Usage:
start by:
a) remove cylinder head assembly
b) remove front cover
c) remove flywheel housing
d) remove governor
1. Fasten a hoist and tooling (B) to engine as shown.
2. Lift engine from engine stand (A) and turn engine on its side with tooling (B). Weight of engine as shown is 3950 lb. (1783 kg).
3. Put engine in place in engine stand (A) as shown and remove tooling (B).
4. Install two 3/8"-16NC forged eyebolts in oil pan (1).
5. Remove bolts from oil pan and remove oil pan. Weight of oil pan is 170 lb. (77 kg).
6. Remove oil tubes (2) and (5).
7. Remove oil pump (3) and oil pump drive (4). Weight of oil pump is 70 lb. (32 kg).
8. Remove the connecting rod caps, bearings and pistons (6).
9. Remove all main bearing caps except No. 4. Install split pieces of rubber hose (7) over studs to give protection to crankshaft journals.
10. Fasten a hoist to crankshaft with tool (C).
11. Remove No. 4 main bearing cap (8) and remove crankshaft. Weight of crankshaft is 550 lb. (250 kg).
12. Remove upper halves of bearings (9) from cylinder block. Remove lower halves of bearings from caps.
Install Crankshaft
1. Install the main bearings (1) in the cylinder block and main bearing caps. Each main bearing has a number on it and must be installed in its respective position in cylinder block and bearing cap.
2. One gear tooth (3) on the crankshaft gear has a mark on it. The mark is on the chamfered end of the tooth next to the oil seal thrower. Put a chalk mark across the top of marked tooth. Put a chalk mark on the two teeth of cluster gear (4) that has an "F" between them.
3. Fasten a hoist to crankshaft (2) with tool (A). Put crankshaft in place in cylinder block and install No. 4 main bearing cap temporarily.
4. Turn crankshaft and check engaging of gear teeth that have chalk marks on them. If gear teeth (3) and (5) do not engage with each other, remove crankshaft. Turn cluster gear (4) until gear teeth (3) and (5) will engage with each other when crankshaft is installed again.
5. Check clearance of bearings with wire (B). Install bearing caps (6), tighten both nuts to 140 ± 5 lb. ft. (190 ± 7 N·m). Put a mark across the nuts and studs, and turn nuts an additional 120° from mark. Remove caps and check thickness of wire (B) to find bearing clearance. Bearing clearance must be .0040 to .0082 in. (0.102 to 0.208 mm) with new parts. Maximum permissible clearance with used parts is .012 in. (0.30 mm).
6. Put clean oil on threads of studs, face of nuts and lower halves of bearings. Put bearing caps in their respective positions with number on cap same as number on block, and notch in bearing cap on same side as notch in cylinder block. Install nuts and tighten to 140 ± 5 lb. ft. (190 ± 7 N·m). Put a mark across the nuts and studs, and turn nuts an additional 120° from mark.
7. Use tool (C) to check the end play of the crankshaft as controlled by the lower half of the center main bearing. The end play must be .012 to .023 in. (0.30 to 0.58 mm).
8. Turn crankshaft until timing marks (10) on cluster gear (7) are in alignment with edge of oil seal thrower (9). Remove idler gear (8).
9. Turn camshaft until "V" mark on gear (11) is in alignment with bolt hole in timing gear housing. Install a bolt (12) between gear teeth as shown.
10. Turn camshaft for fuel injection and install timing pin (13) in camshaft.
11. After bolt is installed in camshaft gear, timing pin is in injection pump camshaft and timing marks are in alignment, install idler gear (14).
12. Put clean oil on cylinder liner, piston and piston rings.
NOTE: Put ring gaps in place 120° from each other.
13. Put compressor (D) on top of cylinder liner. Install piston (15) through compressor into cylinder liner using the liner as a guide. Turn piston until "V" mark on piston is in alignment with "V" mark on cylinder block.
14. Carefully push piston into cylinder making sure each ring takes its place in the piston groove.
15. Install the upper half of bearing in connecting rod.
16. Put clean oil on upper half of bearing and crankshaft journal. Turn crankshaft into place in the connecting rod. Install the bolts in connecting rod.
17. Put clean oil on lower half of bearing and install the cap (17) and nuts (16).
| NOTICE |
|---|
Notch in cap must be installed on same side as notch in connecting rod. Make sure heads of bolts are in correct position in rod. |
18. Tighten nuts (16) to 75 ± 5 lb. ft. (100 ± 7 N·m). Put a mark across bolt and nut. Tighten nuts 60° from marks on bolts.
19. Do Steps 13 through 18 for remainder of pistons.
20. Install oil pump (22) and oil tubes (18) and (23).
21. Install oil pump drive (20). Two bolts in each bracket are ground body bolts and must be installed in holes (19) and (21).
22. Install oil pan (24) on engine.
23. Fasten a hoist and tooling (E) to engine as shown. Lift engine from engine stand (F) and turn engine upright.
24. Lower engine on to stand (F) and remove tooling (E).
end by:
a) install governor
b) install flywheel housing
c) install front cover
d) install cylinder head assembly