PSI (Power Solutions Intl) 53L — TDC #1.

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Procedure

1. 21)
2. Figure 21
3. g) Use feeler gauges (Figure 22) to check the clearance between the rocker arm and the valve
4. bridge (Figure 23). Lash should be set to 0.55mm (0.022 in) for the intake and 1.00mm (0.039 in)
5. for the exhaust. Repeat on all other valves with arrows of the same color as shown above.
6. Figure 22
7. 34
8. Maintenance Instructions - continued
9. h) Rotate the crankshaft 360 degrees until the timing mark is back at TDC #1 again. If the valves
10. with the blue arrows were checked first, the valves with the red arrows may now be checked. If
11. the valves with the red arrows were checked first, the valves with the blue arrows may now be
12. checked.
13. i)
14. Check lash on all rockers that were not previously checked. Adjust as necessary.
15. j)
16. Reinstall valve covers.
17. Figure 23
18. Tighten all hose clamps on CAC piping boots: Check the tightness of the clamps at each
19. silicone boot on the CAC system as shown (Figure 24 and 25). Start at the turbocharger
20. compressor outlet and follow the piping to the charge air cooler inlet, then from the charge air cooler
21. outlet to the throt tle body. Tighten as necessary.
22. Figure 24
23. Figure 25
24. Typical to both sides of the engine
25. 35
26. Maintenance Instructions - continued
27. Drain LPL vaporizer oil buildup (if LP fuel system is being used):
28. Remove the vapor hose from the propane vaporizer and look for oil/paraffin buildup inside. Clean
29. out any accumulated oils. Check the vapor hose for residue and clean if present.
30. Inspect ignition coils, coil boots, and harnesses:
31. Check for any damage to the ignition coils, any evidence of heat damage to the coil boots (melting,
32. burn marks, cracking), and any damage to the ignition coil harness as shown in Figure 26 (typical of
33. 12). Repair/replace any damaged components.
34. Figure 26
35. Replace spark plugs:
36. a) Remove the spark plugs.
37. b) Inspect the spark plugs upon removal (Figure 27). Look at the porcelain around the center
38. electrode of each plug. You can detect many engine problems from the color and type of
39. deposits that have built up on the white porcelain. For example, if the deposits are a glossy
40. brown, that cylinder is burning excess oil. If the deposits are a very dark gray or sooty black
41. color, your engine is running rich, and you are burning excess fuel. The optimum color of the
42. deposits on the porcelain is light tan or light brown. This shows optimum fuel mixture and proper
43. engine running conditions. If the deposits are almost white, the engine may be running
44. excessively lean.
45. c) Install the new spark plugs and torque to 22 lb-ft. Use only spark plugs purchased from PSI Parts
46. & Service. NOTE: The engine is equipped with iridium-tipped spark plugs which are set to the
47. proper gap by the manufacturer. Do not attempt to adjust the spark plug gap; this could
48. damage the tips.
49. Figure 27
50. 36
51. Maintenance Instructions - continued
52. Drain, flush, and replace engine coolant:
53. Draining the Cooling System:
54. a) Shut off engine and allow it to cool below 100°F (38°C) and remove the overflow tank filler cap.
55. b) Attach a hose to the radiator drain valve and run the hose to a container large enough to
56. hold the contents of the cooling system – approximately 65 gallons. Open drain valve.
57. c) Inspect cooling system hoses and clamps and adjust/tighten as necessary. Replace any
58. worn hoses or clamps before adding new coolant to the system.
59. d) After the coolant has stopped draining, close off all drain plugs.
60. e) Open coolant drains on both oil coolers (as shown in Figure 28, typical of both sides of
61. engine), and allow the coolant to drain. Close the drains when empty.
62. Figure 28
63. Flushing the Cooling System:
64. a) Connect a coolant pump to the proper radiator fill fitting. CAUTION: Use of a fill pump is
65. required to properly purge the system of air during a fill procedure. Coolant should be added
66. to the overflow tank filler neck for top-off only. Failure to do so can result in engine damage.
67. b) Fill the system with clean deionized/distilled water. Tap water is acceptable but is not
68. preferred.
69. c) Disconnect the fill pump. Replace the radiator cap or overflow tank filler cap.
70. d) Start the engine and run

Source: manual:56100039-11-53L-Operations-Maintenance-Manual.pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.