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NAVISTAR PSI 8.8L Service MANUAL

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NAVISTAR PSI 8.8L Service MANUAL

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NAVISTAR PSI 8.8L Service MANUAL

What does this catalog contain?

NAVISTAR PSI 8.8L Service MANUAL contains high quality images, diagrams, instructions to help you to operate, maintenance, diagnostic, and repair your machine. This document is printable, without restrictions, contains searchable text and bookmarks for easy navigation.

NAVISTAR PSI 8.8L Service MANUAL includes:

  • Numbered table of contents easy to use so that you can find the information you need fast.
  • Detailed sub-steps expand on repair procedure information.
  • Numbered instructions guide you through every repair procedure step by step.
  • Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
  • Notes, cautions and warnings throughout each chapter pinpoint critical information.
  • Bold figure number help you quickly match illustrations with instructions.
  • Detailed illustrations, drawings and photos guide you through every procedure.
  • Enlarged inset helps you identify and examine parts in detail.

What will you get when you get this service catalog?

  • After payment has been received, a few minutes later.
  • Lifetime PDF and Access To Download (By Request).
  • Compatible With Windows, Mac, IOS, Android and Other Systems.
  • Searchable Text and Built-in Index For Instant Information Search Bookmarks.
  • Printable – Pages Or Entire Manual.
  • Zoomable – Detailed Exploded Diagrams, Picture.

TABLE OF CONTENT OF THE NAVISTAR PSI 8.8L Service MANUAL

PREFACE ……………………………………………………………………………………………..
WARNING SUMMARY ………………………………………………………………………………………….. 1
REVISION CONTROL INFORMATION …………………………………………………………………… 2
TABLE OF CONTENTS ………………………………………………………………………………………… 3
01 THEORY OF OPERATION AND ENGINE COMPONENTS …………………………
THEORY OF OPERATION ………………………………………………………………………………….. 09
ENGINE COMPONENTS VIEWS …………………………………………………………………………. 11
02 ENGINE LUBRICATION …………………………………………………………………………
LUBRICATION……………………………………………………………………………………………………. 17
03 SPECIAL INSTRUCTIONS ……………………………………………………………………..
SAFETY INFORMATION …………………………………………………………………………………….. 20
DISASSEMBLY, CLEANING, AND MARKING ……………………………………………………….. 22
SEPARATING COMPONENTS…………………………………………………………………………….. 22
ENGINE GASKETS …………………………………………………………………………………………….. 22
CLEANING GASKET SURFACES ………………………………………………………………………… 23
SEALANT TYPES AND USES ……………………………………………………………………………… 23
AEROBIC SEALANT RTV ……………………………………………………………………………………. 23
ANAEROBIC GASKET SEALANT ………………………………………………………………………… 24
ANAEROBIC THREADLOCK SEALANT ……………………………………………………………….. 24
ANAEROBIC PIPE SEALANT ………………………………………………………………………………. 24
04 MECHANICAL DIAGNOSTIC PROCEDURES …………………………………………..
GENERAL INFORMATION ………………………………………………………………………………….. 26
STRATEGY BASED DIAGNOSTICS …………………………………………………………………….. 26
ENGINE COMPRESSION TEST…………………………………………………………………………… 26
CYLINDER LEAKAGE TEST ……………………………………………………………………………….. 27
OIL CONSUMPTION DIAGNOSIS ………………………………………………………………………… 28
OIL PRESSURE TEST AND DIAGNOSIS ……………………………………………………………… 28
ENGINE FLUID LEAK DIAGNOSIS ………………………………………………………………………. 29
CRANKCASE VENTILATION SYSTEM ………………………………………………………………….30
DRIVE BELT NOISE DIAGNOSIS …………………………………………………………………………30
05 FRONT ENGINE ACCESSORY DRIVE (FEAD)…………………………………………
ENGINE BELT ROUTING…………………………………………………………………………………….33
RIGHT-HAND PULLEY SYSTEM ………………………………………………………………………….34
AIR COMPRESSOR PULLEYS …………………………………………………………………………….35
LEFT-HAND PULLEY SYSTEM …………………………………………………………………………….36

06 ENGINE MOUNTS …………………………………………………………………………………
INSPECTION ……………………………………………………………………………………………………… 38
FRONT ENGINE MOUNT REMOVAL ……………………………………………………………………38
FRONT ENGINE MOUNT INSTALLATION …………………………………………………………….39
REAR ENGINE MOUNT REMOVAL………………………………………………………………………40
REAR ENGINE MOUNT INSTALLATION ……………………………………………………………….41
07 LPG FUEL SYSTEM SERVICE ……………………………………………………………….
FUEL RAIL REMOVAL ………………………………………………………………………………………..43
FUEL INJECTOR REMOVAL………………………………………………………………………………..45
FUEL INJECTOR INSTALLATION…………………………………………………………………………46
FUEL RAIL INSTALLATION………………………………………………………………………………….47
FUEL LINE FILL PROCEDURE …………………………………………………………………………….48
08 INTAKE MANIFOLD ……………………………………………………………………………..
PCV HOSE REMOVAL ………………………………………………………………………………………..52
INTAKE MANIFOLD REMOVAL ……………………………………………………………………………53
MAP SENSOR REMOVAL ……………………………………………………………………………………54
THROTTLE BODY REMOVAL………………………………………………………………………………54
INTAKE MANIFOLD INSTALLATION …………………………………………………………………….55
PCV HOSE INSTALLATION …………………………………………………………………………………57
THROTTLE BODY INSTALLATION ……………………………………………………………………….58
MAP SENSOR INSTALLATION …………………………………………………………………………….59
09 VALVE COVERS …………………………………………………………………………………..
VALVE COVER REMOVAL…………………………………………………………………………………..61
VALVE COVER INSTALLATION……………………………………………………………………………61
10 EXHAUST MANIFOLD …………………………………………………………………………..
EXHAUST MANIFOLD REMOVAL ………………………………………………………………………..63
EXHAUST MANIFOLD INSTALLATION …………………………………………………………………63
11 OIL LEVEL INDICATOR TUBE………………………………………………………………..
OIL LEVEL INDICATOR TUBE REMOVAL …………………………………………………………….65
OIL LEVEL INDICATOR TUBE INSTALLATION ……………………………………………………..65
12 VALVE TRAIN……………………………………………………………………………………….
VALVE TRAIN REMOVAL…………………………………………………………………………………….67
VALVE TRAIN INSTALLATION……………………………………………………………………………..67
13 VALVE LIFTERS……………………………………………………………………………………
VALVE LIFTER REMOVAL…………………………………………………………………………………..69
VALVE LIFTER INSTALLATION……………………………………………………………………………69
14 CYLINDER HEADS ………………………………………………………………………………
CYLINDER HEAD DISASSEMBLY………………………………………………………………………..71
CYLINDER HEAD ASSEMBLY……………………………………………………………………………..73

15 CYLINDER HEAD INSPECTION ……………………………………………………………..
CLEANING ………………………………………………………………………………………………………… 78
FLATNESS MEASUREMENT……………………………………………………………………………….79
VALVE INSPECTION …………………………………………………………………………………………..80
VALVE SPRING INSPECTION……………………………………………………………………………..81
VALVE GUIDE INSPECTION ………………………………………………………………………………..81
16 CRANKSHAFT BALANCER AND FRONT SEAL ……………………………………….
CRANKSHAFT BALANCER REMOVAL …………………………………………………………………83
CRANKSHAFT BALANCER INSTALLATION ………………………………………………………….83
17 TIMING COVER, TIMING CHAIN, AND SPROCKETS ……………………………….
REMOVAL ………………………………………………………………………………………………………….87
INSTALLATION …………………………………………………………………………………………………..87
18 OIL PUMP DRIVE………………………………………………………………………………….
OIL PUMP DRIVE REMOVAL……………………………………………………………………………….90
OIL PUMP DRIVE INSTALLATION ………………………………………………………………………..90
19 CAMSHAFT REMOVAL, CLEANING AND INSPECTION,
AND INSTALLATION…………………………………………………………………………….
CAMSHAFT REMOVAL ……………………………………………………………………………………….92
CAMSHAFT CLEANING AND INSPECTION …………………………………………………………..92
CAMSHAFT INSTALLATION ………………………………………………………………………………..93
20 CAMSHAFT BEARING REPLACEMANT ………………………………………………….
CAMSHAFT BEARING REMOVAL………………………………………………………………………..96
CAMSHAFT BEARING INSTALLATION…………………………………………………………………97
21 OIL FILTER ADAPTER AND BYPASS VALVES ……………………………………….
OIL FILTER ADAPTOR AND BYPASS VALVES REMOVAL …………………………………….99
OIL FILTER ADAPTOR AND BYPASS VALVES INSTALLATION ……………………………..99
22 OIL PAN……………………………………………………………………………………………….
OIL PAN REMOVAL……………………………………………………………………………………………101
OIL PAN INSTALLATION …………………………………………………………………………………….101
23 OIL PUMP…………………………………………………………………………………………….
OIL PUMP REMOVAL………………………………………………………………………………………..103
OIL PUMP ASSEMBLY………………………………………………………………………………………104
OIL PUMP INSTALLATION …………………………………………………………………………………105
24 FLYWHEEL, TRANSMISSION ADAPTER AND REAR OIL SEAL ………………..
REMOVAL ………………………………………………………………………………………………………..107
INSTALLATION …………………………………………………………………………………………………107
25 ENGINE OIL FILTER AND OIL REPLACEMENT ……………………………………….
OIL FILTER REMOVAL………………………………………………………………………………………111
OIL FILTER INSTALLATION ……………………………………………………………………………….111
26 WATER PUMP………………………………………………………………………………………
WATER PUMP REMOVAL………………………………………………………………………………….114

27 WATER CROSSOVER AND THERMOSTAT …………………………………………….
WATER CROSSOVER AND THERMOSTAT REMOVAL ………………………………………. 116
WATER CROSSOVER AND THERMOSTAT INSTALLATION ………………………………..117
28 CRANKSHAFT AND CRANKSHAFT POSITION SENSOR REMOVAL AND
INSTALLATION …………………………………………………………………………………………
CRANKSHAFT POSITION SENSOR REMOVAL…………………………………………………..119
CRANKSHAFT REMOVAL………………………………………………………………………………….120
CRANKSHAFT INSTALLATION…………………………………………………………………………..121
CRANKSHAFT POSITION SENSOR INSTALLATION ……………………………………………124
29 CRANKSHAFT CLEANING AND INSPECTION…………………………………………
CRANKSHAFT CLEANING…………………………………………………………………………………126
CRANKSHAFT INSPECTION ……………………………………………………………………………..127
CHECKING MAIN BEARING CLEARANCE ………………………………………………………….127
30 CYLINDER BLOCK CLEANING AND INSPECTION …………………………………..
BLOCK PLUG REMOVAL …………………………………………………………………………………..131
CYLINDER BLOCK CLEANING…………………………………………………………………………..133
CYLINDER BLOCK INSPECTION……………………………………………………………………….134
CYLINDER HONING ………………………………………………………………………………………….135
BLOCK PLUG INSTALLATION……………………………………………………………………………136
31 PISTON REMOVAL, CLEANING, INSPECTION, AND INSTALLATION………..
PISTON AND CONNECTING ROD REMOVAL……………………………………………………..140
PISTON AND CONNECTING ROD CLEANING…………………………………………………….141
PISTON AND CONNECTING ROD INSPECTION …………………………………………………142
PISTON AND CONNECTING ROD ASSEMBLY……………………………………………………145
PISTON AND CONNECTING ROD INSTALLATION………………………………………………147
32 AIR COMPRESSOR AND BRACKET ……………………………………………………….
REMOVAL ………………………………………………………………………………………………………..151
INSTALLATION …………………………………………………………………………………………………151
HOSE AND FITTING INSTALLATION………………………………………………………………….152
33 POWER STEERING PUMP AND BRACKET …………………………………………….
REMOVAL ………………………………………………………………………………………………………..155
INSTALLATION …………………………………………………………………………………………………155
34 ALTERNATOR BRACKET ………………………………………………………………………
REMOVAL ………………………………………………………………………………………………………..157
INSTALLATION …………………………………………………………………………………………………157
35 OIL COOLER AND OIL COOLER HOSES………………………………………………..
OIL COOLER HOSE REMOVAL………………………………………………………………………….159
OIL COOLER REMOVAL ……………………………………………………………………………………160
OIL COOLER BRACKET REMOVAL……………………………………………………………………160
OIL COOLER BRACKET INSTALLATION …………………………………………………………….160
OIL COOLER INSTALLATION …………………………………………………………………………….161
OIL COOLER HOSE INSTALLATION …………………………………………………………………..161

36 STARTER MOTOR ………………………………………………………………………………..
REMOVAL ……………………………………………………………………………………………………….. 164
INSTALLATION …………………………………………………………………………………………………168
37 OIL PRESSURE SWITCH/SENSOR………………………………………………………..
REMOVAL ………………………………………………………………………………………………………..172
INSTALLATION …………………………………………………………………………………………………172
38 WINTERIZATION KIT …………………………………………………………………………….
OIL HEATER REMOVAL…………………………………………………………………………………….174
OIL HEATER INSTALLATION ……………………………………………………………………………..174
BLOCK HEATER REMOVAL ………………………………………………………………………………175
BLOCK HEATER INSTALLATION ……………………………………………………………………….175
39 TORQUE SPECIFICATIONS……………………………………………………………..177
40 MECHANICAL SPECIFICATIONS………………………………………………………182
41 SPECIAL TOOLS LIST ……………………………………………………………………..186
42 SERVICING ALTERNATIVE FUEL TANK ASSEMBLY………………………….191

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