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5715434AM General CorporationMILITARYHMMWVComponent Testing andTroubleshootingM998A1 Series Vehicles
AM General CorporationTraining DepartmentP.O. Box 728408 South Byrkit StreetMishawaka, IN 46546-0728 USAPhone: (219) 258-6624Fax:(219) 254-2260January 1995Revised October, 1996Copyright 1999, AM General CorporationThis publication, or parts thereof, may not be reproduced in any form, by any method, for anypurpose without written permission from AM General Corporation.
ContentsSECTION 1 COOLING SYSTEMA.B.C.D.E.F.G.H.I.J.K.L.M.N.O.FAN CLUTCH TEST PROCEDURE . 1-1FAN THERMOSTATIC SWITCH TESTING . 1-1FAN CLUTCH SOLENOID RESISTANCE TEST . 1-2FAN CLUTCH VALVE PRESSURE TEST . 1-3FAN CLUTCH PRESSURE TEST . 1-3ATTACHING COOLANT PRESSURE TESTER . 1-4RADIATOR EXTERNAL PRESSURE LEAK TESTING . 1-5RADIATOR INTERNAL PRESSURE LEAK TESTING . 1-5HEAD GASKET LEAK TEST . 1-6COMPRESSION OR COMBUSTION LEAK TEST . 1-6TESTING THE PRESSURE CAP . 1-7READING THE GAGE . 1-9FAN SHROUD ADJUSTMENT . 1-10ENGINE COOLING SYSTEM FLOW OIL/COOLANT . 1-10ENGINE NORMAL OIL FLOW SCHEMATIC . 1-11SECTION 2 AIR INTAKE AND EXHAUST SYSTEMSA.B.MANOMETER INTAKE RESTRICTION TEST . 2-1ENGINE STOPS DURING NORMAL OPERATION . 2-1SECTION 3 FUEL SYSTEMA.B.C.D.E.F.G.H.I.J.K.L.M.N.O.P.Q.R.S.6.2L V8 DIESEL ENGINE . 3-1DIAGNOSING ABNORMAL ENGINE OPERATION . 3-2BLACK OR WHITE SMOKE COMING FROM EXHAUST . 3-4BLUE SMOKE COMING FROM EXHAUST . 3-5DIESEL ENGINE KNOCK . 3-5ENGINE HARD STARTING (HOT) . 3-5ENGINE HARD STARTING (COLD) . 3-5FUEL SYSTEM FLOW SCHEMATIC . 3-7TROUBLESHOOTING AND TESTING . 3-9ELECTRICAL FUEL SOLENOID CHECK . 3-9COLD ADVANCED SOLENOID CHECK . 3-9CHECKING HOUSING PRESSURE COLD ADVANCE SWITCH . 3-9FUEL INJECTION PUMP TEST . 3-9UNDERSTANDING DIESEL FUEL . 3-10TYPICAL FUEL PROPERTIES . 3-11ENGINE CRANKING SPEED TEST . 3-11FUEL PUMP PRESSURE TEST . 3-11FUEL FILTER. 3-12FUEL ECONOMY . 3-12Page I
SECTION 3 FUEL SYSTEM J.KK.LL.MM.NN.OO.FUEL FILTER PRESSURE TEST . 3-12FUEL FILTER FLOW TEST . 3-13FUEL TANK CONTAMINATION TEST . 3-13FUEL INJECTION PUMP TEST . 3-13FUEL INJECTOR NOZZLE TEST (TEST STAND) . 3-15FUEL INJECTOR NOZZLE TEST (IN VEHICLE) . 3-166.2L INJECTION NOZZLE RETURN HOSE . 3-16FUEL SOLENOID TEST - ENGINE CRANKS BUT WILL NOT START . 3-17COLD ADVANCE SOLENOID-SWITCH TEST . 3-18INJECTION PUMP AIR PRESSURE TEST . 3-19INJECTOR LINE LENGTH . 3-19WATER IN INJECTOR PUMP . 3-19FUEL RETURN VALVE TEST . 3-20FUEL SHUTOFF SOLENOID TEST (Figure 3-9) . 3-20DIESEL FUEL QUALITY . 3-21DIESEL FUEL CONTAMINATION . 3-22DIESEL FUEL SYSTEM CLEANING PROCEDURE. 3-23CLEANING PROCEDURE: GASOLINE IN FUEL . 3-24FUEL FLOW TEST . 3-24VACUUM TEST FUEL LIFT PUMP INLET . 3-25MECHANICAL FUEL PUMP TESTS . 3-25SECTION 4 ENGINEA.B.C.D.E.F.Page IIGENERAL ENGINE DATA . 4-1MANOMETER - BLOW-BY TEST . 4-2GLOW PLUG TIP REMOVAL (DAMAGED OR BROKEN) . 4-2ENGINE INJECTION PUMP TIMING PROCEDURESUSING KENT-MOORE TACH-N-TIME METER . 4-3a. Connecting Power Leads . 4-4b. Enter Offset Chart . 4-5c. Injection Pump Timing Adjustment . 4-6d. Engine Injection Pump Timing . 4-7ENGINE INJECTION PUMP TIMING PROCEDURESUSING SNAP-ON LUMY/MAG II TIMING . 4-8a. Accessories Included with the MT-1480 . 4-9b. Display Codes . 4-10c. Operator Tips. 4-11c. Equipment Tips . 4-11e. Checking Cranking Speed . 4-12f. Hookup Procedures and Testing Tips . 4-12g. Diesel Engine Timing . 4-13h. Injection Pump Timing Adjustment LUMY/MAG II . 4-14i. Cranking RPM Test. 4-16j. Enter Offset Chart . 4-17USE OF TORQUE COMPUTER . 4-18
SECTION 4 ENGINE (Continued)G.H.I.J.K.L.M.N.ENGINE COMPRESSION TEST . 4-19CHECK FOR ENGINE MECHANICAL OR HYDRAULIC SEIZURE. 4-20PRE-CHAMBER CRACKS . 4-20NOISY VALVES & VALVE SPRING CHECK . 4-21VALVE LIFTER DIAGNOSIS . 4-21V-8 DIESEL HEAD GASKET LEAKAGE . 4-22LEAKING CYLINDER HEAD GASKET . 4-22DIESEL HEAD GASKET PRE-INSTALLATION INSPECTION . 4-23SECTION 5 BRAKESA.B.C.D.E.F.G.H.I.WHAT IS HYDRO-BOOST? . 5-1WHY HYDRO-BOOST? . 5-1HYDRO-BOOST II . 5 - 2TROUBLESHOOTING . 5-3SEAL LEAKSHYDRO-BOOST DIAGNOSIS . 5-6a. Booster Functional Test . 5-6b. Leakdown Test . 5-9PARKING BRAKE LIGHT SWITCH TEST . 5-9BLEEDING THE HYDRO-BOOST SYSTEM . 5-10BRAKE FLUID . 5-10SECTION 6 TRANSMISSIONA.B.C.D.E.F.G.MODULATOR MAINTENANCE AND ADJUSTMENT . 6-1TRANSMISSION OIL PRESSURE TESTS . 6-2TRANSMISSION CONTROL VALVE AND GOVERNOR PRESSURE TEST . 6-6TRANSMISSION ROAD TEST . 6-7TRANSMISSION DETENT SOLENOID RESISTANCE TEST . 6-7TRANSMISSION KICK-DOWN SWITCH TEST & ADJUSTMENT . 6-8TRANSMISSION MALFUNCTIONS . 6-9Malfunction 1. No 1-2 Upshift or Delayed Upshift . 6-9Malfunction 2. 1-2 Shift or Slips . 6-10Malfunction 3. 1-2 Shift Firm or Rough . 6-11Malfunction 4. No 2-3 Upshift or Delayed Ups . 6-11Malfunction 5. 2-3 Shift Soft or Slips . 6-11Malfunction 6. 2-3 Shift Firm or Rough . 6-12Malfunction 7. No Engine Braking - Second Gear . 6-12Malfunction 8. No Engine Braking - First Gear . 6-12Malfunction 9. No Detent Downshifts . 6-13Malfunction 10. No Drive or Drive Slips . 6-13Malfunction 11. No Reverse or Reverse Slips . 6-13Malfunction 12. Vehicle Moves in Neutral . 6-14Malfunction 13. Transmission Noisy . 6-14Page III
SECTION 6 TRANSMISSION (Continued)H.J.TORQUE CONVERTER END PLAY CHECK . 6-14TORQUE CONVERTER LEAK TEST . 6-16SECTION 7 ALIGNMENT PROCEDURESA.B.C.D.TOE-IN/FRONT WHEEL CHECK AND INSPECTION . 7-1a. Preliminary Inspectionb. Ball Joint Inspection . 7-2c. Idler Arm Inspection . 7-3d. Toe-In Check . 7-6e. Toe-In Adjustment . 7-9TOE-OUT REAR WHEEL CHECK ADJUSTMENT . 7-10a. Preliminary Inspection . 7-10b. Toe-Out Check . 7-11c. Toe-Out Adjustment. 7-14STEERING STOP CHECK & ADJUSTMENT . 7-15a. Removal . 7-15b. Installation .
AM General Corporation MILITARY HMMWV M998A1 Series Vehicles Component Testing and Troubleshooting 5715434
