CATERPILLAR’ ae September 1981 Disassemiolly Assemioly G379, G398 & G399 Engines e G379: G398: G399: 72B468 - UP 73B906 - UP 49C261 - UPDISASSEMBLY AND ASSEMBLY IMPORTANT SAFETY NOTICE Proper repair is important to the safe and reliable operation of a machine. This Service Manual outlines basic recommended procedures, some of which require special tools, devices or work methods. Although not necessarily all inclusive, alist of additional skills, precautions and knowledge required to safely perform repairs is provided in the SAFETY section of this Manual. Improper repair procedures can be dangerous and could result in injury or death, READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND WARNINGS BEFORE PERFORMING REPAIRS ON THIS MACHINE Basic safety precautions, skills and knowledge are listed in the SAFETY section of this Manual and in the descriptions of operations where hazards exist. Waming, labels have also been put on the machine to provide instructions and identify specific hazards which if not heeded could cause bodily injury or death to you or other persons. These labels identify hazards which may not be apparent to a trained mechanic. There are many potential hazards during repair for an untrained ‘mechanic and there is no way to label.the machine against all such hazards. These ‘wamings in the Service Manual and on the machine are identified by this symbol: Ce Operations that may result only in machine damage are identified by labels on the ‘machine and in the Service Manual by the word CAUTION. Caterpillar cannot anticipate every possible circumstance that might involve @ potential hazard. The warnings in this Manual are therefore not all inclusive. If @ procedure, tool, device or work method not specifically recommended by Caterpillar is used, you must satisfy yourself that itis safe for you and others. You should also ensure that the machine will not be damaged or made unsafe by the procedures you choose. IMPORTANT The information, specifications and illustrations in this book are on the basis of information available at the time it was written. The specifications, torques, pressures of operation, measurements, adjustments, illustrations and other items can change at any time. These changes can effect the service given to the product. Get the complete and most current information before you start any job. Caterpillar Dealers have the most current information which is available, For alist of the most current modules and form numbers available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE REG1139F. 67200x2DISASSEMBLY AND ASSEMBLY SAFETY Poe ‘The proper and safe lubrication and mainte- nance procedures for this machine, recom- mended by Caterpillar, are outlined in the LU- BRICATION & MAINTENANCE GUIDE for this machine. Improper performance of lubrication or main- tenance procedures is dangerous and could result in injury or death. Read and understand the LUBRICATION & MAINTENANCE GUIDE before performing any lubrication or The serviceman or mechanic may be unfamiliar with many of the systems on this machine. This makes it important to use caution when performing service work. A knowledge of the system and/or component is important before the removal or disassembly of any component, Because of the size of some of the machine compo- nents, the serviceman or mechanic should check the weights noted in this Manual. Use proper lifting proce- dures when removing any components, Following is a list of basic precautions that should always be observed. 1. Read and understand all Warning plates and de- cals on the machine before operating, lubricating or repairing the machine. 2. Always wear protective glasses and protective shoes when working around machines. In particu- lar, wear protective glasses when pounding on any part of the machine or its attachments with a ham- mer or sledge. Use welders gloves, hood/goggles, apron and other protective clothing appropriate to the welding job being performed. Do not wear loose-fitting or torn clothing. Remove all rings from fingers when working on machinery. @ so viscera say an charge ny cnc before starting to work on machine. Hang ‘Do Not Operate’ tag in the Operator's Compartment. A\warninc Do not operate this machine unless you have read and understand the instructions in the OPERATOR'S GUIDE. Improper machine oper- ation is dangerous and could result in injury or death. ool 4, If possible, make all repairs with the machine parked on a level, hard surface. Block machine so it does not roll while working on or under machine. 5. Do not work on any machine that is supported only by lift jacks or a hoist. Always use blocks or Jack stands to support the machine before per- forming any disassembly. 6. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are dis- connected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure. 7. Lower the bucket, blade, ripper or other imple- ‘ments to the ground before performing any work ‘on the machine. If this can not be done, make sure the bucket, blade, ripper or other implement is blocked correctly’ to prevent it from dropping ‘unexpectedly. 8. Use steps and grab handles when mounting or dismounting a machine. Clean any mud ot debris, from steps, walkways or work platforms before using. Always face machine when using steps, ladders and walkways. When it is not possible co use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations. 9. To avoid back injury, use a hoist when lifting components which weigh 50 Ib. (23 kg) or more. Make sure all chains, hooks, slings, etc., are in ‘good condition and are in the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during alifting operation, ,ENGINE 10. u 12, 13, 14, 15 16. DISASSEMBLY AND ASSEMBLY A WARNING To avoid bums, be alert for hot parts on machines which have just been stopped and hot fluids in lines, tubes and compartments. Be careful when removing cover plates. Gradual- ly back off the last two bolts or nuts located at opposite ends of the cover or device and pry cover loose to relieve any spring or other pressure, be~ fore removing them completely. Be careful when removing filler caps, breathers and plugson the machines. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the machine has just been stopped because fluids ‘can be hot. Always use tools that are in good condition and be sure you Understand how to use them before per~ forming any service work. Reinstall all fasteners with same part number. Do not use a lesser quality fastener if replacements are necessary. Repairs which require welding should be per- formed only with the benefit of the appropriate reference information and by personne] adequate- ly trained and knowledgeable in welding proce- dures. Make reference to “*Techniques of Struc- ‘ural Repair Course’ form number JEGO3719. Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of parent metal Do not damage wiring during removal operations. Reinstall the wiring so itis not damaged nor will it bbe damaged in operation by contacting sharp cor- ners, or by rubbing against some object or hot surface. Do not connect wiring to a line containing fluid. 173 19, 21. Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution, Always use lift arm supports to keep bucket arms raised and bucket tilted down when maintenance or repair work is performed which requires the bucket in the raised position. Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in event of, a line, tube or seal failure must be installed correctly Do not operate a machine if any rotating part is damaged or contacts any other part during oper- ation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing. On track-type machines, be careful when servic- ing or separating tracks. Chips can fly when re- moving or installing a track pin. Wear safety glasses. Track can unroll very quickly when sepa- rated. Keep away from front and rear of machine. ‘The machine can move unexpectedly when both tracks are disengaged from the sprockets. Block the machine to prevent it from moving. CATERPILLAR’DISASSEMBLY AND ASSEMBLY BOLTS AND Ni GENERAL, EIGHTENING TORQUE FOR The following charts give the standard torque values for bolts, nuts and taperiock studs-of SAE Grade 5 or better quality. Exceptions are aiven in other sections of the Service Manual where needed, ee THREAD DIAMETER ‘STANDARD TORQUE inches millimeters 1b. f Nm ‘Standard thread Use these torques for bolts and nuts . <= with standard threads. va 635, 923 5116 798 1825 38 959 225 76 nat 50= 10 42 1270 75210 a6 1429 10 = 15 150 = 20 5/8 1528 150 = 20 205 = 27 aa 19.05 960 + 47 m8 nes 570 = 60 1 25.40 870 = 110 18 258 1085 = 135, 1a 3175 1355 = 165, 138 3493 v2 38.10 Use these torques for bolts and nuts on hydraulic valve bodies with standard threads, She 794 1322 123 38 asa Dane 323 76 aw 9922 323 v2 1270 6o=3 wo=4 5/8 1588 18 =4 160=5 Use these torques for studs with Taper- lock threads. 635, 794 953 wit 1270 1429 15.88 19.05 25.40 28.58 3175 38.10 7354168Accessory Drive Goats and Pate ‘Accessory Drive Housing ‘Aftrcooler Cores ‘Attercooler Housing ‘Ae Cleaners Camshatt ‘Camshaft Bearings Carburetor Carburetor, isassembe & Assemble ‘Connecting Fld Bearings Grankshatt Grankshatt Front Seal (Lip Type) and Wear Sieve Crankshaft Front Seal Ring and Thrower Grankshatt Man Bearings CGrankshatt Rear Seal Ring and Thrower Gyinder Heads Cylinder Liners Electric Starting Motors Engine Oil Cooler Ergne Ot Gookrs, Disassemble & Assemble Exhauet Manos Ftywhes! Flywheel Housing Gas Pressure Regulator Gas Pressure Regulator, Disassemble & Assemble Governor (Hydra MechanicaD, Disassemble & Assemble Governor (Woodward UG-8) Governor (Woodward UG-8), Disassemble & Assemble Governor Drive Housing (Upper) (Woodward UG-8) Governor Drive Housing (Upper) (Woodward UG-®), Disassemble & Assomble, Governor Drive Housing Governor Drive Housing, Bisassamibie & Assemble Instrument Pano! Intake Manito ‘Magneto Magneto Coll and Mechanical Brive, Dieascemble & Assemble ‘Magneto Distribution Board ‘Magneto Power Boara ‘Magneto Power Resistor and Zener Diode DISASSEMBLY AND ASSEMBLY INDEX 114 Ob Fitters 79 Ol Fiter Housing 7.142 Oil Pressure Role Vaive 7-138 Ol Pressure Relief Valve, Disassemble & Assemble 7-103. Oil Pump (Earier) 7-154 Ol Pump (Earlier), Disassomble & Assemble TIS? Ol Pump (Later, Disassemble & Assemble m9 7.121 Pistons 7-48 Pistons, Disassombie & Assemble 7-158 Piston Goong Tubes 75 73 788 Rear Timing Gears ia? Rocker Shatt and Push Rods 7-89 Rocker Shalt, Disassomble & Assomble 799 7-143 Service Moter and Tachometer Drive 7-33 Spark Plugs. 7-38 Spark Plug Adaptors 774 7144 Turbocharger... 7-145 Turbocharger, Disassemble & Assemble 7115 _Tutbochsrgor Lubrication Valve Tete Turbocharger Lubrication Vavve, fred ‘Disassemble & Assomble 7-50 Turbocharger Reguator Assembly 753 Turbocharger Regulator Assembly, 750 Disassemble & Assemble 751 Vanes 776 Valve Covers 778 Vatve Guides 7-161 Vave Lifters 7-80 Valve Seat inserts rion Wbration Damper (G88 and 6389) 7-105 Water Directors 7-113 Water Pump 7-114 Water Pump, Disassemble & Assemble 7-114 Water Temperature Regulators, DISCONNECT BATTERIES BEFORE PERFORMANCE OF ANY SERVICE WORK. “0 A warning 736 rar 78 18 719 721 rer 7.98 737 738 rag 781 782 rr 74196 rar 736 7137 7401 7-102 7124 7-128 791 7-80 793 784 7189 teENGINE DISASSEMBLY AND ASSEMBLY CRANKSHAFT FRONT SEAL RING AND THROWER e REMOVE CRANKSHAFT FRONT SEAL RING AND THROWER 1160-14 a) remove vibration damper (G398 and G399 only) 1, On G379 only, remove cover (1). 2. Put a mark on two bolts from location (2) for installation purposes. 3. Remove ten bolts (4) from adapter, Remove adapter (3). It can be necessary to remove adapter with tooling (A). Oe eee 5. Remove ring and spring assembly (7) from the thrower. 6. Install tooling (B) on thrower, If necessary use heat on the outer diameter of thrower with an open flame at a maximum temperature of 400° F (204°C), Remove the thrower with tooling (B). | 7. Remove the ring from the accessory drive hous- | ing. | is cs) TYPICAL EXAMPLE TYPICAL EXAMPLEENGINE, DISASSEMBLY AND ASSEMBLY CRANKSHAFT FRONT SEAL RING AND THROWER INSTALL CRANKSHAFT FRONT SEAL RING AND THROWER, 1160-12 Toole Needed a FTI05 Push Pk 1 Te0s Bolt === “SH1031 Washer 2 1. Put 6VI541 Quick Cure Primer and 983265 Retaining Compound on ring. Install ring (2) with holes at the bottom and with chamfer toward inside of housing, 2. Heat thrower (1) to a maximum temperature of 400 - 450°F (204 - 232°C). Install thrower fon crankshaft. Use tooling (A) to install thrower in correct location on crankshaft. CAUTION Do not install a used oil thrower, seal ring or spring. 3. With the thrower at room temperature, put 6V2055 High Vacuum Grease in the groove for the seal ring at assembly one half or more of the depth of the groove, 4, Install the spring and seal ring on thrower with the word “OUT” on the seal ring installed away from the crankshaft. Put the gap of seal ring to top of crankshaft when installed 5. Put clean engine oil on inside diameter of baf- fle. Install baffle (3). 6, Put 953263 Thread Lock on threads of bolt for adapter. Install the adapter (5) on G379 only. Put 7M7456 Loctite Sealer on the two bolts for the cover. Install cover (6). Install bolts with Loctite in location (4). end by: a)install vibration damper (G398 and G399 only) wen \. ) 3 \ é 7.4ENGINE DISASSEMBLY AND ASSEMBLY | CRANKSHAFT FRONT SEAL (LIP TYPE) AND WEAR SLEEVE , eee MF ewe FRONT SEAL (LIP TYPE} at bieee AND WEAR SLEEVE 1160-11 f 4 Ee Tools ied Puller Assembly start by: a) remove vibration damper (G398 and G39 only) 1. OnG379 only, remove cover (1); put a mark on two bolts (2) for installation, 2. Remove ten bolts (3) and remove adapter (4) Remove eight bolts (5) and spacers. 3. Make two holes (180° apart) in the metal sur- face of crankshaft front seal (6). Remove the seal with tooling (A), e@ 4. Remove wear sleeve (7) from the crankshaft.ENGINE DISASSEMBLY AND ASSEMBLY CRANKSHAFT FRONT SEAL (LIP TYPE) AND WEAR SLEEVE INSTALL CRANKSHAFT FRONT SEAL (LIP TYPE) AND WEAR SLEEVE 1160-12 Tools Needed ~ A 5P3022 Installer i 1. Clean the contact surfaces of the wear sleeve and crankshaft with 88060 Quick Cure Pri- mer. Put 953265 Retainer Compound on the contact surfaces, Install the wear sleeve on the crankshaft with tooling (A). The tapered ‘edge on the outside of the wear sleeve goes toward the end of the crankshaft. 2, Puta thin layer of SAE 30 oil on the seal lip. Install the seal over tooling (A). The seal lip goes toward the inside of the engine. Install spacers and bolts which hold the seal in the adapter. Tighten the bolts in the number se- quence shown. Tighten each bolt a maximum of three turns each round until all the bolts are tight. 3, Put 5P3413 Sealant on the threads of the bolts which fasten the adapter to the crank- shaft. Install adapter (9) on the crankshaft. 4, Install the cover on G379 only. Put SP3413 Sealant on the threads of the bolts in the loca- tions with the X mark. end by: '2) install vibration damper (G398 and G399 only) tome 16ENGINE, DISASSEMBLY AND ASSEMBLY SERVICE METER AND TACHOMETER DRIVE REMOVE SERVICE METER AND TACHOMETER ORIVE 7478-11 1570 1, Remove two bolts (1) and service meter (2) 2, Remove two bolts (3), lockwashers, clamps and tachometer drive assembly (4), 3. Remove four bolts (5), lockwashers and housing (6). 4, Remove the lip type seal from housing (6) with tooling (A). 5, Remove two bolts (7) and adapter (8), 982788x1 .ENGINE DISASSEMBLY AND ASSEMBLY SERVICE METER AND TACHOMETER DRIVE INSTALL SERVICE METER AND TACHOMETER DRIVE 7478-12 Tools Needed TRIO dive 1, Install two washers, adapter (2) and bolts(1). Bend the locks. 827 86K2 2. Install the lip type seal in housing (3) with tooling (A). Install the seal with the seal lip toward the engine. Puta thin layer of SAE 30 oil on the seal lip and the seal bore in the housing, 3, Install a new gasket and housing (3) on the engine with four bolts and lockwashers. 4, Inspect and make a replacement, if neces- sary, of O-ring seal (4) on tachometer drive (5). Install the tachometer drive on the hous- ing with two clamps, lockwashers and bolts. 5. Inspect and make a replacement, if neces- sary, of O-ring seal (6) on service meter (7). Put a thin layer of SAE 30 oil in the counter- bore of the tachometer drive. Install the ser- vice meter with two clamps, lockwashers and bolts. Tighten the boltstoa torque of 8 + 2b. ft. 11 £3 Num). 9927621 JENGINE DISASSEMBLY AND ASSEMBLY ACCESSORY DRIVE HOUSING e@ REMOVE ACCESSORY DRIVE HOUSING 1207-11 aa7E8 ~a57650 SFTSay anes ‘8B7661 Step Plate SPOTS Bracket Link 1, On G379 only, remove adapter cover (1). Re move ten bolts (3) from adapter. Remove adapter (2). Use tooling (A) if necessary to remove adapter 2. Remove twelve bolts (4) and baffle (5). Put a mark on two bolts from location (X) for instal- lation purposes. e 3. Remove four bolts that hold plate (6) for oil pump to oil pan base 4. Remove the four bolts (7) that hold water pump to housing. Remove four bolts (9) that hold oil pump to housing. 3. Fasten a hoist to the front of the engine. Loosen the bolts that hold cylinder block to oil pan base. Lift the engine to install spacers (8) between cylinder block and the oil pan base. omme TYPICAL EXAMPLE TYPICAL EXAMPLEENGINE DISASSEMBLY AND ASSEMBLY ACCESSORY DRIVE HOUSING 6. Remove four bolts (12) that hold tube assembly (13) to the auxiliary water pump. Remove bolt (0) from block and loosen clamp (11) that holds tube assembly and coupling together. Re- move tube assembly (13). 7. Remove ten bolts (14) that fasten plate to accessory housing, 8. Remove bolts and auxiliary water pump (15). 9. Install tooling (B) and a hoist to the accessory drive housing. Remove twelve bolts (16) that fasten housing to the cylinder block. Remove accessory drive housing. Weight is 200 Ib. (90 kg). 7-10ENGINE DISASSEMBLY AND ASSEMBLY ACCESSORY DRIVE HOUSING INSTALL ACCESSORY DRIVE = HOUSING 3207-12 me Teo Needed —SC~—“~“~*s~C CS Bracket Link NOTE: Put 6V2055 High Vacuum Grease in the groove for the seal ring at assembly one half or more of the depth of the groove. 1. Install the spring and seal ring (1) on thrower with the word “OUT” on seal ring installed away from crankshaft. Put the gap of seal ring to top of crankshaft when installed. 2. Install two {6-13 NC bolts as a guide in the cylinder block. Install tooling (A) and a hoist ‘on the accessory drive housing and put in posi- tion on the cylinder block. 3. Install twelve bolts (2) to fasten housing to block. Remove tooling (A). 4, Put auxiliary water pump (3) in position and install bolts to fasten pump to accessory drive housing. 5. Put tube assembly (4) and gasket in position on auxiliary water pump and install four bolts. Put clamp (5) in position and install bolt, Install clamp (6) on pipe assembly and coupling. 6. Fasten a hoist and lift the front of engine en- ough to remove spacers (8) from between cylin- der block and oil pan base. Tighten the bolts that hold cylinder block to base. 7. Install bolts (7) and (9) that hold the water pump and the oil pump to the accessory drive paw housing i TYPICAL EXAMPLE,ENGINE DISASSEMBLY AND ASSEMBLY ACCESSORY DRIVE HOUSING 8. Install the four bolts that hold plate (10) for oil pump to oil pan base. 9. Put clean engine oil on the inside diameter of baffle. Install baffle (11). 10. Put 9S3263 Thread Lock on threads of bolts for adapter. Install the adapter (12) on G379 only. Put 7M7456 Loctite Sealer on two of bolts for cover. Install cover (13) for adapter. Put bolts with Loctite in locations (14) and (15). end by: a) install vibration damper (G398 & G399 only) TYPICAL EXAMPLEENGINE DISASSEMBLY AND ASSEMBLY SAE STANDARD ROTATION ILLUSTRATION G379 LL | * e 4 Thi aa | 3 i, 5 ene al a ‘@)) ‘ Rope” eae SAE STANDARD ROTATION ILLUSTRATION G379ENGINE DISASSEMBLY AND ASSEMBLY ACCESSORY DRIVE GEARS AND PLATE REMOVE ACCESSORY DRIVE GEARS AND PLATE 1206-11 Tools Needed 256415 Puller Group wPaTO start by: a) remove fresh water pump b) remove oil pump ) remove accessory drive housing 1, Remove seal (1) from thrower. 2. Install tooling (A) on thrower (2). If necessary, use heat on the outer diameter of thrower with ‘an open flame at a maximum temperature of 400°F (205°C). Remove the thrower imme- diately with tooling (A). NOTE: The installation of two crankshaft bolts (6) can be used to turn engine for access to gear bolts. 3. Remove six bolts (5) used to hold oil tube on plate. 4, Bend the tabs on lock and remove bolts, washer, plate (7) and the balancer gear. 5. Remove bolts (4) and the gear and shaft assem- bly (3) from plate, 6, Bend the tabs on lock and remove bolts (8), washer and gear assembly (9). 7. Remove seven bolts (10) and idler gear assem- bly (11),ENGINE DISASSEMBLY AND ASSEMBLY ACCESSORY DRIVE GEARS AND PLATE a 8. Remove four nuts that hold oil tube (13) to plate. Remove oil tube (13). 9. Remove six bolts (14) and shaft assembly (12) from plate. 10, Remove four bolts and service meter (15) from block. 11, Remove five bolts (16) and plate from cylinder block. Weight of the plate is 75 Ib. (34 kg). 12, Remove the bearings from the gears if dam- aged or worn, NOTE: Check the mark on plate for correct installa tion. The front of plate for SAE standard rotation engine (counterclockwise as seen from flywhee! end) is marked "FRONT STD. ROT.” The front of plate for SAE opposite rotation engine (clockwise as seen from the flywheel end) is marked “FRONT REV. ROT.” INSTALL ACCESSORY DRIVE GEARS AND PLATE 1206-12 __ ‘Tools Needed AB 1P520 Driver Group. 1 FT105 Push Plate 1 T6083 _ a ‘8H1031 Washer 2 NOTE: Put 5P3413 Thread Sealant on all bolts that fasten plate to the cylinder block. 1. Put plate (1) in position on the cylinder block dowels. [nstall five bolts and tighten to a torque of 90 + 5 Ibft, (120 + 7 N-m). NOTE: Be sure the plate is installed on correct side as indicated in removal. 2. Install service meter (2) in position on block. NOTE: Put 7M7260 Liquid Gasket Material on sealing surfaces of idler shafts and oil tube. 3. Install idler shaft (3) in position on plate and tighten bolts toa torque of 90 + 5ib.ft. (120 + 7 Nem). 4, Putoil tube (4) in place and installl only the nuts to hold tube in position. Install small gaskets, under nuts that hold the right end of tube. Put 5P3413 Thread Sealant on nuts.ENGINE DISASSEMBLY AND ASSEMBLY ACCESSORY DRIVE GEARS AND PLATE 5. Put idler gear assembly (5) in position and install bolts. The six similar bolts are tightened toa torque of 90 + Sb.ft. (120 + 7 N-m). The two oil tube bolts are tightened toa torque of 32 + 3 ib.{t, (43 4 Nem). The single bolt at the bottom of the bolt circle is tightened toa torque of 40 + 4 Ib.ft. (55 + 5 N-m). 6. If necessary, install bearings in gear (7) with tooling (A). Install gear (7) on idler shaft (3). Install washer (6), lock and bolts. 7. Put main idler gear assembly (8) in position and install bolts. Tighten bolts to a torque of 90 + 5Ib.ft. (20 + 7 N.m). Tighten oil tube bolts to a torque of 32 + 3 Ib.ft. (43 + 4 Nem). 8, On G379 engine only, install bearing in ba- lancer gear with tooling (A). 9, Install washer (10) and gear (9) on shaft.ENGINE DISASSEMBLY AND ASSEMBLY ACCESSORY DRIVE GEARS AND PLATE 10. Install washer (12) and plate (11), Install lock and bolts, NOTE: The gear train of accessory drive are the same on the 8, 12, and 16 cylinder engines, except for balancer gear used on 8 cylinder engine. On SAE standard rotation (counterclockwise) engines, the balancer gear timing mark “B” must be in alignment with the tooth on erankshaft gear with punch marks (four, five ot six punch marks). The balancer gear timing mark “B™ must be in alignment with the “B” mark on the main idler gear. | 7 omen ft NOTE: On SAE opposite rotation (clockwise) e gine, the balancer gear timing mark “R” must be in aligoment with the "R” on the small idler gear. The other “R” on the small idler gear must be in align- ‘ment between two teeth on crankshaft gear with wo punch marks. On 12 and 16 cylinder engines, no timing of accessory drive gears is necessary. CAUTION Do not use an old oil thrower, seal ring or wees neers I spring. SAE STANDARD ROTATION 8 CYLINDER ENGINE 11. Heat the thrower (13) to a maximum tempera- ture of 400 - 450°F (204 - 232°C). Install thrower on crankshaft with tool (B). , 4 2. Install regulators (1) in the housing assembly, —*~ 3. Clean the cover (2), housing assembly (3) and tube assembly and install new gaskets. we 4, Put housing assembly (3) in position and install ten bolts, 5. Put tube assembly (5) in position on the hous- ing assembly and install four bolts (6). Install tube assembly (4) to fitting. @ 6. Fill the engine with coolant to the correct level. 7.39ENGINE, 1 7-40 WATER PUMP REMOVE WATER PUMP 1361-11 Remove the coolant from the engine. . Remove the oil from the oil cooler. Remove bolts (4) and clamp that fastens elbow to oil cooler. Remove elbow (1). Turn pipe (3) from work area. Remove bolts (2) that hold elbow to oil cooler and water pump, Remove elbow (5). Remove two bolts (6) from pipe assembly. Re- move clamp from opposite end of pipe and re- move pipe assembly (7). Disconnect plug (8) from magneto. Remove two bolts (9) that hold magneto to drive hous- ing. Remove magneto (10). Remove six bolts (12) and cover (14) from housing. Remove retainer (15). Fasten a hoist to water pump and remove six bolts (13), Remove water pump (11). Weight ‘of pump is 86 Ib. (39 ke). Remove seal (16) from retainer. Remove bearing (17) from retainer. eaasax DISASSEMBLY AND ASSEMBLY ezesixtENGINE DISASSEMBLY AND ASSEMBLY WATER PUMP INSTALL WATER PUMP 1361-12 I. Inspect gaskets and seals and make replace- ments if damaged. 2. Fasten a hoist to water pump (1). Put the pump on engine. Install the six bolts that hold the pump to the accessory drive housing, 3. Install gaskets and oil cooler elbow (2) in posi- tion on oil cooler and water pump. 4, Install gasket, elbow (3) and pipe in position on the oil cooler. 5. Install pipe assembly (4) in position on water pump. Install clamp on the end of pipe. 7-41ENGINE DISASSEMBLY AND ASSEMBLY 10. u 7-42 WATER PUMP Install bearing in retainer with a press and tooling (A). Make sure the hole in bearing is in alignment with the hole in retainer. Install seal in retainer as shown with tooling (A). Install retainer (5) and cover (6) in position on the accessory drive housing. NX a sae Put magneto (7) in position on drive housing. Install two bolts and connect plug to magneto. Fill the engine with coolant. Add oil to engine as needed.ENGINE DISASSEMBLY AND ASSEMBLY WATER PUMP DISASSEMBLE FRESH WATER PUMP 1361-15 Toots Needed SSC 1p2374 1 Frees 2 887560 Step Plat H 282698 Bol 2 start by: a) remove fresh water pump 1, Remove bolts (4) and gear (2) from shaft (5). Remove bolts (3) and bearing (1). 2. Remove four bolts (9) and elbow (8). Re- move bolts (6) and cover (7). 3. Remove cotter pin (11). Loosen, but do not remove nut (10) an ees sare 4, Install tooling (A) as shown and loosen im- peller (12) on the shaft. Remove tooling (A), nut (10), washer and impeller. sem 7-44ENGINE WATER PUMP 5. Remove shaft (5) from spring (13) and seal assembly (14). 6. Remove retainer (16) from housing (15). 7. Remove the bearing and seal (17) from re- tainer (16) A82867x1 8, Remove rubber seal and ceramic ring (18) from adapter (19) in the housing. DISASSEMBLY AND ASSEMBLY para0xs 7-45DISASSEMBLY AND ASSEMBLY WATER PUMP ENGINE, ASSEMBLE FRESH WATER PUMP 1361-16 Toole Needed a “P6510 Driver Ser 7 CAUTION Clean water only is permitted for use as a lubricant for assistance at installation. Do not ‘damage or put hands on the wear surface of the carbon ring or the ceramic ring. Install the ceramic ring with the smoothest face of the ring toward the carbon seal assembly. 1, Install the lip type seal in retainer (1) with tooling (A). The seal lip goes toward the in- side of the retainer. Put a thin layer of SAE 30 oil on the seal lip. 2. Install the bearing in retainer (1) with tooling, (A). Install the bearing until it is even with the surface of retainer. Put a thin layer of SAE 30 oil on the bearing. 3. Install new gasket (2) between housing (3) and retainer (1). Put the retainer in position on the housing. 4, Put shaft (4) in position in the housing. In- stall bearing (5) on the housing with four bolts and locks. Bend the locks. 5. Put the ceramic ring (6) in position in the rubber seal. Use hand pressure and tool (7) (which is with the replacement ring) to in- stall ceramic ring (6). Use hand pressure and the tool (which is with the replacement ring) to install the seal assembly. Push seal as- sembly on shaft until seal faces make light contact. 7-46ENGINE DISASSEMBLY AND ASSEMBLY WATER PUMP 6. Install spring (9) and impeller (8) on the shaft. Install the washer and nut which hold the impeller on the shaft. Tighten the nut to 58 Ib. ft. (75 N.m). Then tighten the nut more until the cotter can be installed 7. Install gasket (10) between the housing and cover (11). Install the eight bolts which fasten the cover to the housing, 8. Use thickness guage (12) to check the clear~ ance betwen the cover and impeller. Use gasket(s) (10) as needed to get a clear- ance of .005 to .020 in. (0.13 to 0.51 mm). 9. Install gear (13) on the shaft with six bolts and three locks. Bend the locks. 10. Install etbow (14) on the pump assembly with four bolts. end by: a) install fresh water pump 7-47ENGINE DISASSEMBLY AND ASSEMBLY CONNECTING ROD BEARINGS REMOVE CONNECTING ROD BEARINGS 1219-11 start by: a) remove engine oil cooler 'b) remove engine oil pump ©) remove water pump 4d) remove oil pressure relief valve 1. Disconnect tube (1) from carburetor and re- move bolt (2) and clip from carburetor base. 2. Loosen clamp (3) to remove pipe from cou- pling. 3. Remove four bolts (4) that fasten gas pressure regulator to cylinder block. Remove gas pres sure regulator (5) and tube and pipe assembly. 4. Remove bolts (6) that hold inspection cover to block. Remove cover (7). 5. Turn the crankshaft (in the direction of normal rotation until rod caps (9) can be removed through the opening. Remove bolts (8) and rod caps (9). 7-48ENGINE DISASSEMBLY AND ASSEMBLY CONNECTING ROD BEARINGS 6. Remove bearing (10) from the rod cap. 7. Remove the upper half of bearings from the connecting rods INSTALL CONNECTING ROD BEARINGS 1219-12 NOTE: Install the rod bearings dry when the clear- ance checks are made. Put clean engine oil on the rod bearings for final assembly. 1. Install the upper half of new rod bearings (1) in the connecting rods. NOTE: Be sure the tab on back of bearing fits in tab groove (slot) in connecting rod. CAUTION When connecting rod cap is installed, be sure that the number on side of cap is near to and respective to the number on side of connecting rod. 2. Install lower half of new bearings (2) in caps G). NOTE: Be sure the tab on back of bearing fits in tab groove (slot) of cap. CAUTION Do not use an impact wrench to tighten the rod bolts the additional 120°. 3. Cheek the bearing clearance with Plastigage (A). Install bearing cap on connecting rod. In- stall the rod bolts. Tighten the rod bolts first to a torque of 40 + 4 Ib.ft. (55 + 5 Nem). Puta mark on bolt heads and bearing caps. Tighten the bolts again 120° from the mark. 4, Remove cap (3), Measure thickness of the Plas- tigage. The clearance between a new rod bea ing and crankshaft journal must be .0031 to 0073 in, (0.079 to 0.185 mm). The maximum permissible clearance is 012 in, (0.30 mm) 5. Put caps (3) in position on the connecting rods and install the bolts. Tighten the bolts to a torque of 40 + 4 Ib.ft. (55 + 5 Nem). Puta mark on the bolt heads and bearing caps then tighten the bolts 120° more. 6. Install inspection covers (4) with new gaskets. 7. Put gas pressure regulator (5) in position and instalt four bolts. Connect pipe (7) 10 coupling with clamp, and tube assembly (6) to carbure- tor. Install clip and bolt on carburetor base. end by: a) install oil pressure relief valve ) install engine oil pump ) install water pump 4) install engine oil cooter 749DISASSEMBLY AND ASSEMBLY GOVERNOR (WOODWARD UG-8), GOVERNOR DRIVE HOUSING (UPPER) (WOODWARD UG-8) REMOVE GOVERNOR (WOODWARD UG-8) 1284-11 1. Disconnect governor control linkage (1) from governor. 2. Remove four bolts (3). 3. Remove governor (2) from the drive housing. Weight of governor is 40 Ib. (18 kg). INSTALL GOVERNOR (WOODWARD UG-8) 1264-12 1, Inspect gasket and make a replacement if necessary. Install gasket (2). 2. Put governor (1) in position on the drive hous- ing and install four bolts to hold it in position. 3. Install governor control linkage to governor. REMOVE GOVERNOR DRIVE HOUSING (UPPER) (WOODWARD UG-8) 1288-11 start by: a) remove governor 1, Disconnect tube assembly (3) from housing as- sembly fitting. 2. Remove six bolts (1) and housing assembly (2). INSTALL GOVERNOR DRIVE HOUSING (UPPER) (WOODWARD UG-8) 1288-12 1. Inspect the governor drive housing gasket and make a replacement if damaged, Install gasket. 2. Put housing assembly (1) in position and install six bolts 3. Connect tube assembly (2) to housing assembly fitting. end by: 1) install governor 7-50 boDISASSEMBLY AND ASSEMBLY GOVERNOR DRIVE HOUSING (UPPER) (WOODWARD UG-8) DISASSEMBLE GOVERNOR DRIVE HOUSING (UPPER) (WOODWARD UG-8) 1288-15 Tools Needed Wiss Phare 1 1510 Driver Grove start by: a) remove governor drive housing 1. Remove gear assembly (2) from housing. NOTE: Gear assembly (3) must be disassembied in housing for removal. Gear assembly (2) is removed. as a unit 2. Remove ring (1) from shaft with tooling (D). 3. Remove gear (4) and washer (5) from shaft. Remove shaft (6) from housing. 4. Remove ring (7) with tool (A). Remove gear (8) and washer (9) from shaft (10). 5. Remove bearing (11) and two bushings (12) from housing with tool (B). 7-51ENGINE DISASSEMBLY AND ASSEMBLY GOVERNOR DRIVE HOUSING (UPPER) (WOODWARD UG-8) ASSEMBLE GOVERNOR DRIVE HOUSING (UPPER) (WOODWARD UG-8) 1288-16 ~~ “Tools Nesded a 1P150___Driver Group 1 P1853 Piers 1 1. Install bearing (1) in housing with tool (A). The hole in the bearing must be in alignment with the housing opening for oil supply. 2. The bushings installed with tool (A) must be even (flush) with the edge of the housing bore. 3. Put shaft (2) in housing and install washer, ‘gear (4) and ring (3) with tool (B). | 4, Install washer (7) and gear (6) on shaft (8). wane Install ring (5) with tool (B). 5. Put gear assembly in housing. end by: a) install governor drive housing, 7-52ENGINE DISASSEMBLY AND ASSEMBLY GOVERNOR (WOODWARD UG-8) DISASSEMBLE GOVERNOR 1284-15 Toole Needed a APSTO Driver Group start by: a) remove governor NOTE: During disassembly many items are not ser- viced. These items if damaged or in need of replace- ment must be ordered as a subassembly. Disassem- bly and assembly of these items will not be shown. CAUTION Put the governor in a stand to prevent damage to the drive shaft. 1, Remove cover screws (1) and cover (2). 2. Remove screws (4) and cover assembly (3). 3. Put identification on two wires (5) and discon- as ® nect from motor assembly. Remove screws (6) and motor assembly (7) from the cover. 4, Turn speed droop knob (8) to zero. 5. Turn speed setting knob (9) clockwise until it stops (high speed position). 6. Set load limit knob (10) at position 10. 7. Turn terminal shaft (right hand side of case) with a vise grip and shop cloth, Turn until the load indicator pointer is approximately 8.5. See location (12). When turning the terminal shaft lever downward. Push down on the load limit strap (16) to release trapped oil. See picture B15613 page 7-54 for strap location. 8. Remove six screws and plate from panel assem- bly (11). 9. Put an identification mark on the load limit boss at the 8.5 position location (12), oon 7-53ENGINE DISASSEMBLY AND ASSEMBLY GOVERNOR (WOODWARD UG-8) 10. Disconnect speed droop spring (17). LL. Remove speed droop cotter pin (14) and speed droop pin. 12. Push speed droop adjusting lever (15) back and lift up on the speed droop lever (13) to release tension on the speeder spring (18). CAUTION Do not turn the speed droop lever (13). It will change the maximum or minimum speed ad- justment limit of the governor. 13, Remove eight panel screws (19). Use a soft hammer to break panel loose from case. 14, Lift load limit strap (16) and pull the bottom of panel (21) out approximately 12" (12.7 mm). Turn terminal shaft (22) downward with a vise grip and a shop cloth. This will turn power lever (20) down for easier panel removal. 15. Hold up speed droop lever (13) and push bot- tom of panel (21) in and top of panel out, Remove spring (23). 16. Remove the cotter pin and pin from power lever and power piston link (24) and compen- sating adjusting and actuating links (25). 7-54eo: 19, 20. 2 DISASSEMBLY AND ASSEMBLY GOVERNOR (WOODWARD UG-8) ‘Turn the governor over and remove the four outside serews (26). . Hold the case and base together and turn as- sembly ove: make a separt as shown. Use a soft hammer to ion of case (27) from base (28). Remove cotter pin (30) and pin (29) from pilot valve plunger. Lift up inner end of floating lever (31). Push down on rod end (33) with screwdriver. Slide lever (31) backward on pin (32) to release lever from rod end pin (33). Remove lever (31). Remove ball head assembly (34), 7-55ENGINE DISASSEMBLY AND ASSEMBLY GOVERNOR (WOODWARD UG-8) 22. Put the speeder rod end of the balll head assem- bly in a brass jaw vise. CAUTION Count the number of turns it takes to remove nut (35) from the rod assembly. 23. Remove nut (35). Remove rod and pin assem- bly (36), spring (37) and bearing (39) from ball head assembly (38). 24, Lift the compensating actuating piston assem- ‘a f bly (40) up and install cotter pin in hole in the 2 link. s99660%1 25. Turn the assembly on its side and remove five bolts (41). Use a soft hammer to remove the control assembly from the base. 26. Remove spring assembly (43), pilot valve bush- ing (42) and pilot valve plunger. 1-56ENGINE 28 30, 3 32, DISASSEMBLY AND ASSEMBLY GOVERNOR (WOODWARD UG-8) ing piston assembly (40) is under spring Pull actuating piston assembly (40) and re- move cotter pin (45). Remove the actuating piston assembly (40) and spring (44) from the control housing. Remove cotter pin (47) and ball head drive gear (46) from assembly. Remove pump drive gear assembly (48). Remove cotter pin (49) Remove lever (50) from spool. Remove spool. (51) from housing, Remove two screws (53) and lever assembly (52) from housing, :ENGINE DISASSEMBLY AND ASSEMBLY GOVERNOR (WOODWARD UG-8) 33. Remove piston rod end (54) and locknut (55) from the receiving piston (56). 34, Remove piston (56), bushing (58) and springs (57) from the housing assembly. sotaeext 35. Remove seat (59) from housing assembly with a wor tool (A). nt @* srasrxt 36. Remove wire, bolts (61) and bi (60). 37. Remove drive shaft and bearing assembly (62) from base housing with a soft hammer. sarasexy 7-58ENGINE DISASSEMBLY AND ASSEMBLY GOVERNOR (WOODWARD UG-8) ASSEMBLE GOVERNOR 1264-16 1. Install the drive shaft and bearing assembly (1) in the base plate housing. 2. Install retainer plate (2) and three serews. There is a 1/8" (3.2 mm) space between the retainer and the housing. Install wire in the screw heads. 3. Install seat in the control housing with a press and tool (A) until the seat is even with the housing land. See location (3). saserax CAUTION jons and shafts for damage and necessary. Put lubricant on compo- nents before assembly. 4. Install springs (7), piston (8), bushing (6), Jocknut (5) and piston rod end (4). 5. Put lever assembly (9) in position and install two screws to hold it in place. aasex 1-59ENGINE DISASSEMBLY AND ASSEMBLY GOVERNOR (WOODWARD UG-8) 6 Put spool (11) in housing and install lever (10) ‘on spool. Install cotter pin to hold lever in posi- tion, osrs602 Install pump drive gear assembly (12). 8. Install ball head drive gear (13) and cotter pin on the pump drive gear. 9. Install spring (15) and actuating piston assem- bly (14) in the control housing. Install a cotter sonnent pin in the piston link to hold assembly in posi- tion until the governor base is installed. 10. Install pilot vaive bushing (16), pilot valve plunger (17) and spring assembly (18) in the control housing, Oy, 7-60ENGINE DISASSEMBLY AND ASSEMBLY GOVERNOR (WOODWARD UG-8) 11. Turn drive shaft (19) to make an alignment of @ the drive shaft lug with the slot (opening) in the ® 7 pilot valve bushing (16). ce 12, Install governor base (20) on the control assem- ao bly. Install five screws. The cotter pin in the actuating piston assembly can now be removed. 13. Install spring (22) and rod and pin assembly (21) in ball head (23). Install bearing (24) and rut (25). Count the number of turns to remove nut from disassembly section. @® ® @&@ 14, Install ball head assembly (26) in the control assembly. soho 15. Put floating lever (27) in the rod end pin (28), son e@ Push piston rod end (29) down with a screw- driver and install floating lever in the piston rod end. CAUTION Do not install pin in the floating lever unless lever can be moved freely. 16. Install pin (30) and cotter pin in position to hold floating lever in position. ennaeaxt T-61ENGINE DISASSEMBLY AND ASSEMBLY GOVERNOR (WOODWARD UG-8) 17. Inspect gasket (32) on the governor base and make a replacement if damaged. 18. Install case (31) in position on the base. Install four screws to hold case in position. 19. Install pin and cotter pin in the power lever and power piston link (33) and the compensating adjusting and actuating links (34). 20, Make sure the load indicator pointer is at 8.5 on the panel, 21. Install spring (36) in the ball head assembly. 22. Use.a soft cloth and a vise grip to turn terminal shaft (37) and power lever down, If necessary turn drive shaft to engage ball head gears. 23. Install panel (35) in case. It will be necessary to push up on the load limit strap (38 ) to install panel. 24. Install spring (36) in position while the speed droop lever is lifted up. 25. Keep the bottom of the load limit strap on the case opening. Pull the bottom of the panel out about #2” (12.7 mm) from the case and the top against it. 26. Turn terminal shaft to move power piston link (33) to its highest position, 27. Push panel in position on the case. Turn the terminal shaft down slowly to engage the power piston link (33) in position in the opening of the rack (39), Install panel screws. 28, Turn the terminal shaft. If oil film remains in control assembly, it will be necessary to release pressure in the power cylinder while terminal shaft lever is turned down and load limit strap (38) is pushed down. The load indicator pointer must travel from 0 to 10. If the terminal shaft does not travel both ways, remove panel and start again at Step 20. If the panel can not be ‘removed push down or pull up on the rack (39) until the load indicator is at the 8.5 position. 29, Push down on the load limit strap. Movement of the strap is 3/16” (4.8 mm). If not, remove panel and start at Step 20. eatoaxs 7-62ENGINE 30, 3. 33. 34. 35 36. 37. 38 DISASSEMBLY AND ASSEMBLY GOVERNOR (WOODWARD UG-8) With the speed droop lever (41) in the vertic position, push down, then push the speed droop adjusting lever (42) back as indicated by arrow. Turn the speed droop lever down. Install speed droop link pin (40) and cotter pin. 2. Install speed droop spring (43), Install dial plate (44). Put the motor assembly (47) in position in cover (46) and install four screws Connect two wires (45) to the motor assembly. Inspect and make a replacement of cover gasket (50) if necessary Install cover assembly (48) on the governor case. Make sure the drive gear (51) and shaft (49) are in alignment. Install eight bolts to hold cover assembly in position. Install cover (52) to cover assembly. end by: ‘a) install governorENGINE DISASSEMBLY AND ASSEMBLY GOVERNOR (HYDRA-MECHANICAL) DISASSEMBLE GOVERNOR 1284-15 Tools Needed * 1P510___Driver Group = start by: 7-64 a) remove governor Remove five bolts (2) and cover (1) from hous- ing assembly. Remove screw (5) and collar (4) from bolt. Bend the tabs on lock and remove two bolts (3) and the torque spring assembly. Remove lock (6), bar (7), spacer (8) and re- tainer (9). Remove collar (11) and spring (10) from bolt. . Remove four bolts (13) and housing assembly (12) from housing. ed 4H @ 240s 2sa0%1 933687x1,ENGINE DISASSEMBLY AND ASSEMBLY GOVERNOR (HYDRA-MECHANICAL) 7. Bend the tab on lock (15) and remove bolt (17). 8. Remove shaft (16) and lever (14) from housing assembly. 9. Remove seal (19), plug and bearing (20) from housing assembly 10, Put identification on screw (18) or count the number of turns when screw is removed. Re- move screw. 11, Remove seat (21), spring (23) and spring washer (22). assembly removal so these parts do not be- come lost, 12, Lift up on retainer ring (25) and remove pin (26) and seat assembly (24). 13, Remove two washers (27), spring (30) and rod (28) from seat (29), saroxs e23691x1 panne 7-65ENGINE 16, 1. 18, 7-66 DISASSEMBLY AND ASSEMBLY GOVERNOR (HYDRA-MECHANICAL) |. Remove sleeve and bearing assembly (31) from the cylinder and weight assemblies. Remove lockring (32) that holds weight assembly to oylinder. Remove ring (33), races (36) and bearing (34) from sleeve (35). Remove weight assembly (37) from cylinder. Bend the tabs on lock (38) and remove three bolts (40), Remove cylinder (39) from cover. To remove the piston assembly from pin (43) lift up on sleeve (41) and slide piston (42) from pin. The bottom of the piston has an opening (notch) that engages with the top of pin, When piston (42) is correctly engaged with top of pin (43), the sleeve (41) can be moved into place. ena 20696%1 Aas091x2ENGINE DISASSEMBLY AND ASSEMBLY GOVERNOR (HYDRA-MECHANICAL) @ 20. Remove valve (45) and sleeve (41) from piston | | (42). Remove seal (44) from sleeve. @ B ; 21, Bend the tab on locks (48) and remove bolts. = ~ Remove bolt (46) and washer used to fasten gear on shaft assembly. Remove cover (47) from housing. essr16% CAUTION shaft assembly to prevent damage 22, With a press and tooling (A) remove shaft assembly (50) from gear and cover (49). 23. Install shaft assembly (50) in press and remove gear (51). 24, Remove gear (52) from bushing. Remove pin (43) from housing. To remove pin from housing turn shaft (53) counterclockwise and remove pin from lever assembly inside housing. The bottom of pin has an opening (notch) that en- gages with lever. 7-67ENGINE DISASSEMBLY AND ASSEMBLY GOVERNOR (HYDRA-MECHANICAL) 25, Remove bearing (54) from housing. 26. Bend the tabs on locks (56) and (57). Remove bolts that hold the shaft in the housing and hold lever to shaft, Slide lever (55) on shaft and remove key from shaft. Remove shaft (53) from housing. wmoig ie @® z Remove plug assembly (58) from housing. 28. Remove seal (60) and two bearings (61) from housing 29, Remove oil bypass valve assembly (59) from housing. 3 Remove pin (65), piston (64) and spring (63) from body (62). sont 7-68ENGINE DISASSEMBLY AND ASSEMBLY GOVERNOR (HYDRA-MECHANICAL) e@ ASSEMBLE GOVERNOR 1264-16 5 1. Install two needle bearing assemblies in hous- ing with a press and tool (A). Install bearing in bore (1) until bearing surface is even with the edge of the housing surface. Install the other bearing until it is even with the top of the seal counterbore. Install seal as shown with tool (a), 2, Install plug assembly (2) in housing and tighten to a torque of 50 + 10 Ib.ft. (70 + 14 N-m), 3. Install washer (3), spring (4), piston (5) and pin (6) in body, e@ 4. Install oil bypass vaive assembly (7) in housing and tighten to a torque of 50 + 10 Ib.ft. (70 = 14 Nm), 5. Slide shaft (8) through lever (9) and install lock and bolt to hold shaft in housing. Install key in shaft. Slide lever (9) on key and install lock and. bolt NOTE: The shaft must turn freely in bearings with 020 to .060 in. (.508 to 1.524 mm) end play. a 7-69ENGINE DISASSEMBLY AND ASSEMBLY 10. es 7-70 . Install pin (11) in housing. Pin has an opening ). Use a press and install gear (14) on shaft (13). GOVERNOR (HYDRA-MECHANICAL) Install bearing (10) in housing with a press and tool (A). Height from housing to top of bearing is 470 + .005 in, (11.94 + 0.13 mm). (notch) that engages in lever (9). Install gear (12) on bearing. Install gear until it makes contact with shoulder of shaft. Install cover (16), gear (15), washer and bolt on shaft assembly. Install assembly in housing.ENGINE DISASSEMBLY AND ASSEMBLY GOVERNOR (HYDRA-MECHANICAL) e 11, Install two locks and bolt position on cover. 12, Inspect O-ring seal (17) and make a replace- ment if necessary. 13, Install valve (19) in piston (20). Install sleeve (18) on piston. suanexe 14, Install piston assembly on pin (11) as follows: ' Lift up on sleeve (18) and slide piston (20) on pin (11). The bottom of the piston has an open- ing (notch) that engages with the top of pin When piston is correctly engaged with pin, the sleeve (18) can be moved into place. 15. Install cylinder (21) on cover. - Install lock (24) and three bolts (23) in position - on cylinder. 17. Install weight assembly (22) on cylinder. In- stall lockpin on weight assembly. 18. Put races (28) and bearing (26) in position on sleeve (27). Install ring (25) that holds the : a races and bearings on the sleeve. S8a7OHKT bes e AB5001x3, TaENGINE 19. 20. 21 22, 23. 24, 26. 8, 722 DISASSEMBLY AND ASSEMBLY GOVERNOR (HYDRA-MECHANICAL) Put sleeve assembly (29) in position on valve. Make an alignment of the holes in the sleeve and valve. Install bolt (31), washers (30) and spring (33) in seat. Put seat (32) in position on sleeve assembly 29). Make an alignment of the holes in the seat, sleeve assembly and valve. Install dowel (35) that holds the seat, sleeve assembly and valve together. Install retaining ring (34) that holds dowel (35) in place. Put spring washer (37) in position on the bolt. Put spring (38) and seat (36) in position on the weight assembly. Install bearing (40) in housing until bearing edge is even with the seat counterbore. Install bearing (41) to the given dimension from bear- ing (40). Install seal (39) as shown. Install plug (42) to dimension given. L Ise, it “ a eG ey aas90x8 1893690%1ENGINE DISASSEMBLY AND ASSEMBLY GOVERNOR (HYDRA-MECHANICAL) e 27. Put lever (43) in position in housing and install shaft (44) to hold it in place. Install lock and bolt in position on lever. Make a replacement of gasket (45) if it is damaged. 28. Put housing assembly (49) in position and in- stall four bolts (50). 29, Install spring (47) and collar (46) on bolt. nse 30. Install screw (48) the same number of turns counted during disassembly. 31. Assemble the torque spring group in the follow- ing sequence: retainer (54), spacer (53), bar (52) and lock (51). 32. Install torque spring group (56) on governor z r) housing 2 33. Install collar (55) and screw on bolt (31). 34, Inspect cover gasket and make a replacement if =a—@ damaged. 35. Install cover (57) on housing assembly. Gi) cnby a a) install governor nssenxt eo « 4 Q 73DISASSEMBLY AND ASSEMBLY EXHAUST MANIFOLD ENGINE REMOVE EXHAUST MANIFOLD 1059-11 ‘Tools Needed a ‘P9736 BracketLink st 1, Remove the nuts and bolts from carburetor rods (2) and (5) and the governor linkage rod a). 2. Remove four bolts (3) and channel assembly (4). Remove four spacers. 3. Remove bolts and elbow assemblies (6) from. exhaust manifold. Remove gaskets 4. Disconnect oil line (7). Disconnect opposite end of oil line (7) from the top of the turbocharger lubrication valve, 5. Remove seven bolts (8) from pipe (9) and ex- ‘haust manifold. 7-14ENGINE DISASSEMBLY AND ASSEMBLY EXHAUST MANIFOLD @ 6. Remove bolts (12) and connector (10) from manifold. 7. Fasten tool (A) and a hoist to exhaust manifold (11), Remove sixteen bolts (13) from the ex- haust manifold. Remove manifold and gaskets. Weight of the manifold is 185 Ib. (84 kg). INSTALL EXHAUST MANIFOLD 1059-12 oak a c sasarves ‘SPO736 Bracket ink 7 1, Inspect all O-ring seals and make replacements if necessary 2. Install tool (A) and hoist on exhaust manifold. 3. Install the exhaust manifold (1) on the engine. Install new manifold gaskets. 4, Put 5P3931 Anti-Seize Compound on threads of bolts. Install the bolts that hold the manifold : sna e to the cylinder head. Tighten bolts to a torque of 110 + 10 Ib.ft. (149 14 N-m). 5. Install oil line (2). 6, Put engine oil on O-ring seals and install con- nector (3) and elbow assemblies (4) and new gaskets in position on manifold. 7. Put spacers (6) in place and install channel assembly (5). 8. Connect carburetor and governor linkage rods, one 7-75ENGINE DISASSEMBLY AND ASSEMBLY GOVERNOR DRIVE HOUSING REMOVE GOVERNOR DRIVE HOUSING 1288-11 _ “Tools Needed SSS™S~*~C ‘5PO7S5___BracketLink cae start by: a) remove governor drive (upper) NOTE; The exhaust manifold channel assembly was removed for photo illustration. 1, Remove two bolts (1) from air cleaner brace. 2. Remove turbocharger cartridge housing tubes (7). Remove four bolts (2) that are used to fasten turbocharger pipe to the support. 3. Remove six bolts (4) that are used to fasten the support assembly in position. Remove support assembly (3). 4, Remove bolt (5) and spacer from clip. Remove turbocharger lubrication valve tube (6). 5. Remove four bolts and cover (9). 6. Remove tube assembly (8) from the turbo- charger lubrication valve and housing, 7. Install tooling (A) and a hoist on the governor Grive housing and remove fourteen bolts (10). 8. Remove governor drive housing. Weight of governor drive for G379 is 90 Ib. (41 kg), for G398 and G399 the weight is 125 Ib. (56 kg). 7-76 4ENGINE DISASSEMBLY AND ASSEMBLY GOVERNOR DRIVE HOUSING INSTALL GOVERNOR DRIVE r HOUSING 1288-12 KN 1. Inspect gaskets and make replacements if necessary. 2. Install tooling (A) and hoist on the governor drive housing, Put gasket and housing in posi- tion and install bolts. Remove tooling (A). 3. Install turbocharger lubrication valve tube as- sembly (2) to housing 4, Install gasket and cover (1) in position on hous- ing. 5. Put support assembly (4) in position and install six bolts. Install four bolts to hold pipe (3) to support assembly. 6. Install turbocharger fubrication valve tube as- sembly (7) to housing. Install spacer and bolt (6) on tube assembly (7). 7. Install two turbocharger cartridge housing tubes (8). 8. Install two braces (5) and bolts to the turbo- charger pipe. end by: a) install governor drive (upper) 7ENGINE DISASSEMBLY AND ASSEMBLY GOVERNOR DRIVE HOUSING DISASSEMBLE GOVERNOR DRIVE HOUSING 1288-15 "Tools Needed x 1p529 Handle 1 18457 _DrivePiote 1 start by: 1-78 a) remove fuel injection pump housing, governor, and governor drive as a unit b) remove governor ¢) remove shutoff control Remove the governor drive housing from the fuel injection pump housing with a hoist. Weight of governor drive for G379 is 80 Ib. (36 kg); for G398 and G399 is 125 Ib. (56 kg). Remove coupling, Remove ring. plunger, spring, and retainer for shutoff control . Remove pin that holds shaft assembly. Re- move lever (2), spring (4), key and shaft assembly (5). Remove the seal from hous- ing |. Remove governor drive pinion (3). . Use tooling (A) to remove gear from thrust, washer (1). Remove the bearing from hous- ing . Remove ting (9). Remove bolts, locks, and gear (8). . Remove thrust plate (10) and shims. Keep shims together for installation. Turn puller bolt (12) counterclockwise and remove drive gear (11). Remove locknut (6), gear (7) and key. Re- move the drive shaft (13). Remove bearings for the shaft from the housing. =NINE DISASSEMBLY AND ASSEMBLY | GOVERNOR DRIVE HOUSING @ sssenere covernon onive HOUSING 1288—16 ‘Tools Needed - ATs 1529 Handle fl 1472 Deve Pato 7 1P475 Drive Plate 852528 Dial Test Indicator Grou i 1. Install the bearings (1) in housing with tooling (A). Put clean engine oil on bearings. 2. Install the drive shaft (2) and locknut, key and gear (3), 3. Install the drive gear. Turn the puller bolt to hold gear on shaft. 4, Heat the thrust washer to a temperature of 250°F (120°C). Install bearing and gear (4) in housing. Push thrust washer ovet gear until washer is even with top of gear. There must be .015 to .045 in. (0.38 to 1.14 mm) end clearance. 5. Install seal (6) in housing with lip of seal to inside. Install lever and shaft assembly 7 (5). Install spring, key and pin, NOTE: Be sure the pin is engaged with groove in shaft and shaft turns freely. The spring must hook over the pin and around shaft lever. 6, Install plunger, spring, retainer and ring for shutoff control 7. Install governor drive pinion (8). Install shims and thrust plate (7). Install bevel gear (10) and ring. End play of drive shaft with new parts is .005 to .009 in. (0.13 to 0.23 mm). Maximum permissible end play with used parts is .015 in, (0.38 mm), 8. Use the tool group (B) to check the clear- ance (backlash) between pinion and bevel gear (10). Make adjustment of backlash by Temoving or adding shims (9) behind thrust plate (7), Amount of free movement (back- lash) between bevel gear and pinion must be 002 to .006 in. (0.05 to 0.15 mm), 9. Install coupling on shaft. Fasten a hoist and install governor drive housing on the fuel injection pump housing. e end by: a) install shutoff control oon: b) install governor ©) install fuel injection pump housing, governor, and governor drive as a unit sorsENGINE DISASSEMBLY AND ASSEMBLY INTAKE MANIFOLDS, VALVE COVERS REMOVE AND INSTALL INTAKE MANIFOLDS: start by: a) remove carburetor 1. Remove intake manifold bolts that fasten clips (3) and brackets (1) and (2) to the head. Fasten the coil bracket away from the intake manifold with a piece of wire. Remove the remainder of the bolts and intake manifold (4) from the cylinder heads. 3, Install new intake manifold gaskets (5) and intake manifold (4) in position on the engine. 4, Install brackets (1) and (2) and clips (3) with the manifold bolts. Install the remainder of the manifold bolts. end by. a) install carburetor REMOVE AND INSTALL VALVE COVERS 1107-10 1. Remove the nuts (1), washers and seals from the studs. 2. Remove valve cover (2). 3, Install a new gasket in the valve cover. Put cover (2) in position on the engine. 4. Install the seal and washer on each stud. Install and tighten nuts until contact is made with the washer. Tighten the nuts toa torque of 10 + 3 Ib.ft. (14 + 4 Nem). 7-80ENGINE DISASSEMBLY AND ASSEMBLY ROCKER SHAFTS AND PUSH RODS e@ REMOVE ROCKER SHAFTS AND PUSH RODS 1102 & 1208-11 art by: a) remove valve covers 1. Loosen adjustment screws (1) to get maximum valve clearance. Disconnect oil line (4) from shaft 2. Remove nuts (3) and studs (2) that hold the shaft on head. NOTE: If studs (2) are removed when nuts are loo- sened, install the studs in the head, Tighten the studs to a torque of 40 + 5 Ibft (55 7 N-m). 3. Remove rocker shaft. Remove push rods (5) from the cylinder head. INSTALL ROCKER SHAFTS AND PUSH RODS 1102 & 1208-12 1, Install push rods (1) in position on the lifters. 2. Install rocker shaft (2) on the cylinder head, 3. Install the nuts and studs that hold the rocker shaft to the cylinder head. Connect oil line to the rocker shat. NOTE: Be sure the studs and nuts are tightened to a torque of 40 + 5 Ib.ft. (55 + 7 Nem). 4. Make an adjustment of the valve clearance, The cold clearance must be: intake .015 in, (0.38 mm) and exhaust .035 in. (0.89 mm). See VALVE CLEARANCE ADJUSTMENT in. TESTING AND ADJUSTING. e@ end by a) install valve coversENGINE DISASSEMBLY AND ASSEMBLY ROCKER SHAFTS DISASSEMBLE ROCKER SHAFTS — 1102-15 —_ Tools Needed a 1P510__Drivar Group start by: a) remove rocker shafts and push rods 1. Remove cotter pins (1), washers and springs. ae 2, Remove intake rocker arms (5) from the rocker shaft. 3. Remove brackets (4) and exhaust rocker arms (3) from shaft. Remove fitting (6) and spring Q). 4, Remove the bearings (7) from the rocker arms with tooling (A). Remove nut (8) and screw (10) for the adjustment from the arms, Remove rings and buttons (9) from the arms. ASSEMBLE ROCKER SHAFTS 1102-16 Tools Needed a FPSIO Driver Grow 1, Install rings and buttons on rocker arms. Install screws and nuts for the valve adjustment on the arms. Install the bearings in the arms with tooling (A). 7-82ENGINE DISASSEMBLY AND ASSEMBLY ROCKER SHAFT @ sore see eines (1 o he bens ain alignment with oil holes in arms. 2. Install spring (3) and fitting (2) on the shaft. exior0x1 7 | 3. Install rocker arms (4), brackets (7), washers (5), springs (8) and cotter pins (6) on each end of shaft NOTE: Be sure exhaust rocker arms and intake rocker arms are installed in correct location on shaft. end by: a) install rocker shafis and push rods ATTE2aX1 faa 7-83ENGINE DISASSEMBLY AND ASSEMBLY VALVE LIFTERS REMOVE VALVE LIFTERS 1209-11 ~ as start by: 2) remove piston cooling tubes ) remove fuel injection pump housing, gover- nor and governor drive as a unit €) remove valve covers 1. Loosen the adjustment screws for valves to get maximum clearance. NOTE: Flywheel housing removed for illustration only. 2. Remove the push rods (2) 3. Remove the oil tubes (1) away from the brackets. 4. Put a wire or large rubber band around the lifters (3) to hold them in place in bracket. 5, Remove the bolts and locks that hold brack- et assembly to cylinder block. Remove the brackets and lifters (3). NOTE: If damage has been caused to lifters, inspect the lobes of camshaft. If necessary make a replacement of the camshaft. See REMOVE. reenene CAMSHAFT. Clearance between lifter and bracket must be no more than .010 in, (0,25 mm) 7-84ENGINE DISASSEMBLY AND ASSEMBLY VALVE LIFTERS @ instant vatve urrens 1209-12 Toa iit 1. Put clean engine oil on lifters, Install lifters in bracket, Put wire or large rubber bands (1) around lifters to hold them in bracket. 3. Put the bracket and lifters in position on dowels. Install the locks and bolts that hold brackets to cylinder biock. Remove the wire or rubber band from lifters. 4, Put the oif tubes (2) on the brackets and install locks and bolts, Put the seals between the bracket assem- blies. 6. Use installer (A) to put the seals in their respective position. @ atest ie push oc. 8. Make an adjustment of valves to get .015 in. (0.38 mm) clearance (cold) on intake valves; 035 in, (0.89 mm) clearance (cold) on ex- haust valves. See VALVE CLEARANCE ADJUSTMENT in TESTING AND AD- JUSTING. end by: ‘) install piston cooling tubes b) install fuel injection pump housing, gover- nor and governor drive as a unit ) install valve covers 7-85ENGINE DISASSEMBLY AND ASSEMBLY CRANKSHAFT MAIN BEARINGS REMOVE CRANKSHAFT MAIN BEARINGS 1203-11 "Toots Needed P8617 Bearing Removal and ‘@Maa79__Wrench start by: a) remove engine oil cooler b) remove water pump ) remove engine oil pump 4) remove oil pressure relief valve €) remove gas pressure regulator 1. Remove the bolts (1) that hold inspection covers to block. Remove inspection covers (2) from each side of block. = SS . Remove the nuts for main bearing caps with wrench (B). Remove the bearing cap with lower half of bearing. 3. Use tool (A) to move out the upper half of main bearing as the crankshaft is turned in the nor- mal direction of rotation. sore CAUTION If the crankshaft is turned in the wrong direc- , the tab of the bearing will be pushed between the crankshaft and cylinder block. This can cause damage to either or both. NOTE: On the bearing journal that has no drilled hole, put a thin piece of fiber, hardwood or plastic against end of bearing opposite tab. Hit the bearing lightly with the above until tab of bearing is free from cylinder block. Remove the upper half of bearing. 7-86ENGINE DISASSEMBLY AND ASSEMBLY CRANKSHAFT MAIN BEARING INSTALL CRANKSHAFT MAIN BEARINGS 1203-12 _ Be oO pPssi7 Be — ~ Installation Tool 1 “6M9G73— Wench —___Pastigaa - CL Indicator Group NOTE: Install the main bearings dry when the clear- ance checks are made. Put clean engine oil on the main bearings for final assembly. 1. Use tool (A) to install upper half of bearing in cylinder block, The bearing with oil hole is upper half, 2, Clean main bearing caps and install lower halves of bearings in caps. NOTE: When the bearing clearance is checked and the engine is in a vertical position, such as in the vehicle, the crankshaft will have to be lifted up and held against the upper halves of the main bearings to get a correct measurement with Plastigage. The Plastigage will not hold the weight of the crankshaft and give a correct indication. If the engine is in a horizontal position, such as on an engine stand, itis riot necessary to hold the crankshaft up. Do not turn crankshaft when Plastigage is in position to check clearance. CAUTION Do not use an impact wrench to tighten the bolts the additional 120°. 3. Use Plastigage (C) to check bearing clearance. Install caps and tighten both nuts with too! (B) 10200 + 10Ib.ft. (270 + 14.N.m). Puta mark ‘on nuts and end of studs. Tighten nuts 120° from the mark. Remove caps and check thick- ness of Plastigage (C) to find bearing clear- ance, Bearing clearance must be .0048 to 0090 in. (0.122 to 0.229 mm) for new parts. Maxi- mum permissible clearance for used parts is 015 (0.38 mm). NOTE: Main bearing caps have numbers as to their location in eylinder block. Install bearing caps so the number on cap is same as number on cylinder block Both numbers must be on same side of cylinder block. 4. Put clean engine oil on threads of studs and seat for nut. Install main bearing caps and nuts. Install thrust plates on dowels on rear cap. The dowels must not be extended more than 160 in. (4.06 mm) from counterbore face of bearing cap. Tighten nuts with wrench (B) to 200 + 10 Tb.ft. (270 # 14 N-m). Put a mark on nuts and ends of studs. Tighten nuts an extra 120° from mark, 5. Use indicator group (D) to check end play of crankshaft as controlled by thrust plates. End play with new parts must be .005 to .021 in. (0.13 to 0.53 mm), Maximum permissible end. play with used parts is .035 in. (0.89 mm) 6. Install the inspection covers. end by: a) install gas pressure regulator b) install oil pressure relief valve ¢) install engine ofl pump ¢) install water pump €) install engine oil cooler 7-87ENGINE, DISASSEMBLY AND ASSEMBLY PISTON COOLING TUBES REMOVE PISTON COOLING TUBES 1307-11 start by: a) remove engine oil cooler b) remove water pump c) remove engine oil pump d) remove oil pressure relief valve €) remove gas pressure regulator 1. Remove bolts (1) that hold inspe cylinder block. Remove inspection covers (2) from each side of block. 2. Remove bolt (3) and lock that holds tube to bottom side of lifter bracket. Remove the piston. cooling tubes (4) INSTALL PISTON COOLING TUBES 1307-12 1. Check the alignment of the piston cooling tubes with tooling (A). See USE OF 5P8709 TOOL GROUP FOR ALIGNMENT OF PISTON COOLING JETS, Form No. SMHS7267, for the correct alignment procedure. 2. Install piston cooling tubes (1) in position on the lifter bracket. Install the locks and bolts. 3. Install the inspection covers on engine. end by: a) install gas pressure regulator b) install oil pressure relief valve ©) install engine oi! pump 4) install water pump ) install engine oil cooler 7-88ENGINE DISASSEMBLY AND ASSEMBLY CYLINDER HEADS e REMOVE CYLINDER HEADS 1100-11 start by 4) remove rocker shafts and push rods ) remove intake manifold ©) remove exhaust manifold 1, Remove the instrument panel from cylinder head to be removed (if so equipped). 2. Remove the coolant from the engine. 3. Remove sixteen nuts (1) from cylinder head. 4, Fasten a hoist to tooting (A) on cylinder head Slowly remove cylinder head from block so studs are not damaged. Weight of cylinder head is 190 Ib. (86 kg). 5. Remove head gasket (3) and water seal assem- blies (2). e 6. Remove O-ring seal (4) from dowel. 7-89ENGINE DISASSEMBLY AND ASSEMBLY CYLINDER HEAD INSTALL CYLINDER HEAD 1100-12 ~__TooisNewded ‘P9736 ink se IL. Clean the block and cylinder head. Install seal (1) on dowel. 2. Put water seal assemblies (2) in position on the block. 3. Install head gasket (3). 4, Install tooling (A) and a hoist to the cylinder head. Slowly lower the head over the studs until it is in the correct position over head gaskets and seals. 5. Put $P3931 Anti-Seize Compound on threads of head studs. Install nuts in the following se- quence: Step I. Tighten nuts by number sequence to a torque of 150 Ib.ft. (205 N-m). Step 2. Tighten nuts by number sequence to a torque of 265 Ib.ft. (360 Nem). Step 3. Tighten nuts by number sequence to a torque of 265 Ib.ft. (360 N-m). 6. Install the instrument panel on cylinder head removed (if so equipped). 7. Fill the engine with coolant to correct level. end by: a) install exhaust manifolds ) install intake manifolds cc) install rocker shafts and push rods 7-90ENGINE DISASSEMBLY AND ASSEMBLY VALVES @ ccaove vaives 1105-11 start by: a) remove cylinder head I. Install cylinder head (1) on tooling (A) as shown. 2. Put identification on the valves and head for correct assembly. Use tooling (B) asshown to put valve spring (4) under compression. Re~ move three locks (3). Slowly release compres- sion from the valve spring and remove too!- ing (B). Remove retainer (2), two springs (4), rotator, spacer and valve from the head. 3. Do Steps I and 2 again for the remainder of valves. 7a easton 791ENGINE VALVES INSTALL VALVES 1105—12 7 Tools Needed FTBO5 Cylinder Head Repair Bench 1 8S2263 Valve Spring Tea 551330 1. Check spring force with tool (B). For the correct spring force, see the subject VALVES in SPECIFICATIONS. 2. Inspect and make a replacement, if neces- sary, of the O-ring seals in the inlet valve retainers. Put the valves, spacer, rotator, springs and retainer in position on the head. Put the springs under compression with tool (C). Install three locks (1). The thick end of the lock goes toward the cylinder head. Ps Locks can be thrown from the valve when tool (C) is released if they are not in their correct position on the valve stem. SSS 3. Remove tool (C) slowly. Hit the valve lightly with a soft hammer to be sure the locks are in their correct position. 4. Do Steps I through 3 again for the remainder of the valves. end by: a) install cylinder head 7-92 DISASSEMBLY AND ASSEMBLYENGINE DISASSEMBLY AND ASSEMBLY VALVE GUIDES | @ ccsove ano israLt vaLvE GUIDES 1104—10 | Tools Needed AB COO 4Had6 Driver 1 '5P1726 Bushing 17430. Drwer 1 2P2313 Bushing start by: 820039 ? - ~ a) remove valves 1. Remove old valve guides (1) with tool (A) as shown. If the valve guides have grooves, use toot (C), 2, Install the valve guides with tools (A & B) as shown. If the valve guides have grooves, use tools (C & D). 3. Dimension (X) for the installed valve guide must be 1.750 + .020 in. (44.45 + 0.51 mm). end by: e a) install valveENGINE, DISASSEMBLY AND ASSEMBLY VALVE SEAT INSERTS, WATER DIRECTORS REMOVE AND INSTALL VALVE SEAT INSERTS. Tools Needed BSI080 __Vatve Seat insert Grown start by: a) remove valves 1. Remove valve seat inserts (1) with tool group (A). 2. Clean and remove burrs from the valve seat bore. 3. Install the new valve seat insert with tool group (A). Do not increase diameter of ex- tractor in valve seat insert when insert is in- stalled in cylinder head. 4, Grind valve seat inserts (1) according to specifications given in SPECIFICATIONS SECTION. end by: a) install valves REMOVE AND INSTALL WATER DIRECTORS 1115-10 - Toole Needed * TP510 Driver Group : start by: a) remove cylinder head 1. Remove water director (1) from cylinder head. 2. Install new water director with tooling (A). CAUTION Hole (2) in water director must be in alignment with “V" mark on cylinder hea end by: a) install cylinder head 7-94DISASSEMBLY AND ASSEMBLY PISTONS REMOVE PISTONS 1214-11 start by: a) remove cylinder heads b) remove engine oil cooler ¢) remove water pump d) remove engine oil pump €) remove oil pressure relief valve NOTE: The following sequence of photos is for the removal of pistons | and 3 only. 1, Disconnect tube (1) from carburetor and re- move bolt (2) and clip from carburetor base. Loosen clamp (3) to remove pipe from cou- pling, 3. Remove four bolts (4) that fasten gas pressure regulator to cylinder block. Remove the gas pressure regulator and tube and pipe assembly. 4, Remove bolts (5) that hold inspection cover to block. Remove cover (6), 5. Turn the crankshaft (in the direction of normal rotation) until the rod caps (8) can be removed through the openings. Remove bolts (7) and rod caps (8). 6. Remove the carbon ridge (9) from the top of the cylinder liner. 7. Push the connecting rod and piston up until the rings are out of the cylinder liner. 8. Remove the piston and connecting rod from the cylinder liner. Te ——__ENGINE DISASSEMBLY AND ASSEMBLY PISTONS INSTALL PISTONS 1214-12 1. Put clean SAE 30 engine oil on the piston, rings, connecting rod bearings and walls of cyl- inder liner. Install upper bearing in connecting rod. 2. Install piston (1) in tool (A). Put the piston and. toal (A) in position on the cylinder liner as shown, 3. Install the piston in the liner slowly on to the journal of crankshaft. Be sure the “V" mark on piston is in alignment with the “V" mark (2) on the block. CAUTION Be careful not to cause d rod bearing or journal on cre installed. ge to connecting shaft when pis- 4, Install the lower bearing (5) in the cap (3) for the connecting rod (4). Be sure the tab on back of bearing fits in groove for tab in cap. Install the cap. 5. Put 5P3931 Anti-Seize Compound on threads of rod bolts. Install rod bolts. Tighten the rod bolts to a first torque of 40 + 4 Ib.ft. (55 + 5 N-m). Put a mark on bolt heads and bearing caps. Tighten the bolts again 120° from the mark. 6. Put inspection covers in position on engine. In- stall the bolts that hold covers to cylinder block 7. Check the inspection cover gasket for damage and make a replacement of gasket if necessary. 8. Put cover (6) in position and install bolts. 9, Put gas pressure regulator (9) in position and install four bolts. Connect pipe (10) to coupling with clamp and tube assembly (7) to carbure- tor. Install clip (8) and bolt on carburetor base. end by: 1) install oil pressure relief valve ») install engine oi! pump ) install water pump 4) install engine oil cooler = ¢) install cylinder heads a70ree 1.96ENGINE DISASSEMBLY AND ASSEMBLY PISTONS @ DISASSEMBLE PISTONS 1214-15 start by: a) remove pistons 1, Use tool (A) to remove piston rings (1) from piston. 270638 ® 2. Remove retainers (6) and pin (4) from the a piston (2). Remove connecting rod (3) from the e piston. CAUTION Do not use a broken ring or carbon scraper to clean carbon. They will cut the ring grooves or ‘cause damage to piston. 3. Remove the carbon from ring grooves on pis- ton, 4. Use tooling (B) to remove and install the piston pin bearing (5). See SPECIAL INSTRUC- @ TIONS, Form No, SMHS7295, for more in- formation. 1-97ENGINE DISASSEMBLY AND ASSEMBLY PISTONS ASSEMBLE PISTONS 1214-16 “Tools Needed a oa ras ‘BHOG2T_Platon Ring Expander 7 - 1. Tofind the correct piston to rod location, make an alignment of the “V” on the piston to the ; “V" on the block, Install the rod (3) on the : piston (2) with the part number on the radius side (R) of the rod toward the radius of the crankshaft journal 2. Install pin (1) and two retainers (6). Each re- = tainer must fit in a groove on each end of pin wD. 3. Use ring expander (A) to install the piston rings. 4, Install spring for oil control ring (bottom ring) in the bottom ring groove of piston. Install oil control ring (4) so the end gap of oil control ring, (4) is 180% from the ends of spring. A 5, Install center ring (5) in center groove of piston so the mark “UP” on ring is toward top of piston. Install top ring in top groove of piston so the mark “UP” on ring is toward top of piston. 6, Turn the piston rings in the grooves so the ring ss gaps are 120° apart. a exr06axs end by: a) install piston 7-98ENGINE DISASSEMBLY AND ASSEMBLY CYLINDER LINERS | @ wenovecrunornunens 1216-1 ~ BPaBES CO) start by: a) remove pistons 1. Puta piece of gasket material or a cover over crankshaft journals as a protection before liner is removed. 2. Put tooling (A) in the cylinder liner. CAUTION Do not cause damage to piston cooling tube (1) when tooling (A) is installed. 3. Use tooling (A) to remove the liner from its e seat in cylinder block. 4, Remove cylinder liner (2) from its bore in cylinder block. 5. Remove filler band (3) and seals (4) from the liner.ENGINE CYLINDER LINERS INSTALL CYLINDER LINERS 1216-12 Tools Needed ABC 72598 Puller Plate 57548 Puller Assembly 7 TPSS1O Liner Projection T "2P8260__ Cylinder Liner Installer 7 1, Clean the cylinder liners and block. Install the liners in the block without the O-ring seals. 2, Install tooling (A) on the liner. Tighten the nuts that hold tooling (A) evenly to a torque of $0 Ib. ft. (70 N.m). 3. Check the liner projection with tool group (B) at . four locations around the liner. The difference 2% between the four measurements must not be more than .002 in. (0.05 mmm). The liner projection must be .004 to .008 in. (0.10 to 0.20 mm). The ‘measurement between liners next to cach other, must not be more than .002 in. (0.05 mm) difference NOTE: The liner projection can change if the liner is turned in the bore. 4, Put a mark on the linerand block so the liner can be installed in the same position from which it was removed. 5. Install new seals (2) on the cylinder liners. Put liquid soap on the seals and in the bores in the cylinder block. 6. Put SAE 30 oil on filler band (1) and install it ‘on the liner. Install the liner immediately in the cylinder block with tooling (C) end by: a) install pistons 7-100 DISASSEMBLY AND ASSEMBLYENGINE DISASSEMBLY AND ASSEMBLY TURBOCHARGER LUBRICATION VALVE REMOVE TURBOCHARGER LUBRICATION valve 1309-11 A mF oan 1. Disconnect oil lines (1) and (2) from top of turbocharger lubrication valve. Loosen other ends and clips of upper oil lines enough to move upper lines from valve. 3. Disconnect the other three oil lines (5) from valves. 4. Remove four nuts (3) that hold valve (4) to channel. Remove the turbocharger lubrica- tion valve. mon INSTALL TURBOCHARGER LUBRICATION VALVE 1309—12 1. Install turbocharger lubrication valve (1) to channel with four bolts (2) and nuts. 2. Connect five oil lines to valve, 3. Tighten all connectors and clips. 7-101ENGINE DISASSEMBLY AND ASSEMBLY TURBOCHARGER LUBRICATION VALVE DISASSEMBLE TURBOCHARGER LUBRICATION VALVE 1309-15 start by: a) remove turbocharger lubrication valve 1, Remove the bolts and cover (3). 2, Remove the body (2) and adapter (1). Re- move the plunger and spring from body. ASSEMBLE TURBOCHARGER LUBRICATION VALVE 1309—16 1, Clean all parts before assembling valve. 2. Install spring (2) and plunger (1) in body @). 3. Install adapter, cover and bolts. end by: a) install turbocharger lubrication valve 7-102 TOENGINE DISASSEMBLY AND ASSEMBLY AIR CLEANERS e REMOVE AND INSTALL AIR CLEANERS 1051-10 1. Loosen clamp (2) that fastens the turbocharger air inlet hose to the air cleaner housing (3). 2. Remove bolt (1) that fastens the brace to the air cleaner housing. 3. Remove two bolts (4) from cach side of the air cleaner housing. Remove the air cleaner hous- ing. The weight of the air cleaner housing as- sembly is 43 Ib. (20 kg). 4, Put the air cleaner housing assembly in position ‘on the engine. Install two bolts (4) on each side of the air cleaner housing. 5. Install bolt (1) that fastens the brace to the air cleaner housing 6. Install the turbocharger air inlet hose on the air @ cleaner housing and tighten the clamp that fas- tens the hose to the air cleaner housing, 103ENGINE DISASSEMBLY AND ASSEMBLY MAGNETO REMOVE MAGNETO 1413-11 1, Disconnect plug (1) from magneto. 2. Remove two bolts (3) that hold magneto to drive housing. 3. Remove magneto (2) and gasket. INSTALL MAGNETO 1413-12 1, See TIMING OF MAGNETO TO ENGINE, in TESTING AND ADJUSTING. See Form No, REGO1305. 2. Put magneto (1) and gasket in position on drive housing 3. Install two bolts (3). 4, Connect plug (2) on magneto, 104ENGINE, DISASSEMBLY AND ASSEMBLY MAGNETO (COIL AND MECHANICAL DRIVE) DISASSEMBLE MAGNETO 1413-15 eis Nooded a 4 ¥ WPSi0 Diver Group Sst 1666 brs +—@) P1857 Phere sate start by. ) remove magneto NOTE: Caterpillar does not have service parts for the early SCS magnetos because there are not very many early SCS magnetos in the field. Make contact with Fairbanks Morse Company if parts for the ear- lier magneto are needed. Caterpillar has service parts for the Air-Gap SCS magnetos. 1, Remove four screws (1) from magneto cover and remove cover (2). 2. Put a screwdriver between the heat sink section (5) and the pulser coil housing. Pull the screw- driver to remove the heatsink (5) and end cap section (6), 3. Remove four screws (3) from plate (4). Re- move plate. aaraext CAUTION gear result. Use a soft cloth and a pli pulser arm (8). 4. Remove nut (7) and washer which fasten the pulser to the shaft. Remove pulser arm (8). 5. Remove magnet (9) and plate (10) from shaft. 6. Remove two screws (12) from the center of the pulser coil. Remove pulser coil (11) from hous- ing. sage 7-105ENGINE DISASSEMBLY AND ASSEMBLY MAGNETO (COIL AND MECHANICAL DRIVE) Put identification on wires (13) and remove from heatsink. Remove pulser coil (11) from assembly. 8. Remove four screws (14) which hold pulser coil housing (15) to the drive end of the magneto. Remove housing (15). 9. Remove nut (16), washer and coupling (17) from drive shaft, Remove key. 10. Remove seal (18) from housing. fe fh ee aS 7-106ENGINE DISASSEMBLY AND ASSEMBLY MAGNETO (COIL AND MECHANICAL DRIVE) 12, Remove three screws (21) that hold support, assembly (20) to housing, CAUTION Use a support for components when removed with a press to prevent dami 13. Install coupling nut on shaft and with a press remove support and magnetic rotor assemblies from housing. 14, Use a press and tool (A). Remove magnetic rotor (22) from support assembly (20). 15. Use a press to push gear assembly (23) from bearing. Remove nut (16) and gear assembly, 16, Remove snap rings (24) from support assembly with tool (C). 83a748x1 7-107ENGINE DISASSEMBLY AND ASSEMBLY MAGNETO (COIL AND MECHANICAL DRIVE) 17. Remove bearings (25) from support assembly with a press and tool (A). 18, Remove two screws (26) and wedges from housing. Remove coil assembly (27). 19. Remove snap ring (28) from housing with tool ©). 20. Remove bearing from housing with tooling (A). 7-108ENGINE DISASSEMBLY AND ASSEMBLY MAGNETO (COIL AND MECHANICAL DRIVE) 54698-2x2 } 2) @ () @ CYLINDER AIR -GAP SCHEMATICENGINE DISASSEMBLY AND ASSEMBLY MAGNETO (COIL AND MECHANICAL DRIVE) ASSEMBLE MAGNETO 1413-16 Tools Needed ——SS=~=“‘*‘s*‘s‘“‘*‘i“(its‘ CS!” 1P510__ Driver Group 1 “PIs Piers “pis? Pies S™~—CSSC—CSC NOTE: Inspect all gaskets and make replacements if torn or damaged. 1. Install two bearings (2) in support assembly with a press and tool (A). Install snap rings (1) with tool (C). 2. Install gear assembly (3) in bearing support (4) with a press and tool (A). 3. Put the mark (drilled hole) on gear of magneti rotor (5) in alignment with the mark (arrow) on gear (3), 4, Put nut (6) on the magnetic rotor and install rotor (5) in bearing support with press. 5, Install bearing in housing (7) with a press and tool (A). Install snap ring in housing with tool (C). 7-110ENGINE, DISASSEMBLY AND ASSEMBLY MAGNETO (COIL AND MECHANICAL DRIVE) 6. Install coil assembly (8) in housing. 7. Put two wedges (9) in position in the housing. Install the two screws to fasten the wedges to the housing, 8. Install drive assembly (10) in the housing. In- stall the three screws in the bearing support. NOTE: Be sure the drive assembly is in the center of the housing when screws are tightened. 9. Install snap ring (11) on shaft with tool (B). 10. Install seal (12) in housing. Install key (13) on the shaft, IL. Install drive coupling (14) on the magneto Grive shaft. Install nut (6) that fastens the drive 833867%1 coupling to the shaft TAM12, 13, 16, 7-112 DISASSEMBLY AND ASSEMBLY MAGNETO (COIL AND MECHANICAL DRIVE) Put pulser coil housing (15) in position on the end of the drive end of the magneto, Install four screws. Put four wires (16) from pulser coil in correct position on heatsink. Install pulser coil (17) in the pulser coil housing. Install plate (18) and magnet (19) on shaft, The side of the magnet with the identification mark must make contact with the pulser rotor. . Install pulser rotor (20) to the shaft. (For mag- netos that operate in the clockwise direction, the mark “C” on the rotor must be toward the outside, the mark “A” is for counterclockwise ‘magnetos). Install the nut that holds the pulser to the shaft. Tighten nut to a torque of 12 + 1 Ib.ft. (17 © 1 Nem). Use a soft cloth and pliers to hold pulser arm. Install plate (21) in the pulser coil housing. Install four screws that fasten the plate to the pulser coil housing,ENGINE 18. DISASSEMBLY AND ASSEMBLY MAGNETO (COIL AND MECHANICAL DRIVE), DISTRIBUTION BOARD Pat heatsink section (22) and end cap section (23)in position on the end of pulser coil housing (15) and install four screws to hold sections in place. Test the magneto as shown in Special Instruc- tion Form No. GEGO2059 to be sure all prob- lems have been corrected end by: a) install magneto REMOVE AND INSTALL DISTRIBUTION BOARD start by: 4) remove magneto Remove four screws (1) from magneto cover (2). Remove cover (2). . Put identification on all wires and remove from terminals (6) and (4). Remove four screws (3) and remove the power board (5). Install the new power board (5) and connect all of the wires as shown in the wiring diagram, . Put cover (2) in position and install four screws (1) in cover. Test the magneto as shown in Special Instruc- tions Form No. GEGO2059 to be sure all prob- lems have been corrected, end by: a) install magneto TUBENGINE DISASSEMBLY AND ASSEMBLY MAGNETO POWER BOARD, POWER RESISTOR AND ZENER DIODE REMOVE AND INSTALL POWER BOARD start by: a) remove magneto 1. Remove four screws from the magneto cover. Remove the cover. 2. Puta screwdriver between heatsink section (2) and pulser coil housing (1). Pull the screw- driver to remove the heatsink (2) and the end cap section. 3. Put identification on all wires and remove from terminal (3), 4. Remove four screws (5) and power board (4) from heatsink. 5. Install a new power board and connect all wires, 6. Install magneto cover. 7. To check magneto for problems see Special Instructions Form No. GEGO2059. end by a) install cover POWER RESISTOR AND ZENER DIODE start by: a) remove magneto 1. Remove the magneto cover. 2. Put a screwdriver between the heatsink section and the pulser coil housing. Pull the screw- driver to remove the heatsink and the end cap section. 3. Remove two wires (2) and two screws from power resistor. Remove resistor (1). 4. Remove wire (3) from zener diode with the use of a soldering gun. Remove nut (5) and zener diode (4) from heatsink. 5. Install the zener diode in the heatsink, Connect, the rod lead to the zener terminal with solder. 6. Install power resistor (1) to the heatsink, Con- nect two wires (2) to the heatsink terminals. 7. Install magneto cover. 8. To check magneto for problems see Special Instructions Form No. GEGO2059. end by: a) install magneto careyDISASSEMBLY AND ASSEMBLY GAS PRESSURE REGULATOR e REMOVE GAS PRESSURE REGULATOR 1270-11 NOTE: Left hand gas pressure regulator shown. ‘Turn off gas supply valve. . Disconnect tube assembly (1) from regulator fitting, . Remove two bolts (2) and elbow from regula- tor. Remove four bolts (3) and gas pressure regula tor (4) from engine. INSTALL GAS PRESSURE REGULATOR 1270-12 Put regulator (1) in position on bracket and install four bolts. Inspect O-ring seal (3) and make a replace- ment if necessary. Put elbow (4) in position and install two bolts. Install tube assembly (2) to elbow fitting. Turn on gas supply. 7-115ENGINE DISASSEMBLY AND ASSEMBLY GAS PRESSURE REGULATOR DISASSEMBLE GAS PRESSURE REGULATOR 1270-15, start by: a) remove gas pressure regulator 1. Remove eight bolts (1) and regulator cover (2). 2 2. Remove upper spring seat (6), spring (5) and lower spring seat (4). 3. Remove diaphragm assembly (3). 4, Remove bolt (12) and pusher post (7). Remove head gasket (8), heads (9) and (11) from dia- phragm (10). 5. Remove pin (14) and lever (13) 6. Remove valve stem assembly (15). 7-116ENGINE DISASSEMBLY AND ASSEMBLY GAS PRESSURE REGULATOR | e 7, Remove three screws (16) and orifice (17). | 8. Remove stem (18), spring (21), lower flapper (19), upper flapper (22) and spring (20). aareix TTENGINE DISASSEMBLY AND ASSEMBLY GAS PRESSURE REGULATOR ASSEMBLE GAS PRESSURE REGULATOR 1270-16 1. Install spring (3), upper flapper (5), lower flap- per (2), spring (4) and stem (1) in position in the regulator housing. a hee hw 2. Put orifice (6) in position and install three b Pat valve stem assembly (8) in regulator hous- ing. Put lever (9) in position and install pin (7). 4, Put together the diaphragm assembly in the sequence as follows: pusher post (10), head gasket (15), head (11), diaphragm (12), head (13) and screw (14). 5. Install lower spring seat (19), spring (17) and upper spring seat in position on the diaphragm assembly. 6. Make an alignment of the diaphragm assembly with the regulator body (18) and the regulator cover (16). Install bolts. 2z5rxt 7-118ENGINE DISASSEMBLY AND ASSEMBLY CARBURETOR @ REMOVE CARBURETOR (RIGHT HAND SHOWN) 1266-11 1. Shut off gas supply line to gas pressure regula- tor. 2. Loosen two hose clamps (1) and slide hose off carburetor. Disconnect tube (2) from fitting. 3. Remove two clamps (3). 4, Remove nut and disconnect rod (4) from throt- tle lever assembly. Remove four bolts (5) that hold carburetor to intake manifold. e@ 5. Remove carburetor (6) from manifold. Re- move gasket (7). 7-119ENGINE DISASSEMBLY AND ASSEMBLY CARBURETOR INSTALL CARBURETOR 1266-12 1, Put a new gasket (2) and carburetor (1) in position on the intake manifold. 2. Put coupling (5) in position between nipple (4) and pipe. Install clamps (6). alana 3. Connect rod (3) to the throttle lever assembly. 4, Connect tube (7) to carburetor fitting. 7-120ENGINE DISASSEMBLY AND ASSEMBLY CARBURETOR DISASSEMBLE CARBURETOR start by: a) remove carburetor 1266-15 1, Put carburetor in vise for disassembly. 2. Put identification on elbow (2), nipple and car- buretor (1) for assembly purposes. 3. Remove carburetor (1) from nipple, 4. Remove five screws (4) and cover (3) from carburetor body. 5. Remove spring (5) and diaphragm assembly (6) from carburetor body. 6. Remove four screws from diaphragm assem- bly. Remove body (7), gasket (8), diaphragm (9) and plate (10). 7. Remove two screws (11) and throttle plate (12). ie. Oe easy 7-124ENGINE DISASSEMBLY AND ASSEMBLY CARBURETOR 8. Remove throttle lever (13), lever stop and shaft as a unit, 9. Remove retaining rings (14) and seals (15) from each side of throttle housing. 10, Remove bearing (17) from each side of throttle housing. 11, Remove idle mixture screw (18) and spring (16) from housing. ASSEMBLE CARBURETOR 1266-16 Tools Needed 1P510___Driver Group, 1 1, Install bearing (1) with tooling (A) to the bot- tom of the bearing bore in the throttle housing. 2. Put seal (2) in position in the seal and retainer ‘counterbore. 3. Install retainer (3) with tooling (A). 4, Turn throttle housing over and do Steps 1 through 3. 5. Install spring (5) and idle screw (4). Turn the idle screw four full turns open from the closed position. 7-122ENGINE DISASSEMBLY AND ASSEMBLY CARBURETOR e CAUTION Be careful when the throttle shaft is installed not to cause damage to the seals. 6. Install throttle lever (6), lever stop and shaft, 7. Put throttle plate (7) in position on the throttle shaft, Install the screws that hold the throttle plate in position finger tight. 8, Turn the throttle plate with throttle lever (6) from the fully closed to fully open position to make an alignment of the throttle plate in the center of the bore. Tighten the serews and make sure that the throttle lever turns freely. 9. Install the diaphragm assembly together in the following sequence: body (8), gasket (9), dia- phragm (10) and cover (11), Install four serews F 10. Put diaphragm assembly (12) in position on © carburetor body. Install spring (13) on dia- phragm assembly. sasaesx Turn power mixture adjustment (14) to center position between “R" (rich) and “L” (lean). 12. Put cover (15) in position on carburetor body and install the five screws to hold cover in posi tion. 13, Install carburetor assembly (16) in position on nipple. Make an alignment of the marks on the elbow nipple and carburetor assembly. end by: a) install carburetor Hietts, We 7-123ENGINE DISASSEMBLY AND ASSEMBLY TURBOCHARGER REGULATOR ASSEMBLY REMOVE TURBOCHARGER REGULATOR ASSEMBLY 1052-11 NOTE: Left hand turbocharger regulator assembly removal is shown, M 1. Disconnect tube assembly (1) from regulator assembly. 2. Remove four nuts (2) and regulator assembly (3) from turbocharger. 3. Remove shield (4) from turbocharger. 4. Remove gasket (5) from turbocharger. INSTALL TURBOCHARGER REGULATOR ASSEMBLY 1052-12 1, Put gasket (2) and shield (1) in position on turbocharger. 2. Put regulator assembly (3) in position and in- stall four nuts. Connect tube assembly (4) to regulator. 7124ENGINE TURBOCHARGER REGULATOR ASSEMBLY DISASSEMBLE AND ASSEMBLE TURBOCHARGER REGULATOR ASSEMBLY 4076-10 start by: a) remove turbocharger regulator assembly Remove breather assembly (1) from cover. NOTE; Put identification on the two bolts used to fasten identification plate (3) for installation pur- poses, 2 3 10. Remove plate and five bolts (2) from assembly. Remove cover (4), shims (5), spacers (6) and spring (7) from base assembly. Remove nut (8) to disassemble base assembly. . Remove retainer (12), diaphragm (11), plate (10), washer (15) and valve (13) from base (4). Inspect gasket (9) on the base and make a replacement if damaged. . Put valve (13) in position in base and install washer (15), plate (10), diaphragm (11), re- tainer (12) and nut (8). Tighten nut toa torque of 55 S Ib.in. (6.3 + 2.3 Nem). . Put spring (7), spacers (6), shims (5) and cover (4) in position on the base assembly and install five bolts in their correct location. Tighten bolts toa torque of $5 + 5 Ib.in. (6.3 + 2.3 Nom). Install identification plate (3). Install breather assembly (1). end by: 4) install turbocharger regulator assembly DISASSEMBLY AND ASSEMBLY omer e2manixt 7-125ENGINE DISASSEMBLY AND ASSEMBLY TURBOCHARGER REMOVE AND INSTALL mh TURBOCHARGER 1052-10 Tools Nooded x o SPR796__ Bracket Link 1 start by: ox. a) remove air cleaner 1, Disconnect tube assembly (1) from regulator soeesixt and tube assembly (2) from cartridge housing, 2. Remove clamp (3) and gasket from elbow and aftercooler housing. 3. Bend tab on lock and remove two bolts (4) that fasten oil supply line (5) to cartridge housing. Remove bolt (7) and clip from bracket. Discon- nect coupling on opposite end of tube assembly so tube can be turned for turbocharger remov- al. 4, Remove two bolts from the turbocharger drain tube (6). Remove supply and drain line gaskets. 5. Install a hoist and tool (A) on turbocharger. Remove four bolts (9) and gasket from elbow. Remove turbocharger (8). 6. Put a new gasket (10) and turbocharger in position on the engine and install gasket and clamp (3). 7. Put 5P3931 Anti-Seize Compound on the threads of four bolts (9). Install the bolts (9) and tighten to a torque of 40 + 4 Ib.ft. (55 + 5 N-m). 8. Remove hoist and tool (A) and install new gas- kets and the turbocharger supply (5) and drain (6) line, Install clip and bolt (7) on bracket. 9. Install tube assemblies (1) and (2) respectively to the regulator and cartridge housing. end by: a) install air cleaner 7-126ENGINE DISASSEMBLY AND ASSEMBLY TURBOCHARGER (SCHWITZER 4MD455) @ DISASSEMBLE TURBOCHARGER — 1052-15 - eee __— a e Tools Needed ABCDEF Q ‘956365 Turbocharaer Fixture Group e @—8 “i out “iP 1853 P1860 start by: | a) remove turbocharger | 1. Put the turbocharger in position on tool (A). Remove hose (1) and elbow (2) from compres- sor housing 3. Remove four nuts (5), regulator assembly (4), | shield (3) and gasket from turbine housing /e@ | 4, Put identification on compressor housing (6), cartridge assembly (7) and turbine housing (8) for installation purposes. | 5. Remove “V” clamp (9) and compressor hous- | ing (6) from cartridge assembly (7). | 6. Remove “V" clamp (10) and cartridge assem- bly (7) from turbine housing (8). | 7. Remove nozzle (11) from turbine housing. 1828405%1 7-127ENGINE DISASSEMBLY AND ASSEMBLY TURBOCHARGER (SCHWITZER 4MD455) CAUTION When the nut is loosened, do not put a force on the shaft. 8. Put cartridge assembly (7) in tool (B). Loosen aut on compressor wheel (12) with tool (C). 9, Remove compressor wheel (12) from wheel and shaft assembly with press. Remove nut and wheel and shaft assembly. 10. Remove two rings (14) from wheel and shaft assembly (13). 11. Remove shims (15) and snap ring (17) with tool (D). Remove insert (16) from housing. w2aatoxt 12, Remove sleeve (18) from insert (16). Bavaraxt 7-128ENGINE DISASSEMBLY AND ASSEMBLY TURBOCHARGER (SCHWITZER 4MD455) 13. Remove two seal rings (19) from sleeve (18) 14, Bend tab on three locks and remove bolts (20). o_-@, asaya 15, Remove deflector (22) and ring (21) from housing. 16. Remove spacer (24) and bearing (23) from housing. : 17. Remove ring (26) and spacer (25). 18, Remove bearing (27) from housing. fasion scare saannxt 7129ENGINE, DISASSEMBLY AND ASSEMBLY TURBOCHARGER (SCHWITZER 4MD455) 19, Remove snap rings (28) with tool (E). 20, Remove bearing (31), sleeve (30) and snap ring (29) with tool (E) from cartridge housing. nO 21. Remove seal (32) from cartridge housing if damaged of worn. enero 22. Remove snap ring (34) with tool (F). Remove werent plate (33) from housing. 7-130TURBOCHARGER (SCHWITZER 4MD455) DISASSEMBLY AND ASSEMBLY 7-131ENGINE DISASSEMBLY AND ASSEMBLY TURBOCHARGER (SCHWITZER 4MD455) ASSEMBLE TURBOCHARGER 1052-16 Tools Needed ABCDEF W186 Pers _ tO 1P1853 Phere: 7 986943 Fixture Assombiy (P1862 Piers: _ 1 852328 Dial Test indicator Group 1 ‘986363 Turbocharger Fixture Group 1 1. Make sure all oil passages are open and clean. Put clean engine oil on all parts before assem- bly. 2, Put plate (1) in position on cartridge housing and install snap ring with tool (A) to hold plate to housing, 3. Install seal (2) in cartridge housing. 4. Install snap ring in housing with tool (B). In- stall sleeve (3) and bearing (4) in housing. In- stall additional snap ring with tool (B). 5. Put wheel and shaft assembly (5) in tool (C), 6. Put 6V20SS High Vacuum Grease in groove for seal rings (6). Make sure the grease fills the groove approximately one half or more of the groove depth for the complete circumference of the groove to help make a carbon dam under the seal ring, Install two rings (6) on the wheel and shaft assembly 7. Before cartridge installation install snap ring in housing with tool (B). Install cartridge housing (7) on wheel and shaft assembly. 1 omens 7-132 \ exesENGINE DISASSEMBLY AND ASSEMBLY TURBOCHARGER (SCHWITZER 4MD455) @ 8, Install bearing (8) on shaft. 9, Install spacer (9) and ring (10) on shaft. 10, Install bearing (11) and spacer (12) on top of ring 11. Put ring and deflector (13) in place and install three locks and bolts (14). Tighten bolts to a torque of 60 Ib.in. (6.7 Nem). Bend tabs on locks. 12. Install two seal rings on sleeve (16). Install sleeve in insert (15). e 244aext 7-133ENGINE DISASSEMBLY AND ASSEMBLY TURBOCHARGER (SCHWITZER 4MD455) 13. Install insert (15) in the housing and install snap ring (18) with tool (D). Install shims (17) as needed to get .018 to .022 in. (0.457 t0 0.559 mm) clearance between the housing and the impeller. 14, Install compressor wheel (19) on shaft. CAUTION When nut is tightened, do not put a side force on the shaft. 15, Put clean engine oil on the threads of the shaft. Install the nut (20) and tighten toa torque of 33, + 2ibét. (45 + 3 Nem). 16, Put the cartridge housing in a vise. Check the shaft end play with tool (E). The end play must be .004 to .006 in. (0.10 to 0.15 mm). Maxi- mum end play with worn parts is 008 in. (0.203, mm). 17, Install turbine housing (22) on tooling (F). Put nozzle (21) in position in turbine housing. s52uaz0x 7-13420, 21 22, DISASSEMBLY AND ASSEMBLY TURBOCHARGER (SCHWITZER 4MD455) Put cartridge assembly (23) in position in the turbine housing (22), Make an alignment of the mark put on at disassembly. Put 5P3931 Anti- Seize Compound on the threads of the “V” clamp. Install “V” clamp (24) and tighten the bolt toa torque of 10 + 1 Ib.ft. (14 + 1 Nem). . Install compressor housing (25) on the car- tridge assembly. Make an alignment of the marks on the compressor housing and the car- tridge. Install “V" clamp (26) and tighten the bolt toa torque of 10 + 1 Ib.ft. (14 & 1 Nem). it (tap) both “V” clamps completely around and tighten again to a torque of 10 + 1 Ib.ft. (4 +1 Nm). Put an application of 5P3931 Anti-Seize Com- pound on bolt threads and in the regulator as- sembly bore. Install gasket, shield (27) and regulator assembly (28) in position in the tur- bine housing. Install elbow (30) and hose (29) on compressor housing. end by: a) install turbocharger 7-135ENGINE, DISASSEMBLY AND ASSEMBLY SPARK PLUGS REMOVE SPARK PLUGS. 1415-11 _ Tools Needed a P7424 ___ Spark Plug Socket 7 1, Remove wire assemblies (1) from the spark plugs and adapter. 2. Use tool (A) to remove spark plugs (2). INSTALL SPARK PLUGS 1415-12 ‘Tools Neoded = TAPT424__ Spark Plug Socket at 1. Use tool (A) to install spark plugs (1). Tighten the spark plugs to a torque of 26 + 4 Ib.ft. (36 + 5.Nm). 2. Install the spark plug wire assemblies (2). Make sure the cover makes a good connection with the spark plug. 7-136ENGINE DISASSEMBLY AND ASSEMBLY SPARK PLUG ADAPTERS e REMOVE AND INSTALL SPARK PLUG ADAPTERS 1114-10 gr a 0S eareer start by: a) remove spark plugs 1. Drain the coolant from the cooling system to a level below the cylinder head. 2. Use tool (A) to remove spark plug adapters (2). e 3. Remove adapter gasket (1) from the c head. 4, Install a new seal (3) and gasket (1) on each of the spark plug adapters. Put liquid soap on the seal and in the bore of the cylinder head. Put ‘SP3931 Anti- Seize Compound on the threads of the spark plug adapters. 5. Install the spark plug adapters in the cylinder head. Use tool (A) to tighten the adapters to a torque of 150 + 10 Ib.ft. (205 + 14 N-m). ea7aayxt 6. Fill the cooling system with coolant to the cor- rect level e end by: a) install spark plugs 7-137DISASSEMBLY AND ASSEMBLY AFTERCOOLER HOUSING REMOVE AFTERCOOLER HOUSING start by: a) remove air cleaners 1063-11 1. Remove the coolant from the engine. Discon- nect regulator tube assembly (2) from fitting. 2, Loosen clamps (3) on tube assembly (1) and elbow. Remove tube assembly (1) and gasket from aftercooler and carburetor. 3. Disconnect tube assembly (5) from fitting. Loosen clamp (4) and remove tube (6) and gasket from aftercooler and carburetor. 4, Loosen clamp (7) on aftercooler elbow, 5. Remove four bolts (8) and make a separation of the auxiliary water pump elbow and after- cooler. Remove ten bolts (9) that fasten the aftercooler to the flywheel housing, 6, Disconnect tube assembly (12) from the turbo- charger lubrication valve. 7, Remove elbow (10) from turbocharger. 8. Remove four bolts (11) to remove the turbo- charger lubrication valve from the channel, 9. Remove bolt and brackets (16) from after cooler housing. Disconnect and remove tube assemblies (14) and (17) from regulator assem- blies. 10. Disconnect tube (15) from turbocharger car- tridge housing. 11, Bend tabs on lock and remove two bolts (13) from the turbocharger supply line. 7-138 seme)ENGINE DISASSEMBLY AND ASSEMBLY AFTERCOOLER HOUSING 12. Disconnect turbocharger cartridge housing tubes (20) from cover. Remove four bolts (18) that are used to fasten turbocharger pipe to support. 13. Remove six bolts (21) that are used to fasten the support assembly in position. Remove sup- port assembly (19). NOTE: The cover is removed for access to bolts that fasten the aftercooler to the flywheel housing. 14, Remove four bolts (22) from the cover. Re- move cover (23). 15, Remove bolt (24) and clip from channel. Re- move tube assembly (12). 16. Fasten nylon straps and hoist to aftercooler (25). 17. Remove six bolts (26) that fasten the after- cooler to the flywheel housing. 18. Remove aftercooler from engine. Weight of aftercooler is 236 Ib. (106 kg). 7-139ENGINE DISASSEMBLY AND ASSEMBLY AFTERCOOLER HOUSING INSTALL AFTERCOOLER HOUSING 1064-12 1. Fasten nylon straps and a hoist and put after- cooler housing (1) and gasket in position on , engine. Install sixteen bolts (2) that hold the after- cooler housing to the flywheel housing, 3. Put tube assembly (3) in position on channel and install bolt through clamp. 4. Put gasket and cover (4) in place and install four bolts. 5. Install six bolts to fasten support assembly (7) in position, 6. Install four bolts ¢o fasten pipe (5) to support. 7. Install two tube assemblies (6) from turbo- charger cartridge housings to cover (4). 7-140AFTERCOOLER HOUSING 8, Install tube assemblies (8) and (11) to the reg- ulator assemblies, Install bolt to hold brackets (10) in position on aftercooler housing, Put ‘gasket and oil supply line (9) in position on top of turbocharger cartridge housing. Install lock and two bolts in position, 9. Install turbocharger lubrication valve in posi- tion on channel. Install four bolts (13) and nuts to hold valve in position. 10, Install tube assembly (15) in position on the turbocharger lubrication valve. 11, Inspect and make a replacement of seals on pipe if damaged. 12. Put engine oil in turbocharger bore and install elbow assembly (12) and gasket in position in turbocharger and aftercooler housing. Install clamp (14) to hold elbow to housing, 13, Install tube assembly and gasket (17) in posi- tion on the aftercooler housing. Install clamp (18). Install tube assembly (16) to elbow fit- ting. 14, Put elbow (21) and tube assembly (20) in posi: tion on the aftercooler housing and install gas- kets and clamps (22) to hold them in position. Install tube assembly (19) to elbow fitting, 15, Install a new gasket and the auxiliary water pump elbow (23) in position on the aftercooler housing. end by: a) install air cleaners DISASSEMBLY AND ASSEMBLY 828000 7141ENGINE DISASSEMBLY AND ASSEMBLY AFTERCOOLER CORES REMOVE AFTERCOOLER CORES 1064-11 start by: a) remove aftercooler housing 1. Remove bolts and channels (1) from after- cooler housing. Remove boits that hold pipe and elbow to aftercooler housing. Remove pipe (2) and elbow (3). Remove the bolts that hold housing together. 2: Remove the top housing, 3. Remove sleeves (4) from the cores. 4. Fasten a hoist to the cores and remove the cores from bottom housing. Weight of each core is 75, Ib. (34 kg). INSTALL AFTERCOOLER CORES 1064-12 1. Fasten a hoist and put the cores (1) in position in bottom housing 2. Install the top housing. 3. Put clean engine oil in bores for sleeves. Install - x04) sleeves in housings. Install bolts that hold hous- ings together and tighten as follows: a) Tighten three bolts in the center of the housing. b) Tighten the flange bolts at the front and rear. c) Tighten the flange bolts at the sides. 4, Install pipe (2) on top housing and elbow on bottom housing. 5, Install channels (3) on aftercooler housing. end by: a) install aftercooler housing e30zexe 7-142ENGINE DISASSEMBLY AND ASSEMBLY ELECTRIC STARTING MOTORS @ rcsove srecrme srantme —— motons sass 1, Disconnect wires from the starting motor and the solenoid, 2. Put identification on wires and terminals for installation. 3. Fasten a hoist to starter. Remove the three bolts (1) that hold starter to the flywheel housing. Remove the electric starter. Weight rms is 80 Ib. (36 ke). INSTALL ELECTRIC STARTING MOTORS 1453-12 1. Fasten a hoist and put the starting motor on engine. Install the three bolts. 2. Connect the wires to starting motor and to i @ solenoid. * ‘TYPICAL EXAMPLE 7-143ENGINE DISASSEMBLY AND ASSEMBLY FLYWHEEL REMOVE FLYWHEEL 1156-11 Tools Needed x FT1004 Lifting Bracket =a 1. Remove cover (1) from flywheel housing. 2. Remove pointer (2) from flywheel housing. 3. Remove two bolts (3) that hold the flywheel in position on crankshaft. Install two 7/8"-14 NF 8 in, long bolts as a guide on G379 and G398. ‘On G399 only use two 1”=14 NF x 10” long bolts as a guide. 4, Install tool (A) on flywheel. Install a hoist and an approved lifting bracket on tool (A). Re- move the remainder of the bolts that hold the flywheel to the crankshaft. 5. Remove the flywheel. For G379 and G398 the ‘weight of the flywheel is 450 Ib. (203 kg). For G399 only the weight of flywheel is 550 1b. (248, kg).ENGINE DISASSEMBLY AND ASSEMBLY FLYWHEEL e INSTALL FLYWHEEL 1156-12 Tess Needed Citing Bracket Zi 1. For G379 and G398, install two 7/8”-14 NF x 8 in, Long bolts (1) as a guide in the crankshaft. ‘On G399 only, Install two 1”=14 NF x 10 in. long bolts as a’ guide. 2. Use a hoist, an approved lifting bracket and tooling (A) to put the flywheel (1) in position on crankshaft, 3. Install the bolts that hold flywheel to crank- shaft. Tighten bolts on G379, G398 to a torque of 450 = 30 Ib.ft. (610 + 40 N-m). On G399 only, tighten bolts toa torque of 670 + $0 Ib.ft. (905 + 70 N.m), 4. Remove tooling (A) from flywheel e 5. Install pointer (2) in flywheel housing. Install cover (3) on flywheel housing. 7145ENGINE DISASSEMBLY AND ASSEMBLY FLYWHEEL HOUSING REMOVE AND INSTALL FLYWHEEL HOUSING 1157-10 Toots Needed = ‘PO7S6 __ BracketLink 2 10. 12. a) remove aftercooler housing b) remove flywheel ©) remove oil pressure relief valve Remove three bolts (1) from tube flange. . Loosen bolts (2) that hold cylinder block to oil pan base. Remove rear crankshaft thrower and baffle (3). See CRANKSHAFT REAR SEAL, RING AND THROWER. Fasten a hoist and lift engine enough to install spacers (3) on each side of oil pan base. Ap- proximate weight of G379 is 8,000 Ib. (3600 kg); G398 is 10,000 Ib. (4500 kg); G399 is 13,000 Ib. (5850 kg). . Remove two bolts from flywheel housing. In- stall two 5/8”-11 NC bolts 6” long as a guide. Install tooling (A) on top of flywheel housing. Remove bolts (4), support assembly and cover from the top of flywheel housing. . Remove the remainder of the flywheel housing bolts (6) and flywheel housing (7). Weight of housing is 450 Ib. (204 kg). Put 7M7260 Liquid Gasket Material on top of, the housing surface that makes contact with governor drive housing, Install bolts (4) to hold cover and support assembly. Install tool (A) and hoist on flywheel housing. Put it in position on the cylinder block and install bolts (6). Install thrower. See CRANKSHAFT REAR SEAL AND THROWER. ._ Fasten a hoist to engine. Lift the engine enough to remove the spacers (5). Tighten bolts. Install three bolts to install tube flange (1) to Rywheel housing, end by: a) install flywheel ») install aftercooler housing ¢) install oil pressure relief valve 7-146 T deat TF se |ENGINE DISASSEMBLY AND ASSEMBLY CRANKSHAFT REAR SEAL RING AND THROWER | e REMOVE CRANKSHAFT REAR SEAL RING AND THROWER, 1161-11 aaresi Ss start by: a) remove flywheel 1, Remove twelve bolts (1) that hold baffle to flywheel housing, Remove baffle (2) from housing. 3. Remove the seal ring and spring from thrower, 4, Install tooling (A) on thrower. If necessary use heat on the outer diameter of thrower with an e open flame at a maximum temperature of 400° F (204°C). Remove the thrower imme- diately with tooling (A), 5. Remove the ring from flywheel housing. INSTALL CRANKSHAFT REAR SEAL RING AND THROWER 1161-12 Tools Neoded * Push Pi Bot 1 Quick Cure Primer and 983265 ing Compound on ring. Install the ring in flywheel housing with holes at the bottom and with chamfer toward inside of housing 2. Heat the thrower (1) to a maximum tempera- e ture of 400 - 450°F (204 - 232°C), Install, thrower on crankshaft,ENGINE DISASSEMBLY AND ASSEMBLY CRANKSHAFT REAR SEAL RING AND THROWER 3. Use tooling (A) to install thrower in correct wi i ty location on crankshaft. CAUTION Do not install a used oil thrower, seal ring or spring. 4. With the thrower at room temperature, put 6V2055 High Vacuum Grease in the groove for the seal ring at assembly one half or more of the depth of the groove. 5. Install the spring and seal ring (2) on thrower with the word “OUT” on the seal ring installed away from the crankshaft. Put the gap of seal ring to top of crankshaft when installed 6. Put clean engine oil on inside diameter of baffle (3). Install the baffle (3) on the flywhee! hous- ing. end by a) install flywheel 7-148ENGINE DISASSEMBLY AND ASSEMBLY REAR TIMING GEARS e REMOVE REAR TIMING GEARS 1206-D-11 + P2922 Puller Assembly 7 P4170 Step Plate 67548 Puller Ascombly ‘BHEE4 Ratchet Box Wrench 7 ‘B7EE9 Adaptors 2 eB7S50 Leo se “Tra Spacer aaaanae nome start by. a) remove flywheel housing 1, Be sure the No. 1 piston is at top center on the compression stroke. See TIMING THE CAM- SHAFT FOR THE FUEL INJECTION PUMPS in TESTING AND ADJUSTING. e 2. On G379 only, remove the seal ring (1) and spring from thrower. 3. Install tooling (A) on thrower. If necessary use heat on the outer diameter of thrower with an open flame at a maximum temperature of 400°F (204°C). Remove the thrower (2) im- mediately with tooling (A). 4. Bend the tabs on locks and remove bolts (3) that hold the large camshaft gear to small cam- shaft gear. Remove gear (4). CAUTION Do not turn the crankshaft with large camshaft gear removed and the camshaft installed. @ 5. Remove bolts (6) and lock that hold the thrust washer (5) to the camshaft. 7-149ENGINE DISASSEMBLY AND ASSEMBLY REAR TIMING GEARS 6. Turn gear (8) for bolt access and remove bolts and lock that hold washer assembly to the cyl- inder block. Remove washer assembly (7). 7. Remove camshaft gear (8) from camshaft with tooling (B). 8, Remove bolts, lock and retainer that hold the balancer gear on its shaft. Remove rear ba- lancer gear (9). Remove bearing from balancer gear. 9, Remove thrust washer (10) on the balancer gear shaft. 7-150REAR TIMING GEARS INSTALL REAR TIMING GEARS —1206-D-12 ‘Toots Needed x 1510 Driver Group 7 FTI0s Push Plate Tes Bot 2 TD 1. On G379 only, use tooling (A) to install the bearing in balancer gear. NOTE: Be sure No. | piston is at top center on the compression stroke. See TIMING THE CAM- SHAFT FOR THE FUEL INJECTION PUMPS in TESTING AND ADJUSTING. 2. Install thrust washer (1) and balancer gear (2) on shaft 3. Install small camshaft gear (3), washer assem- bly (4), lock and bolts. Install retainer. Tighten bolts to a torque of 60 to 70 Ib.ft. (80 to 95 Nem). 4, Put a mark with chalk on the camshaft gear at the location of timing mark “C”. Put a mark with chalk on the tooth of crankshaft gear with punch marks. The back of gears can be marked so the marks can be seen with a mirror (5) after installation. DISASSEMBLY AND ASSEMBLY T-ASIENGINE DISASSEMBLY AND ASSEMBLY REAR TIMING GEARS 5. Install large camshaft gear (6). Be sure the “C” mark on gear is in alignment with punch mark on crankshaft gear. On G379 only, move large camshaft gear out enough to turn the balancer ‘gear until “A” marks are in alignment. 6. Put large camshaft gear in position on the dowel on small camshaft gear. Install locks and bolts. 7. Heat thrower (7) to a maximum temperature of 400 - 450° F (204 - 232°C). Install thrower (1) on crankshaft. 8. Use tooling (B) to install thrower in correct, location on crankshaft, CAUTION 9. With the thrower at room temperature, put 6¥2055 High Vacuum Grease in the groove for the seal ring at assembly one half or more of the depth of the groove, 10. Install the spring and seal ring (8) on thrower with the word “OUT” on the seal ring installed away from the crankshaft. Put the gap of seal ring to top of crankshaft when installed, end by a) install flywheel housing 7-152ENGINE DISASSEMBLY AND ASSEMBLY VIBRATION DAMPER (G398 AND G399) @ REMOVE VIBRATION DAMPER (398 & G399) 1205-11 1, On G398, remove bolts (1). Put an identifica- tion mark on bolts (3) and (4) and housing. Remove cover (2), On G399, remove bolts that hold the cover. Remove the cover. 3. On G398, remove the bolts that hold vibration damper, Install two $P9736 Bracket-Links on the vibration damper. Fasten a hoist. 4, On G399, remove the bolts that hold vibration damper. Install two bolts (6) as a guide. Move the vibration damper out on the guide bolts with forcing screws (5). Fasten a hoist_and remove vibration damper. Weight of G399 damper is 270 Ib. (122 kg) and the G398 is 130 Ib. (59 kg). CAUTION Do not hit the vibration damper. INSTALL VIBRATION DAMPER (G398 & G399) 1208-12 1. Install two bolts as guide. Fasten a hoist to the vibration damper. Put the damper in position on the adapter. Put 953263 Thread Lock on the threads of bolts for vibration damper. Put thread lock on the two bolts with a mark for cover on the 6398, 3. Install the bolts and remove guide bolts. Tighten 1 in. bolts (1) to 670 + 50Ib.ft, (905 + 70 N-m) on G399. Tighten bolts (1) on G398 to 280 + 20 Ib.ft. (377 + 25 N-m). G398 with bolts that have a mark in respective | e 4, Install cover (2) on G399. Install cover on | place on housing | | | 7-183ENGINE DISASSEMBLY AND ASSEMBLY CAMSHAFT REMOVE CAMSHAFT 1210-11 “Tools Needed a6 FT751. Camshaft Alignment Tool 1 807548 Puller Assombly 1 867550 Leg 2 8F3672. Puller Powe 1 79540 Hydraulic Puller 1 486280 Washer 2 11329 _ ott 2 start by: a) remove fuel injection pump housing, shut- off control, governor and governor drive as a unit b) remove flywheel housing ) remove vibration damper (G399 only) 1. Loosen the adjustment screws for valves to get maximum clearance. 2, Remove the push rods. 3. Disconnect the oil lines (1) from lifter brackets (3). 4, Use a magnet and pull the lifters (2) up enough to put rubber bands or wire on them. This will hold lifters away from cam- shaft. 5. Remove housing for vibration damper, if so equipped, Remove power takeoff, if so equipped, 6. Remove the service meter and tachometer drive from front of engine. Install the align- ment tool (A). 7. Remove the large camshaft gear (4). Remove the bolts and locks that hold thrust washer (). 8, If small camshaft gear (6) is to be removed, bend the lock and remove the two bolts and plate from the end of the camshaft 7154ENGINE DISASSEMBLY AND ASSEMBLY CAMSHAFT 9. Use tools (B) to remove the small camshaft gear (6) from the camshaft 10, Remove the camshaft. Weight of the cam- shaft is approximately: G379 Engine 60 th. (27 ke) G398 Engine .. 85 Ib, (39 ke) 399 Engine 100 Ib. (45 kg) INSTALL CAMSHAFT 1210-12 "Toole Needed Fs shalt Aligoment Toot 1. Put the key and small camshaft gear on the camshaft. Put clean engine oil on camshaft. NOTE: On SAE standard rotation engines, (counterclockwise as viewed from flywheel end) stall the small camshaft gear on the end opposite the F-mark on camshaft. For SAE opposite rota- tion engines (clockwise as viewed from flywheel end) install this gear on end with the F-mark. 2. Install the plate, lock, and bolts that hold small gear on camshaft. Tighten bolts to 60 to 70 Ib. ft. (80 to 95 Nem). Install alignment tool (A) on end of camshaft. Install camshaft in engine 3. Install the thrust washer, locks, and bolts that hold small camshaft gear in cylinder block NOTE: Be sure the crankshaft is in position with No. | piston at top center on compression stroke, 4, Put a mark with chalk on “C” mark of gear (2) and tooth of erankshaft gear with punch marks. Put a mark on back of gears so they can be checked with a mirror after installation. Put the large gear (1) on small camshaft gear. Be sure “C” mark and punch mark of crankshaft gear are in alignment. On G379 move gear (1) ‘out enough to turn balancer gear to make “A” marks in alignment. ¢ | neteet TOOLS (B) FOR REMOVING SMALL CAMSHAFT GEARENGINE DISASSEMBLY AND ASSEMBLY CAMSHAFT 5, Remove the alignment tool (A) from front of camshaft. Install the service meter and tachometer drive. Install housing for vibra~ tion damper or power takeoff if so equipped, 6, Remove rubber bands or wires from lifters. Install the push rods (4). Connect the oil ines (3) for rocker shaft assemblies. 7. Make adjustment of valve clearance. The cold clearance must be: intake .015 in. (0.38 mm) and exhaust .035 in. (0.89 mm). See VALVE CLEARANCE ADJUSTMENT in TESTING AND ADJUSTING. end by a) install flywheel housing ») install fuel injection pump housing, shutoff control, governor and governor drive as a unit

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