SECTION 1.
15
GENERAL INFORMATION
SECTION MAIN POINTS
· Overview of the overhaul and repair process, includ-
ing general considerations before starting the work
such as engine handling and removal.
· Engine description, details and specifications.
· Specialized engine tool list.
· Conversion tables.
OVERHAUL/REPAIR PROCESS
Overhaul is the complete disassembly, examination,
repair or replacement of components, and reassembly
of the entire engine. Repair deals strictly with individual
engine components. When properly planned and
executed, the overhaul and repair process can be
effectively completed in a safe and timely manner.
PREVENTING ENGINE DAMAGE
Throughout this manual CAUTIONS and NOTES em-
phasize procedural items that need to be carefully
followed to avoid serious engine damage. Other points
to remember are:
· DON’T assume that procedures used for other
engines also apply to the VHP Series Four engine
series. DO be certain of procedures and information
for this specific engine before starting the work.
· DON’T remove gears, pulleys and other related parts
by prying or pounding. DO use the correct pullers or
special tools.
· DON’T throw nuts and bolts into a single box or
container. DO identify and store nuts and bolts
according to their proper assemblies. Different
lengths and grades of bolts are used for specific
purposes in certain applications.
· DON’T use parts from another engine. These parts
have wear-in patterns that may not match in another
engine. DO use new parts, if replacement is
necessary.
FORM 6296 First Edition
· DON’T try to compensate for torque wrench length-
ening. DO use the correct tool and torque values.
· DON’T force parts together. DO look for burrs, foreign
material or improper fits if an assembly is difficult to
put together.
· DON’T inspect a part for precision fit if it is oil
varnished, rusty or carbonized. DO clean parts first.
True fits cannot be calculated until true, accurate
measurements are taken. Keep records of the engine
history for yourself and the customer.
· DON’T check parts for precision fit if they are
abnormally hot or cold. Temperature will greatly affect
dimensions, especially large diameters. DO measure
all parts at room temperature, or check composite
assembly pieces at the same temperature.
· DON’T jump from one subassembly to another. DO
complete each subassembly from start to finish.
· DON’T reassemble the engine in a contaminated
parts cleaning area. DO keep the overall assembly
area free from flying foreign particles which will settle
on and contaminate the engine. Cover the exposed
engine with a sheet of plastic at the end of each day.
When a component is removed, seal the engine
opening to prevent foreign material from entering the
engine.
· DO work in a safe environment. No job should be
started if it cannot be finished safely and correctly.
HANDLING AND SHIPPING
Whenever an overhaul of a VHP Series Four engine is
anticipated, a decision must be made to do the work on
site or remove the engine to a more suitable overhaul
facility. Factors which can effect your decision are:
· Operational requirements of the user. What is the
owner’s turn-around time?
· Adequate lifting equipment. Is the proper lifting
equipment available? Can it be safely used on site?
1.15 -- 1
GENERAL INFORMATION
· Cleanliness of the site. A reasonably clean reas-
sembly area will be required.
· Proximity of an adequate overhaul facility.
Realistically, most VHP Series Four engine overhauls
will be done on site. Practicality and customer require-
ments will be the determining factors. The VHP Series
Four engine was designed so that it could be easily
serviced on site. Only the most unusual situations will
require the removal of the engine. If the engine work will
be done on site, then some external engine connections
may not need to be disconnected. Common sense,
practicality and safety need to be your guidelines in such
a situation. However, if engine removal from the site is
necessary, use the steps that follow.
Use extreme care when working on or near engine
installations. Make sure all fuel supply lines are
CLOSED and all electrical power is OFF. Place all
engine controls in the OFF position to prevent
accidental restarting. If possible, lock all controls in
the OFF position and take the key. Place a sign on
the instrument panel advising that the engine is
being serviced. Never attempt any work on an
engine while it is running. Disregarding this in-
formation could result in severe personal injury or
death.
ENGINE REMOVAL
Fluids in the engine remain hot after the engine is
shutdown. These hot fluids can cause severe burns.
Use care when working with engine fluid connec-
tions. Wait until the engine and its fluids cool down
before proceeding with any service. Disregarding
this information could result in severe personal
injury or death.
Be sure to follow the cor-
rect shutdown proce-
dures before starting any work on the engine. When
the engine is disconnected from its support equip-
ment, be sure to seal all engine openings to prevent
dirt and moisture from entering. Disregarding this
information could result in product damage and/or
personal injury.
1.15 -- 2
An approved engine
shipping skid, designed
to remain with the engine during any handling and
shipping, should be used. This skid is available
from Waukesha Engine. If this skid is already
attached, do not remove it. If not present, arrange to
get the skid to the site before engine removal is
attempted. Disregarding this information could
result in product damage and/or personal injury.
NOTE: Tag all electrical, pneumatic, fuel, coolant and
lubrication oil lines to ensure correct reassembly.
1. Check the installation for potential problems. If
problems are found, ensure that corrections are made
before the engine is reinstalled. Consult the Waukesha
Engine Installation Manual, Form 1091 (chapters 1
through 8) and the VHP Series Four 12 cylinder gas
engine Installation Drawings for installation recommen-
dations.
2. Disconnect driven equipment from the engine
flywheel.
3. Drain and properly discard coolant from the engine
and cooling system.
4. Disconnect coolant lines from the inlet and outlet
engine connections.
5. Drain and properly discard lubricating oil from the oil
pan, filter and cooler. Disconnect the oil filter lines.
6. Disconnect or remove air intake equipment.
7. Disconnect engine exhaust connections.
8. Remove any auxiliary instrument panels and sup-
ports. Disconnect wiring cables, fuel lines, throttle
linkage and any other accessory controls as required.
Never walk or stand under an engine or component
while it is suspended. Always consider the weight of
the engine or component and use only properly
rated lifting equipment and approved lifting meth-
ods. Make sure the transport vehicle is adequate to
handle the weights involved and can safely move
the engine. Disregarding this information could
result in severe personal injury or death.
NOTE: See Section 1.10 Rigging And Lifting Engines
for correct lifting methods. See Table 1.15-2 for compo-
nent weights.
FORM 6296 First Edition
 GENERAL INFORMATION

Follow approved rigging

procedures so that no
undue strain is placed on the lifting eyes and
hoisting chains/cable sling when the engine is
raised. Use the proper lifting device to avoid
product damage and/or personal injury.

9. Using a suitable lifting device carefully, lift engine as

required.

SERIAL NUMBER AND ENGINE

NAMEPLATE
The engine model, size, specification, serial, and
governing speed numbers are stamped on a nameplate
(see Figure 1.15-1 and Figure 1.15-2). This nameplate
is mounted on the left side of the crankcase just below
the #1L cylinder head. Figure 1.15-1. Engine Nameplate Location
When requesting information about the engine or parts,
it is important to reference both the engine model
number and serial number. If the nameplate is defaced
or detached, the serial number can be obtained directly
from the crankcase. It is stamped on the left firing deck,
just forward of the #1L cylinder head.

SAA # SERVICE TYPE

MODEL
WAUKESHA ENGINE
SERIAL DRESSER INC.
NUMBER WAUKESHA, WISCONSIN U.S.A. DATE
COMP.
RATIO

THIS ENGINE IS FACTORY EQUIPPED AS LISTED. HP(kW) ARE PER

ISO 3046/1. CONSULT A W.E.D. AUTHORIZED DISTRIBUTOR OR W.E.D.
APPLICATION ENGINEERING FOR ADDITIONAL INFORMATION.
ALTITUDE LIMIT
PRIMARY SECONDARY FT/M
FUEL
TM AIR INLET TEMP
MIN. WKI LIMT O
F/ C
O

IGN.TIMING
BTDC GOVERNED SPEED RPM

CARB ADJ.

SERVICE VALVE CLEARANCE IN. /mm

211853M

HP/kW INTAKE EXHAUST

OVERLOAD
HP/kW

FIRING ORDER

Figure 1.15-2. Engine Nameplate

FORM 6296 First Edition 1.15 -- 3

GENERAL INFORMATION

ENGINE IDENTIFICATION VIEWS

RIGHT SIDE VIEW

1 2 3 4
5

9
23
10
11

22 13 21 20 19 18 17 16 15 14 13 12

1. Exhaust Manifold Assembly (Right Bank) 13. Engine Leveling Bolts (Right Bank)
2. Control Panel (Right Bank) 14. Magneto Adapter
3. Water Piping 15. CEC Ignition Module
4. CEC Detonation Sensing Module Filter 16. Junction Box
5 Oil Cooler 17. Lube Oil Dipstick (Right Bank)
6. Jacket Water Pump 18. Regulator, Gas (Right Bank)
7. Governor 19. Carburetor (Right Bank)
8. Governor Speed Control Hand Lever 20. Manual Shutdown Lever
9. CEC Detonation Sensing Module 21. Lube Oil Strainer
10. Magneto Drive 22. Lube Oil Drain (Right Bank)
11. Vibration Damper 23. Water Drains (Right Bank)
12. Lube Oil Pump

Figure 1.15-3. Right Side View -- 12 Cylinder GSI

1.15 -- 4 FORM 6296 First Edition

 GENERAL INFORMATION

LEFT SIDE VIEW

1 2 3 4 5

23

22

21

20
6

19 7

18 17 16 15 14 13 12 11 10

1. Thermostat Cluster Housing 13. Lube Oil Pan

2. Control Panel (Left Bank) 14. Regulator, Gas (Left Bank)
3. Water Manifold 15. Lube Oil Dipstick (Left Bank)
4. Exhaust Manifold Assembly (Left Bank) 16. Crankcase
5. Cylinder Head Assemblies (Left Bank) 17 Engine Jacket Water Drains (Left Bank)
6 Wastegate Backpressure Regulator 18. Prelube Pump and Motor
7. Flywheel and Housing 19. Safety Guarding
8. Manual Barring Device 20. Lubricator
9. Lube Oil Filler 21. Microspin Oil Filter Housing
10. Lube Oil Drain (Left Bank) 22 Crankcase Breather (2)
11. Engine Leveling Bolts (Left Bank) 23. Oil Cooler
12. Lube Oil Pan Access Doors (Left Bank)

Figure 1.15-4. Left Side View -- 12 Cylinder LT

FORM 6296 First Edition 1.15 -- 5

GENERAL INFORMATION

END VIEW

3 2 2 3

4
5

5
6
6
7

8
8

10

1. Flexible Exhaust Connection 6. Lifting Eyes (4) (2 each front and rear)
2. Wastegates (2) 7. Intake Manifolds (2)
3. Turbochargers (2) 8. Carburetors (2)
4. Cylinder Head Assemblies (12) 9. Oil Outlet to Filter
5. Air Cleaners (2) 10. Intercooler

Figure 1.15-5. Rear View -- 12 Cylinder

1.15 -- 6 FORM 6296 First Edition

 GENERAL INFORMATION

BASIC ENGINE DESCRIPTION SERVICE TOOLS LIST

The Waukesha VHP Series Four 12 cylinder gas engine Table 1.15-1 lists tools to perform the tasks indicated on
series has the following models: L5774LT, L5794GSI/LT VHP Series Four 12 cylinder gas engines. In some
and L7044GSI. Engines designated “GSI” are turbo- instances, substitute items may be used, but only if
charged and intercooled. Engines designated “LT” are specifically approved by Waukesha. To order these
turbocharged, intercooled and lean combustion. special tools, contact your local Waukesha Engine
All engines are four cycle and rotate in the standard Distributor.
counterclockwise direction, as viewed from the rear Table 1.15-1. Service Tools
(flywheel) end. The 12 cylinders are arranged in a WAUKESHA TOOL DESCRIPTION
V-configuration, six on each bank. The crankcase is a TOOL P/N
single piece, rigid gray iron casing. The main bearings 475075 Spark Plug Extension Puller
are replaceable. The main bearing caps are held in Spark Plug Socket/Ext. (1 inch socket with
place with vertical studs and lateral tie bolts. The 167164D 10 inch extension, for Shielded, CSA w/ F.M.
coils)
counterweighted crankshaft is made of forged steel and
has seven main bearing journals. Each engine is 474001 Camshaft Bearing Rollout Tool
equipped with viscous vibration dampers. 474003 Reducer

There are 12 interchangeable cylinder heads, each with 474005 Crankshaft Pulley Stop Liner
two Stelliteâ faced intake and two Stelliteâ faced 474013 Water Pump Rebuilding Tool Kit
exhaust valves. The intake valve is Stelliteâ faced and 474016 VHP V- Belt Tester
the exhaust valve seat is water cooled. Roller type valve 474018 Piston Puller (8.5 inch bore)
lifters and hydraulic push rods are standard. The
474019 Piston Puller (9.38 inch bore)
camshaft consists of two individual segments. The
connecting rods are made from drop forged steel and 474029 Valve Seat Installer
are rifle drilled. The cylinders have replaceable wet 474038 Valve Seat Extractor
cylinder liners. The pistons are aluminum alloy with full 474039 Spark Plug/Ignitor Liner Remover Tool
floating piston pin. The flywheel is machined and has a 474040 Valve Bridge Guide Puller
ring gear attached.
475073 Deluxe Infrared Thermometer
NOTE: “Stelliteâ is a registered trademark of Stoody 475074 Infrared Thermometer
Deloro Stellite, Inc.” 475004 Control Display Unit
The exhaust driven turbocharger compresses intake air. 475064 Digital Thermometer
This charged air is cooled in the intercooler then enters 475007 Oxygen Analyzer -- 110V, Battery
the carburetor and mixes with pressurized fuel gas. The 475357 Oxygen Analyzer -- 110V
turbocharged air/fuel mixture enhances the engine’s
475067 CO/HC Analyzer
power and performance.
475068 Oxygen Analyzer -- 220V
The pressurized lubricating system consists of an oil
475069 Oxygen Analyzer -- 220V, Battery
sump, gear driven pump, piping network, filters, strain-
ers and cooler. The full flow oil filter is externally 475039 Oxygen Sensor Socket
mounted, separate from the engine. The system also 475015 Filter (Box Of Ten)
consists of an externally mounted oil cooler. 475019 Torque Wrench
The cooling system has two water pumps. The main 475020 Standard Borescope Kit
water pump is belt driven and circulates the jacket water 475025 Deluxe Borescope Kit
of the engine. The other belt driven pump, the auxiliary 475076 Deluxe Borescope Kit (with swinging prism)
water pump, circulates water for the oil cooler and the 475023 AC/DC Light Source Cable
intercooler. The engine jacket, cylinder heads, exhaust
475022 DC Battery Pack
manifold, turbocharger, oil and charged intake air are all
water cooled. 475026 Regulator Adjuster
475072 Digital Manometer/Calibrator Kit

FORM 6296 First Edition 1.15 -- 7

GENERAL INFORMATION

WAUKESHA TOOL DESCRIPTION WAUKESHA TOOL DESCRIPTION

TOOL P/N TOOL P/N
475032 CEC Ignition Tester Valve Seat Grinding Stone (20° Seat Angle
494014 Stone)
Spark Plug Socket (7/8 inch socket w/rubber
475037 insert) Valve Seat Grinding Stone (30° Seat Angle
494305 Stone)
474041 Piston Ring Expander (9-3/8² pistons)
494283 Magnafluxt Dye Penetrant Kit
474042 Piston Ring Expander (8-1/2² pistons)
494287 Valve Adjusting Wrench
494029 O-Ring Lube
494288 Dial Indicator Kit
494085 Piston Ring Compressor (8-1/2² pistons)
494292 Mechanical Deflection Gauge
494206 Piston Ring Compressor (9-3/8² pistons)
494424 Digital Metric Crankshaft Deflection Gauge
494087 Spark Plug Thread and Seat Cleaner (18 mm)
494331 Valve Guide Machining Tool
494215 Compression Tester
494335 Valve Seal Installation Tool
494217 Compression Tester Adapter (18 mm)
494338 Induction Timing Light
494234 Flexible Cylinder Deglazing Hone (9-3/8² bore)
494344 Pilot Mandrel
494236 Flexible Cylinder Deglazing Hone (8-1/2² bore)
494345 Exhaust Probe
474034 4 Valve Spring Compressor
494360 Emissions Accessory Kit
494257 Valve Guide Remover Tool
494363B Spreader Beam
494258 Slack Tube Manometer
494366 Main Bearing Installation Tool
494261 VHP Hand Tool Kit
494388 Oxygen Cell
494262 Depth Gauge
494389 Span Gas Bottle
494266 Socket
494498 Piston Pin Retaining Plier
494267 Extension
499233 Cylinder Liner Puller
494268 Socket
Spark Plug Thread And Seat Cleaner (18 mm)
494269 Torque Multiplier 475065 for 13/16 reach spark plug bores
494272 Torque Wrench, 3/4 -- 200 to 600 ft-lb KrytoxR GPL--206 grease -- For spark plug boot
489341 and extension
494273 Torque Wrench, 1/2 -- 40 to 250 ft-lb
475077 Ignition Analyzer
494276 Hand Held Digital Tachometer
Camshaft Dummy Gear - Allows for easy end
494277 Valve Grinder (110V) 474000 play adjustment
475070 Valve Grinder (220V)
499953 Valve Guide Reamer
494278 Valve Seat Dial Indicator

1.15 -- 8 FORM 6296 First Edition

 GENERAL INFORMATION

ENGINE STANDARDS COMPONENTS lb. kg

COMPONENT WEIGHTS Turbocharger 67 (MAX) 30
Thermostat Housing Assembly 67 30
Table 1.15-2. VHP Series Four 12 Cylinder Engine
Component Weights Carburetor 24 11
Water Pump, Main 101 46
COMPONENTS lb. kg
Water Pump, Auxiliary 44 20
Air Duct 53 24
Camshaft Cover 198 90 CLEARANCES
Camshaft Gear 32 15
The clearances section of the manual contains both new
Camshaft 114 52
part tolerances as well as field condemning limits. These
Carburetor 24 11 part tolerances are published to establish engine ratings
Cover, Gear 157 71 and warranty limitation on liability of new engines and
Connecting Rod Assembly 62 28 service parts.
Crankcase w/Main Bearing Caps/ Wear limits are published as guidelines for engine
Studs/Nuts and Camshaft Bearing 4965 2252 overhaul and repair. These guidelines can be the basis
Caps
for the reuse of parts which, though worn, still retain
Crankshaft Assembly 1828 829
service life at a reduced performance rating. Waukesha
Cylinder Head 195 89 Engine emphasizes that these wear limits are guidelines
Cylinder Liner 63 28 and, as such, must be used with discretion and with the
Vibration Damper 303 137 understanding that new engine performance may not be
Elbow, Turbo Inlet RB 34 15 achievable.
Elbow, Turbo Inlet LB 35 16
While Waukesha Engine
Elbow, Turbo Exhaust 7 3
does not recommend the
Extractor, Venturi 15 7 reuse of pistons during engine overhauls, we
Housing, Gear 138 63 recognize that this is a common field practice.
Housing, Flywheel, Front Section 202 97 Pistons experience a combination of mechanical
Housing, Flywheel, Rear Section 107 49 and thermal cyclic stresses during operation. Alu-
minum piston life is unknown beyond recom-
Flywheel w/ Ring Gear 878 398
mended overhaul. If and when end users make the
Governor Assembly 52 24
decision to reuse pistons, inspection steps need to
Idler Gear 27 12 be taken to minimize failure risks. Contact your
Intercooler, Without Bracket or Piping 389 177 authorized Waukesha Distributor for assistance.
Intercooler Assembly w/Bracket 423 192 Disregarding this information could result in prod-
Magneto Drive Assembly 92 41
uct damage and/or personal injury.
Magneto Drive Gear 78 35 Waukesha Engine’s position for these wear limits is that
Manifold, Exhaust 92 42 the reuse of an engine part that does not meet the new
Manifold, Intake 86 39 part specifications is solely the responsibility of the
Manifold, Water 102 46
person making the inspection and repair. Under no
circumstances is the reuse of any part exceeding the
Oil Cooler 225 106
following wear limits justified.
Oil Cooler With Support Brackets 350 156
Waukesha Engine assumes no liability for any damage
Oil Filter 254 115
that may occur through the reuse of engine parts which
Oil Pump 123 56 fall outside of the new part tolerances.
Oil Pan 1790 812
Piston 33 15
Piston Pin 12 6
Pulley, Rear Crankshaft 81 37
Regulator, Gas (Fisher 99) 78 35
Skid, Shipping 466 211

FORM 6296 First Edition 1.15 -- 9

GENERAL INFORMATION

TORQUE SPECIFICATIONS
GENERAL TIGHTENING SEQUENCE PROCEDURE 1
8 0 5
The sequence in which capscrews, bolts and nuts are
tightened influence the distribution of fastener clamp
load. Parts that use several fasteners such as cylinder 2 3
heads, flywheels, oil pans, water pumps, cover plates,
etc. must have the fasteners tightened (or loosened) 1 3 4 1
gradually and in a specific sequence. This is necessary 4 2
to avoid the excessive uneven loads that can cause 6 7
gasket leakage, or the locking and warpage that cause 9
damage to the parts during assembly or disassembly.
If a special torquing sequence diagram is not available,
the following procedure should be used. CIRCULAR FOUR-BOLT NON-CIRCULAR MULTI-BOLT

First, assemble all the fasteners loosely and align and

adjust the part as required to assure proper alignment 4 14 9
7 6
with mating parts and to eliminate possible interference
12 1
with adjacent parts, then begin torquing sequence. 1 3
15 16
The torquing of fasteners to their torque specifications
should be done in a minimum of three steps, with no 2 11 4 2
more than 50 percent of the final required torque being 5 8
applied in the initial step. The fasteners should be 10 13 3
tightened in a criss-cross or diagonal pattern, as shown
in Figure 1.15-6 and Figure 1.15-7, to distribute the CIRCULAR MULTI-BOLT SQUARE FOUR-BOLT
fastener load evenly throughout the part. Use the same
Figure 1.15-6. Tightening Sequence For Multi-Bolt
sequence of torquing for each subsequent step until Patterns
each fastener is torqued to its torque specification. To
loosen or remove the fasteners, the procedure should Special thread lubricants such as Molycoteä Paste G or
be done in reverse. Bostik Never Seezâ reduce the friction on the threads so
much that the actual torque on the fastener may exceed
THREAD LUBRICATION FOR TORQUE
the actual torque wrench indication by as much as
FASTENERS
41 percent. This over-torquing puts an excessive strain
Use only clean engine oil as a thread lubricant on those on the fasteners, which could be critical on such
fasteners that have been assigned specific torque fasteners as the capscrews and studs that attach VHP
values. Series Four cylinder heads.
Also when working on a crankcase that has been
Do not use Molycoteä hot-tank cleaned, be sure to generously apply engine oil
Paste G, Bostik Never on all studs that were hot-tanked as part of the
Seezâ or any other special thread lubricant unless crankcase assembly.
specifically instructed to do so by Waukesha Engine.
Disregarding this information could result in prod-
uct damage and/or personal injury.

23 17 15 9 7 1 3 5 11 13 19 21

FRONT REAR

22 20 14 12 6 4 2 8 10 16 18 24

Figure 1.15-7. Manifolds, Headers, etc.

1.15 -- 10 FORM 6296 First Edition

 GENERAL INFORMATION

CRITICAL ENGINE TORQUE VALUES

Table 1.15-3 lists critical fastener torque specifications. Fasteners not listed here should be tightened according to the
general torque specification tables. All torque values assume dry hex head screws unless oil is stated.
Table 1.15-3. VHP Series Four 12 Cylinder Torque Values
DESCRIPTION ft-lb/in-lb N×m
Breather System 3/8-16 (chamber and gasket flange) 31 42
Butterfly Housing, Intake 1/2-13 (intake horn to carburetor) 53 72
Butterfly Housing, Intake 5/8-11 (butterfly to intake manifold) 53 72
Carburetor 1/2-13 (carburetor to butterfly) 53 72
Carburetor 1/2-13 (air horn to carburetor) 53 72
Camshaft Gear Nut 1-1/2-12 433 -- 450 587 -- 610
Camshaft Bearing Cap 3/8-16 31 42
Camshaft Valley Cover (Valve Lifter Housing) (3/8-16 hex head capscrew) 31 42
Camshaft Valley Cover Ends (3/8-16 ferryhead capscrew) 31 42
Connecting Rod Capscrews 5/8-18 185 (oil) 251 (oil)
Counterweight Capscrews 7/8-14 483 -- 500 655 -- 678
Crankshaft End Plate Capscrews Check annually 410 556
Crankshaft End Plate Capscrews (built after November 15, 2002) 515 698
Crankshaft Pulley 80 -- 84 108 -- 114
Cylinder Head Spark Extension on GL models (apply anti--seize) 275 -- 280 373 -- 380
Cylinder Head Capscrews (see “Cylinder Head Tightening Sequence” in Section 4.05) 625 -- 650 (oil) 847 -- 881 (oil)
Dipstick 3/8-16 31 42
DSM Knock Sensor 35 -- 40 54
Exhaust Manifold To Cylinder Head Capscrews 1/2-13 66 -- 70 (oil) 89.5 -- 95 (oil)
Exhaust Outlet M18 SS plug 35 47
Exhaust Outlet V--band clamp (elbow tee) 110 -- 130 149 -- 176
Front Gear Cover 1/2-13 70 95
Front Gear Cover 1/2-20 studs and nuts (alternator delete cover) 75 102
Front Gear Cover 3/8-16 (cover plates) 31 42
Flywheel Housing 5/8-11 (front) 150 203
Flywheel Housing 1/2-13 (rear) 75 102
Flywheel, Plate 3/4-10 275 -- 285 373 -- 386
Flywheel To Crankshaft Capscrews 5/8-18 171 -- 175 (oil) 232 -- 237 (oil)
Governor Drive Housing 3/8-18 31 42
Governor Drive Housing Cover 3/8-18 31 42
Governor Mount 3/8-16 31 42
Governor Overspeed Drive Cover 5/16-18 18 24
Idler Gear (Camshaft) Capscrews 1/2-20 87 118
Idler Gear Spindle Nut 1-1/2-12 (in crankcase, LH thread) (use Loctiteâ 271 on threads) 775 -- 780 1051 -- 1058
Ignition Coil Nuts 11 -- 13 15 -- 17.6
Intake Manifold 1/2-13 66 -- 70 89 -- 95
Intake Manifold 1/2-13 (end covers) 53 72
Intercooler 1/2-13 (intercooler bracket mount) 105 142
Lifting Eye 1/2-13 75 102
Magneto Delete Covers 3/8-16 studs with nuts 30 41
Magneto Drive Gear to Shaft 7/6-20 78 106
Magneto Drive to Cover 1/2-20 studs with nuts 80 108
Main Bearing Studs (in crankcase) (use Loctiteâ 271 on threads) 50 68
Main Bearing Caps (see Figure 2.05-79 for tightening sequence) 75 (oiled) 102 (oiled)
C ti C 3/4 10 250 ( il d) 339 ( il d)
Oil Cooler Piping 1/2-13 capscrews and nuts 75 102
Oil Cooler Lifting Brackets 1/2-13 105 142
Oil Filter Cover Bolts 33 - 37 47 - 50

FORM 6296 First Edition 1.15 -- 11

GENERAL INFORMATION

DESCRIPTION ft-lb/in-lb N×m

Oil Header 1-1/4 NPT countersunk headless pipe plugs 233 316
Oil Header 3/4 NPT pipe plugs 50 68
Oil Pan Door 5/8-11 (explosion relief) 18 - 20 24 - 27
Oil Pan Door 1/2-13 (standard) 18 - 20 24 - 27
Oil Pan Drain Back Cover 1/2-13 75 102
Oil Pan Mounting 1/2-13 75 (oiled) 102 (oil)
Oil Pan Mounting 3/4-10 260 - 280 352 - 379
Oil Pan Mounting 5/8-11 140 - 160 190 - 217
Oil Pump Body 1/2-20 capscrew and nut 85 115
Oil Pump Cover 3/8-16 31 42
Oil Pump Idler Spindle 3/4-16 capscrew and nut (use Loctiteâ 271 on threads) 300 - 325 407 - 441
Oil Pump Manifold 3/8-16 31 42
Oil Strainer Elbow 1/2-13 75 102
Oil Strainer 5/16-18 (strainer to inlet elbow) 17 23
Pushrod Dust Covers 3/8-16 31 42
Prelube Pump 3/8-16 (oil supply tube flange to oil pump) 31 42
Rear Crankshaft Seal Retainer 3/8-16 31 42
Rear Crankshaft Seal Retainer 7/16-14 49 66
Rocker Arm Cover (Valve Cover) 4.2 (oiled) 5.65 (oiled)
Rocker Arm Support 1/2-13 x 5-1/2 66 - 70 (oiled) 89 - 95 (oiled)
Rocker Arm Support 3/8-16 x 6-3/4 (center capscrew) 17 (oiled) 23 (oiled)
Spark Plug Carrier Extension (nut) 17 23
Spark Plugs (13/16 inch reach spark plugs must be used with P/N 205002) 32 - 38 43 - 52
Spark Plug Sleeve (nut) 17 23
Stub Shaft to Vibration Damper 1/2-13 ferryhead capscrews 80 - 84 108 - 114
Timing Disk 10-32 socket head screw 50 in-lb 5.6
Thermostat Housing Outlet Tubes 1/2-13 ferryhead capscrew (flange to water pump) 75 102
Thermostat Housing Outlet Tubes 1/2-13 (flange to thermostatic housing) 75 102
Turbocharger V--Band Clamp 110 - 130 12.4 - 14.6
Turbocharger Flanges 13.3 - 17.3 18 - 23.5
Valve Lifter Housing to Valve Lifter Housing 3/8-16 (ferry head capscrew) 31 42
Valve Lifter Screw (fixed type only) 9/16-18 55 - 60 75 - 81
Vibration Damper Capscrew 1/2-13 (vibration damper to pulley) 80 - 84 108 - 114
Vibration Damper 87 - 92 118 - 125
Water Outlet Elbow to Cylinder Head 3/8-16 (ferryhead capscrew) 27 - 29 37 - 39
Water Outlet Elbow to Exhaust Manifold 1/2-13 66 - 70 89 - 95
Water Header 3/4-10 capscrew and nut (water header flange cap) 105 142
Water Header Plugs 50 68
Water Pump Mount 3/8-24 studs with nuts 35 47
Water Pump Elbow 1/2-13 70 95
Water Pump Header Inlet 1/2-13 75 102
Water Manifold, Top 3/8-16 ferryhead capscrew (jumper to exhaust manifold) 31 42
Water Manifold, Top 3/8-16 (manifold to thermostat housing) 31 42
Wastegate Regulator 3/8-24 stud, nut and jam nut (elbow mount) 35 47
Wastegate Elbow 3/8-16 (turbocharger flange to elbow flange) 31 42
Wastegate Elbow 3/8-16 ferryhead (exhaust elbow to exhaust manifold) 29 39
Wastegate Elbow 3/8-16 allen head (turbocharger oil supply/drain tube flange) 31 42
Wastegate Elbow 3/8-16 (turbocharger water supply/drain tube flange) 31 42

1.15 -- 12 FORM 6296 First Edition

 GENERAL INFORMATION

GENERAL TORQUE RECOMMENDATIONS

The values specified below are to be used only in the absence of specified torquing instructions and are not to be
construed as authority to change existing torque values. A tolerance of ±3 percent is permissible on these values,
which are for oiled threads.
Table 1.15-4. U.S. Standard Capscrew Torque Values

SAE
GRADE
NUMBER
Grade 1 or 2 Grade 5 Grade 8
SIZE/
THREADS TORQUE TORQUE TORQUE
PER INCH in-lb (N×m) in-lb (N×m) in-lb (N×m)

THREADS DRY OILED PLATED DRY OILED PLATED DRY OILED PLATED
1/4-20 62 (7) 53 (6) 44 (5) 97 (11) 80 (9) 159 (18) 142 (16) 133 (15) 124 (14)
1/4-28 71 (8) 62 (7) 53 (6) 124 (14) 106 (12) 97 (11) 168 (19) 159 (18) 133 (15)
5/16-18 133 (15) 124 (14) 106 (12) 203 (23) 177 (20) 168 (19) 292 (33) 265 (30) 230 (26)
5/16-24 159 (18) 142 (16) 124 (14) 230 (26) 203 (23) 177 (20) 327 (37) 292 (33) 265 (30)
3/8-16 212 (24) 195 (22) 168 (19) 372 (42) 336 (38) 301 (34) 531 (60) 478 (54) 416 (47)
ft-lb (N×m) ft-lb (N×m) ft-lb (N×m)
3/8-24 20 (27) 18 (24) 16 (22) 35 (47) 32 (43) 28 (38) 49 (66) 44 (60) 39 (53)
7/16-14 28 (38) 25 (34) 22 (30) 49 (56) 44 (60) 39 (53) 70 (95) 63 (85) 56 (76)
7/16-20 30 (41) 27 (37) 24 (33) 55 (75) 50 (68) 44 (60) 78 (106) 70 (95) 62 (84)
1/2-13 39 (53) 35 (47) 31 (42) 75 (102) 68 (92) 60 (81) 105 (142) 95 (129) 84 (114)
1/2-20 41 (56) 37 (50) 33 (45) 85 (115) 77 (104) 68 (92) 120 (163) 108 (146) 96 (130)
9/16-12 51 (69) 46 (62) 41 (56) 110 (149) 99 (134) 88 (119) 155 (210) 140 (190) 124 (168)
9/16-18 55 (75) 50 (68) 44 (60) 120 (163) 108 (146) 96 (130) 170 (230) 153 (207) 136 (184)
5/8-11 83 (113) 75 (102) 66 (89) 150 (203) 135 (183) 120 (163) 210 (285) 189 (256) 168 (228)
5/8-18 95 (129) 86 (117) 76 (103) 170 (230) 153 (207) 136 (184) 240 (325) 216 (293) 192 (260)
3/4-10 105 (142) 95 (130) 84 (114) 270 (366) 243 (329) 216 (293) 375 (508) 338 (458) 300 (407)
3/4-16 115 (156) 104 (141) 92 (125) 295 (400) 266 (361) 236 (320) 420 (569) 378 (513) 336 (456)
7/8-9 160 (217) 144 (195) 128 (174) 395 (535) 356 (483) 316 (428) 605 (820) 545 (739) 484 (656)
7/8-14 175 (237) 158 (214) 140 (190) 435 (590) 392 (531) 348 (472) 675 (915) 608 (824) 540 (732)
1.0-8 235 (319) 212 (287) 188 (255) 590 (800) 531 (720) 472 (640) 910 (1234) 819 (1110) 728 (987)
1.0-14 250 (339) 225 (305) 200 (271) 660 (895) 594 (805) 528 (716) 990 (1342) 891 (1208) 792 (1074)

NOTE: Dry torque values are based on the use of clean, dry threads.
Oiled torque values have been reduced by 10% when engine oil is used as a lubricant.
Plated torque values have been reduced by 20% for new plated capscrews.
Capscrews which are threaded into aluminum may require a torque reduction of 30% or more.
The conversion factor from ft-lb to in-lb is ft-lb x 12 equals in-lb.

FORM 6296 First Edition 1.15 -- 13

GENERAL INFORMATION

SPLIT RING WASHER USABILITY

T5
CRITERIA
Split ring washers are washers that, once compressed,
keep an outward pressure applied on screw threads
allowing friction to hold them in place. Depending on the
location and application, these washers may be suitable
for re-use. Do not re-use split ring washers that have
flattened due to high temperatures or over-use (see
Figure 1.15-8). If you are not sure if a split ring washer is
suitable for re-use, replace it with a new one.

Figure 1.15-10. Water Manifold Probe

DO NOT RE-USE RE-USE

Figure 1.15-8. Split Ring Washers

During overhauls, and on all components subjected to

high temperatures, Waukesha recommends replacing
split ring washers.

TEMPERATURE AND PRESSURE TEST

POINTS
Refer to Figure 1.15-13 through Figure 1.15-14 for T2
location of temperature and pressure test points on all
VHP Series Four engines. Figure 1.15-9 through
Figure 1.15-12 show close--ups of some of the Figure 1.15-11. Turbocharger Elbow Probe
installations.

P6
P1, T1

P5

Figure 1.15-12. Fuel Regulator Ports

Figure 1.15-9. Intake Manifold Port

1.15 -- 14 FORM 6296 First Edition

 GENERAL INFORMATION

P3, T3
EP

P2, T2

Pressures Temperatures
P2 Exhaust Manifold T2 Exhaust Manifold
P3 Exhaust Back Pressure T3 Exhaust Stack
Other
EP Exhaust Probe

Figure 1.15-13. Temperature And Pressure Test Points -- Rear View -- 12 Cylinder GSI, LT

FORM 6296 First Edition 1.15 -- 15

GENERAL INFORMATION

LEFT SIDE

P2, T2

T6 P8 P1, T1

RIGHT SIDE
T5

P2, T2

T4 P4 P6 P5

Pressures Temperatures
P1 Intake Manifold T1 Intake Manifold
P2 Exhaust Manifold T2 Exhaust Manifold
P3 Exhaust Back Pressure T3 Exhaust Stack
P4 Oil T4 Oil
P5 Carburetor Air T5 Jacket Water Outlet
P6 Carburetor Fuel T6 Auxiliary Water Inlet
P8 Crankcase Vacuum Other
EP Exhaust Probe
Figure 1.15-14. Temperature And Pressure Test Points -- Right And Left Side Views -- 12 Cylinder GSI, LT

1.15 -- 16 FORM 6296 First Edition


ENGLISH/METRIC CONVERSIONS
Table 1.15-5. English To Metric Formula Conversion Table
CONVERSION
Inches to Millimeters
Cubic Inches to Litres
Ounces to Grams
Pounds to Kilograms
Inch Pounds to Newton-meters
Foot Pounds to Newton-meters
Pounds per Square Inch to
Kilograms per Square Centimeter
Pounds per Square Inch to
Kilopascals
Fluid Ounces to Cubic Centimeters
Gallons to Litres
Degrees Fahrenheit to Degrees
Centigrade
Table 1.15-6. Metric To English Formula Conversion Table
CONVERSION
Millimeters to Inches
Litres to Cubic Inches
Grams to Ounces
Kilograms to Pounds
Newton-meters to Inch Pounds
Newton-meters to Foot Pounds
Bar to Pounds per Square Inch
Kilograms per Square Centimeter
to Pounds per Square Inch (psi)
Kilopascals to Pounds per Square Inch
(psi)
Cubic Centimeters to Fluid Ounces
Litres to Gallons
Degrees Centigrade to Degrees Fahren-
heit
FORM 6296 First Edition
FORMULA
Inches and any fraction in decimal equivalent
multiplied by 25.4 equals millimeters.
Cubic inches multiplied by 0.01639 equals litres.
Ounces multiplied by 28.35 equals grams.
Pounds multiplied by 0.4536 equals kilograms.
Inch pounds multiplied by 0.11298 equals
Newton-meters.
Foot pounds multiplied by 1.3558 equals
Newton-meters.
Pounds per square inch multiplied by 0.0703 equals
kilograms per square centimeter.
Pounds per square inch multiplied by 6.8947 equals
kilopascal.
Fluid ounces multiplied by 29.57 equals
cubic centimeters.
Gallons multiplied by 3.7853 equals litres.
Degrees Fahrenheit minus 32 divided by 1.8 equals
degrees Centigrade.
FORMULA
Millimeters multiplied by 0.03937 equals inches.
Litres multiplied by 61.02 equals cubic inches.
Grams multiplied by 0.03527 equals ounces.
Kilograms multiplied by 2.205 equals pounds.
Newton-meters multiplied by 8.85 equals
inch pounds.
Newton-meters multiplied by 0.7375 equals
foot pounds.
Bar multiplied by 14.5 equals pounds per square
inch.
Kilograms multiplied by 14.22 equals pounds per
square inch.
Kilopascals multiplied by 0.145 equals pounds per
square inch.
Cubic centimeters multiplied by 29.5 equals
fluid ounces.
Litres multiplied by 0.264 equals gallons.
Degrees Centigrade multiplied by 9/5 plus 32 equals
Degrees Fahrenheit.
GENERAL INFORMATION
EXAMPLE
2-5/8 in. = 2.625 x 25.4 = 66.7 mm
9388 cu. in. = 9388 x 0.01639 = 153.9 litres
21 oz. = 21 x 28.35 = 595.4 grams
22,550 lbs. = 22,550 x 0.4536 = 10.228.7
kg
360 in-lb = 360 x 0.11298 = 40.7 N×m
145 ft-lb = 145 x 1.3558 = 196.6 N×m
45 psi = 45 x 0.0703 = 3.2 kg/cm2
45 psi = 45 x 6.8947 = 310.3 kPa
8 oz. = 8 x 29.57 = 236.6 cc
148 gal. = 148 x 3.7853 = 560.2 litres
212° F - 32 ¸ 1.8 = 100° C
EXAMPLE
67 mm = 67 x 0.03937 = 2.6 in.
153.8 L = 153.8 x 61.02 = 9384.9 cu. in.
595 G = 595 x 0.03527 = 21 oz.
10,228 kg = 10,228 x 2.205 = 22,554 lbs.
40.7 N×m = 40.7 x 8.85 = 360 in-lbs.
197 N×m = 197 x 0.7375 = 145 ft-lb
685 Bar = 685 x 14.5 = 9,932.5 psi
3.2 kg = 3.2 x 14.22 = 45.5 psi
310 kPa = 310 x 0.145 = 45 psi
236 cc = 236 x 29.5 =8 oz.
560L = 560 x 0.264 = 147.8 gal.
100° C = 100 x 9/5 + 32 = 212° F
1.15 -- 17
GENERAL INFORMATION

INDEX OF SEALANTS, ADHESIVES AND be used to match the general description to a specific
LUBRICANTS product or its equivalent (ie. pipe sealant = Perma Lokâ
Heavy Duty Pipe Sealant with Teflon or its equivalent).
The following is a list of sealants, adhesives and Waukesha does not endorse one brand over another. In
lubricants (see Table 1.15-7) required to perform the all cases, equivalent products may be substituted for the
tasks in this manual. Where possible, brand names are brand name listed. All part numbers listed are the
included with the task. When they are not, this index may manufacturer’s numbers.
Table 1.15-7. Sealants, Adhesives, And Lubricants
NAME USED IN TEXT BRAND NAME/DESCRIPTION
FEL--PROâ C5--Aâ, P/N 51005 or Loctiteâ Anti--Seize 767/Copper based anti--seize
Anti--seize (High Temperature) compound
Bostik Never Seezâ Anti--Seize and Lubricating Compound/Nickle based anti--seize
Anti--seize compound
Black Silicone G.E. Silmateâ Silicone Rubber
Bluing Agent Permatexâ Non Drying Prussian Blue (mfg. by Loctite Corporation)
Cleaning Solvent/Mineral Spirits Amisolt Solvent (mfg. by Standard Oil)
Dielectric Silicone Grease Dow Corning DC--200, G.E. G--624, GC Electronics 25
Engine Oil New oil of the type used in the crankcase
Scotch Weldâ No. 270 B/A Black Epoxy Potting Compound/Adhesive, P/N’s. A and B
Epoxy Sealant 3M ID No. 62--3266--7430--6 (PA)
Gasket Adhesive Scotch Gripâ 847 Rubber and Gasket Adhesive (mfg. by 3M), 3M ID No. 62--0847--7530--3
Gear Oil Vactraâ 80W90 Gear Oil (mfg. by Mobil)
Krytoxâ GPL--206 Krytoxâ GPL--206 high temperature grease
Lithium Grease See Molycotet Paste G
CITGO Lithoplexâ Grease NLGI No. 2 Product Code 55--340/a molybdenum--based grease
Lithoplexâ or Molycoteä Paste G or Dow Corning Molycotet Paste G
Locquicâ Primer “T” Item No. 74756 (mfg. by Loctite Corporation)
Loctiteâ 222 Loctiteâ Item No. 22220/low strength threadlocker
Loctiteâ 242 Loctiteâ Item No. 24241/blue colored removable thread locking compound
Loctiteâ 271 Loctiteâ Item No. 27141/red colored thread locking compound
Loctiteâ 5699 Grey Loctiteâ Item No. 18581/High Performance RTV Silicone Gasket Maker
Loctiteâ 620 Loctiteâ Item No. 620-40/High Temperature Retaining Compound
Loctiteâ Compound 40 Loctiteâ Item No. 64041/High Temperature Retaining Compound 40
Loctiteâ Hydraulic Sealant Loctiteâ Item No. 56941
Loctiteâ RCt/609 Loctiteâ Item No. 60931
Lube-Lokâ Lube-Lokâ 1000 or equivalent/ceramic bonded high temperature solid film lubricant
Lubriplate No. 105t Lubriplate No. 105t/lubricating grease
Metal Assembly Spray Dow Corning Lubricant G--n
Magnafluxâ Products: Penetrant (SKL--HF/S) Developer (SKD--NF--ZP--9B) Cleaner/
Magnafluxt Remover (SKC--NF/ZC--7B)
O-ring Lubricant Parker Super O-Lubet/dry silicone lubricant
Permatexâ Aviation Form-A-Gasketâ Sealant Loctiteâ Item No. 3D
Permatexâ Form-A-Gasketâ No. 2 Sealant Loctiteâ Item No. 2C
Permatexâ High Tack Spray-A-Gasketâ Sealant Loctiteâ Item No. 99MA
Pipe Sealant Perma Lokâ Heavy Duty Pipe Sealant with Teflon, Item No. LH050
Plastigaget Plastigaget/used for measuring small clearances
RTV Dow Corning RTV #734 or GE Red RTV 106
Slide Riteâ 220 CITGO/lubricating oil
Stelliteâ Stelliteâ is a registered trademark of Stoody Deloro Stellite, Inc.
WD-40â WD-40â is a registered trademark of the WD-40 Company.

1.15 -- 18 FORM 6296 First Edition