.

servicing instructidrns
maintenance
and
engine
data A4.318

©
Perkins Engines Ltd.
Peterborough
1976

Phone Peterborough 67411

Cables : Perkoil Peterborough
Publication No. 801 SER 07761134

This publication has been produced with the kind permission and
co-operation of Massey Ferguson Inc., Indiana, U.S.A.

Publl1htd by the Servii:a Public:a1lon1 Dop1nmen1 of P9rkln1 En;lnN Ltd••

■nd prinlad in Engl11nd by Peterborough Cantral Printera Limiled, P1tarbo1ough,
PARTONE POST DELIVERY CHECK-OVER

MAINTENANCE After a customer has taken delivery of his Perkins diesel engine, a general checkover of the engine must be carried
out after the first 50 hours in service.
The maintenance operations should be carried regularly and with great care. Only then can full benefit be attained
from this engine. The checkover should comprise o_f the following:-
1. Drain the lubricating oil sump and refill to the correct level with the correct grade and viscosity of oil.
When changing oil or fuel filters always throw the old canisters away.
2. Renew the lubricating oil filter element.

LUBRICATING OILS 3. Check that the cylinder head securing nuts and setscrews are to the correct torque. See p.3, Part 2.

Always use the correct grade and viscosity. 4. Set valve tappet clearance to 0.012 in (0.30 mm) Engine cold.

5. Check coolant level and check tor any leaks.

Lubricating oib fo, normally aspirated engines should ·meet tho' i9qulremonts of the U.S. Ordnance
Specilications MIL•L4162 or Mll·l·2104C.
6. Check external fastenings, mountings etc., for tightness.
·
Some. of these oils are listed below. Any other o; :;;;�•: �t these specificanons are
7. Check belt tension.
also
=

suitable.

MillM�it�fo�\· 8. Check electrical equipment and connections.

Company I .. Br.a nd ,. SAE Designation

I O'F.(·18'C) 30"F (·1'C)
9. Check for lubricating oil and fuel oil leaks.
i. to to Over
30'F (·1'CJ 80'F (27"C) 80 F (27'C)
° 10. Check general performance of the engine.
B.P. Lid. VanellusM 10W 20W 30
I VanellusM 20W-50 20W·50
Caslrol Lid. Castrol/Deusol CRB 10W 20 30
Caslrol/Deusol CRB SW/20
IOW/30 lOW/30
COLD WEATHER STARTING
Castrol/Deusol CRB 10Wi30
Caslrol/Deusol CRB 20W/50 20W/50
A. Duckham & Co. Lid. I Fleetol HDX 10 20 30
1. Set the throttle to maximum speed.
OMotorOil 20W/50 20W/50
Fleetol Multi V 20W/50 2. Push the fuel cut-off knob fully in.
lOW/30
2Wl/50
FleelolMullilile 10W/30 10W/30
Farmadcol HDX 20 30
Mobil Oil Co. Lid. Delvac 1200 Series 1210 1220 1230
3. Tum the starter switch key to the heat position and hold it there for 15 to 20 seconds.
10W/30 10W/30
Shell I
Oelvae Special
Rotella TX
Rotella TX
10W/30
10W 20W/20
20W/40
30
20W/40
4. Turn the key to the heat/start position and engage the starter.

5. If the engine fails to start within 15 seconds, return the key to the heat position for a further 10 seconds.

6. Re-engage the starter by moving the key back to the heat/start position.

MIL-1.-2104C OILS
Company Brand SAE Designation
7. As the .engine starts, tum the key to the heat position for up to 15· seconds maximum, until the engine runs
O"F (-ta'C) 30 F (·1'C)
steadily.
to Over
°

30'F (·1"C) SO'F 127'Cl a0•F (27'Cl

lo

B.P. Ltd. Vanellus C3 ,ow 20W/20 30

Cas1rol Ltd. Castrol/Deusol CRD 10W 20 CAUTION
20
30
Agricaslrot HOD 10W 30
A. Duckham & Co. Lid. Fleetol 3 3/10 3/20
Farmadcol 3 3/10 3/20 3/30
3/30 Ensure the starter motor pinion is at rest before re-engaging the starter.

Esso Petroleum Co. Ud. Essolube D-3 HP 10W 20W 30

Mobil Oil Co. Lid. Oelvac 1300 Series 1310 1320 1330
Shell Rlmula CT 10W 20W/20 30 STOPPING THE ENGINE
Rotella TX 10W 20W/20 30
Ro!ella TX 20W/40 20W/40
To stop the engine pull the fuel cut-off knob out. Turn the key to the "off" position.

Where oils to the MIL-L-46152 or.MIL-L·2104C specification ere not available, lhen oils to the previous
specification MIL·l.2104B for normally aspirated engines and MIL-IA5199B or Series 3 specification for
turbocharged engines may continue to be used providing they give satisfactory HNice.

The above specifications are subject to alteration without notice.

PREVENTIVE MAINTENANCE
PART 2 � ENGINE (A4.318)

Daily
CONTENTS
Check coolant level .

Check lubricating oil level.This should be done with the engi�e and machine standing on level ground. PAGE PAGE

In extreme dusty conditions, clean oil bath air. cleaner, or, empty the dust bowl in dry type air cleaners. INTRODUCTION .. .. .... ...... ....• ... . .. .... 2 Tappets ... ... ...... .... ... . ............ . 24
General Information .. ... ...... .... .• ...... 2 Installing Camshaft .. ...... ........• ... .. 24
Engine Serial Number Location ...... ... ... . 2 Checking Valve Timing ........ ... ...... .. 24
Crankshaft and Main Bearings . .....• . ... .. 24
EVERY 250 HOURS SPECIFICATIONS .... . .. ... .... .... ... ....... 3 Crankshaft End-Play . ...... . .. ....... .... 25
General •.......... .. .... ... .... ... .. . ... . 3 Removing Crankshaft ......... ... ...... .. 25
Drain and renew engine lubricating oil. Torque Tension . ...... ...... ..... ..... .... 3 Inspecting Crankshaft ..... . ......... .. .• . 26
Engine Overhaul . . .• . ........... .... ... .. . 3 Regrinding Crankshaft ..... ......• ....... 26
Lubrication System ...,. ...........:...... . 6· Installing Crankshaft ....... ...... ........ 26
Renew lubricating oil filter element. Fuel System ......... .... .. ............... 7 Rear Crankshaft Oil Seal .... . ....... .. ... .. 27
Cooling System ...... ... . ... .. .... ...... .. 7 Replacing Oil Seal. ... .... .. ...... .. .... . 27
Check drive belt tension. Installing Oil Seal Retainer .. ............ . 27
ENGINE REMOVAL ANO Engine Flywheel ........... ....... ....• .. . 28
INSTALLATION ........... ..• .. ............ .. 8 Replacing Flywheel Ring Gear ....• ... .... 28
Clean oil bath air cleaner. Engine Removal .... ......... ......... ..... Flywheel Installation ...... .. .....• ... ... . 28
8
Engine In stallation . ....... ... ... ...... .... 9
Empty dust bowl in dry type air cleaner.
ENGINE OVERHAUL PROCEDURES ..... ... ... 10
Cylinder Head ... ... ... . .. ........ ...... ... 10 LUBRICATION SYSTEM ...................... 29
Clean fuel filter water trap.
Removing Cylinder Head ........... ... ... 1o Oil Pan ...........................•....... 29
Disassembly and Inspection of Removing Oil Pan ....... .... .. .. .• ...... 29
Cylinder Head . .... .......... .. ....... ... 10 Installing Oil Pan .................. ... ... 29
Valve Guides . ... .. ........... .. ... ... ... 11 Replacing Oil Filter ............ .. ....... ... 30
Valves and Valve Seats ......... ...... ... 11 Oil Pump .........................••...... 30
EVERY 500 HOURS Exhaust Valve Seat Insert Replacement ... 12 Removing Oil Pump ........ . ..•. .. ...... 30
Rocker Arm Shaft Assembly .......... . .. . 12 Disassembling Oil Pump .. .. . ...... ... .. . 30
Renew the final fuel filter elements. Reassembling Cylinder Head . ............ 13 Inspecting Oil Pump .... ..• . . ......... . .. 30
Installing Cylinder Head . ... ...... ..... ... 13 Reassembling and Installing Oil Pump .. .. 31
Adjusting Valve Clearance ............. .. 14
Clean the fuel lift pump gauze strainer. Engine Balancer Assembly .......• ...• .•... 14
Removing Engine Balancer .. ..... ...... .. 14
Check hoses and clips. Disassembling Engine Balancer ....... ... 14 FUEL ANO AIR SYSTEM . ...... ...... . .. .. ... 32
Reassembling Engine Balancer ..... ... ... 15 Air Cleaner ..........................·.. ... 32
Installing Engine Balancer .......... ...• . 16 Servicing Outer Filter Element ..... ... ... 32
Piston and Connecting Rod Assemblies ..... 16 Servicing Inner Filter Element .. ... . ... ... 32
Every 1000 HOURS Removing Piston and Connecting Air-Bleeding Fuel System . .. . ...... .. ... ... 32
Rod Assemblies ........: .... ............ 16 Fuel Lift Pump . . .... ... .... . •.• •... ....... 33
Clean element of dry type air cleaner, or renew. Separating Pistons from Connecting Fuel Lift Pump Removal and Disassembly . 33
Rods ................................... 16 Fuel Lift Pump Reassembly and Installation 33
Service atomisers . Connecting Rods ........ ...... ... ... ... . 17 Fuel Filter Element Replacement . ... ....... 34
Pistons and Rings ....• ....... ... ....... . 17 Fuel Injection Pump ........ .. ... .......... 34
Installing Pistons Onto Connecting Removing Fuel Injection Pump .... ....... 34
Check and adjust tappets. Rods ... ... ... .• . ..... .. .. .............. 18 Installing Fuel Injection Pump ... .. ...• ... 35
Installing Piston and Connecting Adjusting Fuel Shut-Off Control . .. .. ... .. 35
Rod Assemblies .... .• ..... .... ....... . .. 18 Adjusting Engine Speed .. ... ..... ....... 35
Cylinder Block am;t Lif')ers ...... ............ 18 Adjusting Throttle Linkage ......, ..... . .. 36
EVERY 2500 HOURS Inspecting and Servicing Cylinder Adjusting Fuel Injection Pump Timing .. ... 36
Liners ............................., ... . 18
Arrange for the examination and servicing of proprietary equipment. Replacing Cylinder Liners .. ... ... ........ 18
Timing Gears and Cover ..... .... ...... .... 19
Timing Gear Cover and Front COOLING SYSTEM ............ ........• .• .... 38
CrankshaftOilSeal ...................... 19 Water Pump .. ... .......... ........... ... . 38
Replacing Front Oil Seal . ... ........... 19 Removing Water Pump ... ........... .. .. 38
Installing Timing Gear Cover ........... 20 Disassembling Water Pump ..... . . ....... 38
Timing Gears . ..... .... ......... ........ 20 Reassembling Water Pump .. ......... .. . . 38
Timing Gear Backlash and End-Play . ... 21 Installing Water Pump .... .. .......... .. .. 39
Removing Timing Gears and Thermostat .... ........ .... .... .... ....... 39
Housing .............................. 21 Replacing Thermostat . ...... . .......... ... 39
Servicing Idler Gears ... ...... ... ...... 22 Testing Thermostat ... ....• .• ...• ........ 39
Installing Timing Gears and Housing Fan Belts .... .. .. ... .. ..... ........ . ... ... 39
and Retiming Engine ... ... ... ...... ... 22
Camshaft. ... .... ...... ..... ... ... ... ... ... 23
Removing Camshaft . ..... ........... .. . . 23
Inspecting Camshaft . .. ... . .. ...... .... . . 23 TROUBLE-SHOOTING ............ , .., ..... . . 40

PREPARED BYD. DICE -1-

- A4.318 ENGINE
 SPECIFICATIONS

INTRODUCTION
GENERAL INFORMATION
This Part contains service information for PERKINS A 4.318 Engine.
Thoroughly clean and inspect all components during servicing. Right and left -hand sides mentioned within
. text refers to engine as viewed from rear of flywheel. Direction of engine rotation is viewed from crankshaft
pulley end.
ENGINE SERIAL NUMBER LOCATION
Engine Serial Number for A 4.318 Engine is located on left rear side of cylinder block. Fig. 1.ALWAYS GIVE
COMPLETE ENGINE SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
GENERAL SPECIFICATIONS
Model .................................................................................Perkins A 4.318
Bore ...................................................•.................................... 4.5 inches
Stroke ..............................•.•........................•.....•.•.•................... 5 inches
Number of Cylinders ............................................•.................................... 4
Firing Order .................................................................................... 1- 3-4-2
Direction of Engine Rotation (Viewing Crankshaft Pulley End) ................................... Clockwise
Total Piston Displacement ............................................................. 318 cubic inches
Compression Ratio ........................................................................... 17.5 to I
Combustion Syst em .......................................•............................ Direct injection
Engine Brake Horsepower (Mfg. Rating with Accessories) .................. 84 BHP minimum at 2000 rpm
Maximum Engine Torque .............-..........................................24 5 ft.-lbs.@ 1300 rpm
Low Idle Speed ........................................................................... 825-87 5 rpm
Maximum Engine Speed (No -Load) ..................................................... 217 0- 2220 rpm
Valve Tappet Clearance:
Intake and Exhaust ............................................. 0.010 inch "hot" - 0.012inch "cold"

*TORQUE TENSION SPECIFICATIONS

Cylinder Head .......•.•........................................................... 136Nm 100ft-lbs.
Connecting Rods .................................................................. 142Nm 105 ft.-lbs.
Main Bearings ....................................................................200Nm 150 ft.-lbs.
Flywheel ..........................................................................110Nm 80 ft.-lbs.
Crankshaft Pulley .................................................................410Nm 300 ft.-lbs.
Engine Balancer:
Weight Frame to Cylinder Block .................................................. 50Nm 36 ft.-lbs.
Balancer Weights to Shafts .. ... ... ... .... ..... .. . .. ... . ..• ... .. ..•.• . ..... ... ... 8Nm 6 ft.,lbs.
Balancer Weight Gears ............•.•............................•.............. 34 Nm 25 ft.-lbs.
Rocker Shaft Brackets .............................................................. 33Nm 24 ft.-lbs.
Intake and Exhaust Manifolds ...........................•.......................... 20Nm 15 ft.-lbs.
Injection Pump Drive Gear ......................................................... 28Nm 21 ft.-lbs.
Camshaft Gear .......... :: ...... .... •.. ........ ... ... .... .. ...... ... ...... ........ 60Nm 4 5 ft.-lbs.
Idler Gear Hub . .. .... .... ...... ... .... .. .. .... .......... • ....... .. ......... ... ..... 33Nm 24 ft.-lbs.
Oil Pan:
Oil Pan to Cylinder Block ..............................................., . .. ... ... 28Nm 21 ft.-lbs.
Oil Pan to Timing Gear Housing .... ...... .... .... .... .. .. ..... ...... ..• ... .... ... 20 Nm 15 ft.-lbs.
Oil Pan· to Rear Bridge Piece ........................................•............13.5Nm 10 ft.-lbs.
Injector Hold -Down Nuts .. .. ... ...... .. . ........ .... ... .. ...... . . .. ... ... ......... . 16Nm 12 ft.-lbs.
Oil Filter to Cylinder Block ......................................................... 41 Nm 30 h.-lbs.
Oil Pump (Pump to Balancer Frame) ................................................. 27 Nm 20 ft.-lbs.

I
Rear Oil Seal Retainer to Cylinder Block and Bridge Piece .. . ..... ......... ... .. .. . .. . 16Nm 12 ft.-lbs.

*THESE TORQUES APPLY WITH THE THREADS CLEAN AND LIGHTLY OILED. DO NOT EXCEED THESE
VALUES AS DAMAGE COULD OCCUR.

ENGINE OVERHAUL SPECIFICATIONS

Pistons:·
Fig. 1 - A4.318 Engine Serial Number Piston Diameter (Measured at Right Angles from Piston Pin Holes):
- Left Rear Side of Engine . , Top Piston Skirt Diameter (Just Below Bottom Ring Groove) .................... 4.4911-4.4921 inches
.
Bottom Piston Skirt Diameter (Just Above Bottom of Piston) .................... 4.4936-4. 494 6 inches
Piston Ring Land Diameter (All Ring Lands Between Top and Bottom Ring Grooves) . 4.476- 4.4 79 inches
Piston Pin Bore Diameter .......... .............. ...... ... ............ ........ . 1.4 37 6- 1.4 379 inches
Piston Height at T.D.C. Relative to Top Face of Block ...... From 0.003 inch BELOW to 0.010 inch ABOVE 0
Piston Clearance in Cylinder Liner ................................................. 0.007 to 0.011 inch iii"
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II)
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- A4.318 ENGINE
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Valve Head Diam_eter:
Type ......················•·····
Inside Diameter of Liner:
. . . . . . . . . . . "''· .,.,.,,.,. �- ,ro,
k:���si"
n
· : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : . : .........
. ......... 1.844-1.848 inches
1.589-1.599 inches

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Production Liner: Valve Stem Diameter:

Se;!{�i�2�����: : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : !:�g��:::�g!� vS:����i-��:;I��::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: �-�-����--��� _;���

................... 4.467-4.471 inches o 3725-0.3735 inch

Outside Diameter of Liner:

. • ................. 4.643-4.644 inches

Cy;����:���:z�- : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : i :::�!�
Valve Seats:
Valve Seat Angle ................................................................................ 450
Liner Fit in Block: Desired Seat Contact Width:
. Intake ................ ; ...•...................................................... 1 /16 to 3/32 inch
0 ·001
Production Liner • •••· · ···· ·· · · ·
· · · · · · · · · · · · · ·· · · · · · · · ..c: ....... 0.001-0.003 inch interference Exhaust ........................................................................ 3/32 to 7/64 inch
Service Liner ...•.••..•·· · · ········· ··· ·..·· ·· ·· ·· ··· · · in h clearance to 0.001 inch interfer�nce
Location of Liner Above Top Face of Block .......••..• •••••• •·· · ··.................... 0.025-0.031 mch Maximum Seat Run-Out ......•...•....................................................... 0.002 inch

Valve Guides:

��ii�����i���i:�� : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : ��������6.;����:�
Piston Pins:
Pin Diameter ............................•..................................... 1.4375-1.4378 inches ....Replaceable, cast iron
Clearance in Connecting Rod Bushing .............................................0.0004-0.0017 inch
Fit in Piston Pin Bore ........................... From 0.0002 inch interference to 0.0004 inch clearance
Valve Guide Clearance:

Piston Rings:
Ring Side Clearance:
n
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o 0015-0.0035 inch
0.002-0.004 inch
Top Compression Ring ...•.. • •• ••· ········•·•···· ·
· · · ···· · ·· ·· ·. ..............0.0025-0.0045 inch
Other Compression Rings ••• • •·· · ·· ······· ·· ·•··· ·········· ·· ···.: ..............0.0015-0.0035 inch Valve Springs:
· Position of Spring Damper Coils (Closely Wound Coils) ...........•................ Toward cylinder head
Oil Control Ring .........•••··· ···· ·· ···· · ··· ·· •···· · · ··•· • · · ·· ······ ···•· · · ··O·0025-0.0045 inch
· ·
o
Ring End Gap (Measured in 4.500 Inch Bore): Outer Springs:

g1��l£��J;�;7��:�'.���: : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : g:gi ::g:g�� :���

_ Spring Pressure
...•................. 0.018-0.025 inch
Ring Width:
All Compression Rings ...• • •••• · ·········· ····· ··· ········•·• · .......•.•.....0.0928-0.0938 inch
· · ·
Oil Control Ring ...•.•.••· ··· ····· ·· ······· ····· ··· ·· ·····•· •· · · · · ·· •··· •·•·· · · · · · o·249-0.250 inch
Connecting Rods:
Connecting Rod Bore Diameter - Bushing End ....................................1.582-1.5835 inches
Inside Bush ing Diameter (Finished) ......................•..•.................. 1.4382-1.43925 inches
Connecting Rod Bore Diameter - Bearing End ..................................... 2.916-2.917 inches
Rod Bearing Inside Diameter (Standard Size) .......................•.............. 2.751-2.7525 inches
Crankpin Journal Diameter .................................................... : ..2.7483-2.749 inches
Bearing Clearance ...•.........................•................................... 0.002-0.0042 inch
Rod Side-Play .................................•...........•........................ 0.008-0.017 inch
Crankshaft and Main Bear ings:
Crankpin Journal Diameter ....................................................... 2.7483°-2.749 inches
Main Bearing Bore in Block and Cap .••.. , .•.....•..............•.•.•••.•.......... 3.166-3.167 inches
Main Bearing Inside D iameter (Standard Size) ......•.............................. 3.0015-3.003 inches
Main Bearing Journal Diameter ....................................•.•.......•... 2.9985-2.999 inches
Main Bearing Clearance ........................•................•.•..............0.0025-0.0045 inch
Crankshaft End-Play ....................•.....•.•................................... 0.005-0.016 inch
Crankshaft Flywheel Flange D iameter ....•............................•............ 5.248'5.250 inches
Crankshaft Fillet Radii:
Crankpin Journal Fillet Radii ...................................................... 0.188-0.203 inch
Main Bearing Journal Fillet Radii ....•.•.•....................•.• .................. 0.145- 0.160 inch
Valves:
Valve Clearance (Intake and Exhaust) ............................ 0.010 inch ""hot'" - 0.012 inch ··cold"'
Valve Head Location - Relative to Face of Cylinder Head:
Production:
Intake ................................................•...........•......0.057-0.071 inch below
Exhaust ......................................... : .......................0.052-0.065 inch below
Service L imits:
Intake ............•......... 0.057 inch minimum to 0.140 inch maximum depth bo;ilow face of head
Exhaust ...........•........ 0.052 inch minimum to 0.140 inch maximum depth below face of head
@ 1-25/32 Inches Length (Valve Closed) .................................. 38-42 lbs.
Spring Pressure @ 1-23/64 Inches Length (Valve Open) .........................•..... 72.1 ± 3.6 lbs.
Inner Springs:
Spring Pressure @ 1-9/16 Inches Length (Valve Closed) .............................. 15,4 ± 0.77 lbs.
Spring Pressure @ 1-9/64 Inches Length (Valve Open) ....................•.....•....33.5 ± 1.67 lbs.
Valve Lifters (Tappets):
Stem Diameter ..........................................................•........0.7475-0.7485 inch
Valve Lifter Bore in Block ......................................................... 0.7495-0.7508 inch
Clearance Limits ................................................................... 0.001-0.0033 inch
Rocker Arm Shaft Assembly:
Rocker Arm Shaft Diameter .......•.•.•.•...•..............................•......0.7485-0.7495 inch
Inside Bushing Diameter ............•.......•.....................................• 0.7505-0.752 inch
Bushing Clearance ................................................................ 0.001-0.0035 inch
Valve Tim ing (Theoret ical-Crankshaft Degrees):
Intake Valve Opens ............................·..................................•........ 9° B.T.D.C.
Intake Valve Closes .............................................•...•..............•... , . 41° A.B.D.C.
Exhaust Valve Opens ...........................................•.•.•.•............•..... 42° B.B.D.C.
Exhaust Valve Closes ...•............................•..........•................•.•...... 8° A.T.D.C.
Timing Gears:
Timing Gear Backlash (All Except Balancer Idler Gear and Balancer Drive Shaft Gear) ... 0.003-0.006 inch
Engine Idler Gear and Hub:
Hub Diameter ..................................................................1.9981 -1 .9988 inch
Idler Gear Bushing Bore Diameter (Fin ished) ..........•....................... 2.0000-2.0019 inches
Clearance Limits ................................................................0.0012-0.0028 inch
Idler Gear End-Play ..................................•........•..·.....•........... 0.003-0.007 inch
Balancer Idler Gear and Hub:
Inside Bushing Diameter (Finished) ..........................•.•................ 1 .590-1.5016 inches
Hub Diameter ..............................................•................ 1 .4984-1 .4990 inches
0
Bushing Clearance .........................· ..................•.......•.......... 0.001 -0.0032 inch
iii"
Idler Gear End-Play ............................................................... 0.002,0.005 inch II)
Backlash Between Idler Gear and Crankshaft Gear ................................0.005-6-0,0086 inch
o"
II)
Backlash Between Idler Gear and Balancer Drive Shaft Gear .....•.................. 0.006-0.009 inch
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 Engine Balancer Assembly:
Front Bearings:
Shaft Diameters (Drive and Driven) ........................................... 1.31 0 9-1.3115 inches
Inside Bushing Diameters (After Line Boring) .................................. 1.3145-1.3161 inches
Bushing Running Clearance ...................................................... 0.0 0 3- 0.0 052 inch
Rear Bearings:
Shaft Diameters (Drive and Driven) ........................................... 1.0 924-1.0 92 9 inches
Inside Bushing Diameters (After Line Boring) .................................. 1.0 957-1.0 96 9 inches
Bushing Running Clearance ..................................................... 0.0 028-0.0 045 inch
Camshaft:
Cam Lift - Tappets ................................................................ 0.304- 0.318 inch
Front Bearing:
ft
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Front Journal Diameter ...................................................... 2.0565-2.0575 inches
Front Bearing Bore Diameter ............................................. , ... 2.0595-2.0615 inches
Clearance limits ................................................................. 0.0 02- 0.0 05 inch
Center Bearing:
Center Journal Diameter ........................................................ 1.966-1.96 7 inches
Center Bearing Bore Diameter .................... : .............................. 1.96 9-1.971 inches
Clearance Limits ...................................... :.......................... 0.0 02- 0.0 05 inch
Rear Bearing:
Rear Journal Diameter .....................................•.................... 1.905-1.906 inches
Rear Bearing Bore Diameter ................. ·................................... 1.91 0-1.912 inches
Clearance Limits ............................ , .................................... 0.0 04- 0.0 0 7 inch
LUBRICATION SYSTEM SPECIFICATIONS
Engine Oil:
Recommended Type:
Massey-Ferguson Multiguard® Engine Oil or equivalent which meets or exceeds following requirements:
MIL-L-2104C (supersedes MIL-L-451 99B and MIL -L-21 04 B), MIL-L-46152, thus qualified for API Service
Classification "CD" or "CC" (Diesel - former API "D S", "DM") and "SE" (Gasoline - farmer API "M S").
Recommended Viscosity:
Above 900 F. ............................................................................... SAE 3 0
From 32° F. to 900 F. . ..................................................... , ....... , ....... SAE 2 0
Below 32° F. ............................................................................... SAE 1 0
Recommended Change Interval:
Engine Oil ..............................................................................1 0 0 hours
Engine Oil Filter .......... , .............................................., ...............2 0 0 hours
Engine Oil Pressure .......................4 0-50 psi at normal operating speeds and working temperature
Crankcase Capacity:
Without Filter Change .................................................... Approx. 9 U.S., 7.5 Imp. qts.
With Installation of New Filter Element ...................................Approx. 1 0 U.S., 8.3 Imp. qts.
Oil Filter By-Pass Valve Opens .................................................................8-12 psi
Oil Pump:
Maximum Theoretical Capacity ...•.........•.....•...............Approximately 16 U.S., 1 3.3 Imp. gpm
at 2200 engine rpm (44 0 0 rpm oil pump)
Pump Clearances:
Inner Rotor to Outer Rotor ...................................................... 0.0 025-0.0 045 inch
Outer Rotor to Pump Body ........................................................ 0.01 0- 0.012 inch
Top of Rotors to Surface of Pump Body. .............................. 0.0 01-0.0 0 3 inch for outer rotor
0.0 015- 0.0 0 35 inch far inner rotor
Oil Pressure Relief Valve:
Relief Valve Opens at ...................................................................... 50-65 psi
Relief Valve Spring:
Free, J�rigth .................. , .............•.•..............................Appro)(. 1-9/16 inches
Spririg Pressure at 1- 9/ 32 inches length ....................................... Approx. 8 lbs. ± 4 ozs.
Spri.ng Pressure at 1 Inch Length ............................................ Approx. 16 lbs. ± 8 ozs.
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FUEL SYSTEM SPECIFICATIONS
Fuel Injection Pump:
Type .............................................. CAV, DPA distributor type with mechanical governor
CAV Specification Number ................................................................. 324 9F242
Service Setting Code ............................................................ SD 90/6 0 0/5(22 0 0
Injection Timing ( Static Timing Angle) ..................................................... 2 0 ° B.T.D.C.
Timing Letter on Injection Pump Rotor for Start of Injection to No. 1 Cylinder ........................ "E"
No. 1 Cylinder High Pressure Fuel Line Outlet Marking ....................................... Letter "X"
Fuel Injectors:
Type ................................................................ CAV multi-hole, long stem nozzle
CAV Holder No. .................................................... ,................. BKBL 6 7 S51 72
CAV Nozzle No. ..................................................................... BOLL 150 S6599
Identification Code Letters .......... .. ... ... .... .. ... ... ... ... ... ..... .... ... ... .. .. .. .. ... .. .. "ED"
·
Nozzle Opening Pressure: . _
Working Pressure (Injector with More than 25 Hours Operation) ...... ?Pc� ..... 257 0 psi (1 75 ATS)
!t.7.
Setting Pressure (New Injector or Used Injector with. New Spring) .....1-PA-.C:<Jr..... 2650 psi (18 0 A T S)
Spray Hole Orifice .............................................. 0.0118-0.0126 inch ( 0.3 0 0- 0.32 0 mm)
Fuel Lift Pump:
Make ..................•.•...•...•.........................................................AC Delco
Operating Pressure ....................... , ................................................... 5-8 psi
Method of Drive .................................................................Eccentric on camshaft
Recommended Diesel Fuel Oil (American Society of Testing
Materials Specifications) .............. 1 ••••.•••..•• A STM/D 975·66T - Nos. 1 D (Winter) or 2D ( Summer)
Fuel Tank Capacity ................ , ...................................... Approx. 23 U.S., 1 9 Imp. gals.
COOLING SYSTEM SPECIFICATIONS
Water Pump:
Water Pump Impeller Clearance:
Rebuild Clearance Setting ......................................................... 0.02 7-0.0 35 inch
Normal Operating Clearance (Includes End-Play) .................................... 0.011-0.0 35 inch
Pulley Fit on Water Pump Shaft .......................•............... 0.0 01 3-0.0028 inch interference
Impeller Fit on Water Pump Shaft ..................................... 0.0 0 05- 0.0 018 inch interference
Thermostat:
Type ...........................................•..............................•...... Wax pellet type
Normal Opening Temperature ........................................................... 1 7 70.1530 F.
Fully Open Temperature ...................... , ... , . , ....•. , .............•.•.•. , ..............2oao F.
Minimum Valve Travel ............................ , .•..................................... 0.350 inch
Recommended Coolant .................................... Water and ethylene-glycol anti-freeze mixture
Cooling System Capacity ................................................Approx. 16.5 U.S.. 1 3.8 Imp. qts.
Radiator Pressure Cap ............................................................................ 7 psi
Fan Belt Deflection ......... , ........... Adjust to provide 1/2 to 3/4 inch deflection when depressed with
15 lbs. load midway on longest span between pulleys
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 ENGINE REMOVAL AND INSTALLATION

Fig. 7 .:... Fuel Tank Support Plate. Fig. 9 - Engine Installation

1. Fuel tank support plate.

Fig. 2 - Right Side of Engine Fig. 4 - Identification of Parts - Right Side

ENGINE REMOVAL
1. Disconnect battery cables and drain coolant.
2. Remove hood.
3. To split front end away from engine:
a. Disconnect:
(1) Radiator hoses from radiator.
(2) Air intake hose.
(3) Battery cable from starter.
(4) Headlight wires behind grille.
(5) Electric ether start wire (if equipped).
b. Disconnect three hydraulic lines and com­
pletely remove hydraulic li,ne shown in Fig. 2.
NOTE: Always cap open fittings and lines.
c. ·Support tractor with a jack at front of
transmission.
d. Place wedge blocks between front axle and
axle support (to prevent tipping) and support
front end assembly at front and rear.
e. Split front end away from engine, Fig. 3.
4. Disconnect:
a. Starter, alternator and water temperature
sending unit wiring, Fig. 4.
of Engine
1. Main fuel llne.
2. Water temperature sending unit.
3, Tachometer drive.
b. Tachometer drive cable, Fig. 4.
c. Fuel shut-off cable.
d. Engine oil pressure line, Fig. 6.
e. Power steeririg pump lines, Fig. 5.
5. Remove exhaust manifold heat shield and
muffler/exhaust pipe assembly on vertical exhaust
Fig. 5- Left Side of Engine
models, Fig. 5. Remove heat shield and disconnect
exhaust pipe on horizontal exhaust models.
6. Shut off fuel tank valve, Fig. 6. Disconnect fuel
level sending unit wire and main fuel line from fuel
tank valve. Remove fuel tank return line, Fig. 6, then
fuel tank and fuel tank ·support plate, Fig. 7.
7. Remove throttle rod and main fuel line (from
fuel tank to fuel lift pump).
8. Assure all lines, wires and linkage are dis­
connected and positioned so they won't interfere with
engine removal.
9. Attach hoist and remove engine, Fig. 8.
ENGINE INSTALLATION
1. Lubricate transmission input shaft splines with
light coating of molybdenum disulfide (MoS 2- 60%)
lubricating grease N.L.G.I. No. 1.
2. Carefully mate engine to transmission, aligning
input shaft splines into clutch splines, Fig. 9. Tighten
7Ii 6'" capscrews to 55 ft.-lbs. and 5/8" capscrews
to 155 ft.-lbs., Fig. 10.
3. Install main fuel line and throttle rod.
4. Install fuel tank support plate, Fig. 7, and fuel
tank. Reconnect main fuel line and fuel tank return
line, then open fuel tank valve; Fig. 6. Reconnect
fuel level sending unit wire.
5. Install or reconnect muffler/exhaust pipe as­
sembly and heat shield, Fig. 5.
6. Reconnect:
a. Power steering pump lines, Fig. 5.
b. Engine oil pressure line, Fig. 6.
c. Fuel shut-off cable.
d. Tachometer drive cable, Fig. 4.
e. Starter, alternator and water temperature
sending unit wiring, Fig. 4.
7. Reconnect front end to engine, Fig. 3.
a. Reconnect hydraulic lines, Fig. 2.
b. Reconnect:
(1) Radiator hoses.
(2) Air intake hose.
(3) Battery cable to starter.
(4) Headlight wires.
(5) Electric ether start wire (if equipped).
8. Install hood.
9. Refill crankcase (if needed) and cooling system.
10. Install fuel tank and radiator caps and re-
connect battery cables.

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Fig. 6 - Left Side of Engine - Muffler/Exhaust ti)

Fig. 3 - Front End Separated Frqm Engine Pipe Assembly Removed Fig. 8 - Engine Removal Fig. 10 - M.F. Clutch Arrangement. ti)
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ENGINE OVERHAUL PROCEDURES
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l Fig. 15 -1. Intake valves. Fig. 17 -Refacing Valve Seats

l 2. Exhaust valves.
� Injector leak-off line. 21-24 ft,Jbs.
Fig. 11 - 1. Fig.13-1.
� 2. High pressure Injector fuel lines. 2. Rocker shaft oil feed pipe. NOTE: Identify above parts so they will be

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1. Press worn valve guides out TOP of cylinder
3, Injector leak-off line. reinstslle(I in their original locations on head.
4. Push rods.
reassembly. 2. To install new valve guide:
a. PRESS (do not drive) guide into position from
� CYLINDER HEAD 2. Cl.ean and inspect all parts.
7. Remove: a. Check cylinder head mating surface, Fig. TOP of cylinder head.
a. Fuel filter assembly. b. Guides are correctly positioned when shouJder

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15, with straightedge.
REMOVING CYLINDER HEAD b. Intake and exhaust manifolds. locates against top of cylinder head.

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b. Cylinder head may be resurfaced up to 0.020
c. Fan and fan belts. inch maximum providing: NOTE: When new valve guides
1. Drain coolant. d. Water pump l;loses. (1) Injector nozzle protrusion does not exceed reface valve seats to insure
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2. Remove hood. e. Injector leak-off line, Fig. 11. 0.230 inch. of seats to new guides.

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3. Remove exhaust manifold heat shield and
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'·)muffler/exhaust pipe assembly on vertical exhaust
w models, Fig. 11. Remove heat shield and disconnect
exhaust pipe on horizontal exhaust models.
4. Shut off fuel tank valve. Disconnect fuel level
sending unit wire and main fuel line from fuel tank
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valve. Remove fuel tank return line. Remove fuel tank
f. High pressure injector fuel lines, Fig. 11.
g. Injectors.
h. Valve cover.
8. Remove rocker shaft _assembly, disconnecting
rocker shaft oil feed pipe, Fig. 13.
9. Remove and identify push rods so they will be
reinstalled in their original locations on reassembly.
(2) Cylinder head thickness is not reduced
below 3.230 inches, Fig. 16. VALVES AND VALVE SEATS
c. If cylinder head is resurfaced, check that ;t
valves are within specified distance below face
of cylinder head. See Fig. 18.
1. Reface valves and valve seats, Fig. 17, to a 4�.
angle. Do not unnecessarily grind valve face or valve;:"
d. Machining of cylinder head should be fol­ seat. .,.:_
lowed by water pressure test with warm water 2. Replace any valves that are damaged or w1:>(n::<

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and fuel tank support plate. 10. Loosen cylinder head fasteners in reverse order at 30 psi.
5. Disconnect, Fig. 12: too thin to allow minimum finished valve head margin'·.
to tightening sequence shown in Fig. 22, and remove of 1/32 inch, or have worn stem diameter of 0.371
a. Air intake hose. cylinder head. VALVE GUIDES inch or less.
b. Alternator adjusting bracket from head.
c. Breather tube. 3. To determine valve seat contact, lightly hand
DISASSEMBLY AND INSPECTION Intake and exhaust valve guides are interchange­ lap each valve to its seat. Seat should be located so
d. Water temperature sending unit wire. OF CYLINDER HEAD able. Inside diameter of valve guide is 0.375-0.376 it contacts middle portion of valve face.
6. Remove fuel filter lines, Fig. 12. After discon­
• necting clamps holding fuel lines to rear of cylinder 1. Using valve spring compressor tool, remove
inch. Desired clearance between valve stems and a. Intake seat width should be 1/16 to 3/32 inch.
guides is 0.0015-0.0035 inch for intake valves and b. Exhaust seat width should be 3/32 to 7/64 inch.
head, reinstall capscrews for lift eye. valve retainer locks, retainer caps, springs and guides and 0.002-0.004 inch for exhaust valves and 4. Check valve head depth below cylinder head
NOTE: Cover all open lif!eS and fittings. valves, Fig. 14. guides. Eleplacement valve guides are presized and face, Fig. 18.
do not require reaming. a. Intake valve head depth should be 0.057-0.140
Replace guides if inside diameter is more than inch.
0.377 inch.

fig. 12 - 1.
2.
3.
Fuel filtal'lines.
Breather tube.
Air intake hose.
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Valve spring �p.
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Outer valve spring.
Cap retainer locks.
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recess in cylinder head fo dimensions shown in Fig.
19.
3. Shrink insert by pIic' king in dry ice. Press insert
fully into position with· tool machined to dimensions
"' shown . in· Fig. 19. Do(not hammer insert or use
ji' lubricant. . }i�
Ii 4. Reface. valve sEiafli'nsert.
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a, Maintain valve'seat width of 3/32 to 7/64 inch.
1 �ECESS FOR. INSERT.
b. Exhaust valve: liead depth should be within
CHAMl'tll .OIS" J4S•MAX., production lirriit of 0.052-0.065 inch.

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INSERTING TOOL

It.'"'"•"° ROCKER ARM SHAFT ASSEMBi�'.:

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MATU:IAL EN.32A. CI\S� HAIID[N[D AND 019.!!_ND
Fig. 19 - Machining Dimensions for Installing
·· Exhaust Valve Seat Inserts
/i;cu,b. El<haust valve head depth should be 0.052-
140 inch.
!c;,: Oo-not reface valves or valve seats to extent
\lf\1alve depth exceeds these specifications.
;:fResbrface rocker arm end of valve stem only
eqiiii'e1k Do not grind excessively, as only extreme
Cast iron rocker arms are equipped with replace­
able bushings, Rocker arms are same for both in­
take and exhaustvalves.
DISASSEMBLY
See Fig. 20.
1. Remove retaining snap ring and washer from
each end of rocker shaft.
2. Remove rocker arms, rocker· shaft supports,
steel washers, spaceis and springs fr'om rocker shaft.
Lay all parts in order so they may be installed in
their original location. •·.'·"•·
3. Observe location of oil holes . in[shlift. Remove
locating screw from oil feed · connection. ,Remove
Fig. 21 - Cylinder Head Gasket Marked
"Front Top"
REASSEMBLY
See Fig. 20.
1. Slide oil feed connection onto rocker shaft and
secure it in place by installing locating screw.
MAKE SURE SHAFT IS TURNED SO OIL HOLES WILL
BE TOWARD VALVES WHEN ASSEMBLY IS INSTALL-
ED ON HEAD. . 4. Install push rods in original locations.
.
2, Lubricate parts and install .rocker shaft sup­
ports, springs and rocker ,arms onto rocker shaft ·in
their proper sequence. The thin steel washers should
be installed_ between spacers and supp<,?rt brackets.
Fig. 23 - Retorque Cylinder. Heads "Hot"
1. Injector aseembly.
2. 11,toctor clamp.
TOP" marking, Fig. 21. Install gasket dry, without
sealing compound.
3. Install and torque cylinder head, following
tightening sequence shol(Vn in Fig. 22. Go through
tightening sequence several times gradually in­
creasing ·torque applied, in 10-15 ft.-lb. increments,
''
to proper value of 85-90 ft.-lbs.
5. Install rocker shaff assembly, Fig. 13.
a. Reconnect rocker shaft oil feed pipe., •:-,.-/;
b. Torque retaining nuts gradually to 21'�24i.....
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c. Adjust valve clearances to 0.012 inch/'co$1,�1
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a,·of valve stem is hardened. connection from shaft. 5 1n
REASSEMBLING CYLINDER HEAD.
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· a. fnj!�tors with dust shields.
s E E SERVICING 1. Lubricate valve stems and gaide bores with
.
(1) USE NEW -COPPER WASHERS;--orie;;ji13r, :;-·
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Et E�lT ... ;'of engine oil. injector. .;:,-�::{?!/:. ·\. \.
��;Jlliiir: ·1. R��;��1ff-liiker,shaft and/or rocker arm bush.•
2. Using a valve spring compressor, install valves {2) Tighten clamps evenly to 10-12''°)f?°.:t�s/_ \
.
M- . . ·· .
:· :-:Valve seat inserts are not installed in production ings, if cl!lafance(e�ceeds 0.006 inch. . ,,. · ,.
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. into their original guides. b. Valve cover. ,
engines. However, service exhaust seat inserts can 2. Wti'en · instlilling:' new bushings, press in place
· a., Mate sprin_gs,,r!'tainer caps and retainer locks c. High pressure injector fuel lines, Fig. 11. · ,:\':
be installed; if needed. with oil hole in bushing a)igned with oil hole in rocker d. Injector leak-off line, Fig. 11.
with their original valves, Fig. 14. \
1. It is advisable to install a new valve guide
before ,installing and finishing valve seat insert.
arm. If required, fi.nisti each new bushing to inside
diameter of 0.7505-0._752 inch.
b. Install closely wound damper coil end of
valve ·springs toward cylinder·.head.
e. Water pump hoses.
f. Fan belts and fan.
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g. Intake and exhaust manifolds.
h. Fuel filter assembly..
INSTALLING CYLINDER HEAD

.
7. Install fuel filter lines; Fig. 12, reclamping lines
to rear of cylinder head.
1. Clean mating· surfaces on. head and cylinder

.
8. Reconnect, Fig. 12:
block. ..
l 2. Install new cylinder head gasket. noting "FRONT
a. Water temperature sending unit wire.
b. Breather tube.

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c. Alternator adjusting bracket.
d. Air intake hose.
9. Install fuel tank support plate and fuel tank.
Reconnect main fuel line and fuel tank· return line,
then open fuel tank valve.. Reconnec,t,;,f_uel level
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•�-��i!U sending unit wire.
10. Install or reconnect muffler/exhaust 'pipe as-
sembly and heat shield.
11. Install hood, refill cooling system and rein-
stall fuel tank and radiator caps.
12. · Air bleed fuel system iis,pee�td.
NOTE: Retorque cylinde/2i/21�ji;;,and,.:adjust

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Fig. 20 - Rocker Arm Shaft Assembly- Parts Sequence valve clearances to o.oiot-'iffktf.�witli' engine
1. Snap Ring (21 5. Rocker Arm Spacer (41 a. Steal Washor (41
at operating temperature/)fiffbr�lie cylinder Q_
Q)
2. End Thrust Washer t2l 6 •.Rocker Shaft Spring (31 9. locating Scraw head "hot" after 50 to 10Ci"bours of oper­ ti)
3. Rocker Arm (81 7. Oil Feed Connection 10. Rocker Shaft Fig. 22 - Cylinder Head Tightening Sequence ation, Fig. 23. !!!.
4. Rocker Shaft Support (41 11. End Plug 121 0
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Fig. 28 - Fully Assembled Balancer_Assembly Fig. 30 - Engine Balancer - Parts Sequence
Aligned with Indicator Balancer Assembly
1. RaarcOverassembly. 1. Rear cover a■sembly.
I• 1. Injection pump static timing mark. 1. Dowels.
2. 011 pump ••••mbly.
" 2. T.D.C. Mark. 2. Oil pump a111embly.
i" 3. Allan haad setscrews. 3. Balancer driven shaft.

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i; 4. Balancer drive shaft.

3. Press shafts .out front end of balancer frame, 2. Install keys into balancer shafts.
A DJUSTING VALVE CLEARANCE REMOVING ENGINE BALANCER Fig. 29. BE CAREFUL NOT TO DAMAGE FRONT 3. Lightly coat bores in balancer weights and
BUSHINGS. Remove balance weights, Fig. 30. their mating surfaces on balancer shafts with
Cylinders are numbered from front to rear of 1. Position crankshaft at T.D.C., Fig. 24. Remove "Loctite" Grade AA (Retaining Compound).
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·HI engine. Firing order is 1-3-4-2.
/ NOTE: Balance, shafts are secured to

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timing gear cover. 4. Lightly coat .rear bushings in balancer frame
1_. Align crankshaft pulley T.D.C. mark with in­ balance weights wHh Loctite (in addition
2. Drain engine oil and remove oil pan. wjth engine oil.
dicator, Fig. 24, - both valves closed on No. 1 cyl­ to two setscrews} and may require sub­
3. Disconnect oil delivery line from cylinder block. 5. Install balance weights in frame. Make sure
inder (rocker arms "loose"). stantial force to remove.
4. Support weight of balancer. Remove retain­ weights are installed with gears properly in mesh

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2. Loosen No.. 1 cylinder rocker arm lock nuts and ing capscrews and remove balancer assembly com­ Replacement bushings for balancer frame are not so flat surfaces on weights are aligned.
turn adjusting screws to correct clearance, Fig. 25: plete with oil pump and oil strainer, Fig. 26. available. If bushings are badly worn or damaged 6. Lubricate front journals on shafts. Install bal­
a. Engine cold .................... 0.012 inch 5. Remove balancer idler gear, Fig. 27. Remove it will be necessary to install a new frame assembly ancer shafts in place from front of balancer frame,

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(intake and exhaust) snap ring and slide thrust washer and idler gear which has bushings already installed and line-bored. Fig. 29. BE CAREFUL NOT TO DAMAGE BUSHINGS
b. Engine .at oper<1ting off hub. WITH BALAN CER SHAFT KEYS.

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temperature ........................ 0.010 inch REASSEllliBLING ENGINE BALANCER
(intake and exhaust)

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DISASSEMBLING ENGINE BALANCER
3. Tighten lock nuts and recheck clearance. IMPORTANT: Balancer shafts, balancer NOTE: When installing shafts, use care not
4. Rotating crankshaft 1 /2 turn each time, adjust to allow "Loctite" coated surfaces to con­

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valves for cylinders 3-4-2 respectively as above.
ENGINE BALANCER ASSEMBLY
SEVERE DAMAGE MAY O C CUR TO ENGINE IF
BALAN CER ASSEMBLY IS NOT TIME D CORRECTLY
TO CRANKSHAFT. When balancer is properly timed,
flat surfaces on balance weights will be facing up­
ward and level with each other, Fig. 28, when crank­
shaft or any of the pistons is at T.D.C. or B.D.C.
1. Remove oil strainer and oil delivery pipe, Fig.
28. Remove oil pump assembly and rear cover as­
sembly.
2. Remove two Allen head setscrews from each
balance weight.
NOTE: The screws are treated with "Loctite"
and secure balance weights to their shafts-.
It may be necessary to heat screws lightly
to remove.
i ft.-lbs.
weights and their locating setscrews must
be installed using "Loctite". Thoroughly
clean and remove all trace of oil from these
parts using a non-petroleum base solvent.
Make sure to follow instructions on Loctite
container regarding cleaning and curing
time.
1. If gears were removed from balance weights,
install them, using "Loctite" Grade C (Nut Lock) on
threads of setscrews. Tighten setscrews to 20-25
tact front bushings. A !so do not allow any
oil onto "Loctite" coated surfaces.
7. Install balance weight locating setscrews,
Fig. 31, using "Loctite" Grade C (Nut Lock).
8. Rotate balancer drive gear by hand to insure
that balancer turns freely.
9. Install rear cover assembly and oil pump with
oil intake and delivery pipes onto rear of balancer
assembly, Fig. 32.

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Fig. 25 - Adjusting Valve Clearance Fig. 27 - Balancer Idler Gear and Front Main Fig. 31 - Installing Balancer Weight Setscrews o"
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Fig. 32 - Use New Gaskets to Install Oil Pump Fig. 34 - Engine Balancer Assembly Installed Fig. 36- Upper and Lower Rod Bearings Are Fig. 38-Engine Piston Ring Arrangement

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and Rear Cover Assembly Onto Cylinder Block Not Interchangeable
� 1. Lower(Rod Capl insert.
2. Upper (Rodi insert.

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INSTALLING ENGINE BALANCER 2. Remove cylinder head.
3. Remove oil pan and engine balancer assembly. CONNECTING RODS PISTONS AND RINGS
�'-�;;[ 1. With timing gear cover and balancer idler gear 4. Turn crankshaft until piston to be removed is
Upper and lower rod bearing inserts are not
H�t, removed, rotate crankshaft until key in crankshaft at bottom of its stroke.
interchangeable, Fi!1, 36.
PISTONS
gear is straight up (No. 1 and 4 pistons will be at 5. Remove carbon and cylinder ridge in cylinder
l/j T.D.C.). liner. Replacement inserts are available in standard 1. Measure bottom piston skirt diameter at right
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2. Reassemble and install balancer idler gear
and front main bearing cap (140-150 ft.-lbs.) so
6. Remove connecting rod capscrews, slip wash­
ers and bearing cap:
size or in 0.010 inch, 0.020 inch and 0.030 inch under­
sizes.
angle to piston pin hole.

single mark in idler is located between two marks 7. Remove piston and connecting rod assembly,
NOTE: Piston is cam ground and is slightly
on crankshaft gear. Fig. 35, from top of cylinder block.
tapered, being larger at bottom of skirt than
CONNECTING ROD AUGNMENT
3. Install balancer assembly in place with single
at top. New bottom piston skirt diameter
mark on balancer drive shaft between two marks on 1. Both parent bores in connecting rod for pis­
NOTE: Identify all parts so if serviceable, is 4.4936-4.4946 inches.
idler gear, Figs. 33 and 34.
they may be reinstalled in their original ton pin bushing and bearing inserts must be square 2. Inspect for worn ring grooves.
4. Reconnect oil delivery line and complete re-
cylinders. and parallel with each other within limits of plus a. New top compression ring and bottom oil
1\t assembly·of engine. 8. Repeat steps for each piston and connecting or minus 0.010 inch, when measured five inches control ring should have a side clearance of
rod assembly to be removed. on each side of rod axis, as shown in Fig. 37. 0.0025-0.0045 inch.
b. Number 2 and 3 compression rings should
,1
NOTE: After overhauling balancer assem­ 2. If piston pin bushing is in place, connecting
SEPARATING PISTONS rod must be square and parallel within limits of have 0.0015-0.0035 inch side clearance.
Ti bly, it should be carefully run-in by opera­
3. Proper fit of new piston and piston pin at
,-:.
FROM CONNECTING RODS 0.0025 inch when checked, as shown in Fig. 37.
i:
ting engine for an hour at 1000 engine rpm.
normal room temperature is from 0.0002 inch inter­
PISTON AND CONNECTING 1. Remove snap ring securing each end of piston ference to 0.0004 inch clearance.
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BUSHING REPLACEMENT
ROD ASSEMBLIES pin and slide pin out.
2. If pin is tight in piston bore, heat piston. in 1. Support· connecting rod and press out worn
REMOVING PISTON AND oil or water to approximately 100-120° F., then push piston pin bushing.
CONNECTING ROD ASSEMBLIES pin out by hand. 2. Press new bushing into place, making sure oil
DO NOT DRIVE PISTON PINS IN OR OUT OF hole in bushing aligns with oil hole in connecting rod.
1. Drain engine oil. 3. Hone new bushing to inside diameter of 1.4382-
PISTON RINGS
PISTONS.
1.43925 inches after installation. Proper clearance 1 . Check ring end gaps.
between piston pin and piston pin bushing is 0.0004- a. Proper ring end gap is approximately 0.018-
0.0017 inch. 0.025 inch for top compression ring and bottom
I�

r oil control ring.

b. Number 2 and 3 compression rings have a
i,,i, normal end gap of 0.014-0.021 inch.
2. Use a piston ring tool when installing piston
rings. Install oil control ring first, then next lowest.
i�
,,�[,(i etc., with top groove ring installed last. Correct piston
ring placement is as follows: Refer to Fig. 38.

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0
5" 5"
No. 1 {Top) Compression Ring - Barrel faced,
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0 111
t chrome-plated, cast iron ring, may be installed
+1
..:i either side up.
�:Ii No. 2 and 3 Compression Rings-Parallel-faced
internal "L" cast iron ring must be installed in·'
second and third grooves, with side marked "Bot­
_ : _ : ··

tom" down. 0
Fig. 33-Balancer Assembly Properly Installed· iii"
No. 4 Oil Control Ring-Chrome-plated, cast iron
., and Timed to Crankshaft Timing Gear ring with integral spring expander, may be installed
Fig. 35 - Piston and Connecting Rod Assemr.ly
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Fig. 37 -Connecting Rod Alignment with either side up. c=;-

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1. Timing marks.
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Fig. 39 - Install Pistons in Original Cylinders
1. Pi1ton location number.
2. ..P" for front.
Fig. 41 - Cylinder Liner Bore Preparation

4. Install connecting rod cap with lower bearing

1.
2.
3.
Fig. 44 - Timing Gear Cover
Tachometer drive cable removed.
lnapectlon cover.
Power steering pump mountirli capscrews.

CT INSTALLING PISTONS

Ia
) ONTO CONNECTING RODS insert, capscrews arid tab washers, Fig. 40. TIMING GEARS AND COVER
5. Check piston height in relation to top face of
1. Position piston on its original connecting rod cylinder block. Piston at T.D.C. should be within Fig. 42 - Removing -Cylinder Liner

,
TIMING GEAR COVER AND
J so that when connec.ting rod location number is limits of 0.003 inch BELOW to 0.010 inch ABOVE top FRONT CRANKSHAFT OIL SEAL
I toward camshaft side of engine, word "front" or
letter ."F" on top of piston will be toward front of
face of cylinder block.
6. Reinstall engine balancer with it properly timed REPLACING FRONT OIL SEAL
engine, Fig. 39. to engine as outlined under headi_ng "Engine Balan­
2. Lubricate piston pins and slide in place by hand. cer Assembly". 1. Remove, Fig. 44:
DO NOT DRIVE PIN INTO PLACE. 7. Reinstall cylinder head and oil pan; then com- 2. THOROUGHLY CLEAN AND INSPECT CYL­
I'
a. Power steering pump.
plete reassembly of engine. INDER BLOCK BORE AND NEW LINER. b. Tachometer drive cable.
�
NOTE:• It may be necessary to heat piston 3. Either:
to 100-1200 F. in warm oil so pin will slip in NOTE: To assist in "Breaking-In" new piston c. Crankshaft pulley.
rings, engine should be operated within a. Chill new prefinished type liners and push d. Timing gear cover.
place by hand. them fully in place by hand;- or- .. .. ·
•

2. Remove oil seal by pressing or tapping it out

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resson11ble limits 11nd not at maximum speed

3. install piston pin snap rings. b. Lubricate outside diameter of cylinder of cover. Prying old seal out may damage aluminum
for first 25 hours of operation.
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liner, then use Special Tool MFN 326 and PRESS cover.

lt INSTALLING PISTON AND

CONNECTING ROD ASSEMBLIES
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1. Apply liberal coating of oil to cylinder liner
tr
bores,. piston assemb_Iies and crankpins.
2. Stagger ring gaps around piston. Using a piston
CYLINDER BLOCK AND LINERS
Cylinder block is fitted with replaceable flanged,
cast iron, dry-'type cylinder liners. -Production type
liner fully into cylinder block. Avoid using a
brush or . rag to apply oil to prevent any• pos­
sibility of foreign particles getting onto surface.
3. Loosely bolt timing gear cover in place.
4. Install Special Tool MFN 306A as shown in Fig.
45.
4. When correctly installed, top of liner will be
5. Tighten capscrews and remove tool.
within limits shown in Fig. 43. 6. Lightly coat bore in cover with sealing com­
5. Make sure liners are fully seated and allow pound.
a 'period of time for liners to "settle-in". MEAS­
7. Lubricate lip.of new seal with oil. Place seal

f
liners are an interference fit and require boring and URE INSIDE DIAMETER OF LINER FOR DISTOR­
ring compressor tool, install assembly into cylinder honing to size after installation. Service replacement onto wide stepped side of Special Tool. LIP OF NEW
TION. Maximum cylinder liner distortion must not
�
liner bore, Fig. 39, with appropriate crankpin at liners are a transitional fit and being prefinished, SEAL MUST BE TOWARD ENGINE.
exceed 0.0025 inch.
B.D.C. will normally require no further machining after
3. Install upper bearing insert and pull rod as­ installation.
sembly onto crankpin. UPPER AND LOWER BEARING
INSERTS ARE NOT INTERCHANGEABLE, FIG. 36.
M INSPECTING AND SERVICING
� CYLINDER LINERS
i
� 1. Replace liners if cylinder bore taper is 0.006

f
inch or more.
2. ·11 liners are serviceable, remove any cylinder
;!;
ridge and deglaze liners, Fig. 41, before installing
;! piston with new rings. 0.025-0.031 11
• :r ABOVE BLOCK FACE
REPLACING CYLINDER LINERS

t,,.
i:: 1. Using Special Tool Puller Plate MFN 326 with
I· a heavy-duty sleeve puller, remove cylinder liner
from top of cylinder block, Fig. 42.
a. 0.001 to 0.003 inch interference fit on prod• 0
uction liner. Fig. 45 - Locating Timing Gear Cover with ii>
II)
Fig. 40 - Correct Installation of b. Cylinder block bore diameter is 4.641-4.642 Fig. 43 - Cylinder Liners Should Extend 0.025-0.031 Narrow Stepped Side of Spacial Tool
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Connecting Rod and Cap inches. Inch Above Face of Block MFN 306A
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Fig. 46 - Installing and Locating New Front Fig. 48 - Installing Timing Gear Cover Fig. 51 - Measuring Gear Backlash Fig. 53 - Removing or Installing Engine Idler Gear

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Crankshaft Oil Seal with Wide Stepped Side of 1. Timing marks.
Special Tool
� 1. Crank pulley caps.crew washer.
1
2. Special tool
j

8. Slide tool with seal onto crankshaft, then use

i
pulley cap.screw and washer, Fig. 46, to push oil seal NOTE: Due to odd number of teeth on en­ c. Balancer idler gear end-play - 0.002-0.005

t
into bore of cover. When MFN 306A Tool contacts gin� idler gear snd balancer idler gear, com­ inch.
front face of cover, new oil s.eal will be correctly plete set of timing marks will not be in align­ Replace thrust washers and other worn parts if

I
located 0.360-0.370 inch inside front face of cover, ment every time No. 1 piston is at T.D.C. on end-play is excessive.
Fig. 47. compression stroke.

11;
Both engine idler and balancer idler gears are REMOVING TIMING GEARS AND HOUSING
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equipped wit'1 replaceable bushings.
INSTALLING TIMING GEAR COVER
1. Remove timing gear cover, oil slinger and oil
I
TIMING GEAR BACKLASH AND END-PLAY pan. C'1eck timing gear backlash and end-play of
1. Install oil slinger if removed earlier, Fig. 48.
camshaft and idler gears before removing· gears.
2. Install timing gear cover, Fig. 48, using Special
1. Chee� timing gear backlash as shown in Fig. 2. Remove rocker arm cover. and release rocker
l
Tool MFN 306A as shown in Fig. 45.
51. arm shaft assembly to avoid possibility of ·damage
3. Reinstall crankshaft pulley, Fig. 49. Tighten
a. Between camshaft, injection pump, crank­ to pistons or valve train.
pulley capscrew to 280-300 ft.-lbs.
�
shaft and engine idler gears - 0.003-0.006 inch. 3. Remove engine idler gear retaining plate with
4. Reinstall power steering pump, tachometer Fig. 49 - Correct Crankshaft Pulley Installation
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drive cable and complete reassembly . 1. Aligning Marks.
b. Between crankshaft, balancer drive shaft
and balancer idler gear- 0.006-0.009 inch.
2. Check end-play as shown in Fig. 52.
spray pipe and idler gear, Fig. 53. Remove idler gear
hub.
4. Remove injection pump drive gear, Fig. 54.
iw TIMING GEARS

When gears are installed with timing marks in

a. Camshaft end-play - 0.007-0.016 inch.
b. Engine idlergear end-play-0.003-0.007 inch.
5. Release camshaft gear lock tab and remove
capscrew, slip washer, lockwasher and retaining

f_i' alignment as shown in Fig. 50, engine will be properly

timed with No. 1 piston at T.D.C. on compression
stroke. IF GEARS ARE NOT PROPERLY TIMED TO
;,; 1 . CRANKSHAFT GEAR, SEVERE ENGINE DAMAGE
MAY OCCUR.

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Fig. 50 - Timing Geers with Marks Properly Fig. 64 - Removing o·r Installing Injection 0
Fig. 47- Correct Installation of Front Aligned - Number 1 Cylinder at T.D.C. on Fig. 52 - Measuring. Camshaft End-Play Pump .Drive Gear iii"
Crankshaft Oil Seal Compression Stroke 1. Slot.
II)

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1, Lip of new seal toward engine. 1. Timing marks. 2. Dowel.

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27, with single mark on idler gear between double
) !: marks on crankshaft gear. Tighten main bearing cap
bolts to 140-150 ft.-lbs. Install balanc!3r assembly
with single mark on balancer drive shaft between
double mark on idler gear, Fig. 50,
.,\'
3. Install new timing gear key in camshaft and
push gear in place· using camshaft gear capscrew.
Remove capscrew and install it again using slip
washer, new lock and retaining plate, Fig. 55. Tighten
to 41-45 ft.-lbs. and bend over lock.
NOTE: There is a plug behind rear end of
[i
;
camshaft. Do not attempt to drive camshaft
�- gear onto camshaft without blocking cam­
shaft forward.
4. Align dowel in injection pump drive gear with
' Fig. 55 - Removing or Installing Camshaft Fig. 57 - Pressing Balancer Idler Gear Hub Fig. 60- Removing Capscrews Securing Camshaft
i; slot in front end of fuel injec1ion pump and position

Ij\I.
Gear Retaining Capscrew into Bearing Cap Thrust Plate to Cylinder Block through Holes
1. lockwasher. 3. Slip washer.
gear in place, Fig. 54. Tighten capscrews to 19-21
2. Retaining plate. ft.-lbs. in Camshaft Gear
5. Install engine idler gear as follows:
plate, Fig. 55. Use a suitable puller tool and pull gear c. PRESS new hub into front of cap, Fig. 57, a. Install idler gear hub. Due_ to offset holes, hub
·off camshaft. until shoulder bottoms against cap. can only be installed in one position.
f�_:, 6. Remove timing gear housing (fuel injection pump b. With key in crankshaft gear straight up (No. REMOVING CAMSHAFT

i�r-t
must ·be removed), INSTALLING TIMING GEARS AND 1 and 4 pistons at T.D.C.), install engine idler gear
,I 1. Remove:
7. Balancer idler gear may be removed by either HOUSING AND RETIMING ENGINE so that its three marks align with those on crank­
of following methods: shaft, injection pump and camshaft gear, Fig. 53. a. Rocker arm shaft assembly and push rods.
Method 1 - With timing gear housing removed, 1. Rotate crankshaft until key in crankshaft gear c. Install idler gear retainer and oil spray pipe. b. Fuel lift pump.
remove snap ring securing idler gear and slide thrust is straight up (No. 1 and 4 pistons at T.D.C.). Tighten nuts to 21-24 ft.-lbs. Lock spray pipe banjo c. Timing gear cover.
washer and gear off hub, Fig. 56. 2. Install balance, idler gear by either of fol­ bolt with wire, if bolt was removed from retainer. d. Engine idler gear.
Method 2 - Remove balancer assembly. Remove lowing methods: 6. Check timing marks alignment, Fig. 50. 2. Either turn engine upside down, or secure
lli front main bearing cap complete with idler gear, Method 1 - 7. Install rocker arm shaft assembly and adjust tappets in their fully raised position.
Fig. 27. Remove idler gear retaining snap ring and a. With timing gear housing removed and bal­ valve clearances. Install oil slinger, timing gear 3. Remove:
,Ii slide thrust washer and gear off hub, Fig. 56. ancer in place, turn balancer drive shaft as re�
quired, and install idler gear with timing marks
cover and oil pan, then complete reassembly of engine. a. Thrust plate retaining capscrews, Fig. 60.
b. Camshaft, Fig. 61.
SERVICING IDLER GEARS aligned. Single mark on idler gear should be be­
il
(, 1. Replace bushings in engine idler gear and bal­
tween double marks on crankshaft gear and single
mark on balancer between double mark on idler
INSPECTING CAMSHAFT

�; ancer idler gear as follows: gear. See Fig. 50. Install idler thrust washer and CAMSI-IAFT 1. Clean all pans and inspect for wear or damage.

K,�it:I
a. Remove old bushing and PRESS in new one retaining snap ring onto idler gear hub. Replace as necessary.
using a bushing driver. b. Install engine idler gear hub onto studs (to Camshaft, Fig. 59, has chill hardened cam lobes a. Correct clearance between No. 1 and No. 2
b. Ream inside diameter of engine idler gear assure correct location of timing gear housing), and is supported by three bearings machined di­ camshaft bearing journals and their bores is
I'! bushing to 2.000-2.0019 inches. Balancer idler Fig. 58. Install timing gear housing and fuel in­ rectly into cylinder block. Camshaft end-play is con­ 0.002-0.005 inch.
gear bushing should be reamed to 1 .500-1.5016 jection pump (see "Installing Fuel Injection Pump"). trolled by a thrust plate bolted to front face of cyl­ b. No. 3 camshaft journal should have 0.004-
0.007 inch clearance.
;ii, inches. Method 2 - With timing gear housing in place inder block which allows removal of camshaft with

�· 2. Replace balancer idler gear hub as follows: and balancer removed, install idler gear thrust timing gear housing still in place. Normal camshaft 2. With camshaft gear and thrust plate installed
, ,I a. Press old idler gear hub out front side of washeF and retaining snap ring onto hub. Install end-play is 0.007-0.016 inch. onto camshaft, measure clearance . of thrust plate
bearing cap. front main bearing cap and idler gear in place, Fig.
f:�/ b. Install new oluQ into rear of new hub, Fig. 56.

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Fig. 61 - Removing or Installing Camshaft Complata 0

Fig. 56 - Balancer Idler Gear and Related Parts
1. Plug. 4. Balancer Idler gear.
Fig. 59 - Camshaft and Related Parts
1'. Key. 4. Lockwasher.
with Gear and Thrust Washer ii>
Fig. 58 - Removing or Installing Idler Gear Hub II)
2. Idler gear hub. 5. Thrust washer. 2. Thrust plate. 5. Sllpwasher,
o"
II)
in Cylinder Block

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3. Bushing. &. Snap ring. 3. Retaining plate, 6. Bolt.
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Fig. 63 - Crankshaft and Main Bearings

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:;.! Fig. 62 - Installing Camshaft Thrust Plate with
I Camshaft Installed in Block
1. Front. Center and Rear Main Bearing lnaert1 (Upper Half}
I' 2. Upper Thrust Wa,hers
f;:, :' 3. lntermttdiato Mein Soaring Insert, (Upper Halli
4. Timing Geer Key
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5. Crankshaft
6. Crankshaft Timing Gear
with a feeler gauge. Remove camshaft gear and in­ 7. Intermediate Main Bearing Inserts {Lower Half)
stall a new thrust plate, Fig. 62, if clearance exceeds
(:ti 0.016 inch.
8. Lower Thrust Washer•
9. Front, Center and Rear Main Bearing lnaert1 {Lower Half)
�1-':"'
fil,,i TAPPETS

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Tappets are mushroom shaped and can only be
removed and reinstalled after oil pan and camshaft
II have been removed.
New tappets should be installed whenever cam­
instant that push rod tightens, indicating intake
valve is startin.g to open. Fig. 64 - Main Bearing Cap Identification Numbers
shaft is replaced. 4. T.0.C. mark should be NEARLY aligned, Fig. 24. 1. Cop location numbers.
Do not attempt to reclaim tappets by regrinding 2. Cy6ndet-block idontiflcotlon numbers.
NOTE: Valve timing may be considered
their faces.
satisfactory if T.D. C. mark is within 2-112 CRANKSHAFT END-PLAY 4. Remove old lower halves of thrust washers
degrees.
I'
� INSTALLING CAMSHAFT from bearing cap and install· new ones, with vertical
Crankshaft end-play is controlled by four re­ grooves facing outward.
There is no adjustment provided for valve

t.
� Lubricate journals and lobes and proceed as fol­
timing. Should . timing be incorrect, gears
placeable 1800 thrust washers on sides of center main
NOTE: A light coating of grease will assist
Q
" lows: can only be one or more teeth out of correct
bearing, which are available iri standard size and
0.0075 inch oversize. Lower halves of thrust washers
in holding washers in place.
1. With engine upside down, or with tappets sup­
t
fu mesh. 5. Install center main bearing cap. Tighten cap­

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ported in their fully raised position, carefully install (which fit in bearing cap) have locating lugs to
camshaft (with gear attached) into cylinder block, 5. Make sure to reset valve clearance to normal prevent them from turning out of position, Fig. 63. screws to 140-150 ft.-lbs. torque and recheck end­
Fig. 61. setting after making this check. Oversize thrust washers may be combined with play.

I
2. Install: standard size washers for an adjustment of 0.0075
CRANKSHAFT AND MAIN BEARINGS inch, or they can be installed on both sides to provide REMOVING CRANKSHAFT
�'" a. Capscrews and lockwashers securing thrust
lIit plate to cylinder block.
b. Engine idler gear, making sure all timing The crankshaft is "Tuffride" hardened. This process
an adjustment of 0.015 inch.
NOTE: Identify all parts so if serviceable,
gear marks are aligned. provides extremely hard, long wearing journal CHECKING CRANKSHAFT END-PLAY they may be installed in their original lo­
c. Push rods and rocker arm shaft assembly. surfaces, but doesn't penetrate deep enough to allow cation.
Adjust valve clearances. regrinding without being "Retufftrided". 1. Force crankshaft either forward . or rearward
d. Fuel pump and timing gear cover. Steel backed, aluminum tin lined, main bearing as far as it will go.
3. Complete reassembly of engine. inserts are available in standard size and 0.010 inch, 2. Measure gap between machined shoulders on
crankshaft web and crankshaft. thrust washer with

W_�1
0.020 inch and 0.030 inch undersizes. Upper and lower
main bearing inserts are not interchangeable, Fig. a dial indicator or feeler gauge, Fig. 65.
CHECKING VALVE TIMING 3. End-play should be within 0.005-0.016 inch.
63.
4 1. Rotate crankshaft in normal direction of en­
Main bearing caps are dowelled and are' number­
ed from front. of engine to rear, Fig. 64. Caps are
gine rotation (clockwise) until both rocker arms of REPLACING THRUST WASHERS
�i:'.. No. 4 cylinder are "rocking" (exhaust valve closing
also marked with a cylinder block identification
H-i
number to prevent bearing caps from being acciden­

t�1
and intake valve opening), indicating that No. 1 1. Remove center main bearing cap and lower
tally installed onto a different cylinder block, Fig.
�
A
piston is at approximately T.D.C. on compression
64. thrust washers.
i stroke. 2. Rotate old upper halves of thrust washers out
2. Adjust INTAKE VALVE CLEARANCE of No. 1 NOTE: Cylinder block and main bearing of recesses in cylinder block.
cylinder to 0.020 inch. cap bores are machined with caps in place. 3. Lubricate new upper halves of thrust washers 0
3. Slowly rotate crankshaft in normal direction If a main bearing cap becomes damaged, (those without locating lugs) and rotate them into iii"
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of rotation until INTAKE PUSH ROD OF NO. 1 CYL­ it will be necessary to replace cylinder block place, WITH VERTICAL GROOVES FACING OUT-
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INDER just tightens. stop turning crankshaft the complete with main bearing caps. WARD TOWARD CRANKSHAFT. Fig. 65 - Measuring Crankshaft End-Play
.
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if 2. Release rocker• arm shaft assembly and remove
i·,' engine idler gear, camshaft gear and injection pump
2. Lubricate bea_ring journals on crankshaft and
carefully install it into place.
gear. 3. Install upper halves of crankshaft thrust wash­
3. Remove: ers (those wi.thout locating tabs), with oil grooves
a. Injection pump and timing gear housing. outward and steel face toward main bearing cap.
"
111
'""
b. Connecting rod bearing caps. Push connecting
rods clear of crankshaft.
Position upper thrust washers so ends are flush with
"UNOU• face of cylinder block.
c. All main bearing caps. 4. Install lower main bearing inserts into their
4. Lift crankshaft from cylinder block.
respective bearing caps and lubricate them.
5. Coat lower thrust washers (those with locat­
ing tabs) with grease and position them in recesses
on sides of center bearing cap.
INSPECTING CRANKSHAFT 6. Install numbered main bearing caps in their
correct locations. TIGHTEN MAIN BEARINGS TO
1. If any journals are worn more than 0.001 inch 140-150 FT.-LBS. TORQUE.
beyond minimum diameter; 0.001 5 inch or more out­ 7. Force crankshaft forward and rearward and
Fig. 68 - fnspect Crankshaft Flange
of-round, or tapered 0.001 inch or more, crankshaft check crankshaft end-play as outlined .under head­
ing "Crankshaft End-Play". If end-play exceeds 0.016 1. Dowel pins.
should be considered unfit for further use. See Fig.
66. inch, install new standard or oversfze thrust washers.
2. Crankshaft should be straightened if it has 8. Install connecting rod bearing caps. Tighten
more than 0.004 inch total runout. bolts to 100-105 ft.-lbs. torque. 4. Press new seal into retainer.
9. Install rear oil seal retainer complete with a. On production, one-piece lip-type seal is fitted

:",I
new oil seal. Install rear bridge piece. Refer to
heading "Rear Crankshaft Oil Seal" for -additional
information.
REGRINDING CRANKSHAFT 10. Reinstall engine balancer and flywheel.
1 1. Rotate crankshaft until key in crankshaft
1. Inspect crankshaft for cracks and demagnetize. gear is straight up in relation to cylinder head end
2. Crankshaft specifications are shown in Fig. 66. of engine. Rotate balancer drive shaft as required
I' a. Main bearing-journal diameter: and install balancer idler gear in place with both
with its rear face in line with rear face of seal. re­
tainer.
b. When renewing this seal, if crankshaft flange,
Fig. 68,. is grooved, press seal slightly further into
seal retainer, in first instance 1 /8 inch and later
to 1/4 inch from retainer rear face.
c. Assure that seal is "square" in retainer bore.

1i1
11
11,, Standard Size ............. 2.9985-2.999 inches sets of marks aligned. INSTALLING OIL SEAL RETAINER
·,
1 Undersizes ......... 0.010, 0.020 and 0.030 inch 12. Reinstall idler gear hub, timing gear housing
b. Crankpin journal diameter: and fuel injection pump. 1. Coat new retainer gasket with non -hardening
Standard Size ............. 2.7483-2.749 inches 13. Reinstall camshaft and injection pump gears, sealing compound and place gasket in position.
Undersizes ......•.. 0.0, 0, 0.020 and 0.030 inch then install engine idler gear with all timing gear 2. Lightly coat seal and crankshaft surface with
3. Remove sharp corners on oil holes after re- ma(ks aligned. Refer to Fig. 50. engine oil.
grinding and inspect for cracks. 14. Install oil slinger, timing gear cover, crank­
1!1 4. CRANKSHAFT MUST BE "RETUFFTRIDED" shaft pulley, oil pan and complete reassembly of
3. Install oil seal retainer, Fig. 67. Tighten cap­
screws to 1-2 ft.-lbs.
lil AFTER REGRINDING. engine. Adjust valve clearances. 4. If rear bridge piece was removed earlier, it
fi
5. Crankshaft must again be inspected for cracks, should be installed as follows:
then demagnetized.
n:
a. Lightly coat rear oil seal retainer face and
REAR CRANKSHAFT OIL SEAL
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metal-to-metal sealing faces of bridge piece and
cylinder block with non-hardening sealing com­
REPLACING OIL SEAL pound.
,.,, INSTALLING CRANKSHAFT b. Install bridge piece in "place using new end
;_;:.
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1. Remove flywheel.
i: seals, Fig. 69. Then align bridge piece with oil pan
1. Install upper halves of main bearing inserts in 2. Remove oil seal retainer, Fig. 67. face on block, and tighten capscrews.
block and lubricate. 3. Press out old seal. 5. Reinstall flywheel and complete reassembly
NOTE: Upper and. lower main bearing in­ of engine.
serts are not interchangeable with one
another, nor are they completely inter­
changeable in different bores. Refer to
following chart to determine which bear­
ings are interchangeable.

No. of Inserts
Fig. 66 - Crankshaft Spacifications
Bearing Position Interchangeable
Front, Center
and Rear Top 3
1. Remove:
a. Flywheel and oil pan. Front, Center
b. Rear crankshaft oil seal and cylinder block and Rear Bottom 3
l: ;�l bridge piece.
c. Engine balancer assembly. Intermediate Top 2 +II �
d. Crankshaft pulley, timing gear cover and Fig. 67 - Rear Main Oil Seal Correctly Installed ti)
oil slinger. Intermediate Bottom 2
o"
ti)
1.· Lip of seal toward engine. Fig. 69 - Installing Rear Bridge Piece

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LUBRICATION SYSTEM

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SPLASH
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Fig. 70 - Removing Flywheel Fig. 72 - Measuring Flywheel Face Run-Out

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2. Release lock tabs to remove capscrews.

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1. Metal bar installed to handle flywheel. I

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3. Heat new ring gear to an approximate tem­

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perature of 475° F.
ENGINE FLYWHEEL J

,r1,,: 4. Position ring gear on flywheel so lead-in side

REPLACING FLYWHEEL RING GEAR

I
� of teeth is. toward front of flywheel, and allow it to
cool. Make sure ring gear is fully located against fly­
wheel shoulder.

l:
·1 1. Remove flywheel as shown in Fig. 70.
1
j, I 2. Flywheel ring gear is shrunk onto flywheel.
Partially chisel cut ring gear and drive it from fly­
wheel.
FLYWHEEL INSTALLATION
- - - - - f¾¼P!ITRA!®- ���-=-

Fig. 73 -Lubrication System Diagram

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I NOTE: A,:, alternate method of removing

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1.. Inspect flywheel and pilot bearing.
ring gear is to flame heat a localized portion

b. Oil pan to timing gear housing capscrews

a. Clutch friction face of flywheel may be re­
I
of ring gear to expand it, then carefully tap

. . . 12-15 ft.-lbs.
faced up to 0.030 inch, providing same amount of
gear off flywheel.

c. Oil pan to rear bridge piece capscrews

OIL PAN
material is also removed from clutch mounting
REMOVING OIL PAN 10 ft.-lbs.
surface of flywheel.
!

3. Install and tighten all capscrews which secure

b. Clutch mounting surface should be main­
'

tained 1 .390-1.420 inches away from clutch friction 1. Drain engine oil. Tractor front end and transmission to oil pan and
1 2. Remove capscrews which secure front and rear cylinder block.
face of flywheel.
ends of oil pan to Tractor front end and transmis­ 4. Refill with engine oil.
1� 2. Install flywheel as shown in Fig. 71.
sion. SLIGHTLY LOOSEN (approximately one turn)
four large capscrews which secure Tractor front end
to cylinder block.
3. Check flywheel runout: CAUTION: Be careful not to allow ex­
a. Flywheel friction face "run-out" should not
exceed 0.001 inch for each inch of RADIUS from
flywheel center to point of measurement, Fig. 72.
b. Flywheel outside diameter (periphery) "run­
out" should not exceed 0.012 inch.
A cessive separation as it could cause
personal injury, or damage sheet metal
and other parts of Tractor.
3. Support oil pan, then remove capscrews secur­
ing oil pan to cylinder block. Lower oil pan from en-
gine.

INSTALLING OIL PAN

1. Install new gasket with sealing compound.

Fig. 71 - Flywheel and Pilot Bearing 2. Raise oil pan into position, then install cap­
Correctly Installed screws, Fig. 74. Tighten as follows:
NOTE: When making these checks, apply
0
a. Oil pan to cylinder block capscrews .. . 19-21 Fig. 74 - Oil Pan Installation
pressure against flywheel center to elimi­
iii"
h.-lbs. 1. Aluminium seaUng wahers.
1. AUgn odd hole in flywheel with odd hole in crankshaft. nate crankshaft end-play which could cause ti)
.2. Pilot bearing. false readings . ti)
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2. Use a feeler gauge and measure: (1) Inner to 77. Install short capscrews which secure pump body
i.l outer rotor clearance, (2) Outer rotor 10 .. pump body and cover together. Tighten capscrews securely.

·1 !
bore clearance and (3) End clearances of both inner 3. Install relief valve plunger, spring and cap in
and outer rotors in relation to rear face of pump body. cover bore and secure by installing new cotter pin,
See "Specifications" heading for proper clearances. Fig. 79.
3. Check tension.of relief valve spring. 4. Install new gaskets onto oil suction and oil
.:1 delivery pipes, using non-hardening sealing com­
REASSEMBLING AND INSTALLING OIL PUMP pound. Position them in place onto rear of oil pump
'I
{ and slide four long bolts into oil pump.

l
�; Dip parts in clean engine oil. 5. Using a new gasket, install oil pump assembly
1. Position outer rotor so chamfered edge will in place and engage oil pump drive shaft with slot
be inside pump body and install inner and outer in rear of balancer shaft, Fig. 76. Tighten oil pump
rotors, Fig. 78, into body. retaining capscrews and oil delivery connection
2. With "O"-rings in place, carefully join dowelled securely.
pump body and pump cover castings together, Fig. 6. Install oil pan.
Fig. 75 - Oil Pump and Related Parts Fig. 77 - Oil Pump Body Separated from
� 1. Oil delivery pipe. Rear Cover

!1/1
2. tl:eliefvaJve. 1. Inner rotor. 3. Outer rotor.
2. '"O" Ring. 4. "O" Rir\9·
and withdraw relief valve cap, spring and plunger,
REPLACING OIL FILTER Fig. 79.

1. Remove old filter and clean filter head.
2. Lightly oil top seal of new filter canister.
3. Screw on new filter until canister seal just
touches filter head, then tighten by hand a further
·half turn.
OIL PUMP
REMOVING OIL PUMP
INSPECTING OIL PUMP
NOTE: Make sure oil pump passages in pump
which supply filtered oil to balancer drive
shaft are fully cleaned and open.
1. Position outer rotor so chamfered edge will be
inside pump body a�d install inner and outer rotor
into body.

1. Remove oil pan.

2. Disconnect oil delivery connection, Fig. 75.
3. Unscrew four long capscrews which secure oil
intake and oil delivery pipes to oil pump. Separate
pump from balancer frame, Fig. 76.
4. Remove oil suction and delivery pipes from
�1 rear cover of oil pump and clean gasket surfaces.
!}

tl DISASSEMBLING OIL PUMP

t 1. Remove two capscrews securing oil pump cover

to pump body and carefully separate the two cast­
ings, Fig. 77.
2. Slide inner and outer rotors out of pump body, Fig. 78 - Inner and Outer Rotors
�' Fig. 78. 1. ..0.. Ring. 3. Outer rotor.
ii
ti 3. Remove cotter pin from end of oil-pump cover 2. Inner rotor. 4. Chamfered edge.

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Fig. 79 - Relief Valve Assembly- 0
Fig. 76 - Removing or Installing Sequence of Parts iii"
Oil Pump Assembly 1. Cotter pin. 3. Plunger ti)
ti)
1. Slot. 2. Spring. 4. Ca p
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2. Thin paper gasket.
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 FUEL AND AIR SYSTEM and no resistance can be felt at end of
strokes, turn engine over ·slightly using starter
motor. This will rotate camshaft slightly
to change position of fuel pump cam and
allow manual operation of fuel lift pump.
5. Loosen two or three connections on high pres,
sure fuel lines, at injector ends. It is not necessary
to loosen all four connections.
6. Move throttle control to "wide-open" position.
Operate starter motor until fuel without foam flows
past loosened high pressure connections.
7. Retighten connections and start engine. Re­
maining injectors will "air-bleed" themselves.

FUEL LIFT PUMP

FUEL LIFT PUMP

REMOVAL AND DISASSEMBLY

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Fig. 80 - Air Cleaner Restriction Indicator Fig. 82 - Fuel Lift Pump and
1. Indicator "Red" signal. Parallel Fuel Fi.lters Refer to Fig. 84.
2. Rubber unloading valve. 1. Air vent plug. 1. Disconnect fuel lines and remove fuel lift pump

K
2. Priming lever. from engine.
2. Make a file mark across flanges of pump to
AIR CLEANER b. Prepare solution (MF Part No. 1900 726 assure proper positioning of parts during reassembly.

The dry element type air cleaner should be serviced

M1) .according to directions on container, or use
solution of lukewarm water (100 ° F.) and non­
3. Separate pump head from pump body.
4. Turn diaphragm assembly 90° and lift diaphragm
6)._____ � ,_, ��
ONLY when "Red" signal in restriction indicator is
locked in full view, Fig. 80.
foaming detergent.
c. Soak element in solution for 15 minutes·
maintaining temperature of 1200-150° F.
and pull rod assembly from body.
5. Pry inlet and outlet valves from pump head.
Remove valve gaskets from bottom of recesses.
,I V
SERVICING OUTER FILTER ELEMENT d. Agitate element. 6. Remove rocker arm pin retainers which are
e. Thoroughly rinse element with clean staked in position. Remove rocker arm pin, spring
Replace outer element after six washings or water (maximum pressure 40 psi), until drain water and washers together with rocker arm and connect­
yearly, whichever comes first. is clean. ing link.
1. Remove outer element, Fig. 81, and carefully 13) 12
wipe inside of housing with a damp cloth. Check
IMPORTANT: DO NOT USE ELEMENT UN­
FUEL LIFT PUMP l,;J
LESS IT IS COMPLETELY DRY.
condition of rubber unloading valve, Fig. 80. REASSEMBLY AND INSTALLATION °(J114
�i1
2. Inspect housing and elements carefully. Replace 4. Check element for ruptures or other damage
by placing a light bulb inside element. Replace if
10�,,,,,,�
as necessary. Refer to Fig. 84.
3. Clean outer filter element as follows: element has even slightest hole or damage. 1. Install new valve gaskets and new valves into
5. Secure element in housing (element is not tight pump head.
a. Back flow element with compressed air. Fig. 84 - Fuel Lift Pump - Sequence of Parts
Direct clean dry air (at a pressure not exceeding if it can be rotated by hand). a. Inlet valve spring must protrude into pump
100 psi) up and down pleats inside element (op­ chamber towards diaphragm. 1. Pump H11d 9. Lever
SERVICING INNER FILTER ELEMENT b. Outlet valve must be installed in r.everse po­
posite to normal direction of air flow through 2. Valve Gasket 10. Spring
element). Keep air nozzle at least 1" away from sition to inlet valve. 3. Valve 11. Washer
Inner filter element should not be disturbed un­ c. Stake casting around each valve in four places 4. Diaphragm 12. Re1ainer
element. Continue cleaning until no dust is being
removed. Be careful not to damage element with less after replacing outer element, indicator still in­ with a punch.
5. Retum Spring 13. Rocker Arm Pin
14. Rocker Arm
dicates "Red" after resetting indicator and operating 2. Install connecting link, rocker arm spring, rocker
6. Retainer
air flow nozzle or jet. 7. Seal 15. Connecting Link
engine. INNER ELEMENT ,CANNOT BE CLEANED, arm. pin and washers. Install retainers and stake in 8. Pump Body 16. Spring
and must be replaced with a new element. J?_lace.

AIR-BLEEDING FUEL SYSTEM

3. Replace diaphragm spring and diaphragm as­
1. Push fuel shut-off control fully "in".
sembly over spring (pull-rod positioned downward)
2. Loosen air vent plug on top of fuel filters; Fig. 82.
and center upper end of spring in lower protector
3. Loosen upper and lower vent plugs on fuel in­
washer.
jection pump, Fig. 83.
4. Manually operate fuel lift pump priming lever, 4. Press downward on diaphragm assembly so
Fig. 82, until fuel without foam flows out vents and notched blade on pull rod aligns with rocker arm
tighten vent plugs in following order: connecting link, then twist it goo to engage pull rod
a. Fuel filter vent plug, Fig. 82. slots in fork of connecting link.
b. LolC)ler vent plug on fuel injection pump, Fig.
5. Push rocker arm toward pump until diaphragm
83. is level with body flanges. Place pump head into po­
0
Fig. 81 - Removing Air Cleaner c. Upper vent plug on fuel injection pump, Fig. iii"
Filter Elements
,.,.
sition. as indicated by mark made on flanges before
83. Fig. 83 - Fuel lnjecti� Pump ti)
disassembly. Install screws and washers and tighten
o"
ti)
1. lnnerelement. 1. Opparventplug.
NOTE: If fuel lift pump does not pump fuel until heads of screws just engage washers.
3
2. Outer element. 2. Lower ventplug.

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---- - ----- -- --- ----- - ----- ----- - ----- ----- ------------ ----- - -

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FILTER HEAD ��
ELEMENT SEAL�
Ftl.TER ELEMENT
ELEMENT SEAL�
FlLTER BOWL�
BASE SEAL
---�-db
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Fig. 85 - Fuel Filter- Sequence of Parts
6. Exert sufficient pressure on rocker arm to draw
diaphragm inward until its edges align with edges of
pump flanges. Fully tighten screws.
7. Test pump to make sure it is working properly,
and reinstall to engine. Air-bleed fuel system as nec­
essary.
FUEL FILTER
ELEMENT REPLACEMENT
Under normal conditions replace both filter ele­
ments every 500 hours of operation.
Refer to Fig. 85.
1. Clean outside of filter before attempting to
•replace element.
2. Loosen drain plug to drain fuel from filter. Un­
screw center bolt at top of filter, while holding base of
filter to prevent it from rotating.
3. Release filter element, complete with base, by
pulling element downward, and at same time turn­
ing it slightly so that it comes free from internal
"O"-ring.
4. Clean and inspect all parts.
5. Install a new sealing ring into filter head and
a new "O"-ring onto center tube. MAKE SURE RINGS
ARE NOT TWISTED OR DAMAGED.
�34-
6. Install new sealing rings. Place new filter ele­
ment into position on base. HEAVY RIM ON ELE­
MENT SHOULD SE TOWARD FILTER HEAD.
7. Install filter base and element onto filter head,
and at same time, turn it slightly so element slides
easily over "O"-ring.
8. Make sure element is seating squarely on seal­
ing rings. Tighten center bolt to 6-10 ft.-lbs. DO NOT
OVERTIGHTEN.
9. Air bleed fuel system.
10. Check for fuel leaks around upper and lower
sealing rings. DO NOT OVERTIGHTEN CENTER BOLT
IN AN ATTEMPT TO STOP FUEL LEAKAGE. If a leak
should persist, disassemble filter and carefully in­
spect for damaged sealing faces or seals.
FUEL INJECTION PUMP
Fuel injection pump is made by CAV and is DPA
distributor type with a built-in mechanical gover­
nor. Internal servicing of injection pump should be
handled by a CAV Service Station. Setting codes and
numbers are stamped on a plate on injection pump
body.
REMOVING FUEL INJECTION PUMP
1. THOROUGHLY
jection pump.
CLEAN ENGINE around
IMPORTANT: Do not steam clean or wash
injection pump off with cold water while
. engine is operating. Failure to observe this
precaution may result in seizure of parts.
2. Disconnect throttle control rod and fuel shut­
off cable from fuel injection pump.
3. Remove fuel supply and fuel return lines, Fig.
86.
4. Remove all four high pressure fuel lines between
injection pump and fuel injectors.
IMPORTANT: Cap all open fuel connections.
5. Remove fuel injection pump drive gear cover.
Working through opening, remove three capscrews
and lockwashers securing gear to pump, Fig. 86. BE
EXTREMELY CAREFUL NOT TO ALLOW CAPSCREWS
OR WASHERS TO FALL DOWN INTO ENGINE.
Fig. 86 - Injection Pump Drive Gear with
Cover Removed
1. Fuel return line.
2. Capscrows.
3. Fuel Supply Line
Fig. 87- Removing or Installing Fig. 89 - Fuel Injection Pump Adjustments
Fuel Injection Pump
1. Fuel shut-off arm
1. Slot. ..Running .. position.
2. Low Idle speed adjusting screw•
3. Wlre aeal and cover sleeve.
4. Maximum speed edjus11ng screw.
6. Withdraw pump from timing gear housing, Fig. "running·· position stop. then tighten setscrew,
87, after removing nuts and washers. Fig. 89.
3. Assure that injection pump fuel shut-off lever
INSTALLING FUEL INJECTION PUMP is pulled against "off" position stop when control
knob ·is pulled out. Shut-off lever must hit "running"
in-
1. Using a new gasket, engage slot in pump hub position stop when control knob is pushed back
against instrument panel.
with gear dowel, Fig. 87, and move pump fully in
place against housing.
2. Position pump so scribed timing marks align,
Fig. 88, and tighten nuts and washers. ADJUSTING ENGINE SPEED
3. Install three capscrews and lockwashers se­
curing pump drive gear onto pump, Fig. 86. Reinstall IMPORTANT: Maximum speed adjustment
inspection cover onto timing gear cover. screw is factory adjusted and sealed. If
4. Reinstall high pressure fuel lines. engine and/or injection pump is still with­
5. Using new rubber sleeves (olives), install fuel in warranty, do not without authorization
supply and fuel return lines, Fig. 86. break seal and attempt to adjust engine
6. Reconnect throttle linkage and fuel shut-off speed. MAXIMUM ENGINE SPEED MUST
cable. Complete reassembly of engine and air-bleed ONLY BE ADJUSTED BY AUTHORIZED
fuel system before attempting to start engine. PERSONNEL.
ADJUSTING FUEL "SHUT-OFF" CONTROL 1. Start engine and allow it to reach normal oper­
ating temperature.
1. Place fuel shut-off control knob 1/16 inch from 2. Disconnect throttle rod from injection pump.
instrument panel. 3. Engine low idle speed (injection pump throttle
2. Loosen setscrew in swivel block on injection lever against low idle speed adjusting screw) should
pump shut-off arm. Place fuel shut-off arm against be 825-875 rpm.
a. If low idle speed is incorrect, loosen lock nut
on low idle speed adjusting screw, Fig.. 89. Turn
I screw "in" to increase idle speed or "out"' to de­
crease speed.
l
b. RETIGHTEN LOCK NUT AFTER COMPLET­
ING ADJUSTMENT.
4. Hold injection pump throttle lever against max­
imum speed adjusting screw. Maximum engine speed
(no load) should be 2170-2220 rpm.
a. To adjust; remove wire seal and cover sleeve
from maximum speed adjusting screw and loosen
lock nut, Fig. 89. Turn screw "in" to decrease max­
imum engine speed, or "out"' to incre·ase speed.
i· b. RETIGHTEN LOCK NUT AFTER COMPLETING
ADJUSTMENT. Reinstall cover sleeve and reseal
adjustment screw. 0
iii"
5. Adjust and reinstall throttle rod. Refer to "Ad­
ti)
Fig. 88 - Timing Marks Aligned justing Throttle linkage".
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1. Timing marks.
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Fig. 92 - Crankshaft Pulley Timing Marks
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Fig. 90 - Hand Throttle Lever in Full
Aligned for Injection Pump Timing
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Throttle Position

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1. Friction pack. 1. Injection pump static timing mark- 2. lncftcator.
2. RodA, 20° B.T,D.C. 3. T,D.C. Mark,
5-17/32 In. Fig.93
3.

ADJUSTING THROTTLE LINKAGE 1. Remove rocker arm cover. l1,

1. Adjust rod A to 5-17 /32 inch (measured between
centerline of ball joints), Fig, 90.
2. Position hand throttle lever 1/16 inch from top
of slot in instrument panel (full throttle position),
Fig. 90.
2. Thoroughly clean outside of fuel injection pump.
Break seal and remove inspection cover from side
of pump. Fuel will spill ou� when cover is removed.
3. Turn crankshaft in normal direction of rotation
(clockwise - as viewed from front) until No. 1 (front)
cylinder is at T.D.C. on compression stroke. j

3. Adjust rod B until injection pump lever contacts
max·imum s_peed adjusting screw, Fig. 91.
4. Adjust hand throttle friction pack, Fig. 90, to
provide approximately 9 lbs. breakaway force meas­
ured at outer end of hand throttle lever with linkage
fully connected.
ADJUSTING FUEL INJECTION PUMP TIMING
IMPORTANT: Following operations should
be performed only by skilled and experienced
personnel. Breaking of seals on fuel injection
pumps and engines, which. are subject to
warranty, must be carried out only by au­
thorized persons. They must then later re­
seal pump.
Injection pump is equipped with a start retard
feature which gives a 20° B.T.D.C. static timing angle.
l
NOTE: At this point, T.D.C. mark will be
aligned end rocker arms of No. 4 cylinder
1
will be "rocking" (exhaust valve closing and
intake starting to open).
4. Rotate crankshaft back {counterclockwise) ap­
proximately 1/4 of a. turn. Then SLOWLY rotate :I
crankshaft forward again in directi'on of normal ro­
tation until pump static timing mark on crankshaft
pulley is ACCURATELY aligned as shown in Fig. 92.
STOP TURNING CRANKSHAFT THE INSTANT THAT
MARKS BECOME ALIGNED.
NOTE: Reason for rotating crankshaft 900
backward and then forward again is ,to
eliminate all backlash within timing gears.
5. Look through inspection opening in fuel in�
jection · pump and observe rotor and snap ring with­
in pump body.
IF FUEL INJECTION PUMP IS PROPERLY TIMED,
LETTER "E" MARK ON ROTOR WILL BE ALIGNED
WITH SQUARE END OF SNAP RING AS SHOWN IN
FIG. 93.
6. II mark on rotor does not align with square
. ·'3
1I
edge of snap ring when crankshaft is properly po-
sitione(I, adjust timing as follows: .
a. Loosen (do not remove) three nuts securing
injection pump to timing gear housing.. SLOWLY
i·
I
twist pump body in required direction and care­
fully align square end of snap ring with letter "E" I

mark on rotor. ;:
b. After marks have been aligned, tighten nuts
securing injection pump. RECHECK PUMP TIM­
ING BEFORE REINSTALLING SIDE COVER AND
RESEALING IT.
7. When satisfied that timing is correct, complete
Fig. 91 - Injection Pump Lever Against reassembly of engine, reseal pump and air-bleed Q..
Q)
Maximum Speed Adjusting Screw fuel system.
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COOLING SYSTEM 4. Install fan, fan belts and alternator. Adjust

belt tension.
5. Refill cooling system.

THERMOSTAT

REPLACING THERMOSTAT

1. Drain radiator.
2. Separate water pump outlet connection from
CERAMIC
water pump body and remove thermostat.
COUNTERFACE
3. Clean gasket surfaces.
REAR 4. Install new, thermostat into water pump body
SEAL with large wound spring toward pump.
SHAFT 5. Using new gasket with -sealing compound, re­
install outlet connection.
Fig. 95 - Measuring Impeller Blade Clearance
REAR while Pressing it onto shaft.·
BODY TESTING THERMOSTAT
FLANGE Z. 0.027 In - 0.035 in.
IMPELLER
� 8. Rotate shaft to assure that it turns freely. 1. Carefully open end of valve and insert end of
CORRECT COUNTERFACI: .POSITION
MAIN ..;r
(FRONT)
�
'¼a;.
Ks, SPACER 9. Press impeller onto shaft so that a clearance
of 0.027-0.035 inch is main.tained between impeller
a thin string or thread into valve opening. Allow
valve to close on thread.
blades and pump body, Fig. 95. 2. Suspend thermostat and an accurate thermometer
BODY in a pail of water.
SEAL NOTE: The 0.027-0.035 inch is a checking
RETAINER 3. Heat the water. Stir water as it is heating and
clearance. Actual running clearance, includ­ observe temperature at which valve opens and al­
ing end-play, is 0.011-0.035 inch. lows thermostat to fall. If thermostat does not fun­
10. Using a new gasket with sealing compound, ction within specified temperature range, or.. ;.p·per\
IMP1:LL£1\ ��
rejoin main (front) body to rear body. fully, it should be replaced.

INSTALLING WATER PUMP FAN BELTS

Fig. 94 - Water Pump Parts Sequence.
Fill cooling system with sufficient water and
ethylene-glycol anti-freeze mixture to protect against
freezing down to minus 30° F.
It is recommended that a sealant pellet be in­
stalled in cooling system whenever cooling system
has been drained.
WATER PUMP
1. Install rear body and reconnect engine lift eye, Fan belt tension should be adjusted to provide
alternator adjusting bracket, temperature indicator 66-86 lbs. tension measured with Borroughs Gauge,
sending unit wire, cylinder block inlet hose and upper or to provide 1/2 to 3/4 inch belt deflection when
radiator hose. depressed with 15 lbs. load at center of longest span
2. Install water pump main (front) body assembly. between pulleys.
3. Reconnect lower radiator hose. Replace fan belts in matched sets.
5. Remove ceramic counterface and rear seal from
shaft.
6. Remove bearing retaining snap ring from body.
7. Press two bearings and spacer out front of
pump body.
8. Remove front seal, seal retainer and flange.
REASSEMBLING WATER PUMP

REMOVING WATER PUMP Refer to Fig. 94.

1. Drain cooling system.
2. Remove alternator, fan belts and fan.
3. Disconnect lowerradiator hose from water pump.
4. Remove water pump main (front) body as­
sembly.
5. Disconnect upper radiator hose, cylinder block
inlet hose, temperature indicator sending unit wire,
alternator adjusting bracket and engine lift eye;
then remove rear body.
DISASSEMBLING WATER PUMP
Refer to Fig. 94.
1. Separate main (front) body from rear body.
1. Press rear bearing onto shaft with shielded face
to rear. Install spacer and press on front bearing
with shielded face to front.
2. Install grease seal flange in position against
back face of rear bearing so center part dishes away
from bearing.
3. Install felt seal and seal retainer so seal bears
on flange.
4. Smear bearings, and half fill space between
them, with high melting point grease.
5. Press complete bearing and shaft assembly into
pump body from front end. Insert snap ring.
6. Press pulley onto shaft until it bottoms against
inner race on front bearing.
7. Lightly coat outside brass portion of rear seal
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2. Remove pulley with puller tool. with sealing compound and push it fully in place with iii"
3. Press shaft, complete with impeller, out rear carbon face towards rear. install ceramic counter­ ti)
of pump body. face onto shaft so ceramic side will contact seal, ti)

_4. Press shaft out of impeller. Fig. 109. c=;-

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 ENGINE TROUBLE-SHOOTING
Causes and corrections have been listed to show more probable and easily checked causes at the beginning.
ENGINE WILL NOT TURN OVER
POSSIBLE CAUSE POSSIBLE CORRECTION
Dead or weak battery Check condition of battery. Recharge or replace
battery as required.
Poor battery cable or ground connections Inspect, clean and tighten battery cables and
ground connections.
Loose or faulty wiring connections Clean and tighten connections.
Faulty starting switch Check and replace switch if necessary.
Starter motor locked or defective Check and repair as necessary. If locked, loosen
mounting bolts to free.
Internal engine seizure Attempt to turn engine manually - if engine
cannot be rotated, check for hydrostatic lock,
foreign object in gears or ·cylinders and for
piston seizure.
i,, ENGINE TURNS OVER, BUT WILL NOT START--
POSSIBLE CAUSE POSSIBLE CORRECTION
Fuel tank empty Check fuel supply. Fill tank and air-bleed fuel
system if required.
Fuel in tank, but no fuel at injectors - may be Loosen high pressure lines at injectors while
due to the following: cranking engine to determine if fuel is being
delivered. If fuel is being delivered, proceed to
next possible cause titled "Cranking Speed- Too
Low". If no fuel - check the following:
Fuel shut-off control in "off" Position or fuel tank Move control to "run" position and check that
shut-off valve (if provided) in closed position any shut-off valve within system is open.
Air in fuel system Open vent plugs on fuel injection pump, then
manually operate fuel lift pump and check for
presence of air in fuel injection pump. If present,
"air-bleed" the fuel system and investigate Ca\JSe
of air entry into system.
Fuel lift pump inoperative Check fuel delivery from fuel lift pump. Rebuild
or replace defective pump.
Fuel filters choked or fuel feed pipe blocked or Check fuel feed to fuel· pump and fuel filters.
damaged Replace elements and make any necessary repairs.
Fuel injection pump not delivering fuel to in­ Remove fuel injection pump and install replace­
jectors ment pump. Have old pump checked by CAV
repair station and repaired if necessary.
Cranking speed too low Check cran"king speed - if below normal, inspect
the following:
Battery not fully charged Check battery condition. Recharge or install new
battery if required.
Poor electrical connections Check connections, especially between battery
and starter motor, and between battery and ground.
:\
-40-
) -41-
L.
. ENGINE TURNS OVER, BUT Will NOT START (Continued}
POSSIBLE CAUSE POSSIBLE CORRECTION
Engine oil too heavy Check engine oil being used. Drain oil and refill
with recommended grade and weight of oil if re­
quired.
Starter motor faulty Check starter motor and repair if necessary.
Low ambient temperature Use cold weather starting procedure. If ether
spray is used, carefully follow Operator's Manual
instructions.
Low compression pressure Check compression pressures within all cylinders.
All cylinder pressures should be uniform and must
not exceed 10% variation between cylinders.
Ex:cessive variation in pressures between cylinders
indicates problem within engine. Attempt to isolate
cause of low compression pressure within one or
more cylinders and repair as required. Refer to
heading "Low Compression" for possible causes.
If the compression pressures within all of the cyl�'.­
inders are uniformly low (after prolonged satisc·
factory engine operation), a complete engine
overhaul will usually be required to restore the
engine. For other causes of poor compression with­
in all the cylinders, refer to heading "Low Com­
pression".
IF THE CYLINDER PRESSURE READINGS ARE
UNIFORM, BUT ARE "BORDERLINE" ENOUGH
TO CAUSE DOUBT AS TO THE CONDITION OF
THE ENGINE OR THE COMPRESSION TEST
GAUGE, PERFORM A COMPARATIVE TEST
USING AN ENGINE WHICH IS KNOWN TO BE
IN GOOD OPERATING CONDITION. A CHECK
OF THIS TYPE USING THE SAME TESTER,
PROCEDURE AND UNDER THE SAME CONDITIONS,
BY COMPARING THE COMPRESSION PRES­
SURES OF A QUESTIONABLE ENGINE TO THOSE
OF A KNOWN GOOD ENGINE CAN BE VERY IN­
FORMATIVE TO A SERVICEMAN.
Water in fuel or improper type of fuel Check fuel being used. Drain fuel, if required
and refill with clean proper-type fuel. Air-bleed
after draining and refilling system.
Dirty or faulty fuel injectors Remove and test old injectors. ServiC13 if required.
Incorrect timing of fuel injection pump or valves Check pump and valve timing. Reset if necessary.
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 ENGINE STARTS, RUNS FOR A FEW MOMENTS, THEN STOPS
POSSIBLE CAUSE
Air in fuel system
Partially choked fuel filters, strainer. or fuel
lines
Fuel lift pump not providing adequate delivery
Restriction in air intake or exhaust system
Wrong fuel tank cap, or vent hole blocked
ENGINE MISFIRING OR RUNNING ERRATICALLY
POSSIBLE CAUSE
Many possible causes - attempt to isolate
-42-
POSSIBLE CORRECTION
Check for presence of air in fuel injection pump.
If present. air-bleed the fuel system and investi-
gate cause. Tighten all fuel connections. Replace
parts if necessary. Old rubber olives which have
been reused on fuel line connections oftentimes
cause this problem.
Trace restriction in fuel flow and service as re-
quired.
Check output of lift pump and repair or replace
as necessary.
Check and service as necessary.
Check for vented cap. Replace or clear if neces-
sary.
POSSIBLE CORRECTION
Determine extent of problem, and if it exists at
"full load", or if it only occurs when fuel injection
pump is supplying minimum fuel delivery to fuel
injectors. Disregard any slight problem if it occurs
only at "idle" or "light load", as cause is probably
due to a very insignificant variation in fuel
delivery between cylinders when under these
conditions.
Attempt to determine if problem exists in all
cylinders, or is associated with only one or more
cylinders. by loosening the high pressure fuel
lines at injectors - one at a time - with engine
running at low idle speed.
If the cylinder is firing properly, there will usually
be a noticeable difference in the sound and
operation when the fuel supply is cut off. This
is similar to "shorting-out" a spark plug on a
gasoline engine.
If there is no change in sound or engine speed
when a particular injector fuel connection is
loosened, assume problem is within that cylinder.
Observe the loosened connection to determine
if fuel is being delivered to the injector. If not,
determine cause and service as required.
If problem cannot be isolated to any particular
cylinder(s). refer to list for possible causes that
would affect all cylinders.
If satisfied that problem is confined to particular
cylinder(s), check the suspected cylinder(s)
further to determine if problem is due to the fuel
system or cylinder compression. These are gen­
erally the two most common causes.
L CD
ENGINE MISFIRING OR RUNNING ERRATICALLY (Continued)
POSSIBLE CAUSE POSSIBLE CORRECTION
A quick "Field-Check" can be made by the
serviceman to further isolate the problem by
removing the injector from the suspl!cted
cylinder and reconnecting it with the nozzle
outside of the engine. Loosen all of the other
high pressure fuel lines at injectors to prevent
engine from starting. Then operate the starter
motor and observe the condition of fuel spray.
If the fuel spray pattern from the four spray holes
is not completely atomized, the injector must be
serviced. If the injector has a good spray pattern,
suspect low compression. Also refer to the
following list for other causes.
Air in fuel system Check for presence of air in fuel injection pump.
If present, air-bleed the fuel system and investi­
gate cause of air entry into system.
Faulty fuel injectors Isolate questionable injectors. Remove and test.
Service as required.
Improper type fuel, or water in fuel injection pump Make sure proper fuel is being used and tha·t
gasoline has not been added by mistake .. Check :
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fuel system for signs of water. Drain system i.f
water is present. then refill with clean proper fuel"'i
and air-bleed the fuel system.
Insufficient fuel or restricted fuel flow
Check thoroughly for plugged fuel filters, strainer,
loose connections. bent or cracked fuel lines. Also
check for defective fuel lift pump.
Low compression
Check engine compression and repair if required.
See heading "Low Compression" for possible
causes.
Low coolant temperature and/or low idle speed Check low idle speed and operation of thermo­
stat. Adjust to recommended speed and replace
thermostat if defective.
Incorrect valve clearance or valve sticking Check valve clearance and adjust if required.
Make sure valves are receiving lubricant.
Incorrect timing of fuel injection pump or valves Check and reset timing, if required.
Mis-matching of fuel injection equipment Recheck fuel system components to make sure
proper parts are installed. Refer to Parts List.
Faulty fuel injection pump Remove pump and have checked by authorized
CAV service station. Have serviced if required.
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 POSSIBLE CAUSE POSSIBLE CORRECTION
ENGINE LACKS POWER ENGINE RUNS, BUT WITH EXCESSIVE EXHAUST SMOKE (Continued)

POSSIBLE CAUSE I POSSIBLE CORRECTION

Engine overloaded Verify that engine actually lacks power and that
problem is not due to engine being overloaded.
Make sure to check for dragging brakes or other Engine oil consumption · Generally associated with poor compression after
BLUE SMOKE

malfunctions which would impose additional load. long period of satisfactory engine operation. See
Also check for poor operational practices which heading "Excessive Oil Consumption·· for possible
would require additional power. Make all neces­ causes.
sary corrections. Reduce load or shift to lower
gear if required.
Restriction in air intake system
BLACK OR GREY SMOKE - (INCOMPLETE COMBUSTION)
f Check air cleaner and service as required.
Restriction in air intake system Check air cleaner and service as required. Install Remove any other restrictions present.
new spare element if available.
Excessive overload or "lugging" of engine Determine if engine is being overloaded. Reduce
Improperly adjusted engine speed Check for bent or damaged throttle linkage which load or shift to lower gear if required.
would restrict travel of lever on injection pump.
Also check maximum engine speed (no-Joadl and Excessive restriction in exhaust system Check and repair as required.
adjust to specifications if required.
Diny or faulty injectors Remove and test operation. Service as required
Clogged fuel filters, strainer or other restrictions Check and service as required. or install replacement set.
in fuel system
Improper timing of fuel injection pump or Check timing and adjust if necessary.
Improper fuel Use recommended fuel. Consult fuel supplier and valves
use correct fuel for operating conditions.
Improper fuel Use recommended fuel. Consult fuel supplrer and -1·;-:;<t:;,
Improper valve clearance Check and adjust valve clearance if required. use proper fuel for operating conditions.

Restriction in exhaust system
Low compression
Dirty or faulty fuel injectors
Fuel injection pump timing incorrect
Injection pump not delivering sufficient quantity
of fuel to meet engine specifications
Mis-matching of fuel injection equipment Check to make sure correct fuel system com-
:I
Check and remove any.restriction present.
ponents have been installed.
·11
Check engine compression, service as required.
See heading "Low Compression" for possible
causes.
1 Fuel injection pump improperly calibrated or
damaged
Have pump tested by authorized CAV service
station. Reset pump for proper engine and altitude
1 conditions.
Remove and test operation. Service as required.
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Check pump timing. Readjust if required.
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Observe throttle linkage for unrestricted travel.
If linkage is satisfactory, have fuel injection pump
checked by authorized CAV service station.
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POSSIBLE CAUSE POSSIBLE CORRECTION
ENGINE NOISE
POSSIBLE CAUSE I POSSIBLE CORRECTION

l
ENGINE RUNS, BUT WITH EXCESSIVE EXHAUST SMOKE

Incorrect or poor quality fuel Carefully investigate fuel being used·- make sure
COMBUSTION KNOCKS - EXCESSIVE
Check air cleaner and service as required.
WHITE SMOKE - (MISFIRING)
Restriction in air intake system
Remove any other restriction present. tank does not contain gasoline by mistake. Use
I
1
j only recommended diesel fuel.
Low engi[le temperature. Allow engine to reach operating temperature. If
problem continues, check thermostat operation. Low engine rpm and/or improper operating Check and adjust engine rpm to recommended
Replace thermostat if defective. tempera.ture (thermostat stuck open, or not speed. Check cooling system. Make sure ther­
installed) mostat is installed and operating properly.
Improper type of fuel Check for low cetane fuel. Consult fuel supplier
II
and use proper fuel for operating conditions. Faulty injectors (nozzle valve sticking or im­ Isolate faulty injectors. Remove and check in­
properly adjusted) jector operation. Service as required, ·or install·
I
Faulty fuel injectors Remove and test operation. Service as required. replacement parts.

Incorrect injection pump timing Check and readjust timing as required. Excessive "lugging" of engine Determine if engine is being overloaded - reduce
load or increase engine speed.
Low compression Check engine compression and service if re­
0
quired. See heading "Low Compression" for Fuel injection pump timing too far advanced Check pump timing and adjust if required.
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possible causes.
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ENGINE NOISE (Continued) ENGINE OVERHEATING (Continued)
POSSIBLE CAUSE POSSIBLE CORRECTION
POSSIBLE CAUSE POSSIBLE CORRECTION Radiator fins partially clogged Clean radiator fins.

Excessively low oil level

MECHANICAL KNOCKS
· Check engine oil level and refill"to "full" mark on
dipstick.
. Many possible causes - refer to heading Attempt to short out cylinders and locate mal­
"Correction" function by loosening high pressure fuel lines at
injectors - one at a time - with engine operat­
ing. If there is no change in sound, assume that
knock is not occurring in that cylinder and
proceed with other cylinders. Refer to following
list.
Excessive valve clearance Check clearance with engine at normal operat­
ing temperature. Adjust to specifications.
Piston striking a valve Check for valve sticking or improper valve
timing. Also check piston height and valve depth
relative to top face of cylinder head if recently
overhauled.
i Thermostat stuck in the closed position (typical
of defective wax pellet type thermostats)
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� solution.
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·, Engine overloaded, particularly in hot weather
J or high altitudes
Radiator or engine coolant passages blocked
- . also radiator hose collapsing or blocked
Restriction in exhaust system
Remove and check thermostat. Replace if re­
quired. Do not operate without thermostat, in­
stalled.
Check cooling system and prepare for winter
operation by addition of permanent anti-freeze
Investigate to make sure engine is not being
overloaded. Reduce load or shift to lower gear if
required.
Ch13ck radiator hose and replace if required.
Flush system thoroughly following instructions
for equipment being used.
Inspect for blocked exhaust system. Repair as
necessary.

Main bearings Generally identified by a heavy, dull knock when Incorrect timing of fuel injection pump or Check timing and readjust if necessary.
accelerating under heavy load - remove bearing valves
caps and examine bearings for excessive clear­ .
ance or damage. Replace if required. Improper water pump operation Remove water pump and inspect parts. Repaii. _.
or replace if required. .. •i
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Connecting rod bearings Sound occurs at idle or light load and usually
disappears under full load. Creek for loos!l or
broken rod bolts, and for exces!;_ive bearing wear.
Service as required.
.; EXCESSIVE FUEL CONSUMPTION
14 POSSIBLE CAUSE POSSIBLE CORRECTION
Loose piston pin and/or piston slap Generally identified by a sharp metallic rap at ;i Clogged or dirty air cleaner Check air intake system. lnstal! new spare ele­
idling speed, especially noticeable when engine :I ment if available. Service air cleaner as recom­
is stilt cold. Remove piston and service as re­ mended. Eliminate any other restrictions present.
quired. :J
1
1 Engine overloaded, also possible low engine Determine if engine is being overloaded. Make
Broken piston ring Generally identified by a sharp clicking noise that -,, power - see heading "Engine Runs Evenly but sure to check for dragging brakes or other mal­
cannot be eliminated by "shorting out" cylinders. ·'
Lacks Power"
I
functions and poor operating practices which
Remove pistons and inspect parts. Service as l
would impose additional loads. Reduce load or
necessary. tj.;
shift to lower gear if required.
Timing gears Worn or loose gears usually rattle, whereas tight
Leaks in fuel system Inspect for fuel leaks and repair as necessary,
gears whine - more noticeable at low engine �·:
speed. Check gear backlash and condition of
{ Low operating temperature Make sure engine is operating at proper tem­
teeth. Replace gears if necessary.
perature. Remove and check thermostat opera­
tion. Replace if defective.

J
Excessive camshaft end-play Generally identified by sharp metallic noise more 'I
noticeable at low engine speed. cannot be
Improper type fuel Use recommended fuel. Consult fuel supplier and
eliminated by "shorting out" cylinders and usually
use proper fuel for operating conditions
will not vary with engine temperature.
j Dirty or faulty fuel injectors Remove and test injector operation. Service as
i required.
.1
ENGINE OVERHEATING Improper injection pump timing Check pump timing and adjust if required.
POSSIBLE CORRECTION
j-
POSSIBLE CAUSE Improper valve clearance or valve timing Check clearance and valve timing. Adjust if
Low coolant level Check and refill cooling system as required. required.
Check for and repair any leaks in system. Use
pressure testing equipment available commer­ :l Improperly calibrated or damaged fuel injection Remove pump and have checked by authorized
cially for this purpose. INCLUDE TEST OF
RADIATOR PRESSURE CAP AND ITS SEAT ·l1 pump CAV service station. Reset pump for proper en­
gine and altitude conditions. 0
WITHIN RADIATOR. iii"
-l Mis-matching of fuel injection equipment Check to make sure correct fuel system com­
Check belt tension and adjust if required.
I.
Fan belt slipping ponents are installed. Refer to Parts List.
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Oil leaks
POSSIBLE CAUSE
EXCESSIVE OIL CONSUMPTION
POSSIBLE CORRECTION
Carefully inspect for, and repair, any oil leak:;
present.
J:jj POSSIBLE CAUSE
LOW OIL PRESSURE (Continued)

New or rebuilt engine not yet fully "broken-in"
Incorrect weight, diluted or inferior oil being used
Oil level too high
Clogged crankcase breather pipe
Worn, broken or stuck piston rings. Also, worn
pistons and liners
Worn valve guide bores and/or guide seals if
engine is so ·equipped
LOW OIL PRESSURE
POSSIBLE CAUSE
Excessively low oil level
Incorrect weight, diluted or inferior oil being used
Defective or improper oil pressure gauge
Oil filter dirty or oil filter by-pass valve sticking
or broken
Plugged oil intake screen
Relief valve "sticking open" or broken relief
valve spring
Air leaks in suction side of oil pump, or badly
worn oil pump
-48-
If engine is new, or recently rebuilt, allow suffi­
cent time for new piston rings to become fully
seated with cylinder liners. Certain operating
practices and conditions may cause the engine
"break-in" to be extended beyond the normal
period.
Drain oil and refill to "full" mark with recom­
mended grade and viscosity of engine oil.
Check for incorrect dipstick or improper tube
placement - also, for improper practices of
checking oil level. Compare actual dipstick part
number with Parts List. Also, check amount of
oil required during oil change to bring level to
"full" mark as compared to capacity listed in
"Specifications".
The oil level should be checked with engine "cold"
and on level ground. Checking the oil level im­
mediately after stopping the engine will result
in overfilling as the oil within the engine will not
yet be drained back into the oil pan.
Check and clean if required.
Disassemble and inspect. Overhaul if required.
Usually occurs after long period of satisfactory
engine operation.
Disassemble and inspect. Service as required.
See Parts Book for parts required.
POSSIBLE CORRECTION
Check oil level and refill to "full" mark on dip•
stick. Determine cause and service as required.
REPAIR ALL OIL LEAKS.
Drain oil and refill with recommended grade and
viscosity of engine oil.
Disconnect gauge and recheck pressure using
a .master gauge. Replace gauge if defective.
Replace oil filter. Repair or replace by-pass valve.
Remove and clean intake screen.
Remove, clean .and examine parts. Clean or re-
place as necessary.
Remove and examine all parts carefully. Use care
as fine "hair-line" cracks in oil lines are hard to
detect. Replace damaged or worn parts.
Oil pump worn or damaged
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1 Excessive bearing clearances within engine
Oil passage plugs loose or missing
HIGH OIL PRESSURE
POSSIBLE CAUSE
Incorrect viscosity of engine oil
Defective or improper oil pressure gauge
Oil pressure relief valve sticking closed or
improper sprirfg installed
. .i,,
LOW COMPRESSION PRESSURE
POSSIBLE CAUSE
Several possible causes - isolate
Worn or damaged piston rings. pistons or liners
Burned or sticking valves
Blown cylinder head gasket
POSSIBLE CORRECTION
Replace oil pump.
.
; Disassemble engine and inspect for worn ri,� i�
and connecting rod bearings - also check all
other bearings (which are pressure lubricated)
for excessive wear. Complete overhaul usually
required to compensate for gradual wear which
has occurred over a long period of operation.
r
Tighten or instat plugs.
POSSIBLE CORRECTION
Check oil being used. Drain oil and refill to "full"
mark with recommended grade and viscosity of
engine oil, if required.
Disconnect gauge and recheck pressure using a
master gauge. Replace gauge if defective.
Remove, clean and inspect parts. Replace dam­
aged or improper parts.
I POSSIBLE CORRECTION
Generally due to normal wear occurring within
t_he cylinders and/or improper valve sealing,
after a long period of satisfactory engine oper­
ation. Attempt to isolate cause before disassembly.
Squirt a small amo.unt of clean engine oil into
cylinder(s) having low compression through
injector hole in head. Direct oil onto piston ring
area. Do not use too much oil or direct onto
valves. Then repeat compression check. If the
pressure increases substantially from the earlier
reading it is usually an indication the cylinder(s)
require servicing. However. if the pressure is still
low the problem will usually be due to valves.
Refer to list for other possible causes. Service
as required.
Disassemble and inspect. Service as required.
Disassemble and inspect. Service as required.
Check for external leaks, also, for indications of
internal leaks such as low compression within
two adjacent cylinders or the presence of air
bubbles within the radiator at low idle rpm. A
more accurate check for combustion leaks· within
the cooling system can be made by using pres­ 0
sure testing equipment available commercially
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for this purpose. Disassemble and service as II)
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 LOW COMPRESSION PRESSURE (Continued}
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POSSIBLE CAUSE POSSIBLE CORRECTION '-�
Wrong valve timing - also little or no valve Check valve clearance and adjust if required.
clearance Also, check va Ive timing, particularly if there has
been previous disassembly of engine involving
timing gears. Reset valve timing if required.

Broken or weak valve springs Disassemble and inspect. Replace if necessary.

Cylinder(s) "washed" with fuel by faulty in- Remove injector(s) and test operation. Repair
jector operation injector if required, then start engine to lubricate
cylinders and repeat compression check.

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