105635-0081 ZEXEL 9 420 616 500 BOSCH 9420616500 1056350081

General Instructions
These instructions are a review of many items which a serviceman encounters in servicing and maintaining a truck engine.PROBLEM ANALYZING: In analyzing a system malfunction, use this systematic procedure to locate and correct the problem. 1. Determine problem.2. List possible causes.3. Devise checks.4. Conduct checks in logical order to determine cause.5. Consider remaining service life against cost of parts and labor.6. Make necessary repair.7. Recheck.SAFETY: Your safety and that of others is always the number one consideration when servicing or maintaining trucks and truck engines. Safety is a matter of thoroughly understanding the job to be done and the application of good common sense. It is not just a matter of "do's" and "don'ts".CLEANLINESS: The most important single item in assuring long engine life is to keep dirt out of vital working parts. Precautions have been taken to safeguard against this. Enclosed compartments, seals and filters have been provided to keep the supply of air, fuel, coolant and lubricants clean. It is important that these safeguards be maintained.Whenever fuel, lubricating oil, coolant lines or air lines are disconnected, clean the point of disconnection as well as the adjacent area. As soon as the disconnection is made, cap, plug or tape the line or opening to prevent entry of foreign material. The same recommendations for cleaning and covering apply when access covers or inspection plates are removed.Clean and inspect all parts. Be sure all passages and holes are open. Cover all parts to keep them clean. Be sure parts are clean when they are installed. Leave new parts in their containers until ready for assembly.REMOVAL AND INSTALLATION: Use a hoist to remove heavy components. Engine removal should be accomplished by using an adjustable lifting beam. All supporting members (chains and cables) should be parallel to each other and as near perpendicular as possible to the top of the object being lifted.
LIFTING COMPONENTSWhen it is necessary to remove a component on an angle, remember that the capacity of an eyebolt diminishes as the angle between the supporting members and the object becomes less than 90°. Eyebolts and brackets should never be bent and should only have stress in tension.Some removals require the use of lifting fixtures to obtain proper balance and to provide safe handling.If a part resists removal, check to be certain all nuts and bolts have been removed and that an adjacent part is not interfering.DISASSEMBLY AND ASSEMBLY: When servicing or repairing the engine, complete each step in turn. Do not partially assemble one part and start assembling some other part. Make all adjustments as recommended. Always check the job after it is completed to see nothing has been overlooked.BOLTS AND BOLT TORQUE: Use bolts of the correct length. A bolt which is too long may "bottom" before the head is tight against the part it is to hold and cause failure. The threads in the assembly can also become damaged when a "long" bolt is used.If a bolt is too short, there may not be enough