder block.

On the TV8.640 engine, the liner will extend 0.61-

0.76 mm (0.024-0.030 in) above the surface of the
cylinder block. The flange of the liner can be 0.00-
0.10 mm (0.00-0.004 in) above the cylinder block. FIGURE 35. REMOVING THE CYLINDER
LINER

FIGURE 36. CYLINDER LINER

 FLYWHEEL AND FLYWHEEL HOUSING
REMOVAL (See Figure 37)
A. On the TV8.640 engine, remove the cover from
the flywheel housing. Remove the coupling from the
flywheel.

B. Remove the capscrews that hold the flywheel to

the crankshaft.

C. Remove the flywheel housing.

REPAIRS (See Figure 37)

A. Install a new ring gear to the flywheel as follows:

1. During removal or installation, do not heat the ring

gear to more than 230° C (450° F).

2. Push the ring gear fully against the flywheel.

INSTALLATION (See Figure 37)

A. Install the flywheel housing.

B. Install the flywheel. Tighten the capscrews for the

flywheel to 108 N.m (80 lbf ft).

C. On the TV8.540 engine, make sure the pilot bush-

ing and spacer are installed in the flywheel (see Figure
37).

D. On the TV8.640 engine, install the coupling on the

flywheel. Tighten the capscrews for the coupling to 45
N.m (33 lbf ft). Install the cover on the flywheel hous-
ing.

FIGURE 37. FLYWHEEL

 FUEL SYSTEM

FUEL PUMP, TV8.540

(See Figure 38)
Removal

A. Disconnect the fuel lines at the fuel pump.

B. Remove the fuel pump from the fuel injection pump.

Disassembly

A. Put identification marks on the two halves of the

pump housing.

B. Remove the top cover and diaphragm.

C. Remove the screws from the top half of the hous-

ing. Remove the diaphragm and spring.

Assembly

A. If removed, install inlet and outlet valves. Install

diaphragm and top cover.

B. Install spring and diaphragm. If the spring was re-

placed, make sure the new spring is the same color as
the one replaced. Make sure the diaphragm is com-
pletely engaged on the rocker arm link.

C. Align the marks and install the halves of the housing

together.

Installation

A. Install the fuel pump on the fuel injection pump.

Connect the fuel lines.

B. Remove air from the fuel system as described in

Checks and Adjustments.

FUEL PUMP, TV8.640

Removal

A. Disconnect the fuel lines at the fuel pump. FIGURE 38. FUEL PUMP

B. Remove the fuel pump from the fuel injection pump.

Disassembly D. Rotate the engine so that the Number 1 piston is at
TDC on the compression stroke. Remove the fuel in-
A. Carefully remove the capscrew at the top of the jection pump from the adapter housing on the air com-
pump body. Remove the spring and piston assembly. pressor.

B. Remove the primer assembly. Remove the plugs Repairs

and O-rings.
Repairs to the fuel injection pump cannot be made
Assembly without special tools. Any repairs must be made by a
dealer.
A. Install the piston assembly with new O-rings.
Installation
B. Install the primer assembly and the plugs with new
O-rings. A. Remove the stall device (see Figure 40). Turn the
screw in four complete turns. This will make sure the
Installation stall device does not change the idle speed of the en-
gine.
A. Install the fuel pump on the fuel injection pump.
Connect the fuel lines.

B. Remove air from the fuel system as described in

Checks and Adjustments. Run the engine and check
for leaks.

FUEL INJECTION PUMP

Removal (See Figure 39)

A. Put identification tags on the fuel lines, then remove

all fuel lines from the fuel injection pump.

B. Disconnect the throttle linkage.

C. Disconnect the oil lines at the fuel injection pump.

FIGURE 40. STALL DEVICE

B. Remove the timing plug from the adapter housing.

Rotate the shaft for the fuel injection pump until the
pointer is aligned with the TDC mark (see Figure 4 l).

C. Remove the rocker arm cover for the Number 1

cylinder. Rotate the engine until the Number 1 piston
is at TDC (compression stoke).

D. Install the drive gear on the fuel injection pump, but

FIGURE39. REMOVING THE FUEL do not tighten all of the capscrews. Tighten the
INJECTION PUMP capscrew that it can be reached through the front cover.

FIGURE 41. TIMING MARK FOR FUEL
INJECTION PUMP
E. Install the fuel injection pump on the adapter on air Installation
compressor. Make sure the timing marks are aligned.
F. Adjust the timing of the fuel injection pump as de-
scribed in Checks and Adjustments.
TURBOCHARGER
REMOVAL
A. Disconnect the exhaust pipe and the air inlet at the fully remove the turbine and the impeller housings.
turbocharger.
B. Disconnect the hose to the inlet manifold.
C. Disconnect the oil lines at the turbocharger.
D. Remove the turbocharger from the exhaust mani-
fold.
DISASSEMBLY (See Figure 42)
A. Clean the outside of the turbocharger with solvent.
Make alignment marks on the housing and covers.
G. Connect the oil lines and fuel lines to the fuel injec-
tion pump. Connect the throttle linkage.
H. Remove the air from the fuel system as described
in Checks and Adjustments.
FUEL INJECTORS
Checks
A. Start the engine and run it at half speed.
B. Loosen the fitting for the high pressure line at the
fuel injector. If the engine speed does not change, that
fuel injector has a defect.
Repairs
Unless special equipment is available, do not repair
the fuel injectors.
A. Use a new gasket when installing a fuel injector.
B. Tighten the nuts for the fuel injector to 16 N. m (12
lbf ft).
B. Remove the capscrews holding the turbine housing
and the impeller housing to the center housing. Care-
C. Put a socket in a vise, then put the end of the tur-
bine shaft in the socket. Hold the center housing in a
vertical position. Remove the lock nut from the impel-
ler. Remove the impeller, shroud and turbine. Remove
the seal ring.
D. Remove the cover plate from the center housing.
Remove the seal ring. Remove the thrust collar, thrust
washer and retainer pins.
E. Remove the bearings from the center housing.
 FIGURE 42. TURBOCHARGER

CLEANING AND INSPECTION D. Align the marks and install the cover plate on the
center housing. Install the lock plates and capscrews.
Tighten the capscrews to 8.5-10.2 N.m (75-90 lbf
Before cleaning, check the parts for burned areas, ar-
eas of contact or other damage. Clean all parts in sol- in).
vent. Clean oil passages in the center housing. Check
all bearing surfaces for damage. Do not make repairs E. Put a socket in a vise, then put the end of the tur-
to the parts with damage. bine shaft in the socket. Hold the center housing in a
vertical position. Install the impeller and the lock nut.
Tighten the lock nut to 2.0-2.3 N.m (18-20 lbf in),
ASSEMBLY (See Figure 42) then tighten it another quarter of a turn (90°).
A. Install the snap rings and bearings in the center hous- F. Align the marks and install the turbine housing on
ing. The round edge of the snap ring fits toward the the center housing. Use Never-Seez on threads and
bearings. Lubricate the bearings during installation. install the capscrews and the lock plates. Tighten the
capscrews to 11.3-14.7 N.m (100-130 lbf in).
B. Install the seal ring on the turbine shaft. Install the
shroud. Install the turbine shaft in the bearings. G. Align marks and install the impeller housing on the
center housing. Install the capscrews and lock plates.
C. Install the seal ring in the groove of the thrust collar. Tighten the capscrews to 11.3-14.7 N.m (100-130
Put the thrust washer on the thrust collar. Install thrust lbf in).
washer on the pins in the center housing. Install the
seal ring in the center housing.
 COOLING SYSTEM
WATER PUMP (See Figure 43) Assembly

Removal A. Press a bearing on the main shaft with the shield

A. Drain the cooling system. Remove the drive bolts
from the pulley. Remove the fan from the pulley.
B. Remove the hoses from the water pump. Remove
the water pump.
Disassembly
A. Remove the plug from the end of the main shaft.
Use a driver to remove the impeller shaft. Remove the
seals fom the shaft.
B. Push the shaft out of the impeller.
C. Use a puller to remove the pulley from the main
shaft.
toward the flange. Install the spacer, then install the
bearing with the shield away from the other bearing.
Fill the bearings and the area between the bearings
half full of high temperature grease.
B. Install main shaft and bearings in the water pump.
Install the snap ring.
C. Install impeller shaft in the main shaft. Install pulley.
Use a thread locking compound on the pulley nut.
Tighten the nut to 95 N.m (70 lbf ft).
D. Install the seals on the impeller shaft, then install
impeller on the shaft. Make sure the center of the im-
peller extends beyond the water pump as shown in
Figure 44.

D. Remove the snap ring holding the bearing in the

water pump. Push out main shaft and bearings. Re-
move main shaft from bearings.

FIGURE 43. WATER PUMP


FIGURE 44. INSTALLATION OF THE
IMPELLER
AIR COMPRESSOR - TV8.540
NOTE: On theTV8.640 engine, use the section 1800
SRM 204, for service information on the air compres-
sor.
REMOVAL
A. Release the air from the system and disconnect the
air lines from the air compressor.
B. Remove the fuel injection pump.
C. Drain the cooling system. Disconnect the coolant
lines at the air compressor.
D. Remove the capscrews that hold the air compres-
sor to the timing case and engine. Remove the air com- E. Remove the bearing caps for the crankshaft.
pressor.
Installation
A. Install the water pump on the engine. Connect the
hoses and the drive belts. Fill the cooling system.
B. Run the engine and check for leaks.
DISASSEMBLY
A. Make alignment marks between the cylinder head,
barrel and the housing.
B. Remove the nuts from the cylinder head. Remove
the cylinder head and barrel.
C. Remove the caps from the connecting rod. Re-
move the connecting rod and piston. Remove the pis-
ton from the connecting rod.
D. Remove the housings from the sides of the air
compressor.
Remove the crankshaft.
INSPECTION B. Lubricate the bearings and the crankshaft. Install
the main bearings, thrust washers and crankshaft. In-
Check the parts of the air compressor against the di- stall the main bearing caps and tighten the capscrews
mensions shown in Specifications. to 28 N.m (20 lbf ft).

C. Check the movement at the end of the crankshaft.

ASSEMBLY The correct dimension is 0.03-0.28 mm (0.001-0.011
in). (See Figure 45.)
A. Install the gears on the crankshaft. Make sure the
gears are in the correct location on the dowels. Tighten D. Install the housing for the fuel injection pump.
the capscrews for the gears to 22 N.m (16 lbf ft). Tighten the capscrews to 22 N.m (16 lbf ft).

E. Install the piston to the connecting rod. Install the

piston pin and the snap rings.

F. Install the piston rings as shown in Figure 46.

FIGURE 45. INSTALLATION OF THE FIGURE 46. PISTON RINGS

CRANKSHAFT

FIGURE 47. CYLINDER HEAD AND MANIFOLD

G. Install the barrel with a new seal ring.

H. Lubricate the piston, then install the piston and con-

necting rod. Lubricate the bearings and install the bear-
ing cap. Tighten the capscrews to 12-15 N. m (9-11
lbf ft). Install the sump cover.

I. Install the valves in the cylinder head and manifold

as shown in Figure 47. Use a new gasket and install
manifold and cylinder head together.

J. Install the cylinder head, making sure the marks are

aligned. Tighten the nuts to 20-22 N.m (15-16 lbf ft).

INSTALLATION
A. Rotate the crankshaft of the engine until the Num-
ber 1 piston is at TDC on the compression stroke.

B. Rotate the crankshaft of the air compressor. Make

sure the gear tooth for the fuel injection pump is ap-
proximately half a tooth to the left of the pointer. (See
Figure 48).

C. Install the air compressor with new gaskets. Make

sure the gear for the air compressor engages with the
camshaft gear. When installed, make sure the gear tooth
for the fuel injection pump is closest to the pointer. FIGURE 48. INSTALLING THE AIR
COMPRESSOR
D. Install the capscrews for the air compressor.

E. Install the fuel injection pump. Check the timing. G. Fill the cooling system. Remove air from the fuel
system. Run the engine and check for correct opera-
F. Connect the coolant and air lines at the compres- tion and leaks.
sor.
CHECKS AND ADJUSTMENTS
REMOVING AIR FROM THE C. Operate the primer lever on the fuel pump until
fuel, free of bubbles, flows from each vent port. If it is
FUEL SYSTEM (See Figure 49) not possible to operate the primer lever, rotate the
crankshaft of the engine l 80°, then try the lever again.
Air must be removed from the fuel system if: (1) the
engine has run out of fuel, or (2) a fuel line has been D. Tighten the vent plug on the fuel filter and then the
disconnected. vent plug on the fuel injection pump.
A. Clean the area around the vent ports.

B. Loosen the vent plug at the top of the fuel filter(s).

Loosen the vent plug on the left-hand side of the fuel
injection pump.

FIGURE 49. REMOVING AIR FROM THE FUEL
SYSTEM
TIMING THE FUEL INJECTION
PUMP (See Figure 50)
A. The excess fuel device must be disengaged before
timing the fuel injection pump. The excess fuel device
is installed on the governor housing.
1. Disconnect the oil line at the excess fuel device.
2. Remove the capscrew and fitting. Install just the
capscrew and turn it until it pushes the internal piston
fully into the excess fuel device.
3. Move the stop control on the fuel injection pump to
the stop position and then to the run pmsition.
B. Put the Number 1 piston at TDC on the compres-
sion stroke.
C. Release a valve of the Number 1 cylinder and let it
sit on the piston (A). Use a collar on the valve stem to
keep it from falling into the cylinder.
D. Install a dial indicator with the plunger on top of the
valve stem. Move the Number 1 piston until it is ex-
actly on TDC (A).
E. Disconnect the fuel line for the Number 1 cylinder
at the fuel injection pump. Remove the valve and spring
from the port (B). Check that the plunger in the fuel
ijection pump is on the correct stroke as follows:
1. The plunger must be coming up the bore as the
Number 1 piston reaches TDC.
2. Rotate the engine backward through 45° and then
forward in the normal direction of rotation. Check
that the plunger is moving as the Number 1 piston
reaches TDC.
F. Connect a fuel line to the Number 1 outlet on the
fuel injection pump (C). Connect a small fuel tank to
the inlet of the fuel injection pump (D). This will give a
gravity supply of fuel for timing.
G. Rotate the crankshaft backward through 90° and
then forward in the normal direction of rotation. Stop
rotation just as the flow of fuel from the Number 1
outlet stops (one drop every 10 seconds) (E). With
the engine in this position, check the position of the
Number 1 piston with the dial indicator. The correct
position of the piston is 10.85 mm (0.27 in) BTDC.
Also check that the exhaust valve on the Number 4
cylinder is open (F).
H. If necessary, adjust the timing by changing the po- in) for the intake valves and 0.65 mm (0.025 in) for
sition of the timing gear for the fuel injection pump. the exhaust valves. Make sure the engine is cold. Ad-
Remove the cover, then loosen the capscrews for the just the clearance between the cap on the valve stem
gear and move it. Tighten the capscrews to 28 N.m and the rocker arm as follows:
(21 lbf ft).
A. Rotate the engine until the Number 4 cylinder is in
I. After any adjustments, rotate the engine through two a position between the opening of the intake valve and
complete revolutions and check the timing again. the closing of the exhaust valve. At this time, adjust
the valves on the Number 1 cylinder.
J. When the timing is correct, assemble the parts on
the fuel injection pump. Connect the oil line to the ex- B. Use the same as described in step B and adjust the
cess fuel device. Install the parts for the valve mecha- clearance of the other valves as follows:
nism. Install the rocker arm cover and fuel lines. Re-
move the air from the fuel system. l. With the Number 6 cylinder in position, adjust the
clearance of the valves on cylinder Number 7.

2. With the Number 2 cylinder in position, adjust the

clearance of the valves on cylinder Number 5.

FIGURE 50. TIMING THE FUEL INJECTION

PUMP

ADJUSTING THE CLEARANCE

OF THE VALVES (See Figure 51)
For the TV8.540 engine, the correct valve clearance
is 0.25 mm (0.010 in) for the intake valves and 0.50
FIGURE 51. ADJUSTING THE VALVES
mm (0.020 in) for the exhaust valves. For the TV8.640
engine, the correct valve clearance is 0.25 mm (0.010
3. With the Number 8 cylinder in position, adjust the ADJUSTING THE STALL DEVICE
clearance of the valves on cylinder Number 3. (See Figure 40)
4. With the Number 3 cylinder in position, adjust the A. Run the engine until it is at the normal operating
clearance of the valves on cylinder Number 8. temperature. Make sure the idle speed is correct.
5. With the Number 1 cylinder in position, adjust the B. Turn the stall device in until it just changes the idle
clearance of the valves on cylinder Number 4. speed. Now, turn the stall device out 2.5 turns and
lock in position with the lock nut.
6. With the Number 7 cylinder in position, adjust the
clearance of the valves on cylinder Number 6. C. Run the engine and make sure the stall device does
not change the idle speed. Operate the lift truck and
7. With the Number 5 cylinder in position, adjust the make sure the engine does not stall during heavy brake
clearance of the valves on cylinder Number 2. operations.
ADJUSTING THE IDLE SPEED
A. Run the engine until it is at the normal operating
temperature.

B. The correct idle speed is 500-550 rpm. Rotate the

adjustment screw as necessary to change the speed.
 TROUBLESHOOTING
PROBLEM CAUSE
The starter rotates the engine slowly. 1, 2, 3, 4.

The engine will not start. 5, 6, 7, 8,9,10,12,13,14,15,16,17,18,19,20,22,31,32,33.

The engine is difficult to start. 5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 24, 29, 31, 32, 33.

The engine does not have enough power. 8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 31, 32, 33, 58, 60.

The engine uses too much fuel. 11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33, 60.

There is black exhaust smoke. 11, 13, 14, 16, 18, 19, 20, 22, 24, 25, 27, 28, 29, 31, 32, 33, 58, 60.

There is blue/white exhaust smoke. 4, 16, 18, 19, 20, 25, 27, 31, 33, 34, 35, 44, 59.

The engine has low oil pressure 4, 36, 37, 38, 39, 40, 42, 43, 44, 56.

The engine makes too much noise. 9, 14, 16, 18, 19, 22, 26, 28, 29, 31, 33, 35, 44, 45, 57.

The engine does not run correctly. 7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 23, 26, 28, 29, 30, 33, 35, 44, 57.

There is too much vibration. 13, 14, 20, 23, 25, 26, 29, 30, 33, 44, 46, 47, 48

The engine has high oil pressure. 4, 37, 40.

The engine gets too hot. 11, 13, 14, 16, 18, 19, 24, 25, 44, 49, 50, 51, 52, 53, 55.

There is too much pressure inside the sump. 25, 31, 33, 34, 44, 54

The engine has low compression. 11, 19, 25, 28, 29, 31, 32, 33, 34, 45, 57.

The engine stops and starts. 10, 11, 12.

List of possible causes for engine problems:

1. The battery is weak
2. Bad electrical connections
3. Starter has defects
4. Wrong oil
5. Starter rotates engine slowly
6. Fuel tank is empty
7. Shut-off solenoid does not work correctly
8. Fuel inlet line has a restriction
9. Fuel pump has a defect
10. Fuel filter(s) are not clean
11. Air inlet system has a restriction.
12. There is air in fuel system
13. Fuel injection pump has a defect
14. Fuel injectors have a defect or are not correct type
15. Cold start aid is not used correctly
16. Cold start aid has a defect
17. The drive for the fuel injection pump has damage
18. The timing for the fuel injection pump is not correct
19. The valve timing is not correct
20. The compression is low
21. Vent for the fuel tank is not clean
22. Type of fuel is not correct
23. Throttle linkage has a restriction
24. Exhaust pipe has a restriction
25. Cylinder head gasket(s) has a leak
26. Engine runs too hot
27. Engine runs too cold
28. Valve clearance is not correct
29. Valve movement is nt free
30. Fuel lines for high pressure are not correct
3 l. Cylinder bores have wear
32. Valves and seats have corrosion
33. Piston rings are worn or have damage
34. Valve stems and guides have wear
35. Crankshaft bearings have wear or damage
36. Not enough oil in the sump
37. Oil gauge reading is not correct
38. Oil pump has wear
39. Relief valve for oil pressure will not close
40. Relief valve for pressure will not open
41. Spring for the relief valve has a defect
42. Oil suction pipe is not clean
43. Oil filter has a restriction
44. Piston does not move freely
45. Piston height is not correct
46. Fan has damage
47. Engine mounts are loose or damaged
48. Flywheel or housing is not in alignment
49. Thermostat(s) has a defect
50. Water passages have a restriction
5l. Drive belts are loose or damaged
52. Radiator passages are not open
53. Water pump has a defect
54. Breather pipe has a restriction
55. Not enough coolant in the engine
56. Suction filter for the sump has a restriction
57. Valve spring(s) has damage
58. Turbocharger impeller has damage
59. Turbocharger oil seals have leaks
60. Air inlet system has leaks.
SPECIFICATIONS - TV8.540
SPECIFICATIONS - TV8.540
SPECIFICATIONS - TV8.540

SPECIFICATIONS - TV8.640
SPECIFICATIONS - TV8.640
SPECIFICATIONS - TV8.640