379,398,399 D and A REV1

C.
ATERPILLAR® SENR2453
September 1981
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G379, G398 & G399 Engines
G379: G398: G399:

728468 - UP 738906 - UP 49C261 - UP
ENGINE DISASSEMBLY AND ASSEMBLY
!J::,WARNING
IMPORTANT SAFETY NOTICE
Proper repair is important to the safe and reliable operation of a machine. This
Service Manual outlines basic recommended procedures. some of which require
special tools, devices or work methods. Although not necessarily all inclusive, a list
of additional skills, precautions and knowledge required to safely perform repairs is
provided in the SAFETY section of this Manual.
Improperrepair procedures can be dangerous and could result in injury or death.
READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND

WARNINGS BEFORE PERFORMING REPAIRS ON THIS MACHINE
Basic safety precautions, skills and knowledge are listed in the SAFETY section
of this Manual and in the descriptions of operations where hazards exist. Warning
labels have also been put on the machine to provide instructions and identify
specific hazards which if not heeded could cause bodily injury or death to you or
other persons. These labels identify hazards which may not be apparent to a trained
mechanic. There are many potential hazards during repair for an untrained
mechanic and there is no way to label.the machine against all such hazards. These
warnings in the Service Manual and on the machine are identified by this symbol:
!J::,WARNING
Operations that may result only in machine damage are identified by labels on the
machine and in the Service Manual by the word CAUTION.
Caterpillar cannot anticipate every possible circumstance that might involve a
potential hazard. The warnings in this Manual are therefore not all inclusive. If a
procedure, tool, device or work method not specifically recommended by
Caterpillar is used, you must satisfy yourself that it is safe for you and others. You
should also ensure that the machine will not be damaged or made unsafe by the
procedures you choose.
IMPORTANT
The information, specifications and illustrations in this book are on the basis of
information available at the time it was written. The specifications, torques,
pressures of operation, measurements, adjustments, illustrations and other items
can change at any time. These changes can effect the service given to the product.
Get the complete and most current information before you start any job. Caterpillar
Dealers have the most current information which is available. For a list of the most
current modules and form numbers available for each Service Manual, see the
SERVICE MANUAL CONTENTS MICROFICHE REG1139F.
67200X2
2
...--------------------------- - - -
A WARNING
SAFETY
In. WARNING In. WARNING

The proper and safe lubrication and mainte- Do not operate this machine unless you have
nance procedures for this machine, recom- read and understand the instructions in the
mended by Caterpillar, are outlined in the LU- OPERATOR'S GUIDE. Improper machine oper-
BRICATION & MAINTENANCE GUIDE for this ation is dangerous and could result in injury or
machine. death.
Improper performance of lubrication or main-
tenance procedures is dangerous and could
result in injury or death. Read and understand
the LUBRICATION & MAINTENANCE GUIDE
before performing any lubrication or 4. If possible, make all repairs with the machine
maintenance. parked on a level, hard surface. Block machine so
it does not roll while working on or under
machine.
5. Do not work on any machine that is supported
The serviceman or mechanic may be unfamiliar with only by lift jacks or a hoist. Always use blocks or
many of the systems on this machine. This makes it jack stands to support the machine before per-
important to use caution when performing service forming any disassembly.
work. A knowledge ofthe system and/or component is
important before the removal or disassembly of any 6. Relieve all pressure in air, oil or water systems
component. before any lines, fittings or related items are dis-
connected or removed. Always make sure all
Because of the size of some of the machine compo- raised components are blocked correctly and be
nents, the serviceman or mechanic should check the alert for possible pressure when disconnecting any
weights noted in this Manual. Use proper lifting proce- device from a system that utilizes pressure.
dures when removing any components.
7. Lower the bucket, blade, ripper or other imple-
Following is a list of basic precautions that should ments to the ground before performing any work
always be observed. on the machine. If this can not be done, make sure
the bucket, blade, ripper or other implement is
I. Read and understand all Warning plates and de- blocked correctly to prevent it from dropping
cals on the machine before operating, lubricating unexpectedly.
or repairing the machine.
8. Use steps and grab handles when mounting or
2. Always wear protective glasses and protective dismounting a machine. Clean any mud or debris
shoes when working around machines. In particu- from steps, walkways or work platforms before
lar, wear protective glasses when pounding on any using. Always face machine when using steps,
part of the machine or its attachments with a ham- ladders and walkways. When it is not possible to
mer or sledge. Use welders gloves, hood/goggles, use the designed access system, provide ladders,
apron and other protective clothing appropriate to scaffolds, or work platforms to perform safe repair
the welding job being performed. Do not wear operations.
loose-fitting or tom clothing. Remove all rings
from fingers when working on machinery. 9. To avoid back injury, use a hoist when lifting
components which weigh 50 lb. (23 kg) or more.
3. Disconnect battery and discharge any capacitors Make sure all chains, hooks, slings, etc., are in
before starting to work on machine. Hang "Do good condition and are in the correct capacity. Be
Not Operate" tag in the Operator's sure hooks are positioned correctly. Lifting eyes
Compartment. are not to be side loaded during a lifting operation.
3
&. WARNING
10. To avoid bums, be alert for hot parts on machines 17. Be sure all protective devices including guards
which have just been stopped and hot fluids in and shields are properly installed and functioning
lines, tubes and compartments. correctly before starting a repair. If a guard or
shield must be removed to perform the repair
It. Be careful when removing cover plates. Gradual- work, use extra caution.
Iy back off the last two bolts or nuts located at
opposite ends of the cover or device and pry cover 18. Always use lift arm supports to keep bucket arms
loose to relieve any spring or other pressure, be- raised and bucket tilted down when maintenance
fore removing them completely. or repair work is performed which requires the
bucket in the raised position.
12. Be careful when removing filler caps, breathers
and plugs on the machines. Hold a rag over the cap 19. Loose or damaged fuel, lubricant and hydraulic
or plug to prevent being sprayed or splashed by lines, tubes and hoses can cause fires. Do not bend
liquids under pressure. The danger is even greater or strike high pressure lines or install ones which
ifthe machine has just been stopped because fluids have been bent or damaged. Inspect lines, tubes
can be hot. and hoses carefully. Tighten connections to the
correct torque. Make sure that all heat shields,
13. Always use tools that are in good condition and be clamps and guards are installed correctly to avoid
sure you understand how to use them before per- excessive heat, vibration or rubbing against other
forming any service work. parts during operation. Shields that protect against
14. Reinstall all fasteners with same part number. Do oil spray onto hot exhaust components in event of
not use a lesser quality fastener if replacements are a line, tube or seal failure must be installed
necessary. correctly.
20. Do not operate a machine if any rotating part is
15. Repairs which require welding should be per-
damaged or contacts any other part during oper-
formed only with the benefit of the appropriate
ation. Any high speed rotating component that has
reference information and by personnel adequate-
been damaged or altered should be checked for
Iy trained and knowledgeable in welding proce-
balance before reusing.
dures. Make reference to "Techniques of Struc-
tural Repair Course" form number JEG03719. 21. On track-type machines, be careful when servic-
Determine type of metal being welded and select ing or separating tracks. Chips can fly when re-
correct welding procedure and electrodes, rods or moving or installing a track pin. Wear safety
wire to provide a weld metal strength equivalent at glasses. Track can unroll very quickly when sepa-
least to that of parent metal. rated. Keep away from front and rear of machine.
The machine can move unexpectedly when both
16. Do not damage wiring during removal operations. tracks are disengaged from the sprockets. Block
Reinstall the wiring so it is not damaged nor will it
the machine to prevent it from moving.
be damaged in operation by contacting sharp cor-
ners, or by rubbing against some object or hot
surface. Do not connect wiring to a line containing
fluid.
C.A.TERPILLAR®
.....----------------------- - - - -
GENERAL TIGHTENING TORQUE FOR

BOLTS AND NUTS
The following charts give the standard torque values for bolts. nuts
and taperlock studs·of SAE Grade 5 or better quality. Exceptions are
~ 2)
given in other sections of the Service Manual where needed.
THREAD DIAMETER STANDARD TORQUE
inches millimeters lb. ft. N·m
Standard thread Use these torques for bolts and nuts
b ii[IlliO with standard threads.
1/4 6.35 9±3 12 ± 4

5/16 7.94 18 ± 5 24 ± 7
3/8 9.53 32 ± 5 43 ± 7
7/16 11.11 50 ± 10 68 ± 14
1/2 12.70 75 ± 10 100 ± 14
9/16 14.29 110 ± 15 150 ± 20
5/8 15.88 150 ± 20 205 ± 27
3/4 19.05 265 ± 35 360 ± 47
7/8 22.23 420 ± 60 570 ± 80
1 25.40 640 ± 80 870 ± 110
1-1/8 28.58 800 ± 100 1085 ± 135
1-1/4 31.75 1000 ± 120 1355 ± 165
1-3/8 34.93 1200 ± 150 1625 ± 205
1-1/2 38.10 1500 ± 200 2035 ± 270
Use these torques for bolts and nuts on

hydraulic valve bodies with standard
threads.
5/16 7.94 13 ± 2 18 ± 3
3/8 9.53 24 ± 2 33 ± 3
7/16 11.11 39 ± 2 53 ± 3
1/2 12.70 60 ± 3 80 ± 4
5/8 15.88 118 ± 4 160 ± 5
Taperlock stud Use these torques for studs with Taper-

lock threads.
UIIID
1/4 6.35 5±2 7±3
5/16 7.94 10 ± 3 14 ± 4
3/8 9.53 20 ± 3 27 ± 4
7/16 11.11 30 ± 5 40 ± 7
1/2 12.70 40 ± 5 55 ± 7
9/16 14.29 60 ± 10 80 ± 14
5/8 15.88 75 ± 10 100 ± 14
3/4 19.05 110 ± 15 150 ± 20
7/8 22.23 170 ± 20 230 ± 27
1 25.40 260 ± 30 355 ± 40
1-1/8 28.58 320 ± 30 435 ± 40
1-1/4 31.75 400 ± 40 540 ± 55
1-3/8 34.93 480 ± 40 650 ± 55
1-1/2 38.10 550 ± 50 745 ± 68
T95416-8
5
INDEX
Accessory Drive Gears and Plate 7-14 Oil Filters 7-36

Accessory Drive Housing 7-9 Oil Filter Housing .. 7-37
Aftercooler Cores 7-142 Oil Pressure Relief Valve 7-18
Aftercooler Housing 7-138 Oil Pressure Relief Valve. Disassemble & Assemble " 7-18
Air Cleaners 7-103. Oil Pump (Earlier) 7-19
Oil Pump (Earlier). Disassemble & Assemble 7-21
Camshaft 7-154
Oil Pump (Later). Disassemble & Assemble 7-27
Camshaft Bearings 7-157
Carburetor 7-119
Carburetor. Disassemble & Assemble 7-121 Pistons 7-95
Connecting Rod Bearings 7-48 Pistons. Disassemble & Assemble 7-97
Crankshaft " 7-158 Piston Cooling Tubes 7-88
Crankshaft Front Seal (Lip Type) and Wear Sleeve 7-5
Crankshaft Front Seal Ring and Thrower 7-3
Crankshaft Main Bearings 7-86 Rear Timing Gears 7-149
Crankshaft Rear Seal Ring and Thrower 7-147 Rocker Shaft and Push Rods 7-81
Cylinder Heads 7-89 Rocker Shaft. Disassemble & Assemble . 7-82
Cylinder Liners 7-99
Electric Starting Motors 7-143 Service Meter and Tachometer Drive 7-7
Engine Oil Cooler 7-33 Spark Plugs 7-136
Engine Oil Coolers. Disassemble & Assemble 7-35 Spark Plug Adapters .. 7-137
Exhaust Manifold 7-74
Flywheel 7-144 Turbocharger 7-126
Flywheel Housing 7-146 Turbocharger. Disassemble & Assemble 7-127
Gas Pressure Regulator . 7-115 Turbocharger Lubrication Valve 7-101
Gas Pressure Regulator. Disassemble & Assemble 7-116 Turbocharger Lubrication Valve.
Governor (Hydra-Mechanical). Disassemble & Assemble 7-64 Disassemble & Assemble 7-102
Governor (Woodward UG-8) . 7-50 Turbocharger Regulator Assembly 7-124
Governor (Woodward UG-8). Disassemble & Assemble 7-53 Turbocharger Regulator Assembly.
Governor Drive Housing (Upper) (Woodward UG-8) 7-50 Disassemble & Assemble 7-125
Governor Drive Housing (Upper) (Woodward UG-8).
Disassemble & Assemble 7-51 Valves 7-91
Governor Drive Housing 7-76 Valve Covers 7-80
Governor Drive Housing. Disassemble & Assemble 7-78 Valve Guides 7-93
Instrument Panel 7-161 Valve Lifters 7-84
Intake Manifold 7-80 Valve Seat Inserts 7-94
Vibration Damper (G398 and G399) 7-153
Magneto 7-104
Magneto Coil and Mechanical Drive.
Disassemble & Assemble . 7-105 Water Directors 7-94
Magneto Distribution Board . 7-113 Water Pump 7-40
Magneto Power Board . 7-114 Water Pump. Disassemble & Assemble 7-44
Magneto Power Resistor and Zener Diode . 7-114 Water Temperature Regulators 7-38
,&WARNING
DISCONNECT BATTERIES
BEFORE PERFORMANCE
OF ANY SERVICE WORK.
7-1
CRANKSHAFT FRONT SEAL RING AND THROWER

REMOVE CRANKSHAFT FRONT SEAL
RING AND THROWER 1160·11
Tools Needed A B
8B7548
8B7550
Puller Assembly
Leg 2 ,
5F7341 Adapter 2 '\\I,
t
8H684 Ratchet Box Wrench
8B7561 Step Plate
1P2321 Puller Assembly
FT884 Leg 3
start by:
a) remove vibration damper (G398 and G399
only)
I. On G379 only, remove cover (I).
2. Put a mark on two bolts from location (2) for

installation purposes.
3. Remove ten bolts (4 ) from adapter. Remove

adapter (3). It can be necessary to remove
adapter with tooling (A).
4. Remove twelve bolts (5) and baffle (6).
5. Remove ring and spring assembly (7) from the

thrower.
6. Install tooling (B) on thrower. If necessary use

heat on the outer diameter of thrower with an
open name at a maximum temperature of
400 0 F (204 0 C). Remove the thrower with
tooling (B).
7. Remove the ring from the accessory drive hous-

mg.
TYPICAL EXAMPLE TYPICAL EXAMPLE
7-3
CRANKSHAFT FRONT SEAL RING AND THROWER

INSTALL CRANKSHAFT FRONT SEAL RING
AND THROWER 1160-12
Tools Needed A
FT105 Push Plate 1
T605 Bolt 2
9H1031 Washer 2
I. Put 6V1541 Quick Cure Primer and 9S3265

Retaining Compound on ring. Install ring (2)
with holes at the bottom and with chamfer
toward inside of housing.
2. Heat thrower (I) to a maximum temperature
of 400 - 450 0 F (204 - 232 0 C). Install thrower
on crankshaft. Use tooling (A) to install
thrower in correct location on crankshaft.
CAUTION
Do not install a used oil thrower seal ring or
J
spring.
3. With the thrower at room temperature, put
6V2055 High Vacuum Grease in the groove for
--.
the seal ring at assembly one half or more of the
depth of the groove.
827·051Xl
4. Install the spring and seal ring on thrower with
the word "OUT" on the seal ring installed away
from the crankshaft. Put the gap of seal ring to
top of crankshaft when installed.
5. Put clean engine oil on inside diameter of baf-
fle. Install baffle (3).
6. Put 9S3263 Thread Lock on threads of bolt for
adapter. Install the adapter (5) on G379 only.
Put 7M7456 Loctite Sealer on the two bolts for
the cover. Install cover (6). Install bolts with
Loctite in location (4).
end by:
a)install vibration damper (G398 and G399
only)
. ,
\
7-4
ENGINE
DISASSEMBLY AND ASSEMBLY
CRANKSHAFT FRONT SEAL (LIP TYPE) AND

WEAR SLEEVE
REMOVE CRANKSHAFT
h'''"''/ v'''~ ~ .. 4ii
i i i. . .
FRONT SEAL (LIP TYPE)
AND WEAR SLEEVE
Tools Needed
1160-11
A
. 1/"
II
start by:
•
•••
a) remove vibration damper (G398 and
G399 only)
•
1. On G379 only, remove cover (I); put a mark on
two bolts (2) for installation.
2. Remove ten bolts (3) and remove adapter (4)

Remove eight bolts (5) and spacers.
3. Make two holes (1800 apart) in the metal sur-

face of crankshaft front seal (6). Remove the
seal with tooling (A).
4. Remove wear sleeve (7) from the crankshaft.
7-5
CRANKSHAFT FRONT SEAL (UP TYPE) AND

WEAR SLEEVE
INSTALL CRANKSHAFT FRONT SEAL
(LIP TYPE) AND WEAR SLEEVE 1160-12
Tools Needed A
5P3022 Installer
1. Clean the contact surfaces of the wear sleeve

and crankshaft with 8 M8060 Quick Cure Pri-
mer. Put 9S3265 Retainer Compound on the
contact surfaces. Install the wear sleeve on
the crankshaft with tooling (A). The tapered
edge on the outside of the wear sleeve goes
toward the end of the crankshaft.
2. Put a thin layer of SAE 30 oil on the seal lip.

Install the seal over tooling (A). The seal lip
goes toward the inside of the engine. Install
spacers and bolts which hold the seal in the
adapter. Tighten the bolts in the number se-
quence shown. Tighten each bolt a maximum
of three turns each round until all the bolts
are tight.
3. Put 5P3413 Sealant on the threads of the

bolts which fasten the adapter to the crank-
shaft. Install adapter (9) on the crankshaft.
I'
~
4. Install the cover on G379 only. Put 5P3413
Sealant on the threads of the bolts in the loca-
tions with the X mark.
end by:
a) install vibration damper (G398 and G399 ..
only)
7-6
SERVICE METER AND TACHOMETER DRIVE

REMOVE SERVICE METER AND
TACHOMETER DRIVE 7478-11
Tools Needed A
1P51 a Driver Group
I. Remove two bolts (1) and service meter (2).

A82790X1
'-'
2. Remove two bolts (3), lockwashers, clamps

and tachometer drive assembly (4).
3. Remove four bolts (5), lockwashers and

housing (6).
4. Remove the lip type seal from housing (6)

with tooling (A).
5. Remove two bolts (7) and adapter (8).
A82788X1
A82787Xl
7-7
SERVICE METER AND TACHOMETER DRIVE

INSTALL SERVICE METER AND
TACHOMETER DRIVE 7478-12
T0015 Needed A
1 P510 Driver Group
I. Install two washers, adapter (2) and bolts (I).

Bend the locks.
2. Install the lip type seal in housing (3) with

tooling (A). Install the seal with the seal lip
toward the engine. Put a thin layer of SAE 30
oil on the seal lip and the seal bore in the
housing.
3. Install a new gasket and housing (3) on the

engine with four bolts and lockwashers.
4. Inspect and make a replacement, if neces- AS21SS)(1

sary, of O-ring seal (4) on tachometer drive
(5). Install the tachometer drive on the hous-
ing with two clamps, lockwashers and bolts.
5. Inspect and make a replacement, if neces-

sary, of O-ring seal (6) on service meter (7).
Put a thin layer of SAE 30 oil in the counter-
bore of the tachometer drive. Install the ser-
vice meter with two clamps, lockwashers and
bolts. Tighten the bolts to a torque of 8 ± 21b.
fL (II ± 3 N.m).
A82783Xl
~i
7-8
ACCESSORY DRIVE HOUSING

REMOVE ACCESSORY DRIVE
HOUSING 1207-11
,
8B7548
Tools Needed
Puller Assembly
A B }D
8B7550 Leg 2
•
.~.
)
5F7341
8H684
8B7561
Adapter
Ratchet Box Wrench
Step Plate
2
•
5P9736 Bracket-Link 2
1. On G379 only, remove adapter cover (I). Re-

move ten bolts (3) from adapter. Remove
adapter (2). Use tooling (A) if necessary to
remove adapter.
2. Remove twelve bolts (4) and baffle (5). Put a

mark on two bolts from location (X) for instal-
lation purposes.
3. Remove four bolts that hold plate (6) for oil

pump to oil pan base.
4. Remove the four bolts (7) that hold water

pump to housing. Remove four bolts (9) that
hold oil pump to housing.
5. Fasten a hoist to the front of the engine. Loosen

the bolts that hold cylinder block to oil pan
base. Lift the engine to install spacers (8)
between cylinder block and the oil pan base.
TYPICAL EXAMPLE TYPICAL EXAMPLE
7-9

6. Remove four bolts (12) that hold tube assembly
( 13) to the auxiliary water pump. Remove bolt
(10) from block and loosen clamp (11) that
holds tube assembly and coupling together. Re-
move tube assembly (13).
7. Remove ten bolts (14) that fasten plate to

accessory housing.
8. Remove bolts and auxiliary water pump (15).
9. Install tooling (B) and a hoist to the accessory

drive housing. Remove twelve bolts (16) that
fasten housing to the cylinder block. Remove
accessory drive housing. Weight is 200 lb. (90
kg).
7-10

INSTALL ACCESSORY DRIVE
HOUSING 1207-12
Tools Needed A
NOTE: Put 6V2055 High Vacuum Grease in the

groove for the seal ring at assembly one half or more
of the depth of the groove.
1. Install the spring and seal ring (1) on thrower

with the word "OUT" on seal ring installed
away from crankshaft. Put the gap of seal ring
to top of crankshaft when installed.
2. Install two 112"- I 3 N C bolts as a guide in the

cylinder block. Install tooling (A) and a hoist
on the accessory drive housing and put in posi-
tion on the cylinder block.
3. Install twelve bolts (2) to fasten housing to

block. Remove tooling (A).
4. Put auxiliary water pump (3) in position and

install bolts to fasten pump to accessory drive
housing.
5. Put tube assembly (4) and gasket in position on

auxiliary water pump and install four bolts. Put
clamp (5) in position and install bolt. Install
clamp (6) on pipe assembly and coupling.
6. Fasten a hoist and lift the front of engine en-

ough to remove spacers (8) from between cylin-
der block and oil pan base. Tighten the bolts
that hold cylinder block to base.
7. Install bolts (7) and (9) that hold the water

pump and the oil pump to the accessory drive
housing.
TYPICAL EXAMPLE
7-11

8. Install the four bolts that hold plate (10) for oil
pump to oil pan base.
TYPICAL EXAMPLE
9. Put clean engine oil on the inside diameter of

baffle. Install baffle (II).
10. Put 9S3263 Thread Lock on threads of bolts for

adapter. Install the adapter (12) on 0379 only.
Put 7M7456 Loctite Sealer on two of bolts for
cover. Install cover (13) for adapter. Put bolts
with Loctite in locations (14) and (15).
end by:
a) install vibration damper (0398 & 0399
only)
TYPICAL EXAMPLE
7-12
SAE STANDARD ROTATION ILLUSTRATION G379
T98541X2
SAE STANDARD ROTATION ILLUSTRATION G379
Ie
7-13
------- -
ACCESSORY DRIVE GEARS AND PLATE

REMOVE ACCESSORY DRIVE
GEARS AND PLATE 1206-11
Tools Needed A
4S5415 Puller Group
5P4170 Step Plate
start by:
a) remove fresh water pump
b) remove oil pump
c) remove accessory drive housing
1. Remove seal (1) from thrower.
2. Install tooling (A) on thrower (2). If necessary,

use heat on the outer diameter of thrower with
an open flame at a maximum temperature of
400°F (205°C). Remove the thrower imme-
diately with tooling (A).
NOTE: The installation of two crankshaft bolts (6)

can be used to turn engine for access to gear boIts.
3. Remove six bolts (5) used to hold oil tube on

plate.
4. Bend the tabs on lock and remove bolts, washer,

plate (7) and the balancer gear.
5. Remove bolts (4) and the gear and shaft assem-

bly (3) from plate.
6. Bend the tabs on lock and remove bolts (8),

washer and gear assembly (9).
7. Remove seven bolts ( 10) and idler gear assem-

bly (11 ).
7-14

8. Remove four nuts that hold oil tube (13) to
plate. Remove oil tube (13).
9. Remove six bolts (14) and shaft assembly (12)

from plate.
10. Remove four bolts and service meter (15) from
block.
II. Remove five bolts (16) and plate from cylinder
block. Weight of the plate is 75 lb. (34 kg).
12. Remove the bearings from the gears if dam-
aged or worn.
NOTE: Check the mark on plate for correct installa- .--~....r-,'
tion. The front of plate for SAE standard rotation
engine (counterclockwise as seen from flywheel end)
is marked "FRONT STD. ROT." The front of plate
for SAE opposite rotation engine (clockwise as seen
from the flywheel end) is marked "FRONT REV.
ROT."
INSTALL ACCESSORY DRIVE

GEARS AND PLATE 1206-12
Tools Needed A B
1P520 Driver Group
FT105 Push Plate
T603 Bolt 2
9H1031 Washer 2
NOTE: Put 5P3413 Thread Sealant on all bolts that

fasten plate to the cylinder block.
I. Put plate (I) in position on the cylinder block
dowels. Install five bolts and tighten to a torque
of 90 ± 5 Ib.ft. (120 ± 7 N·m).
NOTE: Be sure the plate is installed on correct side
as indicated in removal.
2. Install service meter (2) in position on block.
NOTE: Put 7M7260 Liquid Gasket Material on
sealing surfaces of idler shafts and oil tube.
3. Install idler shaft (3) in position on plate and
tighten bolts to a torque of 90 ± 5 Ib.ft. (120 ±
7 N·m).
4. Put oil tube (4) in place and install only the nuts
to hold tube in position. Install small gaskets
under nuts that hold the right end of tube. Put
5P3413 Thread Sealant on nuts.
7-15

5. Put idler gear assembly (5) in position and
install bolts. The six similar bolts are tightened
to a torque of90 ± 5 lb.ft. (120 ± 7 N·m). The
two oil tube bolts are tightened to a torque of 32
± 3 lb.ft. (43 ± 4 N·m). The single bolt at the
bottom of the bolt circle is tightened to a torque
of 40 ± 4 Ib.ft. (55 ± 5 N.m).
6. If necessary, install bearings in gear (7) with

tooling (A). Install gear (7) on idler shaft (3).
Install washer (6), lock and bolts.
7. Put main idler gear assembly (8) in position

and install bolts. Tighten bolts to a torque of 90
± 5lb.ft. (20 ± 7 N·m). Tighten oil tube bolts
to a torque of 32 ± 3 lb.ft. (43 ± 4 N·m).
8. On G379 engine only, install bearing in ba-

lancer gear with tooling (A).
9. Install washer (10) and gear (9) on shaft.
7-16

_ 10. Install washer (12) and plate (II). Install lock
and bolts.
NOTE: The gear train of accessory drive are the

same on the 8, 12, and 16 cylinder engines, except for
balancer gear used on 8 cylinder engine. On SAE
standard rotation (counterclockwise) engines, the
balancer gear timing mark "B" must be in alignment
with the tooth on crankshaft gear with punch marks
(four, five or six punch marks). The balancer gear
timing mark "B" must be in alignment with the "B"
mark on the main idler gear.
NOTE: On SAE opposite rotation (clockwise) en-

----------------~
gine, the balancer gear timing mark "R" must be in ._. . f1..4liE POSTl to",
alignment with the "R" on the small idler gear. The ....- - - - INDICATION MARK )
other "R" on the small idler gear must be in align- I

ment between two teeth on crankshaft gear with two I I
punch marks. On 12 and 16 cylinder engines, no I I
timing of accessory drive gears is necessary.
I I
( I
\ , CRAM;S~tAq Gtl,R /)
CAUTION ...........--~... r~~'--~
Do not use an old oil thrower, seal ring or T87432-A

I
l ._, .__:~= -.:. .- _ . . . . J
B'A[J:·W:fR CiA8
~
I
spring.
SAE STANDARD ROTATION
II. Heat the thrower (13) to a maximum tempera- 8 CYLINDER ENGINE
ture of 400 - 450°F (204 - 232°C). Install
thrower on crankshaft with tool (B).
/ PlAJIE POSHlOfl
{ ~~ IND!C~T10_~_f¥tARK
NOTE: With the thrower at room temperature, put
6V2055 High Vacuum Grease in the groove for the
I
seal ring at assembly one half or more of the depth of
I
the groove.
I : GRANKSfiAH
I
\
12. Install seal ring (14) and spring on thrower.
end by: "
T!lOO6J-A
a) install accessory drive housing

b) install oil pump SAE OPPOSITE ROTATION
c) install fresh water pump 8 CYLINDER ENGINE
7-17
OIL PRESSURE RELIEF VALVE

REMOVE OIL PRESSURE
RELIEF VALVE 1315-11
start by:
a) remove magneto
I. Remove two bolts (I) from oil cooler elbow.
2. Remove two bolts (3) that hold valve to oil pan.
3. Remove bolts, clamp (2) and oil pressure relief

valve.
INSTALL OIL PRESSURE

I. Inspect O-ring seals and make replacements if
necessary.
2. Put engine oil on tube assembly O-ring seals (I)

and put oil pressure relief valve assembly (2) in
position.
3. Install elbow and oil pan bolts.
4. Put clamp in position and install bolts.

end by:
a) install magneto
DISASSEMBLE OIL PRESSURE

start by:
a) remove oil pressure relief valve
I. Remove bolts (2) that hold tube to housing (3).

Remove tube (I ).
2. Remove the piston, spring and guide from the

housing.
ASSEMBLE OIL PRESSURE

I. Install new seals.
2. Put clean engine oil in the bore of housing (I ).
3. Install guide (2), spring (3) and piston (4) in

housing. Install the tube (5) on housing.
end by:
63376X2
a) install oil pressure relief valve
7-18
OIL PUMP (EARLIER)

REMOVE OIL PUMP 1304-11
start by:
a) remove magneto
b) remove oil pressure relief valve (if
equipped)
I. Remove bolts (I) and water pump elbow (2).
2. Remove six bolts (3) and retainer (4).
3. Remove bearing (5) from retainer (4).
4. Remove oil pump drive gear(6) from the acces-

sory drive housing.
5. Fasten a hoist to the oil pump. Remove bolt (9).

Remove six bolts (8) that fasten the oil pump to
the accessory drive housing. Remove oil pump
(7). The weight of the oil pump is 110 lb. (49.5 A82829X2
kg).
7-19
OIL PUMP (EARLIER)

INSTALL OIL PUMP 1304-12
Tools Needed A
lP510 Driver Group
I. Install a new gasket (1) between oil pump (2)

and accessory drive housing. Inspect and make
a replacement of O-ring seal (3) if necessary.
Fasten a hoist to the oil pump and put it in
position on the accessory drive housing. Install
bolts to hold pump in position.
2. Install oil pump drive gear (4) in the accessory

drive housing.
3. Use a press and tooling (A) to install bearing

(5) in retainer (6).
4. Install a new gasket (7) between the accessory

drive housing and retainer (6). Install the re-
tainer with six bolts.
5. Install a new gasket (8) and water pump elbow

(9) in position and install eight bolts.
end by:
a) install magneto
b) install oil pressure relief valve (if equipped)
7-20
OIL PUMP (EARLIER)

DISASSEMBLE OIL PUMP 1304-15
Tools Needed A B c
8H663 Bearing Puller Attachment
8H684 Ratchet Box Wrench
8B7548 Puller Assembly
887550 Leg 2
T774 Spacer
lP2321 Puller Assembly
FT1048 Puller 824212Xl
start by:
a) remove oil pump
I. Bend the tabs on two locks and remove bolts

and locks (I) and retainer (2) from manifold.
2. Remove bearing (3) from retainer.

B24211Xl
3. Remove bolts (4), pipe (6) and cover assembly

(5) from pump assembly.
4. Put cover assembly in vise and install tooling

(A) on gear (7) and remove gear from shaft
assembly. Remove shaft assembly from cover.
835589Xl
5. Remove bearing (8) from cover.
B35574Xl
7-21
ENGINE DISASSEMBLV AND ASSEMBLV
OIL PUMP (EARLIER)

6. Remove bolt (10) and washer (9) from shaft
assembly.
7. Install tool (8) on gear and remove gear (I I)

from shaft. Remove key.
8. Remove nine bolts (12) and housing assembly

(13) from pump.
9. Remove bearings (14) and (15) from housing.
10. Remove manifold assembly (18) from mani-

fold assembly (19). Remove seals (17) from
each side of manifold assembly (18).
II. Remove two gears (16) from shaft.
B35552Xl
7-22
OIL PUMP (EARLIER)

12. Remove two bearings (20) from gears (16).
B24214Xl
13. Remove shaft assembly (21) from manifold

assembly (19).
14. Use a press to remove shaft (22) from gear

(23). Remove key from shaft.
15. Remove two shafts (25) from the manifold with

tooling (C) as shown. Remove bearing (24)
from manifold.
7-23
OIL PUMP (EARLIER)

ASSEMBLE OIL PUMP 1304-16
Tools Needed A
1P510 Driver Group
I. Lower the temperature of two shafts (I) and

install in manifold. Install the bearing in the
manifold (2) with tooling (A). The installed
bearing must be .030 in. (0.76 mm) below the
machined surface of the manifold.
2. Lower the temperature of shaft (3). Install the

key in the shaft and install the shaft in gear (4)
with a press until the gear makes contact with
the shoulder on the shaft.
3. Put a thin layer of SAE 30 oil on the shaft

assembly and bearing. Install shaft assembly
(5) in manifold (2).
4. Install two bearings in each gear (6) with tool-

ing (A) and press. Install the bearings until
they are even with the surface of the gear.
5. Put a thin layer of SAE 30 oil on gears (6).

Install the two gears on manifold shafts.
6. Install two O-rings (8) on manifold. Install

manifold (7) on manifold (2). B35563X 1
7-24
OIL PUMP (EARLIER)

7. Install two bearings in housing with tooling
(A). Make an alignment of the oil hole in bear-
ing (9) with the oil hole in housing. Install
larger bearing even with housing surface.
8. Put housing assembly (10) in position on oil

pump and install nine bolts.
9. Put key in shaft assembly and install gear (11).

Put 9S3263 Thread Lock on the thread of bolt.
Install washer and bolt. Tighten bolt to a torque
of 18 ± 2 lb.ft. (24 ± 3 N.m).
B35565Xl
10. Install bearing in cover (12) with tool (A).

Bearing is installed even with the edge of cover.
II. Heat gear (13) to a temperature of 275° F

(135°C). Install shaft assembly in cover. Use a
press and tool (A) to install shaft assembly on
gear (13). Install shaft assembly until shaft
shoulder is even with the edge of gear.
7-25
OIL PUMP (EARLIER)

12. Inspect cover gasket (14) and make a replace-
ment if necessary.
e:H:>%lXl
13. Install gasket (I 4) and cover (I2) on the oil

pump.
14. Use tooling (A) and a press to install bearing

(I 5) in retainer (I 6).
15. Put retainer assembly (17) in position on mani-

fold and install two locks and five bolts.
16. Instal1 pipe (I 8) on oil pump.

end by: B35668Xl
a) install oil pump
7-26
OIL PUMP (LATER)

DISASSEMBLE OIL PUMP 1304-15
Tools Needed A 8 c
8H663 8earing Puller Attachment
8H684 Ratchet 80x Wrench
887548 Puller Assembly
887550 Leg 2
T774 Spacer
lP232l Puller Assembly
FT1048 Puller B24212Xl
start by:
a) remove oil pump
I. Bend the tabs on two locks and remove bolts,

locks (I) and retainer (2) from manifold.
2. Remove bearing (3) from retainer.

824211 Xl
3. Remove bolts (4), pipe (6) and cover assembly

(5) from pump assembly.
4. Put cover assembly in vise and install tooling

(A) on gear (7) and remove gear from shaft
assembly. Remove shaft assembly from cover.
837364X1
5. Remove bearing (8) from cover.
B37369Xl
7-27
- --------------------
OIL PUMP (LATER)

6. Remove bolt (10) and washer (9) from shaft
assembly.
7. Install tool (B) on gear and remove gear (II)

from shaft. Remove key.
8. Remove nine bolts (12) and housing assembly

(13) from pump.
9. Remove bearings (14) and (I5) from housing.
10. Remove two bolts (19) from manifold assem-

bly. Remove manifold assembly (18). Remove
three seals (17) from manifold assembly (18).
II. Remove two gears (16) from shaft.
83S552Xl
7-28
OIL PUMP (LATER)

Ie 12. Remove two bearings (20) from gears (16).
13. Remove shaft assembly (21) from manifold

assembly (22).
B24214Xl
14. Use a press to remove shaft (23) from gear

(24). Remove key from shaft.
Ie 15. Remove plug (25), spring (26) and plunger

(27) from manifold.
16. Remove two shafts (29)fromthe manifold with

tooling (C). Remove bearing (28) from mani-
fold.
-
63Q:S13Xl
7-29
OIL PUMP (LATER)

ASSEMBLE OIL PUMP 1304-16
Tools Needed A
1P51 a Driver Group
I. Install bearing (I) in manifold with tool (A).

The installed bearing in the manifold must be
.030 in. (0.76 mm) below the machined surface
of the manifold.
2. Lower the temperature of two shafts (2) and

install in manifold.
3. Install plunger (5), spring (4) and plug (3) in

manifold.
4. Lower the temperature of shaft (6). Install the

key in the shaft and install the shaft in gear (7)
with a press until the gear makes contact with
the shoulder on the shaft.
5. Put a thin layer of SAE 30 oil on the shaft

assembly and bearing. Install shaft assembly
(8) in manifold. 836822Xl
7-30
OIL PUMP (LATER)

6. Install two bearings in each gear (9) with tool-
ing (A) and a press. Install the bearings until
they are even with the surface of the gear.
7. Put a thin layer of SAE 30 oil on gears (9).

Install the two gears on manifold shafts.
8. Install two O-rings (12) and G-ring (10) on

manifold. Install manifold (II) on manifold
(13 ).
9. Install two bearings in housing with tooling

(A). Make an alignment of the oil hold in bear-
ing (14) with the oil hole in housing. Install
larger bearing even with housing surface.
10. Put housing assembly (15) in position on oil

pump and install nine bolts.
II. Put key in shaft assembly and install gear (16).

Put 9S3263 Thread Lock on the thread of bolt.
Install washer and bolt. Tighten bolt to a torque
of 18 ± 2 lb.ft. (24 ± 3 N·m).
~"''''.
635557X2 •
TYPICAL EXAMPLE
7-31
OIL PUMP (LATER)

12. Install bearing in cover (17) with tool (A).
Bearing is installed even with the edge of cover.
13. Heat gear (18) to a temperature of 275°F

(135 ° C). Install shaft assembly in cover. Use a
press and tool (A) to install shaft assembly on
gear (18). Install shaft assembly until shaft
shoulder is even with the edge of gear.
14. Inspect cover gasket ( 19) and make a replace-

ment if necessary.
15. Install gasket (19) and cover (17) on the oil

pump.
16. Use tooling (A) and a press to install bearing

(20) in retainer (21).
17. Put retainer assembly (22) in position on mani-

fold and install two locks and five bolts.
18. Install pipe on oil pump.

end by:
a) install oil pump
636831Xl
7-32
ENGINE OIL COOLER

REMOVE ENGINE OIL COOLER 1378-11
I. Remove the coolant from the engine.
2. Remove the oil from the oil cooler.
3. Disconnect turbocharger lubrication valve tube

assembly (I) from the tube assembly fitting.
4. Remove two bolts (2) and clamp (3). Remove

two bolts (4) that hold elbow to tee and two
bolts (5) that hold bracket to the engine block.
5. Remove four bolts (7) and gasket that fastens

oil cooler elbow (6) to the water pump.
. ri
6. Remove clamp (8) from tube assembly.
7-33
ENGINE OIL COOLER

7. Remove two nuts (10) that hold the oil cooler
support to block.
8. Remove three bolts (9) that fasten flange to the

flywheel housing.
9. Use two persons to remove the engine oil cooler

from the engine. Weight of the cooler is 90 lb.
(41 kg).
INSTALL ENGINE OIL COOLER 1378-12

I. Inspect all O-ring seals and gaskets. Make re-
placements if needed.
2. Use two persons to put the oil cooler in position

on the engine.
3. Install two nuts (4) that hold the support to the

block.
4. Install the three bolts that hold the flange (I) to

the flywheel housing.
5. Install gasket and four bolts to hold elbow (3)

in position on the water pump.
6. Install tube assembly (2) from the turbo-

charger lubrication valve to elbow fitting.
7. Install two bolts that hold bracket (6) to block.

Install two bolts to fasten elbow (5) to tee. Put
clamp in position and install two bolts to hold it
in position.
8. Install elbow and clamp (7) for oil line from the
oil filter housing to the oil cooler.
9. Fill the engine with coolant.
10. Add oil to engine as needed.
7-34
ENGINE OIL COOLER

DISASSEMBLE ENGINE OIL COOLER 1378-15
start by:
a) remove engine oil cooler
I. Put identification on support and elbow for

assembly purposes.
B14247XI
2. Remove bolts (I), support (2) and gasket from

core assembly.
3. Remove bolts (6), bracket (3), two spacers (5),

gasket and elbow (4) from the core assembly.
4. Clean the tubes of the engine oil cooler core

with a .156 in. (3.96 mm) diameter rod.
ASSEMBLE ENGINE OIL COOLER 1378-16

I. Install the gasket, elbow (2), bracket (I) and
two spacers on the oil cooler core assembly.
2. Install gasket and support (3) to core assembly

as shown.
end by
a) install engine oil cooler '11 824245)(1
\
B24243Xl
7-35
OIL FILTERS
REMOVE OIL FILTERS 1318-1318-11
1. Remove oil from the filter housing.
2. Remove bolts (3) and two nuts (1) from studs.
3. Remove cover (2).
4. Remove oil filters (4).
INSTALL OIL FILTERS 1318-12

1. Inspect gasket (l) and make a replacement if
necessary.
-.
2. Install filters (2) in position in housing.
3. Install cover (3) in position on housing and

install nuts and bolts.
4. Check the oil level in crankcase. Fill to the

correct level.
7-36
OIL FILTER HOUSING

REMOVE AND INSTALL OIL
FILTER HOUSING 1306-10
T0015 Needed A
I. Drain oil from the oil filter housing.
2. Remove bolts (2) and two nuts (3) from studs.

Remove cover (4).
3. Remove bolt and clamp (5) from manifold

bracket. , .",..
)(
.
,
4. Remove two bolts (I) and clip from housing.
5. Remove clamp from opposite end of tube as-

~'
~J~---
sembly (6).
NOTE: Indicator assembly must be removed to in-

stall tool (A).
6. Remove indicator assembly (7) from housing.

Remove nut and bolt (8) that is used to fasten
clip to bracket.
7. Install a hoist and tooling (A) on oil filter hous-

mg.
8. Remove four bolts (9) and oil filter housing

(10) from engine. Weight of oil filter housing is
115 lb. (52 kg).
9. The following steps are for the installation of

the oil filter housing.
10. With tool (A) and a hoist on housing (10), put

in position and install four bolts (9). Install bolt
(8) in brackets. Remove tool (A) and install
indicator assembly (7).
II. Put engine oil on O-ring seal (11) and install

tube assembly (6) in housing. Install clip and
bolts (I). Install bracket (5).
12. Inspect and make a replacement of gasket ( 12)

if necessary. Install cover (4) in position.
13. Check oil level in the crankcase. Fill to the

correct level.
7-37
WATER TEMPERATURE REGULATORS

REMOVE WATER TEMPERATURE
REGULATORS 1355-11
I. Remove coolant from engine to a level below
the regulator housing.
2. Disconnect tube assembly (I) from elbow fit-

ting.
3. Remove four bolts (2) that fasten tube assem-

bly to housing assembly.
4. Remove ten bolts (5) from the bottom of the

regulator cover (4). •t
5. Remove housing assembly (3). Weight of the

housing assembly is 45 lb. (20 kg).
B2:4277Xl
6. Remove regulators (6) from housing.
B24216Xl
7. Remove seals (7) from housing.
7-38
WATER TEMPERATURE REGULATORS

INSTALL WATER TEMPERATURE
REGULATORS
Tools Needed A
lP510 Driver Group
I. Put new seals in housing with tooling (A) as

shown.
2. Install regulators (I) in the housing assembly.

,
B242T4Xl
3. Clean the cover (2), housing assembly (3) and

tube assembly and install new gaskets.
4. Put housing assembly (3) in position and install

ten bolts.
5. Put tube assembly (5) in position on the hous-

ing assembly and install four bolts (6). Install
tube assembly (4) to fitting.
l
'.'.--
;t!lJl'l
--',-,
4
'''' ..
',
1~9a
6. Fill the engine with coolant to the correct level. .~'~

7-39
WATER PUMP
REMOVE WATER PUMP 1361-11
I. Remove the coolant from the engine.
2. Remove the oil from the oil cooler.
3. Remove bolts (4) and clamp that fastens elbow

to oil cooler. Remove elbow (1). Turn pipe (3)
from work area.
4. Remove bolts (2) that hold elbow to oil cooler

and water pump. Remove elbow (5).
5. Remove two bolts (6) from pipe assembly. Re-

move clamp from opposite end of pipe and re-
move pipe assembly (7).
5. Disconnect plug (8) from magneto. Remove

two bolts (9) that hold magneto to drive hous-
ing. Remove magneto (10).
6. Remove six bolts (12) and cover (14) from

housing. Remove retainer (15).
7. Fasten a hoist to water pump and remove six

bolts (13). Remove water pump ( II ). Weight
of pump is 86 lb. (39 kg).
8. Remove seal (16) from retainer.
9. Remove bearing (17 ) from retainer.
7-40
WATER PUMP
INSTALL WATER PUMP 1361-12
1. Inspect gaskets and seals and make replace-
ments if damaged.
2. Fasten a hoist to water pump (I). Put the pump

on engine. Install the six bolts that hold the
pump to the accessory drive housing.
.
827006)(1
3. Install gaskets and oil cooler elbow (2) in posi-

tion on oil cooler and water pump.
4. Install gasket, elbow (3) and pipe in position on

the oil cooler.
5. Install pipe assembly (4) in position on water

pump. Install clamp on the end of pipe.
7-41
WATER PUMP
6. Install bearing in retainer with a press and
tooling (A). Make sure the hole in bearing is in
alignment with the hole in retainer.
7. Install seal in retainer as shown with tooling

(A).
8. Install retainer (5) and cover (6) in position on

the accessory drive housing.
9. Put magneto (7) in position on drive housing.
10. Install two bolts and connect plug to magneto.
11. Fill the engine with coolant.
12. Add oil to engine as needed.
7-42
WATER PUMP
7-43
WATER PUMP
DISASSEMBLE FRESH WATER
PUMP 1361-15
Tools Needed A
1 P2321 Puller Assembly
FT884 Le9 2
887560 Step Plate
282694 80lt 2
start by:
a) remove fresh water pump
I. Remove bolts (4) and gear (2) from shaft (5).

Remove bolts (3) and bearing (I).
2. Remove four bolts (9) and elbow (8). Re-

move bolts (6) and cover (7).
3. Remove cotter pin (11). Loosen, but do not

remove nut (10).
4. Install tooling (A) as shown and loosen im-

peller (12) on the shaft. Remove tooling (A),
nut (10), washer and impeller.
7-44
WATER PUMP
5. Remove shaft (5) from spring (13) and seal

assembly (14).
6. Remove retainer (16) from housing (15).
7. Remove the bearing and seal (17) from re-

tainer (16).
8. Remove rubber seal and ceramic ring (18)

from adapter (19) in the housing.
7-45
WATER PUMP
ASSEMBLE FRESH WATER
PUMP 1361-16
Tools Needed A
1P510 Driver Set
CAUTION
Clean water only is permitted for use as a
lubricant for assistance at installation. Do not
damage or put hands on the wear surface of the
carbon ring or the ceramic ring. Install the
ceramic ring with the smoothest face of the ring
toward the carbon seal assembly.
I. Install the lip type seal in retainer (I) with

tooling (A). The seal lip goes toward the in-
side of the retainer. Put a thin layer of SAE
30 oil on the seal lip.
2. Install the bearing in retainer (I) with tooling

(A). Install the bearing until it is even with
the surface of retainer. Put a thin layer of
SAE 30 oil on the bearing.
3. Install new gasket (2) between housing (3)

and retainer (I). Put the retainer in position
on the housing.
4. Put shaft (4) in position in the housing. In-

stall bearing (5) on the housing with four
bolts and locks. Bend the locks.
5. Put the ceramic ring (6) in position in the

rubber seal. Use hand pressure and tool (7)
(which is with the replacement ring) to in-
stall ceramic ring (6). Use hand pressure and
the tool (which is with the replacement ring)
to install the seal assembly. Push seal as-
sembly on shaft until seal faces make light
contact.
A828~Xl
7-46
WATER PUMP
6. Install spring (9) and impeller (8) on the

shaft. Install the washer and nut which hold
the impeller on the shaft. Tighten the nut to
55 lb. ft. (75 N.m). Then tighten the nut more
until the cotter can be installed.
7. Install gasket (10) between the housing and

cover (II). Install the eight holts which fasten
the cover to the housing.
8. Use thickness guage (12) to check the clear-

ance betwen the cover and impeller. Use
gasket(s) (10) as needed to get a clear-
ance of .005 to .020 in. (0.13 to 0.51 mm).
9. Install gear (13) on the shaft with six bolts

and three locks. Bend the locks.
10. Install elbow (14) on the pump assembly with

four bolts.
end by:
a) install fresh water pump
A18431Xl
7-47
L
CONNECTING ROD BEARINGS

REMOVE CONNECTING
ROD BEARINGS 1219-11
start by:
b) remove engine oil pump
c) remove water pump
d) remove oil pressure relief valve
I. Disconnect tube (I) from carburetor and re-

move bolt (2) and clip from carburetor base.
2. Loosen clamp (3) to remove pipe from cou-

pling.
3. Remove four bolts (4) that fasten gas pressure

regulator to cylinder block. Remove gas pres-
sure regulator (5) and tube and pipe assembly.
4. Remove bolts (6) that hold inspection cover to

block. Remove cover (7).
5. Turn the crankshaft (in the direction of normal

rotation until rod caps (9) can be removed
through the opening. Remove bolts (8) and rod
caps (9).
7-48
CONNECTING ROD BEARINGS

6. Remove bearing (10) from the rod cap.
7. Remove the upper half of bearings from the
connecting rods.
INSTALL CONNECTING ROD
BEARINGS 1219-12
Tools Needed A
Plastigage
NOTE: Install the rod bearings dry when the clear-

B27421X~
ance checks are made. Put clean engine oil on the rod
bearings for final assembly.
I. Install the upper half of new rod bearings (I) in
the connecting rods.
NOTE: Be sure the tab on back of bearing fits in tab
groove (slot) in connecting rod.
CAUTION
When connecting rod cap is installed, be sure
that the number on side of cap is near to and
respective to the number on side of connecting
rod.
2. Install lower half of new bearings (2) in caps
(3).
NOTE: Be sure the tab on back of bearing fits in tab
groove (slot) of cap.
CAUTION
Do not use an impact wrench to tighten the rod
bolts the additional 120 0 •
3. Check the bearing clearance with Plastigage
(A). Install bearing cap on connecting rod. In-
stall the rod bolts. Tighten the rod bolts first to
a torque of 40 ± 4Ib.ft. (55 ± 5 N·m). Put a
mark on bolt heads and bearing caps. Tighten
the bolts again 120 0 from the mark.
4. Remove cap (3). Measure thickness of the Plas-
tigage. The clearance between a new rod bear-
ing and crankshaft journal must be .0031 to
.0073 in. (0.079 to 0.185 mm). The maximum
permissible clearance is .012 in. (0.30 mm).
5. Put caps (3) in position on the connecting rods
and install the bolts. Tighten the bolts to a
torque of 40 ± 4 Ib.ft. (55 ± 5 N·m). Put a
mark on the bolt heads and bearing caps then
tighten the bolts 120 0 more.
6. Install inspection covers (4) with new gaskets.
7. Put gas pressure regulator (5) in position and
install four bolts. Connect pipe (7) to coupling
with clamp, and tube assembly (6) to carbure-
tor. Install clip and bolt on carburetor base.
end by:
a) install oil pressure relief valve c) install engine oil pump
b) install water pump d) install engine oil cooler
7-49
- - - - ---------------
GOVERNOR (WOODWARD UG-8), GOVERNOR DRIVE HOUSING

(UPPER) (WOODWARD UG-8)
REMOVE GOVERNOR
(WOODWARD UG-S) 1264-11
I. Disconnect governor control linkage (I) from
governor.
2. Remove four bolts (3).
3. Remove governor (2) from the drive housing.

Weight of governor is 40 lb. (I8 kg).
INSTALL GOVERNOR
(WOODWARD UG-S) 1264-12
I. Inspect gasket and make a replacement if
necessary. Install gasket (2).
2. Put governor ( I ) in position on the drive hous-

ing and install four bolts to hold it in position.
3. Install governor control linkage to governor.
REMOVE GOVERNOR DRIVE HOUSING

(UPPER) (WOODWARD UG-S) 1288-11
start by:
a) remove governor
1. Disconnect tube assembly (3) from housing as-

sembly fitting.
2. Remove six bolts (I) and housing assembly (2).
INSTALL GOVERNOR DRIVE HOUSING

(UPPER) (WOODWARD UG-S) 1288-12
I. Inspect the governor drive housing gasket and
make a replacement if damaged. Install gasket.
2. Put housing assembly (I) in position and install

six bolts.
3. Connect tube assembly (2) to housing assembly

fitting.
end by:
a) install governor
7-50
- - - - - - - -
GOVERNOR DRIVE HOUSING (UPPER) (WOODWARD UG-8)

Ie DISASSEMBLE GOVERNOR DRIVE HOUSING
(UPPER) (WOODWARD UG-8) 1288-15
I
Tools Needed A B
I
lP1853 Pliers
1P51 0 Driver Group
I start by:
a) remove governor drive housing
I
B24252Xl
I. Remove gear assembly (2) from housing.

I
NOTE: Gear assembly (3) must be disassembled in

I housing for removal. Gear assembly (2) is removed
as a unit.
Ie
B24248Xl
2. Remove ring (1) from shaft with tooling (D).

I
3. Remove gear (4) and washer (5) from shaft.

Remove shaft (6) from housing.
824233:)( 1
4. Remove ring (7) with tool (A). Remove gear

(8) and washer (9) from shaft (0).
5. Remove bearing (11) and two bushings (12) B24250X\

from housing with tool (B).
7-51
GOVERNOR DRIVE HOUSING (UPPER) (WOODWARD UG-S)

ASSEMBLE GOVERNOR DRIVE HOUSING
(UPPER) (WOODWARD UG-8) 1288-16
Tools Needed A B
1P150 Driver Group
1P1853 Pliers
I. Install bearing (I) in housing with tool (A).

The hole in the bearing must be in alignment
with the housing opening for oil supply.
2. The bushings installed with tool (A) must be

even (flush) with the edge of the housing bore.
TJ
3. Put shaft (2) in housing and install washer,
gear (4) and ring (3) with tool (B).
4. Install washer (7) and gear (6) on shaft (8).

Install ring (5) with tool (B).
5. Put gear assembly in housing.

end by:
a) install governor drive housing
7-52
GOVERNOR (WOODWARD UG-8)

DISASSEMBLE GOVERNOR 1264-15
Tools Needed A
1P51 a Driver Group
start by:
a) remove governor
NOTE: During disassembly many items are not ser-
viced. These items if damaged or in need of replace-
ment must be ordered as a subassembly. Disassem-
bly and assembly of these items will not be shown.
CAUTION
Put the governor in a stand to prevent damage
to the drive shaft.
I. Remove cover screws (I) and cover (2).
2. Remove screws (4) and cover assembly (3).
3. Put identification on two wires (5) and discon-
nect from motor assembly. Remove screws (6) --0
and motor assembly (7) from the cover.
4. Turn speed droop knob (8) to zero.
5. Turn speed setting knob (9) clockwise until it
Bl72B7Xl
stops (high speed position).
6. Set load limit knob (10) at position 10.
7. Turn terminal shaft (right hand side of case)
with a vise grip and shop cloth. Turn until the
load indicator pointer is approximately 8.5.
See location (12). When turning the terminal
shaft lever downward. Push down on the load
limit strap (16) to release trapped oil. See
picture 815613 page 7-54 for strap location.
8. Remove six screws and plate from panel assem-
r
bly (II).
9. Put an identification mark on the load limit
boss at the 8.5 position location (12). B-30460Xl
B9019Xl
7-53

10. Disconnect speed droop spring (17).
I I. Remove speed droop cotter pin ( 14) and speed

droop pin.
12. Push speed droop adjusting lever (15) back and

lift up on the speed droop lever (13) to release
tension on the speeder spring (18).
CAUTION
Do not turn the speed droop lever (13). It will
change the maximum or minimum speed ad-
justment limit of the governor.
13. Remove eight panel screws (19). Use a soft

hammer to break panel loose from case.
14. Lift load limit strap ( 16) and pull the bottom of
panel (21) out approximately 1/2" (12.7 mm). 89003Xl
Turn terminal shaft (22) downward with a vise
grip and a shop cloth. This will turn power lever
(20) down for easier panel removal.
15. Hold up speed droop lever (13) and push bot-

tom of panel (21) in and top of panel out.
Remove spring (23).
16. Remove the cotter pin and pin from power

lever and power piston link (24) and compen-
sating adjusting and actuating links (25).
7-54

17. Turn the governor over and remove the four
outside screws (26).
18. Hold the case and base together and turn as-
sembly over as shown. Use a soft hammer to
82084SX\
make a separtation of case (27) from base (28).
19. Remove cotter pin (30) and pin (29) from pilot
valve plunger.
20. Lift up inner end of floating lever (31). Push

down on rod end (33) with screwdriver. Slide
lever (31) backward on pin (32) to release lever
from rod end pin (33). Remove lever (31).
83 IJ40X 1
21. Remove ball head assembly (34).
831345X1
7-55
GOVERNOR{WOODWARDUG-8)
22. Put the speeder rod end of the ball head assem-
bly in a brass jaw vise.
CAUTION
Count the number of turns it takes to remove
nut (35) from the rod assembly.
23. Remove nut (35). Remove rod and pin assem-

bly (36), spring (37) and bearing (39) from ball
head assembly (38).
24. Lift the compensating actuating piston assem-

bly (40) up and install cotter pin in hole in the
link.
B33669Xl
25. Turn the assembly on its side and remove five

bolts (41). Use a soft hammer to remove the
control assembly from the base.
26. Remove spring assembly (43), pilot valve bush-

ing (42) and pilot valve plunger.
B3134BX1
7-56
ill WARNING
Actuating piston assembly (40) is under spring
tension.
27. Pull actuating piston assembly (40) and re-

move cotter pin (45). Remove the actuating B31352X 1
piston assembly (40) and spring (44) from the
control housing.
28. Remove cotter pin (47) and ball head drive

gear (46) from assembly.
29. Remove pump drive gear assembly (48).
B31358Xl
30. Remove cotter pin (49).
31. Remove lever (50) from spool. Remove spool

(51) from housing.
32. Remove two screws (53) and lever assembly

(52) from housing.
63 1300Xl
B31:361Xl
7-57
----------

33. Remove piston rod end (54) and locknut (55)
from the receiving piston (56).
34. Remove piston (56), bushing (58) and springs

(57) from the housing assembly. B31368Xl
35. Remove seat (59) from housing assembly with

tool (A).
fl3136JX\
36. Remove wire, bolts (61) and bearing retainer

(60).
37. Remove drive shaft and bearing assembly (62)

from base housing with a soft hammer.
7-58

ASSEMBLE GOVERNOR 1264-16
Tools Needed A
lP510 Driver Group
I. Install the drive shaft and bearing assembly (I)

in the base plate housing.
833673X1
2. Install retainer plate (2) and three screws.

There is a 1/8" (3.2 mm) space between the
retainer and the housing. Install wire in the
screw heads.
3. Install seat in the control housing with a press

and tool (A) until the seat is even with the
housing land. See location (3).
CAUTION
Inspect all pistons and shafts for damage and
repair as necessary. Put lubricant on compo-
nents before assembly.
4. Install springs (7), piston (8), bushing (6),

locknut (5) and piston rod end (4).
5. Put lever assembly (9) in position and install

B31363Xl
two screws to hold it in place.
B31369Xl
7-59

6. Put spool (II) in housing and install lever (10)
on spool. Install cotter pin to hold lever in posi-
tion.
7. Install pump drive gear assembly (12).
8. Install ball head drive gear ( 13) and cotter pin

on the pump drive gear.
9. Install spring ( 15) and actuating piston assem-
bly (14) in the control housing. Install a cotter
pin in the piston link to hold assembly in posi-
tion until the governor base is installed.
10. Install pilot valve bushing (16), pilot valve

plunger (17) and spring assembly (18) in the
control housing.
83135lX1 11313S3XI
7-60

I I. Turn drive shaft ( 19) to make an alignment of
the drive shaft lug with the slot (opening) in the
pilot valve bushing (16).
12. InstalI governor base (20) on the control assem-

bly. InstalI five screws. The cotter pin in the
actuating piston assembly can now be removed.
13. InstalI spring (22) and rod and pin assembly

(21) in balI head (23). InstalI bearing (24) and
nut (25). Count the number of turns to remove
nut from disassembly section.
® ®®
14. InstalI balI head assembly (26) in the control
assembly.
83367.0Xl
15. Put floating lever (27) in the rod end pin (28).
e Push piston rod end (29) down with a screw-

driver and instalI floating lever in the piston rod
end.
CAUTION
Do not install pin in the floating lever unless
lever can be moved freely.
16. InstalI pin (30) and cotter pin in position to

831346Xl
hold floating lever in position.
B31341Xl
7-61

17. Inspect gasket (32) on the governor base and
make a replacement if damaged.
18. Install case (31) in position on the base. Install

four screws to hold case in position.
19. Install pin and cotter pin in the power lever and
power piston link (33) and the compensating
adjusting and actuating links (34).
20. Make sure the load indicator pointer is at 8.5 on

the panel. 831339Xl
21. Install spring (36) in the ball head assembly.
22. Use a soft cloth and a vise grip to turn terminal

shaft (37) and power lever down. If necessary
turn drive shaft to engage ball head gears.
23. Install panel (35) in case. It will be necessary to

push up on the load limit strap (38 ) to install
panel.
24. Install spring (36) in position while the speed

droop lever is lifted up. 8
25. Keep the bottom of the load limit strap on the

case opening. Pull the bottom of the panel out
about Ijz" (12.7 mm) from the case and the top
against it.
26. Turn terminal shaft to move power piston link

(33) to its highest position.
27. Push panel in position on the case. Turn the

terminal shaft down slowly to engage the power
piston link (33) in position in the opening of the
rack (39). Install panel screws.
28. Turn the terminal shaft. If oil film remains in

control assembly, it will be necessary to release
pressure in the power cylinder while terminal
shaft lever is turned down and load limit strap
(38) is pushed down. The load indicator pointer
must travel from 0 to 10. If the terminal shaft
does not travel both ways, remove panel and
start again at Step 20. If the panel can not be
removed push down or pull up on the rack (39)
until the load indicator is at the 8.5 position.
29. Push down on the load limit strap. Movement

of the strap is 3/16" (4.8 mm). If not, remove 824402X1
panel and start at Step 20.
7-62
--------------------------- - - - -

30. With the speed droop lever (41) in the vertical
position, push down, then push the speed droop
adjusting lever (42) back as indicated by arrow.
Turn the speed droop lever down.
31. Install speed droop link pin (40) and cotter pin.
32. Install speed droop spring (43).
33. Install dial plate (44).
34. Put the motor assembly (47) in posItIOn in

cover (46) and install four screws.
35. Connect two wires (45) to the motor assembly.
36. Inspect and make a replacement of cover gasket

(50) if necessary.
37. Install cover assembly (48) on the governor

case. Make sure the drive gear (51 ) and shaft
(49) are in alignment. Install eight bolts to hold
cover assembly in position.
38. Install cover (52) to cover assembly.

end by:
a) install governor
---®
S17268X1
7-63
GOVERNOR (HYDRA-MECHANICAL)
DISASSEMBLE GOVERNOR 1264-15
Tools Needed A
1P51 0 Driver Group
start by:
a) remove governor
1. Remove five bolts (2) and cover (1) from hous-

ing assembly.
2. Remove screw (5) and collar (4) from bolt.
3. Bend the tabs on lock and remove two bolts (3)

and the torque spring assembly.
4. Remove lock (6), bar (7), spacer (8) and re-

tainer (9).
CD--~I'·)·
5. Remove collar (1) and spring (10) from bolt.

0...----
6. Remove four bolts (13) and housing assembly
835580Xl
02) from housing.
833689Xl
7-64
- - - -----------
7. Bend the tab on lock ( 15) and remove bolt ( I 7).
8. Remove shaft (16) and lever (14) from housing

assembly.
9. Remove seal (19), plug and bearing (20) from

housing assembly.
10. Put identification on screw (18) or count the

number of turns when screw is removed. Re-
move screw.
II. Remove seat (21), spring (23) and spring

washer (22).
CAUTION B33700Xl
There are two washers and one spring under

seat assembly. Care must be used during seat
assembly removal so these parts do not be-
come lost.
12. Lift up on retainer ring (25) and remove pin

(26) and seat assembly (24).
13. Remove two washers (27), spring (30) and rod

(28) from seat (29). 8J3710Xl
27
i!!>\>
f~'),
30
1133691 Xl 833711)( 1
7-65
14. Remove sleeve and bearing assembly (31) from
the cylinder and weight assemblies. Remove
lockring (32) that holds weight assembly to
cylinder.
15. Remove ring (33), races (36) and bearing (34)

from sleeve (35).
B33693Xl
16. Remove weight assembly (37) from cylinder. 33
17. Bend the tabs on lock (38) and remove three

bolts (40).
A&5091X2
18. Remove cylinder (39) from cover.
19. To remove the piston assembly from pin (43)

lift up on sleeve (41) and slide piston (42) from
pin. The bottom of the piston has an opening
(notch) that engages with the top of pin. When
piston (42) is correctly engaged with top of pin
B3369BXl
(43), the sleeve (41) can be moved into place.
833700Xl
7-66
20. Remove valve (45) and sleeve (41) from piston
(42). Remove seal (44) from sleeve.
21. Bend the tab on locks (48) and remove bolts.

Remove bolt (46) and washer used to fasten
gear on shaft assembly. Remove cover (47)
from housing.
833716Xl
CAUTION
Support shaft assembly to prevent damage
during disassembly.
22. With a press and tooling (A) remove shaft

assembly (50) from gear and cover (49).
B33717Xl .'
23. Install shaft assembly (50) in press and remove

gear (5 I).
24. Remove gear (52) from bushing. Remove pin

(43) from housing. To remove pin from housing
turn shaft (53) counterclockwise and remove
pin from lever assembly inside housing. The
bottom of pin has an opening (notch) that en-
gages with lever.
833121 Xl
7-67
25. Remove bearing (54) from housing.
26. Bend the tabs on locks (56) and (57). Remove

bolts that hold the shaft in the housing and hold
lever to shaft. Slide lever (55) on shaft and
remove key from shaft. Remove shaft (53)
from housing.
833730X
II-_@
27. Remove plug assembly (58) from housing.
28. Remove seal (60) and two bearings (61) from

housing.
833133Xl
29. Remove oil bypass valve assembly (59) from

housing.
30. Remove pin (65), piston (64) and spring (63)

817272)( 1
from body (62).
B24232Xl
7-68
ASSEMBLE GOVERNOR 1264-16
Tools Needed A
1P510 Driver Group
I. Install two needle bearing assemblies in hous-

ing with a press and tool (A). Install bearing in
bore (1) until bearing surface is even with the
edge of the housing surface. Install the other
bearing until it is even with the top of the seal
counterbore. Install seal as shown with tool
(A).
2. Install plug assembly (2) in housing and

tighten to a torque of 50 ± 10 Ib.ft. (70 ± 14
N·m).
3. Install washer (3), spring (4), piston (5) and

pin (6) in body.
4. Install oil bypass valve assembly (7) in housing

and tighten to a torque of 50 ± 10 Ib.ft. (70 ±
14 N·m).
5. Slide shaft (8) through lever (9) and install lock

and bolt to hold shaft in housing. Install key in
shaft. Slide lever (9) on key and install lock and
bolt.
NOTE: The shaft must turn freely in bearings with

B3S581X1
.020 to .060 in. (.508 to 1.524 mm) end play.
815619;(1
7-69
6. Install bearing (10) in housing with a press and
tool (A). Height from housing to top of bearing
is .470 ± .005 in. (I1.94 ± 0.13 mm).
7. Install pin (II) in housing. Pin has an opening

(notch) that engages in lever (9).
J1
8. Install gear (I 2) on bearing.
9. Use a press and install gear (I 4) on shaft (13).

Install gear until it makes contact with
shoulder of shaft.
10. Install cover (16), gear (15), washer and bolt

on shaft assembly. Install assembly in housing.
7-70
I I. Install two locks and bolts in position on cover.
20
12. Inspect O-ring seal (17) and make a replace-

ment if necessary.
13. Install valve (19) in piston (20). Install sleeve

(18) on piston. B33.7116X2
14. Install piston assembly on pin (II) as follows:

Lift up on sleeve (18) and slide piston (20) on
pin ( II). The bottom of the piston has an open-
ing (notch) that engages with the top of pin.
When piston is correctly engaged with pin, the
sleeve (18) can be moved into place.
I
15. Install cylinder (2 I) on cover.

I
Ie 16. Install lock (24) and three bolts (23) in position

on cylinder.
I
17. Install weight assembly (22) on cylinder. In-

I
stall lockpin on weight assembly.
18. Put races (28) and bearing (26) in position on

sleeve (27). Install ring (25) that holds the
races and bearings on the sleeve.
A85001X'3
7-71
19. Put sleeve assembly (29) in position on valve.
Make an alignment of the holes in the sleeve
and valve.
20. Install bolt (31), washers (30) and spring (33)

in seat.
21. Put seat (32) in position on sleeve assembly B33694Xl

(29).
22. Make an alignment of the holes in the seat,

sleeve assembly and valve. Install dowel (35)
that holds the seat, sleeve assembly and valve
together.
23. Install retaining ring (34) that holds dowel (35)

in place.
B33690X1
24. Put spring washer (37) in position on the bolt.
25. Put spring (38) and seat (36) in position on the

weight assembly.
26. Install bearing (40) in housing until bearing

edge is even with the seat counterbore. Install
bearing (41) to the given dimension from bear-
ing (40). Install seal (39) as shown. Install plug
(42) to dimension given.
~ 41
7-72
27. Put lever (43) in position in housing and install
shaft (44) to hold it in place. Install lock and
bolt in position on lever. Make a replacement of
gasket (45) if it is damaged.
28. Put housing assembly (49) in position and in-

stall four bolts (50).
29. Install spring (47) and collar (46) on bolt.
30. Install screw (48) the same number of turns

counted during disassembly.
31. Assemble the torque spring group in the follow-

ing sequence: retainer (54), spacer (53), bar
(52) and lock (51).
32. Install torque spring group (56) on governor

housing.
33. Install collar (55) and screw on bolt (31).
34. Inspect cover gasket and make a replacement if

damaged.
35. Install cover (57) on housing assembly.

end by:
B35582Xl
a) install governor
833682X1 83-3684Xl
7-73
EXHAUST MANIFOLD
REMOVE EXHAUST MANIFOLD 1059-11
Tools Needed A
5P9736 Bracket-Link
I. Remove the nuts and bolts from carburetor

rods (2) and (5) and the governor linkage rod
(I ).
2. Remove four bolts (3) and channel assembly

(4). Remove four spacers.
3. Remove bolts and elbow assemblies (6) from

exhaust manifold. Remove gaskets.
4. Disconnect oil line (7). Disconnect opposite end

of oil line (7) from the top of the turbocharger
lubrication valve.
5. Remove seven bolts (8) from pipe (9) and ex-

haust manifold.
7-74
EXHAUST MANIFOLD
6. Remove bolts (12) and connector (10) from
manifold.
7. Fasten tool (A) and a hoist to exhaust manifold

(II). Remove sixteen bolts (13) from the ex-
haust manifold. Remove manifold and gaskets.
Weight of the manifold is 185 lb. (84 kg).
INSTALL EXHAUST MANIFOLD 1059-12

B2447tXl
Tools Needed A
5P9736 Bracket-Link
I. Inspect all O-ring seals and make replacements

if necessary.
2. Install tool (A) and hoist on exhaust manifold.
3. Install the exhaust manifold (I) on the engine.

Install new manifold gaskets.
4. Put 5P393l Anti-Seize Compound on threads

of bolts. Install the bolts that hold the manifold 814?29Xl
to the cylinder head. Tighten bolts to a torque

of 110 ± 10 Ib.ft. (149 ± 14 N·m).
5. Install oil line (2).
6. Put engine oil on O-ring seals and install con-

nector (3) and elbow assemblies (4) and new
gaskets in position on manifold.
7. Put spacers (6) in place and install channel

assembly (5).
8. Connect carburetor and governor linkage rods.
:e
I
7-75
L
GOVERNOR DRIVE HOUSING

REMOVE GOVERNOR DRIVE
HOUSING 1288-11
Tools Needed A
start by:
a) remove governor drive (upper)
NOTE: The exhaust manifold channel assembly was

removed for photo illustration.
1. Remove two bolts (1) from air cleaner brace.
2. Remove turbocharger cartridge housing tubes

(7). Remove four bolts (2) that are used to
fasten turbocharger pipe to the support.
3. Remove six bolts (4) that are used to fasten the

support assembly in position. Remove support
assembly (3).
4. Remove bolt (5) and spacer from clip. Remove

turbocharger lubrication valve tube (6).
5. Remove four bolts and cover (9).
6. Remove tube assembly (8) from the turbo-

charger lubrication valve and housing.
7. Install tooling (A) and a hoist on the governor

drive housing and remove fourteen bolts (10).
8. Remove governor drive housing. Weight of

governor drive for G379 is 90 lb. (41 kg), for
G398 and G399 the weight is 125 lb. (56 kg).
7-76

INSTALL GOVERNOR DRIVE
HOUSING 1288-12
Tools Needed A
1. Inspect gaskets and make replacements if

necessary.
a27012X\
2. Install tooling (A) and hoist on the governor

drive housing. Put gasket and housing in posi-
tion and install bolts. Remove tooling (A).
4. Install gasket and cover (I) in position on hous-

ing.
5. Put support assembly (4) in position and install

six bolts. Install four bolts to hold pipe (3) to
support assembly.
6. Install turbocharger lubrication valve tube as-

sembly (7) to housing. Install spacer and bolt
(6) on tube assembly (7).
7. Install two turbocharger cartridge housing

tubes (8).
8. Install two braces (5) and bolts to the turbo-

charger pipe.
end by:
a) install governor drive (upper)
7-77

DISASSEMBLE GOVERNOR DRIVE •
HOUSING 1288-15
Tools Needed A
lP529 Handle
1P457 Drive Plate
start by:
a) remove fuel injection pump housing,
•
governor, and governor drive as a unit
b) remove governor
c) remove shutoff control .'UXt
I. Remove the governor drive housing from the

fuel injection pump housing with a hoist.
Weight of governor drive for G379 is 80 lb. (36
kg); for G398 and G399 is 125 lb. (56 kg).
Remove coupling.
2. Remove ring. plunger, spring, and retainer

for shutoff control.
3. Remove pin that holds shaft assembly. Re-

move lever (2), spring (4), key and shaft
assembly (5). Remove the seal from hous-
ing.
4. Remove governor drive pinion (3).
5. Use tooling (A) to remove gear from thrust

washer (1). Remove the bearing from hous-
ing.
6. Remove ring (9). Remove bolts, locks, and

gear (8).
7. Remove thrust plate (10) and shims. Keep

shims together for installation.
8. Turn puller bolt (12) counterclockwise and

remove drive gear (11).
9. Remove locknut (6), gear (7) and key. Re-

move the drive shaft (13). Remove bearings 801SSXl
for the shaft from the housing.
7-78

ASSEMBLE GOVERNOR DRIVE
HOUSING 1288-16
Tools Needed A B
lP529 Handle 1
lP472 Drive Plate 1
lP475 Drive Plate 1
8S2328 Dial Test Indicator Group 1
I. Install the bearings (1) in housing with

tooling (A). Put clean engine oil on
bearings.
2. Install the drive shaft (2) and locknut, key
and gear (3).
3. Install the drive gear. Turn the puller bolt to

hold gear on shaft.
4. Heat the thrust washer to a temperature of
250° F (120°C). Install bearing and gear (4)
in housing. Push thrust washer ovet gear
until washer is even with top of gear. There
must be .015 to .045 in. (0.38 to J.l4mm)
end clearance.
5. Install seal (6) in housing with lip of seal to
inside. Install lever and shaft assembly 80156)('
(5). Install spring, key and pin.

NOTE: Be sure the pin is engaged with groove in
shaft and shaft turns freely. The spring must hook
over the pin and around shaft lever.
6. Install plunger, spring, retainer and ring for

shutoff control.
7. Install governor drive pinion (8). Install
shims and thrust plate (7). Install bevel gear
( 10) and ring. End play of drive shaft with
new parts is .005 to .009 in. (0.13 to 0.23
mm). Maximum permissible end play with
used parts is .015 in. (0.38 mm).
8. Use the tool group (B) to check the clear-
ance (backlash) between pinion and bevel
gear (10). Make adjustment of backlash by
removing or adding shims (9) behind thrust
plate (7). Amount of free movement (back-
lash) between bevel gear and pinion must be
.002 to .006 in. (0.05 to 0.15 mm).
9. Install coupling on shaft. Fasten a hoist and
install governor drive housing on the fuel
injection pump housing.
end by:
a) install shutoff control
b) install governor
c) install fuel injection pump housing,
governor, and governor drive as a unit
7-79
INTAKE MANIFOLDS, VALVE COVERS

REMOVE AND INSTALL INTAKE
MANIFOLDS 1058-10
start by:
a) remove carburetor
I. Remove intake manifold bolts that fasten clips

(3) and brackets ( I) and (2) to the head. Fasten
the coil bracket away from the intake manifold
with a piece of wire.
2. Remove the remainder of the bolts and intake

manifold (4) from the cylinder heads.
3. Install new intake manifold gaskets (5) and

intake manifold (4) in position on the engine.
4. Install brackets (I) and (2) and clips (3) with

the manifold bolts. Install the remainder of the
manifold bolts.
end by:
a) install carburetor
REMOVE AND INSTALL

VALVE COVERS 1107-10
I. Remove the nuts (I), washers and seals from
the studs.
2. Remove valve cover (2).
3. Install a new gasket in the valve cover. Put

cover (2) in position on the engine.
4. Install the seal and washer on each stud. Install

and tighten nuts until contact is made with the
washer. Tighten the nuts to a torque of 10 ± 3
Ib.ft. (14 ± 4 N.m).
7-80
, -
ROCKER SHAFTS AND PUSH RODS

REMOVE ROCKER SHAFTS AND
PUSH RODS 1102 & 1208-11
start by:
a) remove valve covers
I. Loosen adjustment screws (I) to get maximum

valve clearance. Disconnect oil line (4) from
shaft.
2. Remove nuts (3) and studs (2) that hold the

shaft on head.
NOTE: If studs (2) are removed when nuts are loo-

sened, install the studs in the head. Tighten the studs
to a torque of 40 ± 5 lb.ft. (55 ± 7 N·m).
3. Remove rocker shaft. Remove push rods (5)

from the cylinder head.
INSTALL ROCKER SHAFTS AND

PUSH RODS 1102 & 1208-12
I. Install push rods (I) in position on the lifters.
2. Install rocker shaft (2) on the cylinder head.
3. Install the nuts and studs that hold the rocker

shaft to the cylinder head. Connect oil line to
the rocker shaft.
NOTE: Be sure the studs and nuts are tightened to a

torque of 40 ± 5 Ib.ft. (55 ± 7 N·m).
4. Make an adjustment of the valve clearance.

The cold clearance must be: intake .015 in.
(0.38 mm) and exhaust .035 in. (0.89 mm). See
VALVE CLEARANCE ADJUSTMENT in
TESTING AND ADJUSTING.
end by:
a) install valve covers
7-81
ROCKER SHAFTS
DISASSEMBLE ROCKER SHAFTS 1102-15
Tools Needed A
lP510 Driver Group
start by:
a) remove rocker shafts and push rods
1324001XI
1. Remove cotter pins (1), washers and springs.
2. Remove intake rocker arms (5) from the rocker

shaft.
3. Remove brackets (4) and exhaust rocker arms

(3) from shaft. Remove fitting (6) and spring 71 631X I
(2).
4. Remove the bearings (7) from the rocker arms

with tooling (A). Remove nut (8) and screw
(10) for the adjustment from the arms. Remove
rings and buttons (9) from the arms.
B24008Xl
ASSEMBLE ROCKER SHAFTS 1102-16
Tools Needed A
lP510 Driver Group
l. Install rings and buttons on rocker arms. Install

screws and nuts for the valve adjustment on the
arms. Install the bearings in the arms with
tooling (A).
7-82
ROCKER SHAFT
NOTE: Be sure oil holes (I) of the bearings are in
alignment with oil holes in arms.
2. Install spring (3) and fitting (2) on the shaft.
3. Install rocker arms (4), brackets (7), washers

(5), springs (8) and cotter pins (6) on each end
of shaft.
NOTE: Be sure exhaust rocker arms and intake

rocker arms are installed in correct location on shaft.
end by:
a) install rocker shafts and push rods
814011 x 1
7-83
VALVE LIFTERS
REMOVE VALVE LIFTERS 1209-11
start by:
a) remove piston cooling tubes "'''
b) remove fuel injection pump housing, gover-
nor and governor drive as a unit
c) remove valve covers
1. Loosen the adjustment screws for valves to

get maximum clearance.
NOTE: Flywheel housing removed for illustration
only.
2. Remove the push rods (2).
3. Remove the oil tubes (1) away from the

brackets.
4. Put a wire or large rubber band around the
lifters (3) to hold them in place in bracket.
5. Remove the bolts and locks that hold brack-
et assembly to cylinder block. Remove the
brackets and lifters (3).
NOTE: If damage has been caused to lifters, inspect
the 10 bes of camshaft. If necessary make a
replacement of the camshaft. See REMOVE
CAMSHAFT. Clearance between lifter and bracket
must be no more than .010 in. (0.25 mm)
7-84
VALVE LIFTERS
INSTALL VALVE LIFTERS 1209-12
Tools Needed
3P2243 Installer
I. Put clean engine oil on lifters. Install lifters

in bracket.
2. Put wire or large rubber bands (I) around

lifters to hold them in bracket.
3. Put the bracket and lifters in position on

dowels. Install the locks and bolts that hold
brackets to cylinder block. Remove the wire
or rubber band from lifters.
4. Put the oil tubes (2) on the brackets and

install locks and bolts.
S. Put the seals between the bracket assem-

blies.
6. Use installer (A) to put the seals in their

respective position.
7. Install the push rods.
8. Make an adjustment of valves to get .0 IS in.

(0.38 mm) clearance (cold) on intake valves;
.035 in. (0.89 mm) clearance (cold) on ex-
haust valves. See VALVE CLEARANCE
ADJUSTMENT in TESTING AND AD-
JUSTING.
end by:
a) install piston cooling tubes
b) install fuel injection pump housing, gover-
nor and governor drive as a unit
c) install valve covers
7-85
CRANKSHAFT MAIN BEARINGS

REMOVE CRANKSHAFT MAIN
BEARINGS 1203-11
Tools Needed A B
2P5517 Bearing Removal and
Installation Tool
8M9379 Wrench
start by:
b) remove water pump
c) remove engine oil pump
e) remove gas pressure regulator
I. Remove the bolts (I) that hold inspection

covers to block. Remove inspection covers (2)
from each side of block.
.~
2. Remove the nuts for main bearing caps with

63957.>:.:2: _..J
wrench (B). Remove the bearing cap with
lower half of bearing.
3. Use tool (A) to move out the upper half of main

bearing as the crankshaft is turned in the nor-
mal direction of rotation.
5Il763xt
CAUTION
If the crankshaft is turned in the wrong direc-
tion, the tab of the bearing will be pushed
between the crankshaft and cylinder block.
This can cause damage to either or both.
NOTE: On the bearing journal that has no drilled

hole, put a thin piece of fiber, hardwood or plastic
against end of bearing opposite tab. Hit the bearing
lightly with the above until tab of bearing is free from
cylinder block. Remove the upper half of bearing.
7-86
CRANKSHAFT MAIN BEARING

INSTALL CRANKSHAFT MAIN
BEARINGS 1203-12
Tools Needed A B C D
2P5517 Bearing Removal and
Installation Tool
8M9379 Wrench
Plastigage
8S2328 Dial Test
Indicator Group
NOTE: Install the main bearings dry when the clear-

ance checks are made. Put clean engine oil on the
main bearings for final assembly.
I. Use tool (A) to install upper half of bearing in
-•••••
cylinder block. The bearing with oil hole is
upper half.
2. Clean main bearing caps and install lower
halves of bearings in caps.
NOTE: When the bearing clearance is checked and

the engine is in a vertical position, such as in the
vehicle, the crankshaft will have to be lifted up and
held against the upper halves of the main bearings to
get a correct measurement with Plastigage. The
Plastigage will not hold the weight of the crankshaft
and give a correct indication. If the engine is in a
horizontal position, such as on an engine stand, it is
not necessary to hold the crankshaft up. Do not turn
crankshaft when Plastigage is in position to check
clearance. 4. Put clean engine oil on threads of studs and seat
for nut. Install main bearing caps and nuts.
CAUTION Install thrust plates on dowels on rear cap. The
Do not use an impact wrench to tighten the dowels must not be extended more than .160 in.
bolts the additional 120 0 • (4.06 mm) from counterbore face of bearing
cap. Tighten nuts with wrench (B) to 200 ± 10
3. Use Plastigage (C) to check bearing clearance. Ib.ft. (270 ± 14 N·m). Put a mark on nuts and
Install caps and tighten both nuts with tool (B) ends of studs. Tighten nuts an extra 120 0 from
to 200 ± 10 Ib.ft. (270 ± 14 N·m). Put a mark mark.
on nuts and end of studs. Tighten nuts 120 0 5. Use indicator group (D) to check end play of
from the mark. Remove caps and check thick- crankshaft as controlled by thrust plates. End
ness of Plastigage (C) to find bearing clear- play with new parts must be .005 to .021 in.
ance. Bearing clearance must be .0048 to .0090 (0.13 to 0.53 mm). Maximum permissible end
in. (0.122 to 0.229 mm) for new parts. Maxi- play with used parts is .035 in. (0.89 mm).
mum permissible clearance for used parts is
.015 (0.38 mm). 6. Install the inspection covers.
end by:
NOTE: Main bearing caps have numbers as to their a) install gas pressure regulator
location in cylinder block. Install bearing caps so the b) install oil pressure relief valve
number on cap is same as number on cylinder block. c) install engine oil pump
Both numbers must be on same side of cylinder d) install water pump
block. e) install engine oil cooler
7-87
PISTON COOLING TUBES

REMOVE PISTON COOLING TUBES 1307-11
start by:
b) remove water pump
c) remove engine oil pump
e) remove gas pressure regulator
1. Remove bolts (1) that hold inspection covers to

cylinder block. Remove inspection covers (2)
from each side of block.
2. Remove bolt (3) and lock that holds tube to

bottom side of lifter bracket. Remove the piston
cooling tubes (4).
INSTALL PISTON COOLING TUBES 1307-12
Tools Needed A
5P8709 Piston Cooling Tube Tool Group
I. Check the alignment of the piston cooling tubes

with tooling (A). See USE OF 5P8709 TOOL
GROUP FOR ALIGNMENT OF PISTON
COOLING JETS, Form No. SMHS7267, for
the correct alignment procedure.
2. Install piston cooling tubes (1) in position on

the lifter bracket. Install the locks and bolts.
3. Install the inspection covers on engine.

end by:
a) install gas pressure regulator
b) install oil pressure relief valve
c) install engine oil pump
d) install water pump
e) install engine oil cooler
7-88
ENGINE DISASSEMBLV AND ASSEMBLY
CYLINDER HEADS
REMOVE CYLINDER HEADS 1100·11
Tools Needed A
5P9736 Bracket-link 3
start by:
a) remove rocker shafts and push rods
b) remove intake manifold
c) remove exhaust manifold
I. Remove the instrument panel from cylinder

head to be removed (if so equipped).
2. Remove the coolant from the engine.

I
e
I
3. Remove sixteen nuts (I) from cylinder head.
4. Fasten a hoist to tooling (A) on cylinder head.

Slowly remove cylinder head from block so
studs are not damaged. Weight of cylinder
head is 190 lb. (86 kg).
5. Remove head gasket (3) and water seal assem-

blies (2).
6. Remove O-ring seal (4) from dowel.
7-89
CYLINDER HEAD
INSTALL CYLINDER HEAD 1100-12
Tools Needed A
1. Clean the block and cylinder head. Install seal

( 1) on dowel.
2. Put water seal assemblies (2) in position on the

block.
3. Install head gasket (3).
4. Install tooling (A) and a hoist to the cylinder

head. Slowly lower the head over the studs until
it is in the correct position over head gaskets
and seals.
5. Put 5P3931 Anti-Seize Compound on threads

of head studs. Install nuts in the following se-
quence:
Step 1. Tighten nuts by number sequence to a

torque of 150 Ib.ft. (205 N.m).

torque of 265 Ib.ft. (360 N.m).

torque of 265 Ib.ft. (360 N·m).
6. Install the instrument panel on cylinder head

removed (if so equipped).
7. Fill the engine with coolant to correct level.

end by:
a) install exhaust manifolds
b) install intake manifolds
c) install rocker shafts and push rods
015 100
20 01 40
60 05 80
013 120 09
7-90
VALVES
REMOVE VALVES 1105-11
Tools Needed A B
H806 Cylinder Head Repair Bench
551330 Valve Spring Compressor
start by:
a) remove cylinder head
I. Install cylinder head (I) on tooling (A) as

shown.
2. Put identification on the valves and head for

correct assembly. Use tooling (B) as shown to
put valve spring (4) under compression. Re-
move three locks (3). Slowly release compres-
sion from the valve spring and remove tool-
ing (B). Remove retainer (2), two springs (4),
rotator, spacer and valve from the head.
3. Do Steps 1 and 2 again for the remainder of

valves.
2810Xl
\
7-91
VALVES
INSTALL VALVES 1105-12
Tools Needed A B C
FTB06 Cylinder Head Repair Bench 1
852263 Valve 5pnng Tester
551330 Valve Spring Compressor
I. Check spring force with tool (B). For the

correct spring force, see the subject VALVES
in SPECIFICAnONS.
A82800Xl
2. Inspect and make a replacement, if neces-
sary, of the O-ring seals in the inlet valve
retainers. Put the valves, spacer, rotator,
springs and retainer in position on the head.
Put the springs under compression with tool
(C). Install three locks (I). The thick end of
the lock goes toward the cylinder head.
&. WARNING
Locks can be thrown from the valve when tool
(C) is released if they are not in their correct
position on the valve stem.
3. Remove tool (C) slowly. Hit the valve lightly

with a soft hammer to be sure the locks are in
their correct position.
4. Do Steps I through 3 again for the remainder

of the valves.
end by:
a) install cylinder head
7-92
VALVE GUIDES
REMOVE AND INSTALL VALVE
GUIDES 1104-10
Tools Needed ABC D

4H446 Driver
5PI726 Bushing
, P7430 Driver
2P2313 Bushing
"
start by:
-
-"""\
A82803Xl
a) remove valves
I. Remove old valve guides (I) with tool (A) as

shown. If the valve guides have grooves, use
tool (C).
2. Install the valve guides with tools (A & B) as

shown. If the valve guides have grooves, use
tools (C & D).
3. Dimension (X) for the installed valve guide

must be 1.750 ± .020 in. (44.45 ± 0.51 mm).
end by:
a) install valve
7-93
VALVE SEAT INSERTS, WATER DIRECTORS

REMOVE AND INSTAll VALVE
SEAT INSERTS 1103-10
Tools Needed A
9S3080 Valve Seat Insert Group
start by:
a) remove valves
1. Remove valve seat inserts (1) with tool group

(A).
2. Clean and remove burrs from the valve seat

bore.
3. Instal1 the new valve seat insert with tool

group (A). Do not increase diameter of ex-
tractor in valve seat insert when insert is in-
stal1ed in cylinder head.
4. Grind valve seat inserts (I) according to

specifications given in SPECIFICATIONS
SECTION.
end by:
a) instal1 valves
REMOVE AND INSTAll

WATER DIRECTORS 1115-10
1P510
start by:
Tools Needed
Driver Group
A
•
••
a) remove cylinder head
~
1. Remove water director (I) from cylinder
head.
A82805X1
•
2. Instal1 new water director with tooling (A).
CAUTION
Hole (2) in water director must be in alignment
with "V" mark on cylinder head.
end by:
a) instal1 cylinder head
7-94
PISTONS
REMOVE PISTONS 1214-11
start by:
a) remove cylinder heads
b) remove engine oil cooler
c) remove water pump
d) remove engine oil pump
e) remove oil pressure relief valve
NOTE: The following sequence of photos is for the

removal of pistons I and 3 only.
I. Disconnect tube (I) from carburetor and re-

move bolt (2) and clip from carburetor base.
2. Loosen clamp (3) to remove pipe from cou-

pling.
3. Remove four bolts (4) that fasten gas pressure

regulator to cylinder block. Remove the gas
pressure regulator and tube and pipe assembly.
4. Remove bolts (5) that hold inspection cover to

block. Remove cover (6).
5. Turn the crankshaft (in the direction of normal

rotation) until the rod caps (8) can be removed
through the openings. Remove bolts (7) and
rod caps (8).
6. Remove the carbon ridge (9) from the top of

the cylinder liner.
7. Push the connecting rod and piston up until the

rings are out of the cylinder liner.
8. Remove the piston and connecting rod from the

cylinder liner.
7-95
PISTONS
INSTALL PISTONS 1214-12
Tools Needed A
5P3528 Piston Ring Compressor
I. Put clean SAE 30 engine oil on the piston,

rings, connecting rod bearings and walls of cyl-
inder liner. Install upper bearing in connecting
rod.
2. Install piston (I) in tool (A). Put the piston and

tool (A) in position on the cylinder liner as
shown.
3. Install the piston in the liner slowly on to the

journal of crankshaft. Be sure the "V" mark on
piston is in alignment with the "V" mark (2) on
the block.
CAUTION
Be careful not to cause damage to connecting
rod bearing or journal on crankshaft when pis-
ton is installed.
4. Install the lower bearing (5) in the cap (3) for

the connecting rod (4). Be sure the tab on back
of bearing fits in groove for tab in cap. Install
the cap.
5. Put 5P3931 Anti-Seize Compound on threads

of rod bolts. Install rod bolts. Tighten the rod
bolts to a first torque of 40 ± 4 Ib.ft. (55 ± 5
N·m). Put a mark on bolt heads and bearing
caps. Tighten the bolts again 120 0 from the
mark.
6. Put inspection covers in position on engine. In-
staH the bolts that hold covers to cylinder block.
7. Check the inspection cover gasket for damage
and make a replacement of gasket if necessary.
8. Put cover (6) in position and install bolts.
9. Put gas pressure regulator (9) in position and
install four bolts. Connect pipe (10) to coupling
with clamp and tube assembly (7) to carbure-
tor. Install clip (8) and bolt on carburetor base.
end by:
a) instan oil pressure relief valve
b) instan engine oil pump
c) instan water pump
d) install engine oil cooler
e) instan cylinder heads
7-96
PISTONS
DISASSEMBLE PISTONS 1214-15
Tools Needed A B
5H9621 Piston Ring Expander
5P8639 Press Group
5P8655 Tool Group
start by:
a) remove pistons
I. Use tool (A) to remove piston rings (I) from

piston.
2. Remove retainers (6) and pin (4) from the

piston (2). Remove connecting rod (3) from the
piston.
B270,75X 1
CAUTION
Do not use a broken ring or carbon scraper to
clean carbon. They will cut the ring grooves or
cause damage to piston.
3. Remove the carbon from ring grooves on pis-

ton.
4. Use tooling (B) to remove and install the piston

pin bearing (5). See SPECIAL INSTRUC-
TIONS, Form No. SMHS7295, for more in-
formation.
7-97
PISTONS
ASSEMBLE PISTONS 1214-16
Tools Needed A
5H9621 Piston Ring Expander
1. To find the correct piston to rod location, make

an alignment of the "V" on the piston to the
"V" on the block. Install the rod (3) on the
piston (2) with the part number on the radius
side (R) of the rod toward the radius of the
crankshaft journal.
836839Xl
2. Install pin (1) and two retainers (6). Each re-

tainer must fit in a groove on each end of pin
(l ).
3. Use ring expander (A) to install the piston

rings.
aUON'Xl
4. Install spring for oil control ring (bottom ring)

in the bottom ring groove of piston. Install oil
control ring (4) so the end gap of oil control ring
(4) is 180 0 from the ends of spring.
5. Install center ring (5) in center groove of piston

so the mark "UP" on ring is toward top of
piston. Install top ring in top groove of piston so
the mark "UP" on ring is toward top of piston.
6. Turn the piston rings in the grooves so the ring

gaps are 120 0 apart.
end by:
a) install piston
7-98
CYLINDER LINERS
REMOVE CYLINDER LINERS 1216-11
Tools Needed A
5P8665 Cylinder Liner Puller
start by:
a) remove pistons
1. Put a piece of gasket material or a cover over

crankshaft journals as a protection before
liner is removed.
2. Put tooling (A) in the cylinder liner.
CAUTION
Do not cause damage to piston cooling tube (1)
when tooling (A) is installed.
3. Use tooling (A) to remove the liner from its

seat in cylinder block.
4. Remove cylinder liner (2) from its bore in

cylinder block.
5. Remove filler band (3) and seals (4) from the

liner.
7-99
CYLINDER LINERS
INSTALL CYLINDER LINERS 1216-12
Tools Needed A 8 C
1P2398 Puller Plate
1 P5510 Liner Proiection Tool Group
2P8260 Cylinder Liner Installer
I. Clean the cylinder liners and block. Install

the liners in the block without the O-ring
seals.
2. Install tooling (A) on the liner. Tighten the

nuts that hold tooling (A) evenly to a torque
of 50 lb. ft. (70 N.m).
3. Check the liner projection with tool group (B) at

four locations around the liner. The difference
between the four measurements must not be more
than .002 in. (0.05 mm). The liner projection
must be .004 to .008 in. (0.10 to 0.20 mm). The
measurement between liners next to each other,
must not be more than .002 in. (O.OS mm)
difference.
NOTE: The liner projection can change if the liner

is turned in the bore.
4. Put a mark on the liner and block so the liner

can be installed in the same position from
which it was removed.
5. Install new seals (2) on the cylinder liners.

Put liquid soap on the seals and in the bores
in the cylinder block.
6. Put SAE 30 oil on filler band (I) and install it

on the liner. Install the liner immediately in
the cylinder block with tooling (C).
end by:
a) install pistons
7-100
TURBOCHARGER LUBRICATION VALVE

REMOVE TURBOCHARGER LUBRICATION
VALVE 1309-11
I. Disconnect oil lines (I) and (2) from top of

turbocharger lubrication valve.
2. Loosen other ends and clips of upper oil

lines enough to move upper lines from
valve.
3. Disconnect the other three oil lines (5) from

valves.
4. Remove four nuts (3) that hold valve (4) to

channel. Remove the turbocharger lubrica-
tion valve.
INSTALL TURBOCHARGER LUBRICATION

VALVE 1309-12
1. Install turbocharger lubrication valve (I) to

channel with four bolts (2) and nuts.
2. Connect five oi1lines to valve.
3. Tighten all connectors and clips.
7-101
TURBOCHARGER LUBRICATION VALVE

DISASSEMBLE TURBOCHARGER
LUBRICATION VALVE 1309-15
start by:
a) remove turbocharger lubrication
valve
I. Remove the bolts and cover (3).
2. Remove the body (2) and adapter (I). Re-

move the plunger and sp~ing from body. 132:S8x:l
ASSEMBLE TURBOCHARGER
LUBRICATION VALVE 1309-16
I. Clean all parts before assembling valve.
2. Install spring (2) and plunger (I) in body

(3).
3. Install adapter, cover and bolts.

end by:
73261Xl
a) install turbocharger lubrication valve
7-102
AIR CLEANERS
REMOVE AND INSTALL
AIR CLEANERS 1051-10
1. Loosen clamp (2) that fastens the turbocharger
air inlet hose to the air cleaner housing (3).
2. Remove bolt (1) that fastens the brace to the

air cleaner housing.
3. Remove two bolts (4) from each side of the air

cleaner housing. Remove the air cleaner hous-
ing. The weight of the air cleaner housing as-
sembly is 43 lb. (20 kg).
4. Put the air cleaner housing assembly in position

on the engine. Install two bolts (4) on each side
of the air cleaner housing.
5. Install bolt (1) that fastens the brace to the air

cleaner housing.
6. Install the turbocharger air inlet hose on the air

cleaner housing and tighten the clamp that fas-
tens the hose to the air cleaner housing.
103
MAGNETO
REMOVE MAGNETO 1413-11
1. Disconnect plug (1) from magneto.
2. Remove two bolts (3) that hold magneto to

drive housing.
3. Remove magneto (2) and gasket.
INSTALL MAGNETO 1413-12

I. See TIMING OF MAGNETO TO ENGINE
in TESTING AND ADJUSTING. See Form
No. REG01305.
2. Put magneto (1) and gasket in position on drive

housing.
,
3. Install two bolts (3).
4. Connect plug (2) on magneto.
104
MAGNETO (COIL AND MECHANICAL DRIVE)

DISASSEMBLE MAGNETO 1413-15
Tools Needed A B c
1P51 0 Driver Group
1P 1855 Pliers
1P 1857 Pliers
start by:
a) remove magneto
NOTE: Caterpillar does not have service parts for
the early SCS magnetos because there are not very
many early SCS magnetos in the field. Make contact
with Fairbanks Morse Company if parts for the ear-
lier magneto are needed. Caterpillar has service
parts for the Air-Gap SCS magnetos.
I. Remove four screws (I) from magneto cover
and remove cover (2).
2. Put a screwdriver between the heat sink section
(5) and the pulser coil housing. Pull the screw-
driver to remove the heatsink (5) and end cap
section (6).
3. Remove four screws (3) from plate (4). Re-
move plate. 833735Xl
CAUTION
Use care when nut (7) is removed. Do not use
the drive coupling to keep the pulser shaft sta-
tionary. Damage to the fiber gear can be the
result. Use a soft cloth and a pliers to hold
pulser arm (8).
4. Remove nut (7) and washer which fasten the
pulser to the shaft. Remove pulser arm (8).
5. Remove magnet (9) and plate (10) from shaft.
6. Remove two screws ( 12) from the center of the
pulser coil. Remove pulser coil ( 11 ) from hous-
633736Xl
mg. :A
7-105

7. Put identification on wires (13) and remove
from heatsink. Remove pulser coil (II) from
assembly.
8. Remove four screws (14) which hold pulser coil

housing (15) to the drive end of the magneto.
Remove housing (15).
9. Remove nut (16), washer and coupling (17)

from drive shaft. Remove key.
10. Remove seal (18) from housing.
11. Remove snap ring (19) from housing with tool

(B).
7-106

12. Remove three screws (21) that hold support
assembly (20) to housing.
CAUTION
Use a support for components when removed
with a press to prevent damage.
13. Install coupling nut on shaft and with a press

remove support and magnetic rotor assemblies
from housing.
14. Use a press and tool (A). Remove magnetic

rotor (22) from support assembly (20).
15. Use a press to push gear assembly (23) from

bearing. Remove nut (16) and gear assembly.
16. Remove snap rings (24) from support assembly

with tool (C).
833748Xl
7-107

17. Remove bearings (25) from support assembly
with a press and tool (A).
18. Remove two screws (26) and wedges from

housing. Remove coil assembly (27).
19. Remove snap ring (28) from housing with tool

(C).
20. Remove bearing from housing with tooling

(A).
7-108

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7-109

ASSEMBLE MAGNETO 1413-16
Tools Needed A B c
lP510 Driver Group
lP1855 Pliers
lP1857 Pliers
NOTE: Inspect all gaskets and make replacements if

torn or damaged.
I. Install two bearings (2) in support assembly

with a press and tool (A). Install snap rings (1)
with tool (C).
2. Install gear assembly (3) in bearing support (4)

with a press and tool (A).
3. Put the mark (drilled hole) on gear of magnetic

rotor (5) in alignment with the mark (arrow)
on gear (3).
4. Put nut (6) on the magnetic rotor and install

rotor (5) in bearing support with press.
5. Install bearing in housing (7) with a press and

tool (A). Install snap ring in housing with tool
(C).
7-110

Ie 6. Install coil assembly (8) in housing.
7. Put two wedges (9) in position in the housing.

I
Install the two screws to fasten the wedges to
the housing.
I
I
8. Install drive assembly (10) in the housing. In-
stall the three screws in the bearing support.
I
NOTE: Be sure the drive assembly is in the center of

the housing when screws are tightened.
9. Install snap ring (11) on shaft with tool (B).
10. Install seal (12) in housing. Install key ( 13) on

the shaft.
11. Install drive coupling (14) on the magneto

drive shaft. Install nut (6) that fastens the drive
coupling to the shaft.
7-111

12. Put pulser coil housing (15) in position on the
end of the drive end of the magneto. Install four
screws.
13. Put four wires (16) from pulser coil in correct

position on heatsink. Install pulser coil (17) in
the pulser coil housing.
14. Install plate (18) and magnet (19) on shaft.

The side of the magnet with the identification
mark must make contact with the'pulser rotor.
15. Install pulser rotor (20) to the shaft. (For mag-

netos that operate in the clockwise direction,
the mark "e" on the rotor must be toward the
outside, the mark" A" is for counterclockwise
magnetos). Install the nut that holds the pulser
to the shaft. Tighten nut to a torque of 12 ± 1
Ib.ft. (17 ± 1 N·m). Use a soft cloth and pliers
to hold pulser arm.
16. Install plate (21) in the pulser coil housing.

Install four screws that fasten the plate to the
pulser coil housing.
7-112
MAGNETO (COIL AND MECHANICAL DRIVE),

DISTRIBUTION BOARD
17. Put heatsink section (22) and end cap section
(23) in position on the end of pulser coil housing
(15) and install four screws to hold sections in
place.
18. Test the magneto as shown in Special Instruc-
tion Form No. GEG02059 to be sure all prob-
lems have been corrected.
end by:
a) install magneto
REMOVE AND INSTALL DISTRIBUTION
BOARD
start by:
a) remove magneto
I. Remove four screws (I) from magneto cover
(2). Remove cover (2).
2. Put identification on all wires and remove from
terminals (6) and (4).
3. Remove four screws (3) and remove the power
board (5).
4. Install the new power board (5) and connect all
of the wires as shown in the wiring diagram.
5. Put cover (2) in position and install four screws
(I) in cover.
6. Test the magneto as shown in Special Instruc-
tions Form No. GEG02059 to be sure all prob-
lems have been corrected.
end by:
a) install magneto
B36836Xl
7-113
MAGNETO POWER BOARD, POWER RESISTOR AND ZENER DIODE

REMOVE AND INSTALL POWER BOARD
start by:
a) remove magneto
I. Remove four screws from the magneto cover.
Remove the cover.
2. Put a screwdriver between heatsink section (2)
and pulser coil housing (I). Pull the screw-
driver to remove the heatsink (2) and the end
cap section.
3. Put identification on all wires and remove from
terminal (3).
4. Remove four screws (5) and power board (4)
from heatsink.
5. Install a new power board and connect all
wires.
6. Install magneto cover.
7. To check magneto for problems see Special
Instructions Form No. GEG02059.
end by:
a) install cover
POWER RESISTOR AND ZENER DIODE

start by:
a) remove magneto
1. Remove the magneto cover.
2. Put a screwdriver between the heatsink section
and the pulser coil housing. Pull the screw-
driver to remove the heatsink and the end cap
section.
3. Remove two wires (2) and two screws from
power resistor. Remove resistor (l).
4. Remove wire (3) from zener diode with the use
of a soldering gun. Remove nut (5) and zener
diode (4) from heatsink.
5. Install the zener diode in the heatsink. Connect
the rod lead to the zener terminal with solder.
6. Install power resistor (I) to the heatsink. Con-
nect two wires (2) to the heatsink terminals.
7. Install magneto cover.
8. To check magneto for problems see Special
Instructions Form No. GEG02059.
end by:
a) install magneto
7-114
--------------------------- - - -
GAS PRESSURE REGULATOR

REMOVE GAS PRESSURE
REGULATOR 1270-11
NOTE: Left hand gas pressure regulator shown.
I. Turn off gas supply valve.
2. Disconnect tube assembly (I) from regulator

fitting.
3. Remove two bolts (2) and elbow from regula-

tor.
4. Remove four bolts (3) and gas pressure regula-

tor (4) from engine.
INSTALL GAS PRESSURE

REGULATOR 1270-12
I. Put regulator (I) in position on bracket and
install four bolts.
2. Inspect a-ring seal (3) and make a replace-

ment if necessary.
3. Put elbow (4) in position and install two bolts.
4. Install tube assembly (2) to elbow fitting.
5. Turn on gas supply.
7-115

DISASSEMBLE GAS PRESSURE
REGULATOR 1270-15
start by:
a) remove gas pressure regulator
824266Xl
I. Remove eight bolts (I) and regulator cover (2).
2. Remove upper spring seat (6), spring (5) and

lower spring seat (4).
B24265Xl
3. Remove diaphragm assembly (3).
4. Remove bolt (12) and pusher post (7). Remove

head gasket (8), heads (9) and (11) from dia-
phragm (10).
8Z4264Xl
5. Remove pin (14) and lever (13).
6. Remove valve stem assembly (15).
7- 116
---------------------------- --_. - -

e 7. Remove three screws (16) and orifice (17).
8. Remove stem (18), spring (21), lower flapper

(19), upper flapper (22) and spring (20).
e
B24761XI
7-117

ASSEMBLE GAS PRESSURE
P
REGULATOR 1270-16
I. Install spring (3), upper flapper (5), lower flap-
per (2), spring (4) and stem (1) in position in
the regulator housing. 1 ep
2. Put orifice (6) III position and install three
screws. 624261>:2
3. Put valve stem assembly (8) in regulator hous-

ing. Put lever (9) in position and install pin (7).
4. Put together the diaphragm assembly in the

sequence as follows: pusher post (10), head
gasket (15), head (11), diaphragm (12), head
(13) and screw (14).
5. Install lower spring seat (19), spring (17) and

upper spring seat in position on the diaphragm
assembly.
6. Make an alignment of the diaphragm assembly

with the regulator body (18) and the regulator
cover (16). Install bolts.
®
j \
824257Xl
1 8242S8Xl
7-118
CARBURETOR
REMOVE CARBURETOR (RIGHT HAND
SHOWN) 1266-11
I. Shut off gas supply line to gas pressure regula-
tor.
2. Loosen two hose clamps ( I ) and slide hose off

carburetor. Disconnect tube (2) from fitting.
• B24441Xt
3. Remove two clamps (3).
4. Remove nut and disconnect rod (4) from throt-

tle lever assembly. Remove four bolts (5) that
hold carburetor to intake manifold.
5. Remove carburetor (6) from manifold. Re-

move gasket (7).
7-119
CARBURETOR
INSTALL CARBURETOR 1266-12
1. Put a new gasket (2) and carburetor (I) in
position on the intake manifold.
2. Put coupling (5) in position between nipple (4)

and pipe. Install clamps (6).
3. Connect rod (3) to the throttle lever assembly.
4. Connect tube (7) to carburetor fitting.
7-120
CARBURETOR
DISASSEMBLE CARBURETOR 1266-15
start by:
a) remove carburetor
I. Put carburetor in vise for disassembly.
2. Put identification on elbow (2), nipple and car-

buretor (I) for assembly purposes.
3. Remove carburetor (I) from nipple.
4. Remove five screws (4) and cover (3) from

carburetor body.
824453X1
5. Remove spring (5) and diaphragm assembly

(6) from carburetor body.
6. Remove four screws from diaphragm assem-

bly. Remove body (7), gasket (8), diaphragm
(9) and plate (10).
7. Remove two screws (II) and throttle plate

(12). B24454xt
1- 624457Xl 8244$6X1
7-121
CARBURETOR
8. Remove throttle lever (13), lever stop and shaft
as a unit.
9. Remove retaining rings (14) and seals (15)

from each side of throttle housing.
10. Remove bearing (17) from each side of throttle

housing.
1 I. Remove idle mixture screw (18) and spring B24458Xl
( 16) from housing.
ASSEMBLE CARBURETOR 1266-16
Tools Needed A
lP510 Driver Group
1. Install bearing (1) with tooling (A) to the bot-

tom of the bearing bore in the throttle housing.
2. Put seal (2) in position in the seal and retainer

counterbore.
3. Install retainer (3) with tooling (A).
4. Turn throttle housing over and do Steps 1

through 3.
5. Install spring (5) and idle screw (4). Turn the

idle screw four full turns open from the closed
position.
d24461Xl
7-122
CARBURETOR
Ie CAUTION
Be careful when the throttle shalt is installed
not to cause damage to the seals.
I
6. Install throttle lever (6), lever stop and shaft. ~

I
7. Put throttle plate (7) in position on the throttle
shaft. Install the screws that hold the throttle
1
plate in position finger tight.
I
8. Turn the throttle plate with throttle lever (6)

I
from the fully closed to fully open position to
make an alignment of the throttle plate in the
center ofthe bore. Tighten the screws and make
I
sure that the throttle lever turns freely.
9. Install the diaphragm assembly together in the

I following sequence: body (8), gasket (9), dia-
phragm (10) and cover (II). Install four
screws.
10. Put diaphragm assembly (12) in position on

carburetor body. Install spring (13) on dia-
e
I
phragm assembly. fJ.24465Xl
II. Turn power mixture adjustment ( 14) to center

position between "R" (rich) and "L" (lean).
12. Put cover (15) in position on carburetor body

and install the five screws to hold cover in posi-
tion.
13. Install carburetor assembly (16) in position on

nipple. Make an alignment of the marks on the
elbow nipple and carburetor assembly.
end by:
a) install carburetor
824467Xl
7-123
TURBOCHARGER REGULATOR ASSEMBLY

REMOVE TURBOCHARGER REGULATOR
ASSEMBLY 1052-11
NOTE: Left hand turbocharger regulator assembly
removal is shown.
I. Disconnect tube assembly (1) from regulator

assembly.
2. Remove four nuts (2) and regulator assembly

(3) from turbocharger.
3. Remove shield (4) from turbocharger.
4. Remove gasket (5) from turbocharger.
INSTALL TURBOCHARGER REGULATOR

ASSEMBLY 1052-12
I. Put gasket (2) and shield (l) in position on
turbocharger.
2. Put regulator assembly (3) in position and in-

stall four nuts. Connect tube assembly (4) to
regulator.
7-124
TURBOCHARGER REGULATOR ASSEMBLY

DISASSEMBLE AND ASSEMBLE
TURBOCHARGER REGULATOR
ASSEMBLY 1076-10
start by:
a) remove turbocharger regulator assembly
1. Remove breather assembly (I) from cover.
NOTE: Put identification on the two bolts used to
fasten identification plate (3) for installation pur-
poses. B27415Xl
2. Remove plate and five bolts (2) from assembly.

3. Remove cover (4), shims (5), spacers (6) and
spring (7) from base assembly.
4. Remove nut (8) to disassemble base assembly.
5. Remove retainer (12), diaphragm (II), plate
(10), washer (15) and valve (13) from base
(14 ).
6. Inspect gasket (9) on the base and make a

replacement if damaged.
827413Xl
7. Put valve (13) in position in base and install
washer (15), plate (10), diaphragm (II), re-
tainer ( 12) and nut (8). Tighten nut to a torque
of 55 ± 5 lb.in. (6.3 ± 2.3 N·m).
8. Put spring (7), spacers (6), shims (5) and cover
(4) in position on the base assembly and install
five bolts in their correct location. Tighten bolts
to a torque of 55 ± 5 lb.in. (6.3 ± 2.3 N·m).
9. Install identification plate (3).
10. Install breather assembly (I).
end by:
827412X1
a) install turbocharger regulator assembly
B27411Xl
B27410Xl
7-125
TURBOCHARGER
REMOVE AND INSTALL
TURBOCHARGER 1052-10 " fit-"
5P9736
Tools Needed
Bracket-Link
A
t .)fI
start by:
a) remove air cleaner r9~~ f J'~f·· r.
1. Disconnect tube assembly (1) from regulator J--L-(D 824451Xl

and tube assembly (2) from cartridge housing.
2. Remove clamp (3) and gasket from elbow and

aftercooler housing.
3. Bend tab on lock and remove two bolts (4) that

fasten oil supply line (5) to cartridge housing.
Remove bolt (7) and clip from bracket. Discon-
nect coupling on opposite end of tube assembly
so tube can be turned for turbocharger remov-
al.
4. Remove two bolts from the turbocharger drain

tube (6). Remove supply and drain line gaskets.
5. Install a hoist and tool (A) on turbocharger.

Remove four bolts (9) and gasket from elbow.
Remove turbocharger (8).
6. Put a new gasket (10) and turbocharger in

position on the engine and install gasket and
clamp (3).
7. Put 5P393I Anti-Seize Compound on the

threads of four bolts (9). Install the bolts (9)
and tighten to a torque of 40 ± 4Ib.ft. (55 ± 5
N·m).
8. Remove hoist and tool (A) and install new gas-

kets and the turbocharger supply (5) and drain
(6) line. Install clip and bolt (7) on bracket.
9. Install tube assemblies (1) and (2) respectively

to the regulator and cartridge housing.
end by:
a) install air cleaner
7-126
TURBOCHARGER (SCHWITZER 4MD455)

Ie DISASSEMBLE TURBOCHARGER 1052-15
I
Tools Needed ABC D E F
I 9S6363 Turbocharger
Fixture Group
I
9S6343 Fixture Assembly
5S9566 T-Wrench
1P1862 Pliers
1P1853 Pliers
1P1860 Pliers
B24403Xl
start by:
a) remove turbocharger
I. Put the turbocharger in position on tool (A).
2. Remove hose (I) and elbow (2) from compres-

sor housing.
3. Remove four nuts (5), regulator assembly (4),

shield (3) and gasket from turbine housing.
4. Put identification on compressor housing (6),

cartridge assembly (7) and turbine housing (8)
for installation purposes.
5. Remove "V" clamp (9) and compressor hous- .,c.----CD

ing (6) from cartridge assembly (7).
6. Remove "V" clamp (10) and cartridge assem-

bly (7) from turbine housing (8).
7. Remove nozzle (II) from turbine housing.
--CD
Ie
I
824407Xl
7-127

CAUTION
When the nut is loosened, do not put a side
force on the shaft.
8. Put cartridge assembly (7) in tool (B). Loosen

nut on compressor wheel (12) with tool (C).
9. Remove compressor wheel (12) from wheel and

-
shaft assembly with press. Remove nut and
wheel and shaft assembly.
10. Remove two rings (14) from wheel and shaft

assembly (13).
II. Remove shims (15) and snap ring (17) with

tool (D). Remove insert (16) from housing.
12. Remove sleeve (18) from insert (16).
B24413Xl 824411>'1
7-128
------------ - --- - -

\3. Remove two seal rings (19) from sleeve (18).
\4. Bend tab on three locks and remove bolts (20).
B24414Xl
\5. Remove deflector (22) and ring (2\) from

housing.
\6. Remove spacer (24) and bearing (23) from

housing.
824415X1
\7. Remove ring (26) and spacer (25).
\8. Remove bearing (27) from housing.
B24418Xl B24417Xl
7-\29

19. Remove snap rings (28) with tool (E).
8244\9Xl
20. Remove bearing (31 ), sleeve (30) and snap ring

(29) with tool (E) from cartridge housing.
824423Xl
21. Remove seal (32) from cartridge housing if

damaged or worn.
22. Remove snap ring (34) with tool (F). Remove 824422Xl
plate (33) from housing.
7-130
7-131

ASSEMBLE TURBOCHARGER 1052-16
Tools Needed ABC D E F

1P1860 Pliers
1P1853 Pliers
986343 Fixture Assembly
1P1862 Pliers
882328 Dial Test Indicator
Group
986363 Turbocharger
Fixture Group 824446Xl
I. Make sure all oil passages are open and clean.

Put clean engine oil on all parts before assem-
bly.
2. Put plate (I) in position on cartridge housing

and install snap ring with tool (A) to hold plate
to housing.
3. Install seal (2) in cartridge housing.
4. Install snap ring in housing with tool (B). In-

stall sleeve (3) and bearing (4) in housing. In-
stall additional snap ring with tool (B).
5. Put wheel and shaft assembly (5) in tool (C).
6. Put 6V2055 High Vacuum Grease in groove

for seal rings (6). Make sure the grease fills the
groove approximately one half or more of the
groove depth for the complete circumference of
the groove to help make a carbon dam under
the seal ring. Install two rings (6) on the wheel
and shaft assembly.
7. Before cartridge installation install snap ring in

housing with tool (B). Install cartridge housing
(7) on wheel and shaft assembly. B24445Xl
B24442Xl B2444JXl
7-132

8. Install bearing (8) on shaft.
9. Install spacer (9) and ring (10) on shaft.
10. Install bearing (II) and spacer (12) on top of

nng.
B24439Xl
II. Put ring and deflector ( 13) in place and install

three locks and bolts (14). Tighten bolts to a
torque of 60 lb. in. (6.7 N·m). Bend tabs on
locks.
12. Install two seal rings on sleeve (16). Install 824438Xl

sleeve in insert (IS).
824431Xl
7-133

13. Install insert (15) in the housing and install
snap ring (18) with tool (D). Install shims (17)
as needed to get .018 to .022 in. (0.457 to 0.559
mm) clearance between the housing and the
impeller.
14. Install compressor wheel (19) on shaft.
CAUTION
When nut is tightened, do not put a side force
on the shaft.
IS. Put clean engine oil on the threads of the shaft.

Install the nut (20) and tighten to a torque of 33
± 2 lb.ft. (45 ± 3 N·m).
16. Put the cartridge housing in a vise. Check the

shaft end play with tool (E). The end play must
be .004 to .006 in. (0.10 to 0.15 mm). Maxi-
mum end play with worn parts is .008 in. (0.203
mm).
17. Install turbine housing (22) on tooling (F). Put

nozzle (21) in position in turbine housing.
824430xt
7-134

18. Put cartridge assembly (23) in position in the
turbine housing (22). Make an alignment of the
mark put on at disassembly. Put 5P3931 Anti-
Seize Compound on the threads of the "V"
clamp. Install "V" clamp (24) and tighten the
bolt to a torque of 10 ± I Ib.ft. (14 ± I N·m).
BZ4421xt
19. Install compressor housing (25) on the car-

tridge assembly. Make an alignment of the
marks on the compressor housing and the car-
tridge. Install "V" clamp (26) and tighten the
bolt to a torque of 10 ± I lb.ft. (14 ± I N·m).
B24426Xl
20. Hit (tap) both "V" clamps completely around

and tighten again to a torque of 10 ± I Ib.ft.
(14 ± I N·m).
21. Put an application of 5P3931 Anti-Seize Com-

pound on bolt threads and in the regulator as-
sembly bore. Install gasket, shield (27) and
regulator assembly (28) in position in the tur-
bine housing.
22. Install elbow (30) and hose (29) on compressor

housing.
end by:
B24424Xl
a) install turbocharger
7-135
SPARK PLUGS
REMOVE SPARK PLUGS 1415-11
Tools Needed A
1P7424 Spark Plug Socket
I. Remove wire assemblies (I) from the spark

plugs and adapter.
2. Use tool (A) to remove spark plugs (2).
INSTALL SPARK PLUGS 1415-12
Tools Needed A
1P7424 Spark Plug Socket
I. Use tool (A) to install spark plugs (I). Tighten

the spark plugs to a torque of 26 ± 4 Ib.ft. (36
± 5 N·m).
2. Install the spark plug wire assemblies (2).

Make sure the cover makes a good connection
with the spark plug.
7-136
SPARK PLUG ADAPTERS

REMOVE AND INSTALL SPARK PLUG
ADAPTERS 1114-10
Tools Needed A
857227 Wrench
start by:
a) remove spark plugs
I. Drain the coolant from the cooling system to a

level below the cylinder head.
2. Use tool (A) to remove spark plug adapters (2).
3. Remove adapter gasket (I) from the cylinder

head.
4. Install a new seal (3) and gasket (I) on each of

the spark plug adapters. Put liquid soap on the
seal and in the bore of the cylinder head. Put
5P3931 Anti- Seize Compound on the threads
of the spark plug adapters.
5. Install the spark plug adapters in the cylinder

head. Use tool (A) to tighten the adapters to a
torque of 150 ± 10 lb. ft. (205 ± 14 N·m).
6. Fill the cooling system with coolant to the cor-

rect level.
end by:
a) install spark plugs
7-137
AFTERCOOLER HOUSING
REMOVE AFTERCOOLER HOUSING 1063-11
start by:
a) remove air cleaners
I. Remove the coolant from the engine. Discon-
nect regulator tube assembly (2) from fitting.
2. Loosen clamps (3) on tube assembly (I) and
elbow. Remove tube assembly (I) and gasket
from aftercooler and carburetor.
3. Disconnect tube assembly (5) from fitting.
Loosen clamp (4) and remove tube (6) and
gasket from aftercooler and carburetor.
4. Loosen clamp (7) on aftercooler elbow.

5. Remove four bolts (8) and make a separation of
the auxiliary water pump elbow and after-
cooler. Remove ten bolts (9) that fasten the
aftercooler to the flywheel housing.
6. Disconnect tube assembly (12) from the turbo-
charger lubrication valve.
7. Remove elbow (10) from turbocharger.
8. Remove four bolts (II) to remove the turbo-
charger lubrication valve from the channel.
9. Remove bolt and brackets (16) from after-
cooler housing. Disconnect and remove tube
assemblies (14) and (17) from regulator assem-
blies.
10. Disconnect tube (15) from turbocharger car-
tridge housing.
II. Bend tabs on lock and remove two bolts (13)
from the turbocharger supply line.
7-138
AFTERCOOLER HOUSING
12. Disconnect turbocharger cartridge housing
tubes (20) from cover. Remove four bolts (18)
that are used to fasten turbocharger pipe to
support.
13. Remove six bolts (21) that are used to fasten

the support assembly in position. Remove sup-
port assembly (19).
NOTE: The cover is removed for access to bolts that

fasten the aftercooler to the flywheel housing.
14. Remove four bolts (22) from the cover. Re-

move cover (23).
15. Remove bolt (24) and clip from channel. Re-

move tube assembly (I2).
16. Fasten nylon straps and hoist to aftercooler

(25).
17. Remove six bolts (26) that fasten the after-

cooler to the flywheel housing.
18. Remove aftercooler from engine. Weight of

aftercooler is 236 lb. (I06 kg).
7-139
- - ---------------
AFTERCOOLER HOUSING
INSTALL AFTERCOOLER HOUSING 1064-12
1. Fasten nylon straps and a hoist and put after-
cooler housing (I) and gasket in position on
engine.
2. Install sixteen bolts (2) that hold the after-

cooler housing to the flywheel housing.
3. Put tube assembly (3) in position on channel

and install bolt through clamp.
4. Put gasket and cover (4) in place and install

four bolts.
5. Install six bolts to fasten support assembly (7)

in position.
6. Install four bolts to fasten pipe (5) to support.
7. Install two tube assemblies (6) from turbo-

charger cartridge housings to cover (4).
7·140
AFTERCOOLER HOUSING
8. Install tube assemblies (8) and (II) to the reg-
ulator assemblies. Install bolt to hold brackets
(10) in position on aftercooler housing. Put
gasket and oil supply line (9) in position on top
of turbocharger cartridge housing. Install lock
and two bolts in position.
9. Install turbocharger lubrication valve in posi-

tion on channel. Install four bolts (13) and nuts
to hold valve in position.
.__,,:\_E::
10. Install tube assembly (15) in position on the
turbocharger lubrication valve.
II. Inspect and make a replacement of seals on

pipe if damaged.
12. Put engine oil in turbocharger bore and install

elbow assembly (12) and gasket in position in
turbocharger and aftercooler housing. Install
clamp (14) to hold elbow to housing.
13. Install tube assembly and gasket (17) in posi-

tion on the aftercooler housing. Install clamp
(18). Install tube assembly (16) to elbow fit-
ting.
14. Put elbow (21) and tube assembly (20) in posi-

tion on the aftercooler housing and install gas-
kets and clamps (22) to hold them in position.
Install tube assembly (19) to elbow fitting.
15. Install a new gasket and the auxiliary water

I pump elbow (23) in position on the aftercooler
housing.
Ie end by:
a) install air cleaners
7-141
AFTERCOOLER CORES
REMOVE AFTERCOOLER CORES 1064-11
start by:
a) remove aftercooler housing
I. Remove bolts and channels (I) from after-

cooler housing. Remove bolts that hold pipe
and elbow to aftercooler housing. Remove pipe
(2) and elbow (3). Remove the bolts that hold
housing together.
2: Remove the top housing.

B24042Xl
3. Remove sleeves (4) from the cores.
4. Fasten a hoist to the cores and remove the cores

from bottom housing. Weight of each core is 75
lb. (34 kg).
INSTALL AFTERCOOLER CORES 1064-12

I. Fasten a hoist and put the cores (l) in position
in bottom housing.
2. Install the top housing.

3. Put clean engine oil in bores for sleeves. Install
sleeves in housings. Install bolts that hold hous-
ings together and tighten as follows:
a) Tighten three bolts in the center of the
housing.
b) Tighten the flange bolts at the front and
rear.
c) Tighten the flange bolts at the sides.
4. Install pipe (2) on top housing and elbow on

bottom housing.
5. Install channels (3) on aftercooler housing.

end by:
a) install aftercooler housing 63028X2
B24044Xl
7-142
ELECTRIC STARTING MOTORS

REMOVE ElECTRIC STARTING
MOTORS 1453-11
I. Disconnect wires from the starting motor

and the solenoid.
2. Put identification on wires and terminals for

installation.
3. Fasten a hoist to starter. Remove the three

bolts (I) that hold starter to the flywheel
housing. Remove the electric starter. Weight
is 80 lb. (36 kg).
INSTALL ELECTRIC STARTING
MOTORS 1453-12
I. Fasten a hoist and put the starting motor on

engine. Install the three bolts.
2. Connect the wires to starting motor and to

solenoid.
TYPICAL EXAMPLE
7-143
FLYWHEEL
REMOVE FLYWHEEL 1156-11
Tools Needed A
FT 1094 Lifting Bracket
1. Remove cover (1) from flywheel housing.
2. Remove pointer (2) from flywheel housing.
3. Remove two bolts (3) that hold the flywheel in

position on crankshaft. Install two 7/8"-14 NF
8 in. long bolts as a guide on G379 and G398.
On G 399 only use two 1"-14 NF x 10" long
bolts as a guide.
4. Install tool (A) on flywheel. Install a hoist and

an approved lifting bracket on tool (A). Re-
move the remainder of the bolts that hold the
flywheel to the crankshaft.
5. Remove the flywheel. For G379 and G398 the

weight of the flywheel is 450 lb. (203 kg). For
G399 only the weight of flywheel is 550 lb. (248
kg).
7-144
FLYWHEEL
INSTALL FLYWHEEL 1156-12
Tools Needed A
FT 1094 Lifting Bracket
I. For G379 and G398, install two 7/8"-14 NF x

8 in. long bolts (1) as a guide in the crankshaft.
On G399 only, Install two 1"-14 NF x 10 in.
long bolts as a guide.
2. Use a hoist, an approved lifting bracket and

tooling (A) to put the flywheel (l) in position
on crankshaft.
3. Install the bolts that hold flywheel to crank-

shaft. Tighten bolts on G379, G398 to a torque
of 450 ± 30 Ib.ft. (610 ± 40 N·m). On G399
only, tighten bolts to a torque of 670 ± 501b.ft.
(905 ± 70 N.m).
73922X2 ..
4. Remove tooling (A) from flywheel.
5. Install pointer (2) in flywheel housing. Install

cover (3) on flywheel housing.
7-145
FLVWHEEL HOUSING
REMOVE AND INSTALL
FLYWHEEL HOUSING 1157-10
Tools Needed A
start by:
a) remove aftercooler housing
b) remove flywheel
c) remove oil pressure relief valve
I. Remove three bolts (I) from tube flange. 827053Xl
2. Loosen bolts (2) that hold cylinder block to oil

pan base.
3. Remove rear crankshaft thrower and baffle ~.:~
(3). See CRANKSHAFT REAR SEAL
RING AND THROWER. ~
4. Fasten a hoist and lift engine enough to install
spacers (5) on each side of oil pan base. Ap-
proximate weight of G379 is 8,000 lb. (3600
kg); G398 is 10,000 lb. (4500 kg); G399 is
13,000 lb. (5850 kg).
5. Remove two bolts from flywheel housing. In-
stall two 5/8"-11 NC bolts 6" long as a guide.
6. Install tooling (A) on top of flywheel housing.
Remove bolts (4), support assembly and cover
from the top of flywheel housing.
7. Remove the remainder of the flywheel housing
bolts (6) and flywheel housing (7). Weight of
housing is 450 lb. (204 kg).
8. Put 7M7260 Liquid Gasket Material on top of
the housing surface that makes contact with
governor drive housing. Install bolts (4) to hold
cover and support assembly.
9. Install tool (A) and hoist on flywheel housing.
Put it in position on the cylinder block and
install bolts (6).
10. Install thrower. See CRANKSHAFT REAR
SEAL AND THROWER.
.~.*/:.:-
f~•. "
II. Fasten a hoist to engine. Lift the engine enough
to remove the spacers (5). Tighten bolts.
12. Install three bolts to install tube flange (I) to
flywheel housing.
end by:
a) install flywheel
b) install aftercooler housing
c) install oil pressure relief valve
7-146
CRANKSHAFT REAR SEAL RING AND THROWER

REMOVE CRANKSHAFT REAR SEAL RING
AND THROWER 1161-11
Tools Needed A
lP2321 Puller Assembly
FT884 Leg 3
8B7561 Slep Plale
start by:
a) remove flywheel
I. Remove twelve bolts (I) that hold baffle to

flywheel housing.
2. Remove baffle (2) from housing.
3. Remove the seal ring and spring from thrower.
4. Install tooling (A) on thrower. If necessary use

open flame at a maximum temperature of
400 0 F (204°C). Remove the thrower imme-
diately with tooling (A).
5. Remove the ring from flywheel housing.
INSTALL CRANKSHAFT REAR SEAL RING

AND THROWER 1161-12
Tools Needed A
FT105 Push Plale
T603 Boll 2
9H1031 Washer 2
1. Put 6V 1541 Quick Cure Primer and 9S3265

Retaining Compound on ring. Install the ring
in flywheel housing with holes at the bottom
and with chamfer toward inside of housing.
2. Heat the thrower (I) to a maximum tempera-

ture of 400 - 450°F (204 - 232°C). Install
thrower on crankshaft.
7-147
CRANKSHAFT REAR SEAL RING AND THROWER

3. Use tooling (A) to install thrower in correct
location on crankshaft.
CAUTION
Do not install a used oil thrower, seal ring or
spring.


with the word "OUT" on the seal ring installed
away from the crankshaft. Put the gap of seal
ring to top of crankshaft when installed.
6. Put clean engine oil on inside diameter of baffle

(3). Install the baffle (3) on the flywheel hous-
ing.
end by:
a) install flywheel
7-148
REAR TIMING GEARS

Ie REMOVE REAR TIMING GEARS 1206-0-11 -"
Tools Needed A 8
I
5P4170 Step Plate
8H684 Ratchet 80x Wrench
887559 Adapters 2
887550 Leg 2
T774 Spacer
821013)(1
start by:
a) remove flywheel housing
I. Be sure the No. I piston is at top center on the

compression stroke. See TIMING THE CAM-
SHAFT FOR THE FUEL INJECTION
PUMPS in TESTING AND ADJUSTING.
2. On G379 only, remove the seal ring (I) and

spring from thrower.
3. Install tooling (A) on thrower. If necessary use

open flame at a maximum temperature of
400 0 F (204°C). Remove the thrower (2) im-
mediately with tooling (A).
4. Bend the tabs on locks and remove bolts (3)

that hold the large camshaft gear to small cam-
shaft gear. Remove gear (4).
CAUTION
Do not turn the crankshaft with large camshaft
gear removed and the camshaft installed.
5. Remove bolts (6) and lock that hold the thrust

washer (5) to the camshaft.
7-149
REAR TIMING GEARS

6. Turn gear (8) for bolt access and remove bolts 1
and lock that hold washer assembly to the cyl-
inder block. Remove washer assembly (7).
4'-1-1-
-~ I y~-
~
7. Remove camshaft gear (8) from camshaft with

tooling (B).
B35591Xl
8. Remove bolts, lock and retainer that hold the
balancer gear on its shaft. Remove rear ba-
lancer gear (9). Remove bearing from balancer
gear.
9. Remove thrust washer (l 0) on the balancer

gear shaft.
7-150
REAR TIMING GEARS

INSTALL REAR TIMING GEARS 1206-0-12
Tools Needed A B
lP510 Driver Group 1
FT105 Push Plate
T603 Bolt 2
9Hl031 Washer 2
1. On G379 only, use tooling (A) to install the

bearing in balancer gear.
NOTE: Be sure No. I piston is at top center on the

compression stroke. See TIMING THE CAM-
SHAFT FOR THE FUEL INJECTION PUMPS
in TESTING AND ADJUSTING.
2. Install thrust washer (1) and balancer gear (2)

on shaft.
3. Install small camshaft gear (3), washer assem-

bly (4), lock and bolts. Install retainer. Tighten
bolts to a torque of 60 to 70 lb.ft. (80 to 95
N·m).
4. Put a mark with chalk on the camshaft gear at

the location of timing mark "C". Put a mark
with chalk on the tooth of crankshaft gear with
punch marks. The back of gears can be marked
so the marks can be seen with a mirror (5) after
installation.
7-151
REAR TIMING GEARS

5. Install large camshaft gear (6). Be sure the "c"
mark on gear is in alignment with punch mark
on crankshaft gear. On G379 only, move large
camshaft gear out enough to turn the balancer
gear until "A" marks are in alignment.
6. Put large camshaft gear in positIOn on the

dowel on small camshaft gear. Install locks and
bolts.
7. Heat thrower (7) to a maximum temperature

of 400 - 450 c F (204 - 232 C C). Install thrower
(7) on crankshaft.
8. Use tooling (B) to install thrower in correct

location on crankshaft.
CAUTION
Do not install a used oil thrower, seal ring or
spring.


with the word "OUT" on the seal ring installed
away from the crankshaft. Put the gap of seal
ring to top of crankshaft when installed.
end by:
a) install flywheel housing
7-152
VIBRATION DAMPER (G39S AND G399)

REMOVE VIBRATION DAMPER
(G398 & G399) 1205-11
1. On G 398, remove bolts (J). Put an identifica-
tion mark on bolts (3) and (4) and housing.
Remove cover (2).
2. On G399, remove bolts that hold the cover.

Remove the cover.
-•••••
3. On G398, remove the bolts that hold vibration
damper. Install two 5P9736 Bracket-Links on
the vibration damper. Fasten a hoist.
4. On G399, remove the bolts that hold vibration

damper. Install two bolts (6) as a guide. Move
the vibration damper out on the guide bolts
with forcing screws (5). Fasten a hoist and
remove vibration damper. Weight of G399
damper is 270 lb. ( 122 kg) and the G 398 is 130
lb. (59 kg).
CAUTION
Do not hit the vibration damper.
INSTALL VIBRATION DAMPER

(G398 & G399) 1205-12
1. Install two bolts as guide. Fasten a hoist to the
vibration damper. Put the damper in position
on the adapter.
2. Put 983263 Thread Lock on the threads of

bolts for vibration damper. Put thread lock on
the two bolts with a mark for cover on the
G398.
3. Install the bolts and remove guide bolts.

Tighten I in. bolts (I) to 670 ± 50 Ib.ft. (905 ±
70 N·m) on G399. Tighten bolts (1) on G398 to
280 ± 20 Ib.ft. (377 ± 25 N·m).
4. Install cover (2) on G399. Install cover on

G398 with bolts that have a mark in respective
place on housing.
7-153
CAMSHAFT
REMOVE CAMSHAFT 1210-11
Tools Needed A B
FT751 Camshaft Alignment Tool
BB754B Puller Assembly 1
8B7550 Leg 2
8F3672 Puller Plate 1
7F9540 Hydraulic Puller 1
4B4280 Washer 2
L1329 Bolt 2
start by:
a) remove fuel injection pump housing, shut-
off control, governor and governor drive as
a unit
b) remove flywheel housing
c) remove vibration damper (G399 only)
1. Loosen the adjustment screws for valves to

get maximum clearance.
2. Remove the push rods.
3. Disconnect the oil lines (I) from lifter

brackets (3).
4. Use a magnet and pull the lifters (2) up

enough to put rubber bands or wire on
them. This will hold lifters away from cam-
shaft.
5. Remove housing for vibration damper, if so

equipped. Remove power takeoff, if so
equipped.
6. Remove the service meter and tachometer

drive from front of engine. Install the align-
ment tool (A).
7. Remove the large camshaft gear (4). Remove

the bolts and locks that hold thrust washer
(5).
8. If small camshaft gear (6) is to be removed,

bend the lock and remove the two bolts and
plate from the end of the camshaft.
7-154
CAMSHAFT
9. Use tools (B) to remove the small camshaft
gear (6) from the camshaft.
10. Remove the camshaft. Weight of the cam-

shaft is approximately:
G379 Engine 60 lb. (27 kg)
G398 Engine 85 lb. (39 kg)
G 399 Engine 100 lb. (45 kg)
TOOLS (B) FOR REMOVING

SMALL CAMSHAFT GEAR
INSTALL CAMSHAFT 1210-12

Tools Needed A
FT751 Camshaft Alignment Tool
I. Put the key and small camshaft gear on the

camshaft. Put clean engine oil on camshaft.
NOTE: On SAE standard rotation engines,
(counterclockwise as viewed from flywheel end) in-
stall the small camshaft gear on the end opposite
the F-mark on camshaft. For SAE opposite rota-
tion engines (clockwise as viewed from flywheel
end) install this gear on end with the F-mark.
2. Install the plate, lock, and bolts that hold
small gear on camshaft. Tighten bolts to 60
to 70 lb. ft. (80 to 95 Nom). Instal! alignment
tool (A) on end of camshaft. Instal! camshaft
m engme.
3. Install the thrust washer, locks, and bolts

that hold small camshaft gear in cylinder
block.
NOTE: Be sure the crankshaft is in position with
No. I piston at top center on compression stroke.
4. Put a mark with chalk on "C" mark of gear (2)
and tooth of crankshaft gear with punch marks.
Put a mark on back of gears so they can be
checked with a mirror after installation. Put
the large gear ( I) on small camshaft gear. Be
sure "c" mark and punch mark of crankshaft
gear are in alignment. On G 379 move gear (I)
out enough to turn balancer gear to make "A"
marks in alignment.
7-155
CAMSHAFT
5. Remove the alignment tool (A) from front
of camshaft. Install the service meter and
tachometer drive. Install housing for vibra-
tion damper or power takeoff if so
equipped.
6. Remove rubber bands or wires from lifters.

Install the push rods (4). Connect the oil
lines (3) for rocker shaft assem blies.
7. Make adjustment of valve clearance. The

cold clearance must be: intake .015 in. (0.38
mm) and exhaust .035 in. (0.89 mm). See
VAL VE CLEARANCE ADJUSTMENT in
TESTING AND ADJUSTING.
end by:
a) install flywheel housing
b) install fuel injection pump housing, shutoff
control, governor and governor drive as a
unit
c) install vibration damper (G 399 only)
7-156
CAMSHAFT BEARINGS
Ie REMOVE CAMSHAFT BEARINGS 1230-11
Tools Needed A
852241 Camshaft Bearing 'nstallat;on

and Removal Group
8H684 Ratchet Wrench
5P1666 Puller Plate

5P1667 Spacer
858292 Extension
start by:
a) remove camshaft 71GQI :<::1
b) remove valve lifters
I. Remove the camshaft bearings with tooling

(A). Use the extensions as needed.
INSTALL CAMSHAFT BEARINGS 1230-12

Tools Needed A
852241 Camshaft Bearing Installation

and Removal Group
8H684 Ratchet Wrench
5P1666 Puller Plate
5P1667 Spacer
858292 Extension
I. Put the bearings in the cylinder block with

tooling (A). Put clean engine oil on
bearings.
NOTE: Be sure the oil holes (I) in the bearings are

in alignment with oil holes in cylinder block.
end by:
a) install camshaft
b) install valve lifters
7-157
CRANKSHAFT
REMOVE CRANKSHAFT 1202·11
start by:
a) remove rear timing gears
b) remove accessory drive gears and plate
c) remove intake manifold
d) remove gas pressure regulator
I. Remove bolts (2) that hold the oil pan base to
the cylinder block. Remove the inspection
•~•
covers from the side of the block.
2. Loosen connecting rod bolts (I) from the side B2743@Xl
opposite the way the block will be turned. This
will permit easier removal of bolts after block is
turned in the horizontal position.
3. Install a hoist to the engine lifting eyes. Put two
nylon straps (3) through block and install a 1
Ih" steel bar (4). The bar must be as long as the
cylinder block. With the engine off the floor,
lift the lift truck and lower the hoist until en-
gine is in position as shown. Install wooden
blocks.
CAUTION
Use care not to hit the floor while the engine is
turned.
4. Install a I" -14 NF bolt (6) in each end of
crankshaft. Install a hoist and straps on bolts.
5. Remove rod caps and fasten rods in position
with bolts and wire.
6. Remove main bearing caps (5) and bearings.
Install rubber hose (7) on studs to prevent ma-
chined surface damage.
7. Lower the crankshaft with hoist. Weight of
crankshaft for G379 is 650 lb. (293 kg); G398
is 890 lb. (406 kg); G399 is 1100 lb. (495 kg).
7-158
CRANKSHAFT
INSTALL CRANKSHAFT 1202-12
Tools Needed A B
Plastigage
882328 Dial Test Indicator Group
1. Fasten hoists and put crankshaft (I) in position

in the cylinder block.
2. Install new upper halves (with oil holes) of
main bearings in cylinder block. Put clean en-
gine oil on all bearings.
3. Lift the crankshaft into position in the cylinder
block. Remove hose (2) from threads of studs.
NOTE: When the bearing clearance is checked and
the engine is in a vertical position, such as in the
vehicle, the crankshaft will have to be lifted up and
held against the upper halves of the main bearings to
get a correct measurement with Plastigage (A). The
Plastigage will not hold the weight of the crankshaft
and give a correct indication. If the engine is in a
horizontal position, such as on an engine stand, it is
not necessary to hold the crankshaft up. Do not turn
crankshaft when Plastigage is in position to check
clearance.
4. Put new bearings (3) in main bearing caps. Use
Plastigage to check bearing clearance. Install
caps and tighten both nuts to a torque of 200 ±
10 lb.ft. (270 ± 14 N·m). Put a mark on the
nuts and end of studs. Tighten nuts an extra
120 0 from the mark. Remove caps and check
thickness of Plastigage to find bearing clear-
ance. Bearing clearance must be .0048 to .0090
in. (0.122 to 0.229 mm) for new parts. Maxi-
mum permissible clearance for used parts is
.015 in. (0.38 mm).
NOTE: Main bearing caps have numbers as to their
location in cylinder block. Install bearing caps so the
number on cap is the same as number on cylinder
block. Both numbers must be on same side of cylin-
der block.
5. Put clean engine oil on threads of studs and seat
for nut. Install main bearing caps (4) and nuts.
Install the thrust plates on dowels on rear cap.
The dowels must not be extended more than
.160 in.'(4.06 mm)fromcounterbore face of
bearing cap. Tighten the nuts to a torque of 200
± 10 Ib.ft. (270 ± 14 N·m). Put a mark on
nuts and ends of studs and tighten nuts an extra
120 0 from mark.
7-159
CRANKSHAFT
6. Put the upper half of new rod bearings (5) in
the rod. Put rod in position on the crankshaft.
7. Install lower half of new rod bearings (6) in

caps (7). Put clean engine oil on bearings.
NOTE: Be sure the tabs on back of bearing fits in tab

grooves of cap and on connecting rod. Install the
bearing caps and bolts. Tighten the bolts first to a
torque of 40 ± 4 Ib.ft. (55 ± 5 N·m). Put a mark on
bolt heads and bearing caps. Tighten bolts again
120° from mark. Only four bolts can be tightened in
this way. The remainder of the bolts must be tight-
ened with the engine in the vertical position.
8. Use tool group (B) to check crankshaft end

playas controlled by thrust plates. End play
must be .005 to .021 in. (0.13 to 0.53 mm).
Maximum permissible end play is .035 in. (0.89
mm).
9. Install bar and straps to lift truck. Install hoist

and turn engine to the vertical position.
10. Install engine on the oil pan base. Tighten re-

mainder of rod bolts as given in note above.
I I. Install the inspection covers on each side of

engine.
end by:
a) install gas pressure regulator
b) install intake manifold
c) install accessory drive gears and plate
d) install rear timing gears
7-160
INSTRUMENT PANEL
REMOVE INSTRUMENT PANEL 7450-11
I. Drain the coolant from the cooling system be-
low the level of the cylinder head.
2. Disconnect water temperature sending unit

(I ).
3. Disconnect oil pressure sensing line (2) from

fitting.
4. Disconnect two wires (3). Remove two bolts (4)

from panel.
5. Remove two nuts (6) and instrument panel (5)

from engine.
6. Put identification on wires (7) and disconnect

the wires from the gauges to the instrument
panel.
7. Remove brackets (8) that hold the gauges in

position. Remove the gauges from the instru-
835587Xl
ment panel.
TYPICAL EXAMPLE
7-161
INSTRUMENT PANEL
INSTALL INSTRUMENT PANEL 7450-12
1. Put gauges (2) in position in the instrument
panel. Install brackets ( I) that hold the gauges
in position.
2. Connect the wires from the gauges (2) to the

instrument panel.
TYPICAL EXAMPLE
NOTE: Put wire (4) in position under instrument

panel.
3. Put instrument panel (3) in position and install

nuts and bolts to hold it in position.
4. Install wires (5) in position on the back of

instrument panel.
5. Install oil pressure sensing line (6).
6. Connect water temperature sending unit (7).
7. Fill the cooling system with coolant to the cor-

rect level.
TYPICAL EXAMPLE
7-162
NOTES
7-163

379,398,399 D and A REV1

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C.

G379: G398: G399:

IMPORTANT SAFETY NOTICE

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND

ENGINE DISASSEMBLY AND ASSEMBLY

In. WARNING In. WARNING

ENGINE DISASSEMBLY AND ASSEMBLY

GENERAL TIGHTENING TORQUE FOR

THREAD DIAMETER STANDARD TORQUE

inches millimeters lb. ft. N·m

Standard thread Use these torques for bolts and nuts

b ii[IlliO with standard threads.

1/4 6.35 9±3 12 ± 4

Use these torques for bolts and nuts on

Taperlock stud Use these torques for studs with Taper-

Accessory Drive Gears and Plate 7-14 Oil Filters 7-36

CRANKSHAFT FRONT SEAL RING AND THROWER

I. On G379 only, remove cover (I).

2. Put a mark on two bolts from location (2) for

3. Remove ten bolts (4 ) from adapter. Remove

4. Remove twelve bolts (5) and baffle (6).

5. Remove ring and spring assembly (7) from the

6. Install tooling (B) on thrower. If necessary use

7. Remove the ring from the accessory drive hous-

TYPICAL EXAMPLE TYPICAL EXAMPLE

CRANKSHAFT FRONT SEAL RING AND THROWER

I. Put 6V1541 Quick Cure Primer and 9S3265

CRANKSHAFT FRONT SEAL (LIP TYPE) AND

2. Remove ten bolts (3) and remove adapter (4)

3. Make two holes (1800 apart) in the metal sur-

4. Remove wear sleeve (7) from the crankshaft.

CRANKSHAFT FRONT SEAL (UP TYPE) AND

1. Clean the contact surfaces of the wear sleeve

2. Put a thin layer of SAE 30 oil on the seal lip.

3. Put 5P3413 Sealant on the threads of the

SERVICE METER AND TACHOMETER DRIVE

I. Remove two bolts (1) and service meter (2).

2. Remove two bolts (3), lockwashers, clamps

3. Remove four bolts (5), lockwashers and

4. Remove the lip type seal from housing (6)

5. Remove two bolts (7) and adapter (8).

SERVICE METER AND TACHOMETER DRIVE

I. Install two washers, adapter (2) and bolts (I).

2. Install the lip type seal in housing (3) with

3. Install a new gasket and housing (3) on the

4. Inspect and make a replacement, if neces- AS21SS)(1

5. Inspect and make a replacement, if neces-

ACCESSORY DRIVE HOUSING

1. On G379 only, remove adapter cover (I). Re-

2. Remove twelve bolts (4) and baffle (5). Put a

3. Remove four bolts that hold plate (6) for oil

4. Remove the four bolts (7) that hold water

5. Fasten a hoist to the front of the engine. Loosen

TYPICAL EXAMPLE TYPICAL EXAMPLE

ACCESSORY DRIVE HOUSING

7. Remove ten bolts (14) that fasten plate to

8. Remove bolts and auxiliary water pump (15).

9. Install tooling (B) and a hoist to the accessory

ACCESSORY DRIVE HOUSING

NOTE: Put 6V2055 High Vacuum Grease in the

1. Install the spring and seal ring (1) on thrower

2. Install two 112"- I 3 N C bolts as a guide in the

3. Install twelve bolts (2) to fasten housing to