® — SENBE106- 3-02 CATERPILLAR See Disassemloly Assemloly 1404 EngineImportant Safety Information Most accidents involving product operation, maintenance and repair are caused by failure to observe basic salety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations belote an accident occurs. A person must be alert to potential hazards, This person should also have the necessary training, skils and tools to perform these functions properly Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate of perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Satety precautions and warhings are provided in this manual and on the product. these hazard warnings are not heeded, bodly injury or death could occur to you or olher persons. ‘The hazards are (denied by the "Safely Alert Symbol” and followed by a “Signal Word" such as WARNING’ as shown below. The meaning of this safety alert symbol is as folows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning, explaining the hazard, can be either wntten or pictonally presented Operations that may cause product damage are identified by NOTICE labels on the product aid in this publication. Caterpilar cannot anticipate every possible circumstance thal might involve a potential hazard. The warnings in this publication and on the product are therefore not all inclusive. If a tool, procedure, work ‘method ar operating technique not specifically recommended by Caterpilar is used, you must satisfy yourself that itis safe for you and others. You should also ensure thal the product will nat be damaged ‘or made unsafe by the operation, lubicatan, maintenance oF repair procedures you choose. The information, specifications, and ilustrations jn this publication are on the basis of information available al the time it was wnitten, The specifications, torques, pressures, measurements, adjustmer iiustrations, and other tems can change at any time, These changes can affect the service gwen to the product, Obtain the complete and most current information before staring any job. Calerpilar dealers have the most current information avaiable, For a list of the most current publication form numbers avaiable, see the Service Manual Contents Microliche, REG! 139FIndex Accessory Drive Accessory Drive, Disassemble & Assemble Air Cleaner ‘Alternator Earlier) Alternator (Later) Camshaft Camshaft Bearings Carburetor (Qual Fuel) Carburetor (Gas - Earlier) Carburetor Gas (Later) Carburetor Gas (Later), Disassemble & Assembie Carburetor, Disassemble & Assemble Coil Connecting Rod Bearings Crankshaft Crankshaft Front Seal Crankshaft Main Bearings Crankshaft Rear Seal Cylinder Head Assembly Distributor (Distributor Type Engines Oniy) Distributor, Disassemble & Assemble Electric Fuel Pump (Dual Fuel) Electric Starting Motor (Earlier) Electric Starting Motor (Later) Fan Fan Belt (Later) Fan Belts (Earlier) Flywhee! Flywhee! Housing Flywhee! Housing Seal Flywhee! Ring Gear Front Housing Fuel Filter & Fuel Pump Fuclock & Filter Earlier - Dual Fuel) Governor (DIS type engines only) Governor (Earlion) Governor (Later) Ignition Module & Ignition Coit Ignition Timing Sensor (DIS Type Engines Only) Inlet & Exhaust Manifolds. LP Fuolock & LP Gas Converter (Dual Fuel) LP Fuelock (Earlier), Disassembe & Assemble LP Gas Carburetor & Gas Converter (Earlicr) LP Gas Carburetor (Earlier), Disassemble & Assemble LP Gas Carturetor (Later) LP Gas Carburetor (Later), Disassemble & ‘Assemble LP Gas Convertor (Dual Fuc)), Disassemble & Assemble BEELELSSSISBS oanay 44 84 56 55 90 93. 92 79 12 42 78 78 7 " 1 18 47 28 22 23. a 48 LP Gas Converter (Earlir), Disassemble & Assemble LP Gas Converter (Later) LLP Gas Fuelock (Later) LP Mixer Assembly (Dual Fuel) LP Mixer Assembly, Disassemble & Assemble Muttler il Filter & Adaptor il Level Switch Oil Pan il Pump Pistons & Connecting Rods Pistons & Connecting Rods, Disassembie & ‘Assemble Radiator (Earlier) Radiator (Later) Rocker Shaft Assembly & Push Rods Rocker Shaft Assembly, Disassemble & Assemble Timing Gears Valve Cover Valve Lifters Valve Seat Inserts Valves Water Pump (Earlier) Water Pump (Later Water Regulator Housing Water Temperature Regulator (Earlier) Water Temperature Regulator (Later) Water Temperature Sensor 25 45 45 4 BRR 65 80 56 64 70 6 59 60 61 57 58 59 Disconnect batteries before performance of any service work. 1404 EngineDisassembly & Assembly Alternator (Earlier) Remove Alternator (Earlier) 1405-011 NOTE: The counterweight is renoved for better photo ilustration, 1. Remove bolt (3) and wire (4). 2. Disconnect wire (1) 3. Pull insulator cover (2) back ‘rom the terminal Remove the nut, washer an wire. ‘4, Remove nut (6) and battery ground wire (8), 5. Remove boll and washer (7) trom the belt tightener bracket. NOTE: Bolt (10) interferes with the radiator and prevents the removal of the allernator from the brackel. 6. Remove two bolts and lockwashers (9) trom the alternator support bracket. Femove alternator (8) ‘and the bracket. 1404 Engine Install Alternator (Earlier) 1405-012 ‘££ 7 Av, NOTE: The counterweight is removed for better photo ilustalion, The alternalor and bracket must be ‘assembled and bot (2) putin position before the alternator is installed 1. Put alternator (1) and the bracket in position, and Install the two lockwashers and bolts that hold the bracket in position, 2. Install washer and bolt (4) that hold the alternator to the belt tightener bracket, 3. Connect wire (3) as shown, 4. Put wire (6) in position, and install the washer and rut that hold it. Tighten the nut to a torcue of 4 + 1 Nem (3 * 1 Ib ft). Put insulator cover (5) in position. 5. Put wire (8) in position, and install bolt (7) that holds Put baltery ground cable @) in position, and install the nut that holds iin postion 7. Adjust the tension of alternator vee belt (10). See Specifications for correct adjustment "Disassembly & AssemblyAlternator (Later) Remove & Install Alternator (Later) 1405-010 NOTE: Hood, seat and dry air cleaner have been removed for photographic purposes, 2. Remove bolt and washer (3), loosen bolt (4) and remove belt 3. Remove bolt and washer (4) and alternator (5), NOTE: For the installation of the alternator, reverse the removal stops, 41404 Engine Electric Starting Motor (Earlier) Remove Electric Starting Motor (Earlier) 1453-011 1. Disconnect two wires (2) and battery cable (1) from the solenoia 2. Remove throe bolts (4). Remove electric starting ‘motor (3) and the gasket from the flywheel housing. Disassembly & AssemblyInstall Electric Starting Motor (Earlier i i 1453-012 6 Motor (Earien Electric Starting Motor (Later) Remove & Install Electric Starting Motor (Later) 1453-010 4. Position the lift Iruck on stands for access underneath, 2. Disconnect the battery As9824P1| k 1. Put the gasket and electric starting motor (1) in Position in the flywheel housing, Install the three bolts that hold itn position, 3, Disconnect wire (1) wire (2) and wire (3) trom the alectric starting motor. 2. Connect two wires (3) and battery cable (2) to the solenoid, 4. Remove two bolts (4) and wire (5). Remove starter ) NOTE: For the installation of the electric starting motor, reverse the removal steps. 1404 Engine 6 Disassembly & AssemblyCoil Remove Coil 1554-011 1. Disconnect five wires (1) from the coll. Put identification marks on the wires for correct installation 2. Remove two bolts and washers (2). Remove coil @) Install Coil 1554-012 Distributor (Distributor Type Engines Only) Remove Distributor (Distributor Engines Only) 1557-011 ag672P 1 1. Disconnect vacuum hose (1) and wires (2) from the distributor to the coil 2. Put identification marks on the distributor cap wires for correct installation. 1. Put coil (1) in position on the engine, instal the two washers and bolts that hold it 2. Connect five wires (2) to the coil. Be suré the wares are connected at the correct locations. 1404 Engine 2 Remove cap (5). Disconnect coll wire (4) and spark plug wires (3). ~~ Disassembly & AssemblyABGESOPt NOTE: Put an alignment mark on the distributor and 3. Install cap (4) and spark plug wires (3) as per the cylinder head assembly to stow the position of rotor identification marks, ©). 4. Remove bolt and washer (8). Remove clamp (9). Remove distributor (7) from the cylinder block, Install Distributor (Distributor Type Engines Only) 1557-012 rt —_ 4. Connect wires (7) and coll wire (6) to the coil 5. Connect vacuum hose (6) to the vacuum advance. 6, Check the ignition timing, See Testing And Adjusting gaes2r 414 Put distributor (1) in positon in the cylinder block, Make sure that rotor (2) is in alignment with the marks on the distributor and the eylinder heat assembly 2. Install the clamp, the washer and the bolt that hold the distributor in position, 1404 Engine 8 Disassembly & AssemblyDisassemble Distributor 1557-015 Start By: a. remove distributor 2. Remove Oring seal (3) ‘aoo4sP) 9. Remove retainer (6), Remove two screws (6) Remove vacuum advance control (4), 1404 Engine cP : so : / ee @— A051) 4, Remove two screws (9). Remove sensor plate assembly (10) 5. Loosen screw (7). Remove bracket (8) and the washer Aate15PY 6. Remove pin (13), retainer (11), the washer and shaft assembly (12) from housing (14) End By: a. install distributor Disassembly & AssemblyAssemble Distributor 1557-016 8. Put vacuum advance control (10) in position, and install the two screws that hold it in position. 1. Check all parts for damage. It any parts are damaged, use new parts for replacement. NOTE: Make sure lever (11) Is over the pin on the sensor plate assembly, 2. Make sure all parts are clean and free of dirt and foreign material 9. install retainer (9) 3. Put shaft assembly (4) in housing (2). 4. Install washer (5) and retainer (1). 5. Install pin (3) ‘ 4 oC! é Bp f~ 4 AS00¢8P1 2 z : in 4 ose? eT 10, install O-ring seal (12) on the shatt. 6. Put the washer and bracket (7) in position, and tighten screw (6) 7. Put sensor plate assembly 8) in position. Install the ‘wo serews that hold it in position. 14. inetall shield (13) and rotor (14), End By: a. instal distributor 1404 Engine 10 Disassembly & AssemblyIgnition Timing Sensor (DIS Type Engines Only) Remove & Install Ignition Timing Sensor (DIS Type Engines Only) 1912-010 4 1. Disconnect wie hares (1), 2. Remove bolt (2), 3. Remove ignition timing sensor (3). NOTE: For the installation of the ignition timing sensor, reverse the removal steps. 4. See Distributorless Ignition System Tests in the Testing and Adjusting Manual, 1404 Engine 1" Ignition Module & Ignition Coil Remove & Install Ignition Module & Ignition Coil 1550-010 ry 41, Mark for identification four wires (1). Disconnect four wes (1), 2, Disconnect wire connections (2) and (3) ~ Disassembly & Assembly3. Remove two bolts, nuts and washers (5). Remove ignition module (6) and remove igniton coll (4), NOTE: For the installation of the ignition module and ignition col, reverse the removal steps Air Cleaner Remove & Install Air Cleaner 1051-010 ry 1, Remove two wing nuts (1). Remove cover (2) the outer element and the gasket 2. Remove six nuts and washers (6). Remove inner clement (3), housing (4) and the gasket. NOTE: For the instalation of the air cleaner, reverse the removal steps. 3. See the Maintenance Guide for cleaning procedures land service replacements of the air cleaner elements, Fuel Filter & Fuel Pump Remove Fuel Filter & Fuel Pump 1261, 1256-011 G ro0050¢ a 41. Loosen nut (1). Remove bow! (3), the element and the spring 2, Disconnect fuel line (2) to the carburetor 1404 Engine Disassembly & Assembly3. Disconnect fue! line (4) from the fuel tank 4. Put element (6), spring (6) and bow (4) in position Tighten nut (7) that holds the bow! in position 4. Remove two bolts (6) and the washers. Remove fuel pump (6) and the gasket. Install Fuel Filter & Fuel Pump 1261, Oil Filter & Adapter 1256-012 Remove Oil Filter & Adapter 1306-011 = ‘Tools Needed [A] ‘2P&BEO Strap Wrench 7 1. Put the gasket and fue! pump (3) in position, Install the two washers and bolts that hold itn position 2. Connect fuel line (2) trom the carburetor. so7e1P1 3. Connect fuel line (1) from the fuel tank. 1, Disconnect four wires (1) 1404 Engine 133, Remove three bolts and washers (8). Remove adapter (4) and gasket, NOTE: Before installation inspect anc replace gaskets, if necessary. NOTE: For the installation of the oil fiter and adapter, reverse the removal steps. 4, Tighten the ol titer to a torque of 70 + 7 Nem (50 +5 1b ty. 5. Fill the engine with ol to the correct level. See the Maintenance Guide, 1404 Engine Muffler Remove & Install Muffler 1062-010 Start By ‘a. remove counterweight Refer to the topic ‘Counterweight in the Power Train ‘Disassembly and Assembly Manual. ASV 763P 14 Remove two nuts and washers (1), 2. Remove the nut, washer and bolt (2) sal 8. Remove two nuts (3). Remove mutiier assembly (4) and the gasket. Tiaassonby & hase4. Put gasket (5) in position on the it truck, 5. Put muffler assembly (4) in position, and install wo, nuts (3) 6. Install the bolt, washer and nut (2) 7, Install two washers and nuts (1) End By: a. install counterweight Reler to the topic ‘Counterweight in the Power Train Disassambly and Assomoly Manual 1404 Engine 15 Inlet & Exhaust Manifolds Remove Inlet & Exhaust Manifolds 1058, 1059-011 Start By a. remove LP gas carburetor and gas converter NOTE: The engine was removed from the lift truck for better photo illustration, 41. Remove bolt (1). Remove LP gas converter bracket Q 2. Disconnect PCV tube assembly (3), and move it away from the inlet manifold. 8. Remove carburetor shield (4). Bee we Pi 4, Remove two bolts (5) and the washers. Remove inlet manitole (6) Disassembly & Assembly\ oe Iq. “6 ‘ * > f = iS, OB oe i ae , ‘AB4903° 1 5. Remove six bolts (7) and the washers. Remove 2. Put inlet manifold (4) in position. install two washers, exhaust manifold (8) and the gaske and. bolts (5) that hold it in position. Install Inlet & Exhaust Manifolds 1058, 1059-012 NOTE: Put 5P3931 Anti-Seize Compound on the exhaust manifold bolts. Tighten the inlet and exhaust manifold bolts at the center frst; then In sequence to the end bolts, 3. Put carburetor shield (8) in position, 4, Install LP gas converter bracket (6) 5. Connect PCV valve tube assembly (7), End By a. install LP gas carburetor and gas converter 1. Put new gasket (1) and exhaust manifold (2) in position. Install six washers and bots (3) that hold it in positon. Tighten bolts (8) toa torque of 50 + 7 Nem (87 £5 bb ft, 1404 Engi 16 Disassembly & AssemblyCarburetor (Gas - Earlier) Remove Carburetor (Gas - Earlier) 1266-011 AEP baer FY 6. Remove carbureto: (11) Install Carburetor (Gas - Earlier) 1266-012 1. Disconnect governor linkage (4) from the carburetor Loosen two screws (3), and remove choke wire (2) 2. Loosen wing bolt (1) and the hose clamp (not shown), Turn the air cleaner elbow assembly away from the carburetor. 1. Put carburetor (1) in position, Install the two ockwashers and ruts that hold it in position, 3, Disconnect spring (5), vacuum hose (6) and fuel line (10). 4. Remove screw (9). Remove solenoid (8) and the bracket 5. Remove Iwo nuts and lockwashers (7). 2. Put solenoid (8) and the bracket in position, Install screw (4), 3. Connect vacuum hose (2) and fuel line (5) to the carburetor. 1404 Engine 7 Disassembly & Assembly44, Put elbow assembly (6) in position on the carburetor, and tighten wing bolt (7) and the hose clamp (not shown), 5. Put choke wire (8) in position, and tighten the two ‘screws thal hold it in position, 6. Connect spring (9) and governor linkage (10) to the carburetor 7. See Testing And Adjusting for carburetor adjustments. Disassemble Carburetor 1266-015 “Tools Neoded a 18525 _ Socket i Start By a. remove carburetor @ AgseaaP} 3. Remove nut (8). Remove throttle linkage (7). 4, Remove four screws (6). asset 5. Remove cover (9) 1, Remove seal (1). Remove screw (2) and choke Cable support (3). 2. Remove Cring (6). Remove the choke idle cam and linkage (4), 1404 Engine 6. Romove screw (11) and the bracket, Remove fast idle cam linkage (10) and the grommet. 7. Remove pump spring assembly (12) Disassembly & Assembly» y ¥ iW 8983791 ©) 8. Romove two scrows (14), Remove coke plate (15). 19, Remove three screws (21), Remove throtle body assembly (22) and the gasket ke 14, Remove two screws (26). Remove throttle plate 9, Remove choke shaft (13) => 10. Remove the spring and the tloal. Turn carburetor (25), Remove thratle lever assembly (27) body (17), and remove weight (16) and the pump check bal 18, Remove fast idle screw (28) and spring (24), 16. Remove air(uel mxture adjusting screw (26) and spring (28). 11. Remove low speed jet (19) and metering rod jet (20) with tool (A. 12, Remove fuel inlet valve (18) 1404 Engine 19 "Disassembly & AssemblyAssemble Carburetor 1266-016 13525 Socket Aae3628P* 1. Check all parts for damage. It any parts are damaged, use new parts for replacement 2, Make sure all parts are clean and free of dirt and foreign material 3, Install air uel mixture adjusting spring (7) and screw (6) in throttle body assembly (6), 4. Install fast idle spring (2) and screw (1). 5. Install throttle lever assembly (4), Put throttle plate (6) in position, and install two screvis (3) A83830P) 6. Put gasket (9) and throttle body assembly (8) in position on carburetor body (10). Install the three ‘screws that Hold it in position, a A83832P1 * -—® 1 oan alba Saha RH aan, , Install ow speed jet (13) and metering rod jet (12) wath tool (A) As385P1 9. Install float (16) and the spring retainer. NOTICE Install the ball and the weight in the correct hole, 10. Install ball (15) and weight (14) in hole (17) 1404 Engine Disassembly & Assembly14. Install choke shaft (20) in cover (19). Put choke plate (18) in position, and install two screws (21) that hold it in position, aggeseP) 12, Put fast idle cam linkage (23) in position, and install grommet (22) on the linkage. 13. Install pump spring assembly (25), 14, Put bracket (24) in position, and install sorew (26) that holds itn position, BE nz anna we 15. Put cover (19) in position on the carburetor body, and incall the four aorows that hold it ia position 1404 Engine Ag3862P* 4 16. Put throtie linkage (27) in position, and instal the ‘ut that holds it in position, peaeasP , a 17. Put choke idle cam and linkage (32) in position, Install Cring (29) 18, Put choke support (31) in position, and install sorew (30). 19, install seal (28). End By: a. install carburetor at Disassembly & AssemblyLP Gas Carburetor And Gas Converter (Earlier) Remove LP Gas Carburetor & Gas Converter (Earlier) 1266 & 1271-011 NOTE: The engine and air cleaner is emoved for better photo jlustration 41. Disconnect vacuum hose (4) from the gas carburetor. 2. Disconnect spring (5) and governor linkage (3) from the gas carburetor. 3. Loosen hose clamps (1), Disconnect hose (2) Disconnect the fuel ine to the fuel lack and the filter 4. Remove two nuts (8) and the washers, 5, Remove nut (9), the washer and the bolt from the bracket 6. Remove bolt (10) and the washer. 7. Remove gas carburetor (6) and gas converter (7) as a.unit. 1404 Engine 22 Ag3935P) 8. Disconnect hose (11) and hose (12) from the gas ccarburelor, Remove gas carburetor (6) from gas converter (7) Install LP Gas Carburetor & Gas Converter (Earlier) 1266 & 1271-012 NOTE: Use P3413 Pipe Sealant with Teflon on the pipe threads, A83934P 1. Connect gas carburetor (2) to gas converter (3) 2, Connect hose (1) and hose (4) to the gas carburetor, ‘Disassembly & AssemblyDisassemble LP Gas Carburetor (Earlier) 1266-015 Start By: a. remove LP gas carburetor and gas converter (earlier) 3. Put new gasket (6), gas carburetor (2) and gas. = ‘converter (3) in position, 4. Install the bolt, washer, nut and the bolt and the washer that hold it in position, 83033) 5. Install the two washers and the nuts that hold the {gas carburetor in position, 1. Remove screws (1), Remove cover (2) 6. Tighten clamp (6), and connect hose (7). Connect the fuel line to the fuel lock and the filter. 2. Remove spring (3). Remove diaphragm assembly 7. Connect governor linkage (8) and spring (10) to the ces ae - carburetor, Connect vacuum hose (9) to the gas. carburetor 8. See Testing And Adjusting to test for leakage and to adjust the carburetor 1404 Engine 28 Disassembly & AssemblyAssemble LP Gas Carburetor (Earlier) 1266-016 ie) ee ABSS70P: of a = «O° 3, Remove screws (5), back-tp plate (6), diaphragm ™" (7) and the air valve ring from the inner carburetor body, 1. Check all parts for damage. Hf any parts are damaged, use new parts for replacement. 2. Make sure all parts are clean and free of dirt and foreign material 3. Put throttie shaft (1) in position in the throttle body, and install stop (2) 4. Put throtte plate (3) in position, and install the two sorews that hold it aga979P? 4. Remove power mixture knob (8), idle mixture screw (9) and the spring. Remove four screws (10) Remove throttle body assenibly (11) and the gasket an AB3O28P 5. Install power mixture knob (6), idle mixture screw (5) and the spring, See Testing And Adjusting for cortect adjustments, 6. Put throttle body assembly (4, and gasket (7) in agse27P) position, Install the four screws that hold it in position 5, Loosen the bolt, and remove stop (14), 6. Remove two screws (12). Remove throttle plate (13), 7. Romove shat assembly (18) from the throttle body, 1404 Engine 24 Disassembly & AssemblyAgi! 7. Put air valve ring (9) diaphragm (10) and back-up plate (11) in position on inner carburetor body (8) Install screws (12) Angos90F 8. Put diaphragm assembly (14) and spring (13) ia position 9. Put cover (16) in position, and install screws (15). 10, See Testing And Adjusting to test the carburetor for leakage, End By: a, install LP gas carburetor and gas converter (earlier) 1404 Engine LP Gas Converter (Earlier) Disassemble LP Gas Converter (Earlier) 1271-015 Start By: ‘a. remove LP gas carburetor and gas converter (earlier) 4. Disconnect hose (1), Remove bolt (3) and the lockwasher. Remove gas converter (2) from the plate. 2. Remove six screws (4). Remove cover assembly (5) from the body, 25 Disassembly & Assembly3. Remove hose (7) and diaphragm (6) from the cover. 6. Remove primary valve pin (13) and primary regulator spring (12). Remove plate (14) and the gasket aaaieeP 4, Remove screw (9), secondary lover (8), the seat, the pin and the spring 7. Remove primary regulator valve (15). Remove elbow and hose (16). Remove tee fiting (17). li 5. Turn the gas converter as shown, Remove screws (11), back cover (10) and the diaphragm, ‘ies tage = Damaaey MebeAssemble LP Gas Converter (Eat 1271-016 j a ee oul Aga318P) wee 6. Put diaphragm (7) and back cover (8) in position. 7. Install screws (6) until they make contact with the 1. Check ail parts for damage. If any parts are cover. Tighten screws thoroughly from one side to damaged, use new parts for replacement. the opposite side unt al he screw have a good seat 2, Make sure all parts are clean and free of dirt and foreign material NOTE: Use 5P3413 Pipe Sealant with Tetion on the pipe threads. 3, Install hose and elbow (1). Install the tee fitting 3 4. Put primary regulator valve (2) in position, 8, Turn the gas converter as shown, Put the spring, the pin, the seat and secondary lever (8) in position. \ % Install screw (10), 5. Put the gasket and plate (6) in position. instal primary regulator spring (3) and primary valve pin 4) 9. install hose (12), and put diaphragm (11) on the: cover. 1404 Engine 7 Disassembly & AssemblyLP Fuelock (Earlier) Disassemble LP Fuelock (Earlier) 1282-015 Start By 1. remove LP gas carburetor and gas converter (earlier) NOTE: See Step 1 of LP Gas Converter Disassembly And Assembly for removal of the gas converter. NOTICE Make sure opening (stot) (15) in the diaphragm plate is ‘engaged with secondary lever (8) 10. Put cover assembly (13) in position on the body. Install screws (14) until contact is made with the cover. Then tighten the screws thoroughly from ‘one side to the opposite side unti all the screws have a good seal ee) Ags3teP) 1. Remove two hoses (1), Remove bolts (3) and the lockwashers. Remove plate (2) Cs oy Asgezsh * 11. Put gas converter (17) in position on the plate, Install the lockwasher and bolt (18) that hold it in asaaiat position. 12. Connect hose (16) End By: 2. Remove screws (4). Remove cover (5) and the é @, install LP gas carburetor and gas converter (earlier) ee 1404 Engine 28 Disassembly & AssemblyAssemble LP Fuelock (Earlier) 1282-016 |Agasi2Pt 3. Turn the fuelock as shown. Remove screws (6). Remove cover (7) and the gasket. 41. Check all parts for damage. If any parts are damaged, use new parts for replacement. 2. Make sure all parts are clean and free of dirt and foreign material 3. Install the Oring sea, the valve and seat (1) 4 Put valve spring (2) in position, and install screw (3) 4. Romove filter (8) and the screen, 5. Install screen (5) and new fier (4), ABs) 5. Remove screw (9). Remove valve spring (10). 6. Remove the seat, the valve and the O-ring seal 1404 Engine 29 "Disassembly & Assembly6. Put gasket (8) and cover (7) in position 7. Install 10 screws (6) until contact is made with the ccover. Then tighten the screws thoroughly from one: side to the opposite side uni all the screws have a {good seat A84a13P1 8. Turn the fuelock as shown. Put gasket (9) and cover (10) in position, 9. Install the six screws until contact is made with the ccover; then tighten the screws thoroughly from one side to the opposite side until all the screws have a ‘good seat 1404 Engine 10. instal plate (11) and the two lockwashers and bolts (73) on the fuelock. 11. Connect two hoses (12) 12. Seo Stops 11 and 12 of LP Gas Converter Disassembly And Assembly for installation of gas converter, End By a. instal LP gas carburetor and gas converter (earlier) LP Gas Carburetor (Later) Remove & Install LP Gas Carburetor (Later) 1266-010 4. Disconnect hase (1) Disassembly & AssemblyDisassemble LP Gas Carburetor (Later) 1266-015 Start By, a. Remove LP Gas Carburetor 2. Disconnect three lines (2), (3) and (5). 3. Disconnect linkage (4). 4, Remove two nuts and washers (6) 5. Remove carburetor (7) and the gasket eon NOTE: For the installation of the LP gas carburetor, reverse the removal steps. 2. Remove spring (8). Remove diaphragm assem! 6. Inspect and replace the gasket if necessary oe — 1404 Engine 3 Disassembly & Assembly3. Remove four screws (6), backup plate (6), diaphragm (7) and the air valve ring from the inner ‘carburetor body. cosas 4, Remove power mixture sorew (8), idle mixture screw (9) and the spring. Remove four screws (10). Remove throttle body assembly (11) and the gasket 5. Remove four screws (12), adapter plate (13) and the gasket, 8 vr + oe V men fe 6. Loosen the bolt and remove stop (16). 563681 7, Remove two screws (14). Remove throttle plate (15) 8. Remove shatt assembly (17) from the throttle body. Assemble LP Gas Carburetor (Later) 1266-016 V i 0563661 4. Check all parts for damage. Replace damaged parts with new as necessary. 2, Make sure all parts are clean and free of dirt and foreign material 3. Put throttle shatt (17) in position in the throttle body, and install stop (16). 4, Put throttle plate (15) in position and install the two screws, Disassembly & Assemblyos6367P1 5. Install gasket, converter plate (13) and four screws (12), cs6368P1 6. Install power mixture knob (8), idle mixture screw (9) and the spring. See Testing & Adjusting Manual for the correct adjustments, 7. Put throttle body assembly (11) and the gasket in position. Install four screws cst 0, Put air valve ring (19), diaphragm (7) and back-up plate (6) in position on inner carburetor body (18), Install screws (6), 1404 Engine ‘sseaz061 9. Place diaphragm assembly (4) and spring (3) in. position. ‘coer 40. Put cover (2) in position and install screws (1). 411. See Testing & Acjusting Manual for proper test and adjust procedures, End By: a. install LP Gas Carburetor Disassembly & AssemblyLP Gas Fuelock (Later) LP Gas Converter (Later) Remove & Install LP Gas Fuelock Remove & Install LP Gas Converter (Later) 1282-010 (Later) 1271-010 Start By a. remove LP gas {uelock Pes ware =~ 41. Disconnect fuel line (1), 2. Disconnect wire (2. 1. Remove lines (1), (2) (3), and (4). 3. Remove fuelock (3) NOTE: For the instalation of the LP gas fuelock, reverse the removal steps. 2. Remove two bolts and washers (5) 3. Remove LP gas converter (6). NOTE: For the installation of the LP gas converter, reverse the removal steps, End By: a. install LP gas fuelock NOTE: For the Disassembly and Assembly procedure {or the LP gas converter, see Disassembly & Assembly for “LP Gas Converter (Oual Fuel) {08 Engine 7 ira Caisnenny 8 AeseDyCarburetor (Dual Fuel) Install Carburetor (Dual Fuel) 1266-012 Remove Carburetor (Dual Fuel) 1266-011 Start By: a. remove LP mixer assembly 4. Put carburetor (1) in positon. Install mounting nuts (3) that old tin position 2. Connect fuel line (4) and vacuum hose (2) 4. Install the solencid; then connect the electrical asEseP connector. 1. Disconnect choke cable (1), throttle linkage (3) and ‘pring (2) fom the carburetor 4, Connect choke cable (5) to the carburetor as shown, Connect thratte linkage (7) and spring (6) to the carburetor as shown, End By: 2. Disconnect electrical connector (8). Disconnect vacuurn hose (4) and fuel line (8) peal al Sac 3. Remove solenoid (7) and the bracket 4, Remove mounting nuts (6), and remove carburetor ® 1404 Engine 35 “Disassembly & AssemblyCarburetor Gas (Later) Remove & Install Carburetor Gas (Later) 1266-010 2. Disconnect fuel line (2) 1404 Engine '3. Remove two bolts and washers (4) 4. Remove carburetor (3) and the gasket. NOTE: For the installation of the carburetor, reverse the removal steps, 5, inspect and replace the gasket i necessary Disassemble Carburetor Gas (Later) 1266-015 Start By: a. remove carburetor 1, Remove clip and disconnect linkage (1). 2, Disconnect and remave three hose assemblies (2). Disassembly & Assembly3. Remove tive screws and washers (4). 4. Remove top of carburetor assembly (3) and the gasket. 5. Remove pin (5) and float (6). 6. Remove seat assembly (7) and the spring 7. Remove needle assembly (8), 1404 Engine ‘saseses 8. Remove clip and disconnect linkage (10). 8, Remove screw (9) end remove linkage bracket (11) 10. Remove two screws and choke piate (12). 11. Romove two screws (13) and the throttle body (14) from the middie carburetor section (15). 12, Remove anti diescing solenoid and copper seal (16). 13. Remove hot idle compensator (17) Disassembly & Assembly 7cso: 6563321 14. Remove four screws (18) and accelerator pump 17. Remove jet (23). (19), (6563301 c86330F1 18. Remove brass tube (24), spring, Oring seal and 15, Remove diaphragm (20) and spring (21) from ball accelerator pump (19), aa Tae ©56391P1 19, Remove jet (25) and O-ring seal (26). 16. Remove plug (22) and copper sea. 1404 Engine 38 Disassembly & Assemblycaer cosessers 20. Remove low idle stop sorew and spring (27) 25. Remove nut (32), bracket (33) and throttle shaft (34) from the thvettle body (14). 21. Remove bolt and linkage (28) Assemble Carburetor Gas (Later) 1266-016 sassrPt 22. Remove gasket spacer (29) and second gasket ‘rom the throttle body (14), 1. Install throttle shaft (94), bracket (93) and nut (82) in the throttle body (14), ccsaanse1 cseaeors 23. Remove two screws and throttle piate (30), 2; Ferre ete tite ew sir rind 2. Install adjustment serew and spring (31). 3. Install throttle plate (20) with two sorews 1404 Engine 39 Disassembly & Assemblyce 4, Install gasket, spacer (29) and seccnd gasket on the throttle body locating pins, 5. Install dle stop screw and spring (27). 6. Install linkage and bolt (28), senna 7. Install O-ring seal (26), 8. Install jet (25). < am OP@ 9. Install ball (35), spring (36), O-ring seal (37) and tube (24) 963451 10. instal jet (23). c96346P1 11, Install copper seal and plug (22). 1404 Engine Disassembly & Assembly@. ©9647 ess 12. install diaphragm (20) in accelerator pump (19), 16, install throttle body (14) on the middle carburetor section (15). Install two screws and washers (13), wi @nvu 18. Insiall spring (21) and accolorator pump (19) in the ‘middle carburetor section (15). Install four screws 1. Insta choke plate (12) with two screws, (18) 48. Install choke linkage bracket (11). Install one screw and washer (2) 19. Connect linkage (10) with clip (38). at hy 9 af. 14 instal ht ice compensator (17) . —® 15. Install copper seal and antidiescling solenoid (16). 20. install needle assembly (8), 21. Install spring (98) and seat assembly (7) secure vith the ero and retainer. 7404 Engine "Disassembly & Assembly23. Install top of carburetor assembly 13) and the gasket to the middle carburetor section (15). Install four screws and washers (4), 24. Connect linkage (1) and secure with the clip. 1404 Engine 25. install three hose assemblies (2). Fuelock & Filter (Earlier - Dual Fuel) Remove Fuelock & Filter (Earlier - Dual Fuel) 1282-011 41. Disconnect electrical connector (2) and hose (1) from the fuelock and filter assembly Disassembly & Assemblyinstall Fuelock & Filter (Ear Fuel) 1282-012 r - Dual 2. Move the fuelock and filter assembly away from the frame of the lift truck 3. Loosea fiting (4) trom the elbow on the tank then 41. Thoroughly clean sediment bow! (1), Make a remove fuelock and filter assembly (3). replacement of the {uel element 4, Make a soparation between filer (6) and fuelock (6) 2. Connect filter (2) to tuelock (3). Q 5. Remove sediment bow! (7), and make an inspection a Put fuslock and filter assembly (4) in position in the of the fuel element. elbow on the tank. 1404 Engine rr) Disassembly & Assembly4. Connect electrical connecto” (6) and hose (5) to the 2. Remove bolts (4) to remove electric [uel pump (3). fuelock and filter assembly, Remove the fuel pump, Install Electric Fuel Pump (Dual Fuel) Electric Fuel Pump (Dual Fuel) ee Remove Electric Fuel Pump (Dual Fuel) 1256-011 1, Put electric tue mounting bracket, (1) in position on the ind install the bolts that hold it 1. Disconnect electrical connector (1) and two fuel lines (2) from the fuel pump. 2. Connect two fuel lines (3). and connect electrical connector (2. 1404 Engine “44 "Disassembly & AssemblyLP Mixer Assembly (Dual Fuel) Remove LP Mixer Assembly (Dual Fuel) 1266-011 1. Disconnect vacuum and balance hoses (4). 2. Disconnect fue! inlet hose (1) and air inlet hose (3) from the LP mixer 3. Loosen scrow (5); then remiove LP mixer (2), Install LP Mixer Assembly (Dual Fuel) 1266-012 41. Put LP mixer (1) in position on the gasoline carburetor, and tighten screw (3). 2. Connect air inlet hose (2) and fuel inlet hose (4) to the LP mixer, 8. Connect vacuum and balance hoses (6), 1404 Engine 45 Disassemble LP Mixer Assembly 1266-015 Start By: a. remove LP mixer assembly (later) sab674P 1. Remove screws (1). Remove elbow (2) and the gasket, Make an inspection of the gasket. 2. Remove screws (4) to remiave cover (3) from the mixer Disassembly & AssemblyAssemble LP Mixer Assembly 1266-016 A85507P2 '3. Remove spring (6) from the diaphragm assembly. Remove diaphragm assembly (5). 41. Check all parts for damage. if any parts are damaged, use new parts for replacement 2, Make sure all parts are clean and free of dirt and foreign material 3. Put air valve ring (2), diaphragm (3) and back-up plate (4 in positon on inner Body (1) of the diaphragm assembly. Install screws (5) 85672P) 4. Remove screws (9), backup plate (7). diaphragm (@) and the air vaive ring from the inner body of the diaphragm assembly. 4, Install diaphragm assembly (6) and spring (7) in the mixer assembly, 7404 Engine 46 Disassembly & AssemblyLP Fuelock & LP Gas Converter (Dual Fuel) Remove LP Fuelock & LP Gas Converter (Dual Fuel) 1282, 1271-011 5, Install cover (8) on the mixer, and instal the screws that hold it a ® , s AY 1. Before any lines or hoses are disconnected, put ~ oe identitcation marks on all hoses and lines. 4 * 2. Disconnect all ines and hoses (1), (2) and (3) from the converter. Be5569P1 6, Install a new gasket on the elbow. Put elbow (9) in position on the mixer, and insall he scrows that hol it End By @. install LP mixer assembly (later) 8. Disconnect hoses (4), (5) and (6) from the fuelock. 1404 Engine 7 Disassembly & Assembly‘4. Remove bolts (7) lo remove fuelock and converter 3, Connect lines and hoses (6), (6) and (7) to the (8) from the mounting bracket. Remove the fuelock converter. Make sure the lines and hoses are and converter. ‘connected at the correct locations. Install LP Fuelock & LP Gas Converter (Cue aed) 122, 271-012 LP Gas Converter (Dual Fuel) Disassemble LP Gas Converter (Dual Fuel) 1271-015 Start By fa. remove LP fuelock and LP gas converter 4. Put tuslock and converter (1) in postion on ‘mounting bracket, and install the bolts that hold it 41. Remove bolt (2) fram the mounting plate, anc remove converter assembly (1). cosserer fl 2. Gonnect hoses (2), (3) and (4) to tre fuelock. Make sure the hoses are connected at the correct locations 1404 Engine ; 48 Disassembly & Assembly2. Remove screws (3), and remove cover assembly (4) from the converter body. 388/030 8. Remove diaphragm (6) from the cover assembly. 4, Remove screw (7), secondary lever (6), the seal, the pin and the spring 5. Turn the converter body around. Remove screws, (@), back cover (8) and the diaphragm. 885701P1 Q 6. Remove diaphragr (10) from the back cover. usuoaP 7, Remove spring (11) and the plunger from the intermediate cover 1404 Engine Disassembly & Assembly@ * paseaeP 8. Remove intermediate cover (12) and the diaphragm from the converter body. 8. Remove diaphragm (13) from the intermediate ‘go U e56960 10. Remove primary regulator valve (14). 1404 Engine Assemble LP Gas Converter (Dual Fuel) 1271-016 Raseosey 1. Check all parts for damage. f any parts are damaged, use new parts for replacement 2. Make sure all parts are clean and free of dirt and foreign materia 3. Put primary regulator valve (1) in position in the converter body, 4. Install diaphragm (2) on intermediate cover. Disassembly & Assemblygue 5. Install intermediate cover (4) on the converter body. 6. Install plunger (5) and spring (3) in the intermediate » 7. Install diaphragm (8) on the back cover. a 8. Put back cover (7) on the intermediate cover, and Install the screws that hold it 9. Turn the screws in until contact is made with the intermediate cover. Tighten the screws thoroughly {rom one side to the opposite side until al the ‘Screws have a good seat 1404 Engine st 10. Turn the converter body around. Put the spring, the pin, the seat and secondary lever (6) in position, Install screw (9) a Basee9r 11. install diaphragm (10) in the cover assembly. 12, Put cover assembly (11) in position. Make sure the notch in tang (12) is in alignment with secondary lever (8). Insiall the screws that hold the cover assembly. Turn the screws in until contact is made with the Intermediate cover. Tighten the screws thoroughly from one side To the opposite side until all the Screws have a good seat ssembly & Assembly1. Put converter assembly (13) in position on the mounting plate, and install the boll that holds it. End By: a. install LP fuelock and LP gas converter Radiator (Earlier) Remove Radiator (Earlier) 1353-011 Start By a. remove counterweight” ne Power Trains, Disassembly “This operation isi ‘Andi Assembly sect 41. Drain the coolant from the cooling system, h 5 : ‘ 2. Disconnect two tube assemblies (1) from the radhator, 1404 Engine 3. Disconnect overtlow hose (3), upper hose (4), lower hose (5) and bypass hose (2) from the radiator, 4, Remove four bolts, washers and lockwashers (7). Remove radiator (6). The weight of the radialor is 16 kg (35 Ib), Install Radiator (Earlier) 1353-012 4. Put radiator (1) in position on the lft truck. Install the tour lockwashers, washers and bolts thal Noid it in position, Disassembly & Assembly2. Connect lower hose (5), upper hose (4), overflow hose (3) and bypass hose (2) to the radiator. fl 7 3. Connect two tube assemblies (6) to the radiator. 4, Fill the cooling system with coolant to the correct level, See the Maintenance Guide. End Ry: a. install counterweight” “This operation isin the Power Train, Disassembly And Assembly Section, Radiator (Later) Remove & Install Radiator (Later) 1353-010 NOTE: The upper and lower hood assemblies and floor plate group have been removed. Start By’ 1. remove counterweight” “This operation is in the Power Trein, Disassembly And Assembly section. 1. Drain the coolant from the cooing system, e se 2. Remove air cleaner tube and vacuum hose (1). 3. Disconnect battery cables (2). 4. Remove upper and lower radiator hoses (3) Disconnect overtiow tube (4) and two transmission ‘cooler lines (8). Disconnect temperature contol (6) Disassembly & AssemblyFan Remove & Install Fan 1356-010 Start By: a. remove radiator 5. Remove four bolts and washers (7). Use two people land remove radiator (8). The weight of the radiator is 16 kg (35 Ib) NOTE: For the installation of the radiator, reverse the removal steps, 6. Fill the cooling system with the proper amount and type of coolant, See the Maintenance Guide. End By: a. install counterweight * * This operation is in the Power Train, Disassembly And ‘Assembly section, 41. Loosen the tension on the vee belts. 2, Remove the four bolts and lockwashers (2). 3. Remove fan (1). 4. Put fan (1) in position. 5. Install the four lockwashers and bolts that hold the fan in position. 6. Adjust the tension on the vee belts. See the Maintenance Guide for the correct adjustment procedure. End By: a. install radiator 1404 Engine 54 Disassembly & AssemblyFan Belts (Earlier) Install Fan Belts (Earlier) 1357-012 1. Check fan belts for damage or wear. Ifthe belts are Remove Fan Belts (Earlier) 1357-011 damaged or worn, use new parts for replacement. NOTE: The engine and fan are removed for better ‘photo ilustration. be Aga259P1 1. Loosen the bracket bolt; then loosen belt adjustment bolt (2) 2. Remove water pump drive belt (1). 2. install alternator drive belt (2) 3. Install water pump ative belt (1). 4, See Testing And Adjusting for correct fan belt tightening procedure. '3. Loosen bolt (3), and remove alternator drive belt (4). 1404 Engine 55 Disassembly & AssemblyFan Belt (Later) Remove & Install Fan Belt (Later) 1357-010 Start By a. remove fan 1. Loosen bolt (1) and bolt (2) 2. Remove belt (3) NOTE: For the installation o the belt, reverse the removal steps. End By: a. install fan 1404 Engine 56 Valve Cover Remove Valve Cover 1107-011 Start By. a. remove PCY valve NOTE: The engine is removed from the lit truck for btter photo ilustration 1. Remove two nuts (1) and the washers, 2. Remove valve cover (2) and the gasket. Install Valve Cover 1107-012 1. Puta new gasket and valve cover (1) in positon. 2. Intal the two washers and nui that hold it in position, Tighten the nuis to a torque of 2.4 = 0.3 Nem (21 £3 bb in). End By a. install POV valve Disassembly & AssemblyWater Temperature Regulator Install Water Temperature Regulator (Earlier) (Earlier) 1355-012 4. Check al parts for damage, any parts are Roinows Watee:Térmpersluve Hegulstor damaged, use new pats for raplacement (Earlier) 1355-011 NOTE: The engine is removed for better photo tstalion, NOTICE Be sure the water temperature regulator is installed correctly to prevent engine overheating, Ag5503P1 1. Drain the coolant to a position below the water temperature reguiator housing, 2, Pul water temperature regulator (1) in position as 2. Remove the radiator hose. tem 3. Remove two bolts (2) and the lockwashers, 4, Remove water temperature regulator housing (1), the gasket and the water temperature regular. ‘ae5s00P1 3. Put new gasket (3) and water temperature regulator housing (2) n postion, and install the two lockwashers and bolts that held i in position. 4, Install the radiator hose, 5. Fill the radiator with coolant tc the correct level. See the Maintenance Guide. 87 Disassembly & AssemblyWater Temperature Regulator Later) Remove & Install Water Temperature Regulator (Later) 1355-010 Start By: a. remove fan b. remove fan belt 3. Remove two bolts (4), 4, Remove regulator housing (5) and the gasket, S6cIeF 5. Remove temperature regulator (6). NOTE: For the installation of the temperature regulator, reverse the removal steps. 6, Inspect and replace the gasket if necessary, End By: a. install fan belt b. install fan 2. Remove two bolts (3) and bracket (2). 1404 Engine 58 Disassembly & AssemblyWater Temperature Sensor Remove & Install Water Temperature Sensor 7453-010 1. Disconnect one wire connection (1), - BM SEN he ba 2. Remove water temperature sensor (2) NOTE: For the installation of the water temperature sensor, reverse the removal steps. 3. Use thread sealant 5P3413 on the water temperature sensor threads. 1404 Engine Water Pump (Earlier) Remove Water Pump (Earlier) 1361-011 Start By: 1. Remove voe belt (1). 2, Remove bolts and lockwashers (6). Remove pulley 4). 3. Disconnect tube assembly (2), and remiove hose (3) from the water pump. & 4, Remove four nuts (7) and clip (6). Remove water pump (8) and the gasket “Disassembly & AssemblyInstall Water Pump (Earlier) 1361-012 agteaart am 1. Put gasket (1) in position, and install water pump (2), Put the clip in position, and install the four nuts, that hold the water pump in position. ro 2. Install hose (4) and connec: tube assembly (3) to the water pump. 3. Put pulley (6) in position, and install the four lockwashers and bolts that hold it. 4, Put the vee belt in position, End By: a. install fan 1404 Engine 60 Water Pump (Later) Remove & Install Water Pump (Later) 1361-010 Start By a. remove fan b. remove fan belt 1. Remove hose (1). 2, Remove two bolts (2) and idler (3). 3. Remove line (6). Remove four bolts (4). Remove water pump (6) and the gasket NOTE: For the installation of the water pump, reverse the removal steps. End By: a, install fan belt b. install fan ‘Disassembly & AssemblyWater Regulator Housing Install Water Regulator Housing 1355-012 Remove Water Regulator Housing 1355-011 NOTE: The engine is removed for better photo itustration, Start By, a remove fan b. remove fan belts 1. Puta new gasket and water requiator housing (1) in position. Put the alternator adjustment bracket in position. Install the three bolts that hold the housing In position, 1. Remove fan pulay (1). Remove bolt (3), the lockwasher and the washer. Remove belt lightener Q, A8i260r' 2, Install belt tightener (3) and fan pulley (2) End By: a. instal fan belts b. install fan 2. Remove three bolts (5). Remove water regulator housing (4) and the gasket. 1404 Engine i 8 Disassembly & AssemblyOil Level Switch Oil Pan Remove & Install Oil Level Switch Remove Oil Pan 1302-011 7421-010 = Ops o~ Via, “@ oe 1. Remove ol level switch (1) from oil pan (2). 1. Remove the engine, 2. Remove 18 bolts (2) and the washers, NOTE: For the installation of the oil level switch, reverse the removal steps. 3, Remove oll pan (1) and the gasket 2. Use thread sealant 5P3413 on the oil level switch 4, Remove the front and rear seals. threads, Install Oil Pan = 1302-012 Ags300°1 1. Put new gasket (4), front seal (3) and rear seal (2) in position on the cylinder block. NOTE: Put 8H5137 Sealant to the oil pan side of the front and rear seals 2. Put ol pan (1) in postion on the cylinder block. Install the 18 washers and bolts that hold it in pposttion. Tighten the four bolts at the front and the two bolts at the rear to a torque of 12 to 17 Nem (9 to 12 Ib ft), Tighten the six bolts on each side to a torque of 4 to § Nem (35 to 45 Ib in) 3. Install the engine 1404 Engine 62 Disassembly & AssemblyOil Pump Install Oil Pump 1304-012 Remove Oil Pump 1304-011 Start By. a. remove oll pan NOTE: Make sure the No. 1 piston is at the Top Dead Center position, and the distributor rotor is at No. 1 terminal position. The notch in oil pump gear (2) must bbe toward the front of the engine. and the drive tang {or the distrioutor must be paralle! with the camshaft 1. Put the new oil pump gasket and oil pump (1) in position. Install the washer and bolt that holds it in 1. Remove bolts (2) and the washers. position al Put new gasket (4) and tube assembly (3) in position. Instal the two washers and bolts that hold tt 2, Remove mut (3) and the washer. 3. Remove tube assembly (1) and the gasket 4. Remove bolt (4) and the washer 3. Install the washer and nut that hold the tube assembly bracket in position. 5. Remove oll pump (6) and the gasket End By a. install of! pan 1404 Engine 63 Disassembly & AssemblyValve Lifters Remove & Install Valve Lifters 1209-010 Start By. a. remove camshaft Rocker Shaft Assembly & Push Rods Remove Rocker Shaft Assembly & Push Rods 1102, 1208-011 Start By: NOTICE Put identification marks on the lifters as to their loca- tion in the cylinder block. Be sure to install the lifters in their original locations. 1. Remove eight valve lifters (1) from the engine block. ABSS09P) Ce Hl 2. Install eight valve lifters (1) in thelr original locations in the engine block. New ters can be mixed, End By a. install camshatt 1404 Engine 1. Remove bolt (5), the washer and the bracket Remove nut (2), the washer and the bracket . Remove oll tubes (1) and (4), |. Remove bolt (3), nut (6) and the washers, 1. Remove rocker shaft assembly (7) 6. Remove push rods (8). Put identification marks on the push rods as to their location in the eylinder block: Disassembly & AssemblyInstall Rocker Shaft Assembly & Push isassemble Rocker Shaft Rods 1102, 1208-012 Assembly 1102-015 Start By a remove rocker shat! assembly and push rods i a ac 1. Install push rods (2) n their original locations. New push rads can be mixed. Loosen valve lash adjustment screws in the rocker arms. 2. Put rocker shaft assembly (1) in position. 1. Remove cotter pin (1) from one end of the rocker shaft assembly. 2. Remove a spacer, a washer and a spacer. 3, Romove arm assembly (2), support (4) and arm assembly (3). , 49 Saal 3. Install the washers, bolt (5) and nut (6) 4, Put oll tubes (3) and (7) in position. install the brackets, the washers, nut (4) and the bolt that Agsazery holds the ol tubes and rocker shaft assembly in position 5. Tighten the nuts and bolts that hold the rocker shaft 4. Remove spring (5). Remove the remainder of the assembly in position toa torque of 45 to 55 Nem arm assemblies, the supports and the springs from (83 to 40 Ib it) rocker shatt (6). 6. See Testing And Adjusting for the correct procedure 5. Remove spacer (7), the washer, the spacer and the to adjust the valve lash (clearance). cotter pin from the other end of the rocker shaft End By: 2. install valve cover 1404 Engine 65 Disassembly & AssemblyAssemble Rocker Shaft Assembly 1102-016 @D —aseeres 1. Check all parts for damage. if any parts are damaged, use new parts for replacement. 2. Make sure all parts are clean and tree of dirt and foreign material 3. Put a small amount of clean engine oil on the parts to be assembled. 4. Install cotter pin (5) in rocker shatt (13). 5. Install spacer (6), washer (2) and spacer (1), NOTE: Make an alignment of rocker shaft oil holes and arm assembly ol holes. 6. Next, install arm assembly '8), support (10), arm assembly (3) and spring (4), 7. Install the remainder of the arm assemblies, the Supports and the springs a8 shown. 8 Install spacer (11), washer (7) and spacor (12) 1404 Engine ABsa74P1 9. Install cotter pin (9) End By: a. install rocker shaft assembly and push rods Cylinder Head Assembly Remove Cylinder Head Assembly 1100-011 Start By a. remove inlet and exhaust manifolds b. remove rocker shaft assembly and push rods 6, remove water regulator housing poseary =, 41. Remove four plug wires (2). Remove vacuum line (1) {rom the cylinder head assembly, Disassembly & Assembyrab 4287P 1 3. Remove 10 bolts (4) 4. Remove cylinder head assembly (6) and the gasket 5. Remove tube assembly (6) and water temperature sending unit (7) 1404 Engine Install Cylinder Head Assembly 1100-012 NOTE: Put 5P3413 Pipe Sealant with Teflon on the threads of the water temperature sending unt. 1. Install water temperature sending unit (3) and tube assembly (2) Tighlen the water temperature sending unit to a torque of 35 + § Nem (25 + 4 Ib ft) NOTE: Make sure the contact surfaces between the ceylinder biock, gasket and cylinder head assembly are clean and free of foreign material, 2. Put anew cylinder head gasket and cylinder head assembly (1) in position NOTE: Put 6V7845 Molykote Paste Lubrication on cylinder head bolt threads before installation. 67 Disassembly & AssemblyA74496P2 3. Install bolts (4) that hold the cylindar head assembly in position, Tighten the bolts to a torque of 70 + 7 Nem (50 + 5 lb ft), Retighten the bolts to a torque of 83 > 4 Nem (61 + 3 Ib Mt) in the number sequence shown, 1404 Engine 4, Install spark plugs (6). Tighten the plugs to a torque of 36 + 5 Nem (26 + 4 Ib ft), vA ae 8. install four plug wires (6). Be sure the wires are ‘connected at the correct locations. install vacuum line (7) to the cylinder head assembly, End By a. install water regulator housing b. install rocker shalt ascembly and push rods ©. install inlet and exhaust manifoldsValves Remove Valves 1105-011 ‘Tools Neoded ale 13527 Valve Spring Compressor 1 ‘952269 Valve Spring Tester 7 Start By. 1a, remove cylinder head assembly (7) A84275P1 1. Compress spring (1) with tool (A). NOTE: The intake valve has a seal under the spring and a retainer in place of a rotator. wx—{s) 2. Remove keys (5), rotator (4), spring (8) and valve (2) from the cylinder head, 1404 Engine 69 ssa: '3. Check the spring force with too! (B). The spring test force is 195 N (43.8 Ib). The length under test force is 47.24 mm (1.860 in), The froe length ator testis 53.3 mm (2.10 in) 4. Do Steps 1 through 3 again for the remainder of the valves Install Valves 1105-012 aeerery 1. Check all parts for damage. any parts are damaged or worn, use new parts for replacement. 2. Make sure all parts are clean and free of dirt and foreign material, 3. Put valve (2) in position in cylinder head (1), NOTE: The intake valves have a seal under the spring and a retainer in place of a rotator. Disassembly & AssemblyLe2nPl g . . oo 44. Put spring (5) and rotator ($) in position are in the correct position on the valve stem. The keys can be thrown from the valve stem when tool (A) is released. 5. Compress the spring with fool (A), and install keys (3). Release the compression on the spring slowly, and remove tool (A), 6. Do Steps 3 through § for the remainder of the: End By: a. install cylinder head assembly 1404 Engine 70 Valve Seat Inserts Remove & Install Valve Seat Inserts 1103-010 Start By a. remove valves Assstert - NOTE: Intake valves do not have inserts 1. Remove exhaust valve inserts (1) from the cylinder head with acceptable tooling 2, Install exhaust valve inserts (1) in the cylinder head with acceptable tooling End By; a. install valves Disassembly & AssemblyPistons And Connecting Rods Remove Pistons & Connecting Rods 1225-011 ‘Tools Needed {882968 Ridge Reamer Start By: ‘a. remove cylinder head assembly . remove oil pump A84267P 41. Tum the crankshaft until two pistons are at bottom Center. Make a note of piston identification, Caps have a number on the cam side of the connecting rods. 2. Use too! (A) to remove the cylinder wall rng ridge. This operation will prevent damage fo the pistons uring removal 1404 Engine n 3. Remove the caps from the connecting rods of the two pistons. Put tape or rubber hose (1) over the connecting rod bolt threads to prevent damage to the crankshatt when the connecting rod and piston are remioved. Push the piston Jp until the piston rings are free of the cylinder wall. Romove the two pistons and connecting rods. 5. Follow Steps 1 through 4 to remove the other pistons. Install Pistons & Connecting Rods 1225-012 aeons Tools Needed Al 6V105 Compressor 1 1. Put tape or rubber hose over the connecting rod bolls, 2, Put clean engine ol on the pistons, piston rings exlinder wall and connecting rod bearings NOTE: Put the oil ing spacer gap opposite the notch ‘on top of the piston, Move the rail gaps 38.1. mm (1.50 in) from each side of the notch. Move the: ‘compression ring gaps approximately 120° trom each side of the oil ring spacer gap. 3. Install tool (A) over the piston fo compress the piston rings. Install piston (1) in the correct cylinder as per identification with the natch in the top of the piston toward the front of the engine block ‘4, Push the piston and the connecting rod in the ‘ylinder unt the connecting rad isin position on the Crankshaft. Remove the tape or rubber hose from the connecting rod bolts. NOTE: See Connecting Rod Beerings Remove And Instal for the correct procedure. "Disassembly & Assembly5. Install caps (2) on the connecting rods. The number on the cap must be the sane as the number on the Connecting rod and on the same side when installed, The side of the connecting rod with the number must be toward the camshatt and the tabs of the rod bearings must be away from the camshaft. Put clean engine oil on connecting rod bolts, Tighten the nuts to a torque of 44 + 3 Nem (33+ 2b M0) 6. Do Steps 1 through § to install the remainder of the pistons. End By: a. install oll pump b. install cylinder head assembly Disassemble Pistons & Connecting Rods 1225-015 “Tools Nevded '5F9058 Ring Expander 1 {P1853 Retaining Ring Pers It TPBI0 Drive Group Li Start By: a. semove pistons and connesting rods 1404 Engine qa As264P | va 1. Remove the rings from the piston with tooling (A). ‘AB4262P1 Daa 2. Remove snap ring (3) with tool (B) from each side of piston (1), 3. Remove pin (2) and the connecting rod. Make a rote of the rod number position in the piston. 4. Remove the rod pin bearing from the connecting rod with a press and a drive plate and handle frorr ‘ool group (C) that will fit the outside diameter of the: bearing, NOTE: Check the condition of the pistons and connecting rods, See the Guideline For Reusable Parts Pistons, Form No. SEBF8049, Disassembly & Assembly‘Assemble Pistons & Connecting Rods 1225-016 Tools Neoded no TPibss Retaining Fig Pers 7 F056 fing 7 [e510 — or - Lh) Age 1. Check all parts for damage. If any parts are ‘damaged, use new parts for replacement 2. Make sure the parts are clean and free of dirt and foreign material 3. install a new rod pin bearing in the connecting rod with @ press and a drive plate and handle trom tool group (C) that wil fit the outside diameter of the bearing. Use a pin boring machine to make the bearing the correct size. See Specttications for the correct bore size 4. Put the connecting rod in piston (2) with the bearing tab groove oppostte the camshatt. Install the rod ‘pin. Install snap rings (1) with tool (A) in piston (2). NOTICE Clean the piston ring grooves on a used piston with acceptable tooling before new rings are installed. 1404 Engine 73 4 et AaazeaP 1 . s Install the oll ring assembly on the piston with too! ©. 6. Install the lower compression ring on the piston with tool (B). The "PIP" mark on the ring must be toward the top of the piston 7, Install the top compression ring on the piston with tool (B) If the ring has a "PIP" mark, the "PIP mark ust be toward the top of the piston, 8. Check the clearance between the piston ring grooves and the rings, The maxmum permissible Clearance between the top compression ring and groove 's 0.20 mm (.008 in) and 0.13 mm (.005 in) for the other two rings, The clearance between the top ring (new) and groove is 0.051 to 0.089 1mm (.0020 to .0035 in). The clearance between the second ring (new) and groove is 0.038 to 0.088 ‘mm (0015 to ,0035 in), The clearance between oil fing assembly and groove is 0.13 mm (.008 in). 9. The maximum end gap clearance for worn Compression rings and cylinder bores is 0.38 mm (015 in). End gap clearance tor new compression fings is 0.08 to 0.25 mm (.003 to .010 in). End gap clearance of the oll ring assombly Is 0.98 to 1.40 mm (.015 to 0.055 in). Make sure the ring gaps are in the correct position before the pistons are installed. See instal Pistons And Connecting Rods. End By: a. instal pistons and connecting rods "Disassembly & AssemblyAccessory Drive Remove Accessory Drive 1207-011 Start By a. remove hydraulic pump* “This operation is in the Vehicle Systems, Disassembly ‘And Assembly section. NOTE: The engine is removed for better photo Teall ‘lustration 41, Disconnect tube assembly (1). 2, Remove accessory drive (2) and the gasket. Install Accessory Drive 1207-012 NOTICE Make an alignment of the accessory drive gear splines and the splines on the governor adapter. The governor housing will be damaged without correct alignment When the hydraulic pump Is installed, 1. Put the new gasket and accessory drive (2) in position. 2. Connect tube assembly (1), End By: a. install hydraulic pump* “This operation (sin the Vehicle Systems, Disassembly ‘And Assembly section, Disassembly & AssemblyDisassemble Accessory Drive 1207-015 [ ‘Toots Needed a '5P4758 _ Piers (internal 7 Start By: a. remove accessory dive = Aat747P1 Ag3948P1 Flemove snap ring (2) with tool (A) 1404 Engine 75 Ag3949P) \ 3, Remove the bearing from adapter (3) with a press, Assemble Accessory Drive 1207-016 “Tools Neoded x 1P520_ Driver Group 1 [Bearse Pers (rena i 1P510 Driver Group “CEE SI 41. Check all parts for damage. If any parts are damaged, use new parts for replacement 2. Make sure all parts are clean and free of dirt and foreign material 3. Puta small amount of clean engine oil on the parts. 4. Install the bearing in adapter (1) with a press and tooling (A). Make sure the bearing is against the bbotlom of the counterbore in the adapterGovernor (Earlier) Remove Governor (Earlier) 1264-011 NOTE: The engine is removed for better photo iMustration. Start By, - a. remove counterweight* —~G) 8305 “This operation is in the Power Train, Disassembly And Assembly section. 5. Install snap ring (2) with too! (B), =" 6. Install gear (3) with a press and tooling (C), 1. Disconnect governor linkage (1) to the carburetor and the linkage to the accelerator. End By: a. install accessory Drive 2. Remove two bolts (3) and the washers. 3, Remove governor (2) and the gasket 1404 Engine 76 Disassembly & AssemblyInstall Governor (Earlier) 1264-012 Governor (Later) Remove & Install Governor (Later) 1264-010 Start By a, remove carburetor NOTICE Make an alignment of the splines of governor adapter (2) and accessory drive gear (3) 1. Put the gasket and governor (1) in position, and install the two washers and bolts that hold it 4. Remove governor (1) and the gasket ane 2. Connect governor linkage (4) from the carburetor and the linkage from the accelerator. 2. Install governor (1) and the gasket End By: End By: a. install counterweight" a. install carburetor “This operation i in the Power Train, Disassembly And ‘Assembly section, 1404 Engine 77 Disassembly & AssemblyGovernor (DIS type engines only) Remove & Install Governor (DIS type engines only) 1264-010 Start By a. remove carburetor 44, Remove governor (6), two sleeves (5) and the gasket NOTE: The following steps are for the installation of the governor. 5. Install he gaskel and governor (6). 6. Install two sleeves (5) 2. Remove two bolts and washers (3) 3. Remove water cooled spacer (4), 7, Wnstall water couled spaces (4), 8. Install two bolts and washers (3), 1404 Engine aT Disassembly & Assembly9. Connect hose assemblies (1) and (2), End By: a. install carburetor Front Housing Remove Front Housing 1166-011 Start By. a. remove muftlor . remove radiator . remove fan d. remove fan belts @. remove accessory drive {. remove governor NOTE: The engine is rerioved for better photo istration, 1404 Engine 4. Remove water pump pulley (1), 2. Remove crankshaft pulley (2). oO. 3. Remove four oil pan bolts (6) and the washers. 4, Remove seven bolts (3) and the washers, 5. Remove three nuts, oolts and washers (4) 6. Romove front housing (5) and the gasket. 79 Disassembly & AssemblyInstall Front Housing 1166-012 Timing Gears Remove Timing Gears 1206-011 Tools Needed THA Spacer P2820 Pullor Assembly Start By, a. remove front housing b. remove oil pan 4. Put the new gasket and front housing (1) in position on the engine 2. Install the seven washers and bolts and the three washers, bolts and nuts thet hold it in position. . Install the four oll pan washers and bolts. 11. Make sure the mark (timing marks) (3) on the Crankshaft gear is in alignment with the mark on the camshatt gear AB42500°1 2. Bend the tabs back on the lock. Remove bolt (2), the lock, the retainer and camshaft gear (1) Remove the key, 4, Install crankshaft pulley (3). Tighten the nut that holds the pulley to a torque of 190 > 7 Nem (140 5 lb ft) Install water pump pulley (2), End By: a. install governor b. install accessory drive Cc. install fan belts 4. install fan €. install radiator f. install muttier 3. Remove bolt (6). Remove idler gear assembly (4). 1404 Engine 80 Disassembly & Assembly7 7) “tagyy? ‘A95399P1 art 4. Remove bearing (7) from shaft (6) 7, Remove Oxing sea (11) from the shalt, Ags334P) att 55, Remove gear (8) trom the shaft 8. Remove bearing cups (12) and snap ring (13) from the gear if necessary @ 3) 6. Remove spacer () and bearing (10) from the shatt 9. Remove two bolts (14) that hold the alternator bracket to the piate 10. Remove bolt (16). Disconnect tube assembly (15) ‘rom the water pump, 1404 Engine at Disassembly & AssemblyInstall Timing Gears 1206-012 11. Remove four nuts (17), the washers and the clip Remove water pump (18), Remove bracket (19) from the LP converter, 41. Check all parts for damage. I any parts aré damaged, use new parts for replacement 12, Remove bolt (21). Remove plate (20) and the gasket. 2. Make sure all parts are clean and free of dirt and foreign material 4 3. Install key 1) in the crankshaft. % gel, [ecetnbe wore semtre a \ mre NOTICE ‘The mark (timing mark) on the crankshaft gear must bbe away from the cylinder block after installation, 4. Heat crankshaft gear (2) to a maximum temperature ‘of 204°C (40°F), install the gear. Make an alignment of the notch in the gear and key (1). 18. Remove crankshalt gear (22) with tooling (A), Remove key (23), 5, Install the gasket and plate (3). 1404 Engine 82 Disassembly & Assembly6. Install bolt (6). Install the LP converter bracket to the converter and to the plate, Put water pump (5) in position, and install clip (4) and the four washers and nuts, 7. Install two bolts (7) that hold the alternator bracket in position. Connect tube assembly (8) to the water pump, NOTE: I a replacement of the idler gear bearings is made, the bearings must be kepl together as an assembly. Put a small amount of clean engine oll on the parts, NOTICE Be sure to support one bearing cup when the other bearing cup is installed. 1404 Engine 83 8. Install snap ring (10) in the idler gear. Install bearing ups (8) with a press. Install the bearing cups unt they are against the snap ring, 9. Install O-ring seal (12) on shalt (11). —@ AaSS19R1 10. Install bearing (14) and spacer (13), sssembly & Assembly11. Install idler gear (15) on the shaft 12. Install bearing (16) on the shat 13. Put idler gear assembly (17) in position, and install the bolt that holds it 14. install the key in the camshaft, Mace an alignment of the key with the notch in the gear. 15. Put camshatt goar (18) in position on the camshaft, Make an alignment of the marks (timing marks) (19) on the camshaft gear and the crankshaft gear 16. Install the retainer, the lock and the bolt that hold the camshaft gear, Tighten the bolt to a torque of 74 £ 4 Nem (85 + 3 Ib ft) Bend the tabs of the lock around the bolt and in position in the retainer notch: End By a. install oll pan b. instal front housing 1404 Engine Disassembly & AssemblyCrankshaft Main Bearings NOTE: Put idenlcation marks on the main bearings for correct installation. Remove Crankshaft Main 5. Do Steps 1 through 4 for the other main bearings. Bearings 1203-011 Stat B Install Crankshaft Main y: Bearings 1203-012 a. remove oll pump 1. Remove bolt (1) and nut (3) oF the two bolts that hold the caps in position. 2, Remove cap (2), 4. Check all parts for damage. If any parts are damaged or worn, use new parts for replacement 3. Remove the lower bearing from the cap. 2. Make sure all parts are clean and free of dirt and foreign material 3. Install an approved bearing installation tool (2) in the cerankshatt journal NOTICE Make sure the upper and lower bearings are installed 50 the tab in the bearing fits into the notch in the cylinder block and the cap. The center main bearings are the same and can be used either in the upper or lower position. The front and rear main bearings have different upper and lower bearings. The upper main bearing has a groove and the lower bearing has only an oil hole. Install old bearings as per identification. 4, Put clean engine oil on the upper main bearing. Put Upper main bearing (1) in position on the crankshatt journal. To install the upper main bearing, turn the crankshall clockwise as seen {rom the flywheel 4, Install an approved bearing removal tool (4) in the oil hole in the crankshaft journal, Turn the crankshaft counterclockwise as seen from the flywheel. Remove the upper main bearing, 1404 Engine 85 Disassembly & AssemblyAB536771 5. Put clean engine oil on lower bearing (2), and install the lower bearing in the cap, NOTICE Do not turn the crankshaft as it will damage the Plastigage. Put the Plastigage in positien on the lower bearing and install the bearing cap. Tighten the bolts and nuts that hold the cap to a torque of 75 to 80 Nem (55 to 60 Ib ft) 8, Remove the bearing cap. Measure the width of Plastigage (4). The bearing clearance with new bearings must be 0.023 to 0.089 mm (.0009 to 0035 in). The maximum clearance with used bearings must not be more than 0.13 mm (.005 in) 9. Put clean engine oil on the bearing and the ccrankshait journal 10. Install the bearing cap. Tighten the bolts and nuts to.a torque of75 to 80 N-m (55 to 60 Ib ft) NOTICE ‘The rear main bearing cap has four oil seals between the block and cap, Install the seals in the cap carefuly to prevent oil leakage. Do not cut (trim) seals after installation, 11, Do Steps 1 through 10 for the other main bearings. 12. Measure the crankshaft end play. The end play ‘must be between 0.10 to 0.23 mm (.004 to .009 in). Maximum end play for a worn crankshaft is 0.33 mm (.013 in) End By: a. install ol pump 1404 Engine Disassembly & AssemblyConnecting Rod Bearings Remove & install Connecting Rod Bearings 1219-010 Start By: a. remove oll pump 85962 Be Make sure all connecting rod caps (1) have identification marks on them so they will be installed on the same rod, 2, Tum the crankshaft unt two pistons are at bottom cer, Remove the nuts, Remove connecting rod caps (1) A85961P) fn 3. Remove the lower bearing half from caps (1) 4, Push the connecting rods away from the crankshaft ‘and remove the upper half of the bearings, NOTE: Install the bearings dry when the clearance checks are made. Put clean SAE 20 ol on the bearings and crankshat journals for final assembly, . Clean the surfaces where the bearings fit, and install the upper half of the new bearings in the rods. Put the connecting rods in position on the crankshaft 6. Clean the surfaces where the bearings fit, and instal the lower hall of the new bearings in caps (1), T. Put clean SAE 30 oll on the threads of all bolts. 8. Use Plastigage to check the bearing clearance. Install bearing cap (1). Tighten the nuts to a torque of 44 3 Nem (32 + 2 Ib ft), 1404 Engine Disassembly & AssemblyA@5360P " 8. Remove bearing cap (1) and measure the width of Plastigage (2). The bearing clearance with new bearings must be 0.033 to 0.079 mm (.0013 to 0031 in), Maximum permissible clearance with Used bearings is 0.114 mm (.0045 in) 10, Put clean SAE 30 oil on the bearings and ‘crankshaft journals, instal cap (1). Tighten the Nuts to a torque of 44 + 3 Nem (32 > 2 Ib ft) 11. Do Steps 1 through 10 again forthe other ‘connecting rod bearings. End By: a. install oll pump Camshaft Remove Camshaft 1210-011 Start By a. remove rocker shaft assembly and push rods b. remove distributor ©. remove oil pump 4. remove front housing 1404 Engine ag5350P1 € NOTE: Push the valve lifters toward the cylinder head assembly. 4. Remove bots (1) that hold the camshafl. The camshaft must be turned to gain access to bolts i) 2, Remove camshatt assembly (2). 9. Bend the tabs on the lock back from the head of the bolt AB55I5P) 4, Remove bolt (6), the lock, retainer (5), gear (7) and plate (4) from camshaft (3). Remove the key from the camshaft 88 Disassembly & AssemblyInstall Camshaft 1210-012 sicily . ‘ ye A 89516P Check all parts for damage. it any parts are damaged, use new parts for replacerent. 2, Make sure all parts are clean and tree of dt and foreign material. Put clean engine ail on the camshaft lobes betore instalation 3, Install the key, plate (4), gear (2), retainer (6), lock (3) and bolt (6) on camshaft (1). Tighten the bolt to a torque of 74 > 4 Nem (55 + 3 Ib ft) 4. Bend the tabs of the lock against the head of the bolt NOTE: Make an alignment of the mark (timing marks) con the camshaft gear with the mark on the crankshaft gear. 5. Put camshaft assembly (7) in position, NOTE: Keep the camshaft gear and crankshalt gear engaged at all umes. 1404 Engine 6. Install the bolts that hold the camshaft in position. Tur the camshatt to gain access to the bolt holes. End By: A. install front housing, b. install ol! pump C. install distributor . install rocker shaft assembly and push rods Camshaft Bearings Remove Camshaft Bearings 1211-011 eee ere ‘882247 Gamshat Bearing Istalaton And 1 Removal Geoup Start By, a. remove camshaft . remove flywheel housing 1, Remove cap plug (1). Disassembly & Assembly2, Remove the camishalt bearings with tooling (A) Install Camshaft Bearings 1211-012 Tools Needed 1852241 Camshaft Bearing instalation And ernoval Group 1. Install the camshaft bearings with tooling (A), 2. Install the front camshaft bearing even with the front surface of the cylinder block. 3. Install the front face of the middle camshaft bearing to a dimension of 280 mm (9.055 in) from the front surface of the cylinder block. 4. Install the front face of the rear carnshal bearing to @ dimension of 460 mm (18.11 in) from the front surface of the engine block NOTE: Put 7M7260 Liquid Gasket Material on the cup plug, 1404 Engine 5. Install cup plug (1) in the eylinder block. Install the plug to a minimum depth of 0.8 mm (.08 in) below the surface of the cylinder block. End By: . install flywheel housing b. install camshaft Flywheel Remove Flywheel 1156-011 Tools Needed [a EPO735 Link Bracket a 1 Start By ‘a. separation of engine and transmission NOTE: The engine is removed for better photo ilustration. Dacnsoniy & haa1. Fasten tool (A) and a hoist to the flywheel 2. Remove bolts (1), Remove flywheel (2). The weight ‘of the flywheel is 37 kg (82 Ib), Install Flywheel 1156-012 Tools Needed ae Bares ew Bracke ali $52008 Dal indent Tost Gop 7 esc WD ae ~ g 1. Fasten tool (A) and a hoist to fywhee! (1), NOTICE Make sure the lip of the lip-type seal in the flywheel housing is not damaged when the flywheel is installed 2. Put flywheel (1) in position, 1404 Engine 1 4. Install six bolts (2) that hold it in position. Tighten the bolts to a torque of 110 Nem (81 Ib ft) NOTE: See Testing And Adjusting for the procedure to check flywheel runout, 4. Put tooling (B) in position on the flywheel housing as shown to check the face runout (axial eccentricity) of the flywheel. See Specifications Manual for the correct face rundul Disassembly & Assembly5, Put tooling (B) in position on the flywheel housing as shown to check the bore runout (radial eccentricity) of the flywheel. See Specifications for the correct bore runout. 6. Put tooling (B) in position on the flywheel housing as shown to check the pil pin bore runout (eccentricity), See Specifications for the correct pilot pin bore runout End By: a. connection of engine and transmission 1404 Engine 92 Flywheel Ring Gear Remove & Install Flywheel Gear 1158-010 Start By a. remove flywheel 1. Remove flywheel ring gear (2) from flywheel (1) NOTICE Donot use an open flame or torch to heat the flywheel. 2. Heat flywheel ring gear (2) 1o a maximum temperature of 185°C (365°C), and instal it on flywheel (1). Install te ring gear against flywheel shoulder with the Part Numbér away fro the flywhee! shoulder. End By: 2. install lywhee! Disassembly & AssemblyFlywheel Housing Remove Flywheel Housing 1157-011 Start By. a. remove flywhee! 1. Remove six bolts (2). Remove flywheel housing (1) and the gasket, Install Flywheel Housing 1157-012 1. Put the new gasket and flywheel housing (1) in position 1404 Engine 8 AT7444P2 2. Install the six bolts that hold it in position. Tighten the bolts to a torque of 55 to 60 Nem (41 to 44 Ib ft) in the number sequence shown, 3. See Testing And Adjusting for the correct procedure to check flywheel housing runout End By: a. instal tlywhee! Flywheel Housing Seal Remove & Install Flywheel Housing Seal Start By: a. remove tlywhee! Remove seal (1) from the flywheel housing, Disassembly & AssemblyA592 Pt 2. Install the seal with tooling (A), The lip of the liptype ‘seal must be toward the flywheel End By: a. install flywheel Crankshaft Front Seal Remove & Install Crankshaft Front Seal 1160-010 ‘Tools Needed a 1510 Start By. ‘a. remove front housing NOTICE Use a press and a support for the housing to remove and install the seal 1. Romove the crankshaft front seal from front housing (1) with tooling (A) and a press. Wasssesp1 2. Install the crankshaft front seal in housing (1) with tooling (A) and a press, The lip of the lip-ype seal must be foward the crankshaft gear after installation, End By instal front housing, Crankshaft Rear Seal Remove & Install Crankshaft Rear Seal 1161-010 Start By; a. remove flywheel housing 1404 Engine Disassembly & AssemblyCrankshaft Remove Crankshaft 1202-011 177 1P2320_Puler Assembly Start By a. remove front housing b. remove flywheel housing ¢. remove oll pump 2, Install the crankshaft rear seal with tooling (A). The lip of the lip-type seal must be toward the cylinder block after installation End By: a. install flywheel housing 1, Make sure the rod caps have identification marks: for correct installation on the respective rods, 2, Remove nuts (3). Remove roc caps (4), 3. Remove five bolts (2) and nut (5). Remove three main bearing caps (1), NOTICE Put tape or rubber hose over the rod bolts to prevent damage to the crankshaft rod jcurnals, 1404 Engine 5 Disassembly & Assembly4. Remove crankshat (6) 5. Remove crankshalt timing gear (7) with tooling (A). Remove the key from the crankshaft 1404 Engine 96 Crankshaft 1202-012 A207 168: NOTE: The mark (timing mark) on the crankshaft gear must be facing away from the orankshal, 1. Install the key in the crankshaft NOTICE Do not use an open flame of torch to heat the erank- shaft gear 2. Heat crankshaft gear (1) to a maximum temperature ‘of 204°C (400°F). instal gear (1), Make an alignment of the notch in the gear and the key in the crankshaft, 3, Clean the cylinder block and main bearing caps thoroughly, NOTICE Put tape or rubber hose over the rod bolts to prevent damage to the crankshaft journals. Disassembly & AssemblyNOTE: Install the bearings dry when the clearance 10. Put clean engine oil on the bearing and the hacks are made, Put clean SAE 30 oll on the bearings crankshaft journal for final assembly 11. Install bearing cap (4), Tighten the bolts to a 4, Put crankshaft 2) in position. Make sure the mark torque of 75 to 80 Nem (55 to 60 Ib ft). (ming mark) on the crankshaft and the mark on the camshaft gear are in alignment. 12. Do Steps § thrcugh 11 for the other main bearings, 5. Install all but one of the main bearing caps. 6. Put the Piastigage in position on the lower half of the bearing, NOTICE Do not turn the crankshaft as it will damage the Plastigage 7, Install the bearing cap, 8, Tighten the bolls to a torque of 75 to 80 Nem (55 t0 60 Ib ft) 13, Measure the crankshaft end play. The end play must be between 0.10 to 0.23 mm (.004 to .009 in), Maximum end play for a worn crankshaft is 0.33 mm (.073 in) NOTE: Install the bearings dry when the clearance checks are made. Put clean SAE 30 oil on the bearings for fina assembly 14, Put clean engine oil an the threads of all bolts, 15. Use Plastigage to check the bearing clearance of the rods, Install the rod bearing cap Tighten the nuts to a torque of 44 + 3 Nem (32 + 2 Ib Mt). 8, Remove the main bearing cap, Measure the width of Piastigage (3). The bearing clearance with new beatings must be 0.023 to 0.089 (.0009 to .0035 in). The maxmum clearance with used bearings ‘must not be moe than 0.13 mm (.005 in), 1404 Engine 7 Disassembly & AssemblyAssacor2, 16. Remove the rod bearing cap and measure the width of Plastigage (5). The bearirg clearance with new bearings must be 0.033 to 0.079 mm (.0013 ‘te .0031 in). Maximum permissible clearance with used bearings is 0.114 mm ¢.0045 in). 17. install the rod bearing eap. Tighten the nuts to a torque of 44 29 Nem (92 2 2 Ib Mt). 18. Do Steps 14 through 17 for the other rod bearings. End By: instal oil pump b. install flywheel housing ©. install front housing 1404 Engine 98 Disassembly & Assembly©1992 Caterpillar Al Rights Reserved (MITSUBISH! CATERPILLAR FORKLIFT AMERICA INC. 5960 HEISLEY ROAD MENTOR, OHIO 44060 Printed in USA