Willys-Overland MD engine, clutch, M38A1 utility truck Technical manual

TM manual I8 correct to 1 Pebma+y 1954

ORDNANCE MAtNTENANCE: ENGINE (WIUYS-OVERLAND

MODEL MD) AND CLUTCH FOR ‘/‘i-TON 4 x 4 UTILITY

TRUCK

M38Al

CarPTEa

Section I.

Gener&____-_-___-___-_______________-_______ water

.

GHAm~ 6. UNDERWATER ENGINE VENTILATING

SYSTEM firwe* pcrpc

Section

I. Deecription and operation

II. Rebuild engine ventilating system- _ _ _ _ _ _ _ _ _ _ 138-140 155-158

7. REPATR AND REBUILD STANDARDS____ 141-152 159-169

INDE~________________---------__----______--______-____________

173

MM

7464 LAWA$TER PIKE

SUITE 321

HOCKISSIN, DE 19707

Tools and equipment and maintenance parts over and above those available to the using organization are supplied to ordnance field maintenance units and depot shops for maintaining, repairing, and/or rebuilding the materiel.

7.

Maintenance parts are listed in Department of the Army Supply

Manual ORD 8 SNL G-758 which is the authority for requisitioning replacements. Parts not listed in the ORD 8 manual, but required by depot shops in rebuild operations may be requisitioned from the listing in the corresponding ORD 9 manual and will be supplied if available. Requisitions for ORD 9 parts will contain a complete justification of requirements.

Standard and commonly used tools and equipment having general application to this materiel are listed in ORD 6 SNL J-8, Sections

7, 12, 13 and 18: ORD 6 SNL J-9, Sections 1, 2, 3, 8 and 10; and

ORD 6 SNL J-10, Sections 4,7, 8, 11, 12 and 15 and are authorized for issue by T/A and T/O & E.

a. Xpecial Tools and Equipment (fig. 7).

The special tools and equipment tabulated in table I are listed in Department of the Army

Supply Manual ORD 6 SNL J-16, Section 38. This tabulation contains only those special tools and equipment necessary to perform the operations described in this manual, is included for information only, and is not to be used as a basis for requisitions. h. Improvised

Tools.

The improvised tools listed in table II and the dimensioned detail drawings shown in figure 8 apply only to field and depot shops in order to enable these maintenance organiza-

tions

to fabricate these tools locally, if desired. These tools are of chief value to maintenance organiz,ations engaged in rebuilding a large number of identical components ; however, they are not essen-

324309 0 - 55 - 2

17

I

Figure 7. Bpecial tools and equipment.

Gal for rebuild and are not available for issue.

The data in table II are furnished for information only.

Table I. Equipment for Field and Depot Maintenance

-

References

Identifying No.

Use

Fig.

I

Par.

---

KIT, gage, valve cap clearance checking.

41-K-84-15 7

‘, 66,

67

Gaging exhaust valve to exhaust) valve rotator cap clearance.

Consisting of:

GAGE___._______

COLLAR________.

BOX____________.

PULLER, crankshaft and camshaft timing gears.

PULLER, water pump impeller.

PULLER, water pump pulle1 four leg, >C

20NC 176 in. center distan’ce.

REFACER, w a t e r pump bushing.

REMOVER AND RE-

PLACER.

41-C-234-275

41-C-2482-15

41-B-1862-250

41-P-295&4

41-P-295&65

41-P-2908-240

41-R-2329-700

41-R-2379-25

WRENCH_____.__. 41 -w-2349-900

7, 19 3

7, 55

7, 56

7, 57

7, 2%

36,

37

7. 56 il,

Removing camshaft drive and driven gears.

Removing pump impeller. water

Used with wrench 4J- w-3249-900 removing pump pulley. for water

Refacing sealing surface in water pump.

Removing and replacing intake and exhaust valve guides.

Used with puller 41-

P-2908-240 for removing water pump pulley. zmprovised

Item

GAGE, checking, clutch pressure plate release lever.

REMOVER AND REPLACER, pi&on pin.

REMOVER AND REPLACER, camshaft front bearing.

SEATING TOOL, expansion

PlW.

References

)

Fig.

1 l’,/

Use

Checking position of pressure plate release levers.

Removing or replacing piston pins.

Removing or replacing camshaft front bes.rings.

Seating expansion cylinder block. plugs in

19

20

Figure t

/

Section 1. GENERAL

10. Purpose

Information in this chapter is for

LISA

of ordnance maintenance personnel in conjunction with and as a supplement to the troubleshooting section in the pertinent oI]erator’s manual. It provides the continuation of instructions where a remedy in the operator’s manual refers to ordnance maintenance personnel for corrective action.

Operation of a deadlined vehicle without a preliminary examina- tion can cause further damage to a disabled component and possible injury to personnel. By careful inspection and troubleshooting, such damage and injury can be avoided and, in addition, the causes of faulty operation of a vehicle or component can often be determined without extensive disassembly.

11. General Instructions and Procedures

This chapter contains inspection and troubleshooting procedures to be performed while a disabled component is still mounted in the vehicle or after it has been removed. a. The inspections made while the component is mounted in the vehicle are for the most part visual and are to be performed before attempting to operate the vehicle. The object of these inspections is to avoid possible damage or injury and also to determine the condition of and, when possible, what is wrong with the defective component.

6. The troubleshooting performed while the component is mounted in the vehicle is that which is beyond the normal scope of the using organization. Check the troubleshooting section of TM 9-804A then

Eroceed as outlined in this chapter. These troubleshooting operations are used to determine if the fault can be remedied without removing the component from the vehicle and also, when subsequent removal is necessary, to indicate when repair can be made without complete disassembly of the component. c. Inspection after the component is removed from the vehicle is performed to verify the diagnosis made when the component was in the vehicle, to uncover further defects, or to determine faults if the component alone is received by the ordnance establishment. This

21

inspection is particularly important in the last case because it is often the only means of determining the trouble without completely disassembling the component.

d. Troubleshooting a disabled component after it has been removed from a vehicle consists of subjecting it to tests on a dynamometer.

This chapter discusses those symptoms which can be diagnosed by using the testing equipment and interprets the results in terms of probable causes. Information on final testing of the engine is con- tained in TB ORD 215.

Most engine troubles are actually accessory troubles. These accessories are fully covered in the pertinent manuals listed in paragraph

1. The design and mounting of the engine covered in this manual permits very complete troubleshooting while the engine is mounted in the vehicle. Remedies and procedures are discussed in detail in

TM g-8048. Some corrective procedures, beyond the normal scope of using organization, can be performed while the engine is mounted ; some require the removal of the power plant from the vehicle. A good rule to follow in locating engine trouble is to make no more than one adjustment at a time.

If starting system is operative but engine, refuses to turn over, remove the starting motor and spark plugs. Depress the clutch pedal and block the pedal to hold the clutch in the disengaged position.

Attempt to turn the crankshaft using a medium length screwdriver or other small pry-bar inserted into the starter mounting hole and engaged between the teeth of the flywheel.

Note.

If this check indicates the engine to be abnormally tight or immovable, the engine must be completely disassembled to determine the initial cause of the trouble and to permit inspection for any secondary damage that may have occurred as a result of the seizure.

If engine operates but stalls frequently or lacks power, stop the engine and remove the valve covers.

Turn the crankshaft over, as necessary, to bring each valve in turn to its closed position.

Using a screwdriver or other comparable tool, press firmly against the lower end of the valve to cause it to move to its open position. Quickly withdraw the screwdriver and note the action of the valve as it returns to its closed position. It should return to the closed position with a definite

22

snap. A valve which fails to close or one which has a sluggish return action is either bent or broken, or fouled with carbon and/or gum deposits. In either case the valve or valves must be removed from the engine

15. Improper Ignition or Preignition

If engine operates satisfactorily but “pings” or knocks when accel- erated and/or continues to fire after ignition switch is turned off, remove the distributor and check the automatic spark advance mechanism against specifications ; TM O-18258 for Delco-Remy distributor ;

TM 9-8627 for Auto-Lite distributor. If complaint is still not corrected, remove the cylinder head and scrape carbon formations from inside surface of cylinder head and top of cylinder block.

16.

low or Unequal Compression in All Cylinders

If engine operates but compression test reveals poor compression in one or more cylinders, improperly seating valves, worn cylinders, worn pist,on rings, or a leaky head gasket can be the cause of low or unequal compression readings. To narrow down these probable causes proceed as follows: a. Remove the spark plugs from all cylinders. b. Pull the throttle control out to the wide open position.

C. Insert a conventional type compression gage into the spark plug opening of one of the cylinders and crank the engine with the starter.

Note and record the highest compression reading obtained.

d. Repeat the procedure on all four cylinders and compare the readings obtained upon completion of the operation. e. Normal compression pressure is 135 psi at cranking speed of 185 rpm. The minimum allowed pressure reading is 100 psi. The readings should not vary more than 20 psi between cylinders. f. Squirt one shot of heavy engine oil (SAE--50) into the cylinders having a low reading (one at a time) using a trigger operated hand oiler.

The heavy oil will work into the ring grooves in the piston and help to seal the cylinder against compression leaks. Repeat the compression test on these cylinders. If these readings are not higher than the initial readings, it indicates that poorly seating valves are the fault. Tf the pressure increases, it indicates that worn rings, worn cylinders, or a leaking head gasket is the fault. g. When the cause of the trouble has been determined, refer to the pertinent sections of this manual and proceed with the repair as instructed therein.

17. leaking Valves

If engine operates but stalls frequently or lacks power, refer to paragraph 14.

23

Carbon is the residue that results from the incomplete combustion of engine lubricating oil. When found in excessive amounts in the combustion chamber of an engine, it indicates that the piston rings or cylinders have become worn beyond limits. Refer to paragraph

516 (3) for method of determining wear of cylinders, and paragraphs

59 through

The excessive consumption of oil is an indication that the piston rings or cylinders have become worn beyond limits or that the clearance between inlet valve stems and guides is excessive.

Refer to paragraph 51b (3) f or method of determining wear of cylinders, paragraphs 59 through paragraph 54b (5) f or methods of checking clearance between valves and stems.

Section I. DESCRIPTION, OPERATION, AND DATA

20. Description a.

The Willys-Overland Model MD engine is an F-head type engine

; which is a combination valve-in-head and valve-in-block type.

For explanation of the construction features of the engine, refer to paragraph

21. b.

This engine is designed and waterproofed, as are all of the accessories, for underwater operation. The engine will operate partially submerged without extra equipment, but when it is to be operated completely submerged, t,he air intake and exhaust openings must be fitted with tube extensions to extend these openings above the surface of the water in which the vehicle is operated. Two shutoff valves, manually controlled by the operator of the vehicle, are included in the engine ventilating system and closed during the time the engine is operated partially or completely submerged. Refer to chapter 6 for an explanation of the principles of operation of the engine ventilating system, and for a description of the parts which make up the complete system.

21.

Construction and Operation

a. General. The following discussion of the construction and operation of the Model MD engine is referenced to figures 9 and 10, as noted. These views are sectioned to show the details of the operating parts of the engine and deviate from a true cross section to the degree necessary to accomplish their intended purpose. b. era&&aft

and Crank&aft Bearings (fig. 9).

The crankshaft

(XX) is supported at three points in the cylinder block on replaceable type lower rear, center, and front two halves main bearings (RN,

SS, and YY). The bearings are prevented from rotating in their supports in the cylinder block by dowel pins (PP, RR, and

W)

. Two dowel pins are used in both the center and the rear bearing supports, but only one is used in the front bearing support. The crankshaft front main bearing (YY) is flanged to take the end thrust of the crankshaft. A flanged section on the rear of the crankshaft (XX) acts as an oil slinger and, in combination with the rear main bearing upper and lower oil seal (LL) instayed in the rear main bearing

25

26

181020

Figure 9.

Engine assembly-side

sectionat

View.

A-Pulley, fan and generator drivt+-

7372558

B-Nut, 1%~ in-7697864

C-Bearing, bushing type, camshaft, front-7744319

D-Plate, thrust, camshaft-7351413

E-Washer, plain, l(1$2 ID, 1% OD-

7741406

F-Screw, cap, 7/lo-14NC-3 x l$$--

122260

G-Cover, timing gear-7372576

H-Plate, front mounting-7372578

J-Gear, camshaft driven-77414lS

K-Pump, water, assy-7372806

L-Thermostat, water temperature-

7348571

M-Valve, exhaust-7375035

N-Spring, exhaust valve-7371235

P-Lock, exhaust valve spring re- tamer-7355033

Q-Bolt, lock, piston pin-7324840

R-Retainer, exhaust valve spring-

i375034

P-Cap, exhaust valve rotator-7375032

T-Screw, adjusting, exhaust valve-

7371258

U-Rod, connecting-7743751

V-Tappet, exhaust valve-7372585

W-Tappet, intake valve-WC-@0550

X-Shaft, rocker arm-8329720

Y-Bracket, rocker arm shaft-8329712

Z-Screw, adjusting, intake valve-

8329718

AA-Nut, lock, r$j-24NF-2-124920

BB-Arm, rocker-29710

CC-Cover, rocker arm-8329713

DD-Spring, rocker arm shaft-8329721

EE-Guide, exhaust valve-7520738

FF-Block, cylinder-7412658

GG-Rod, push, intake valve--8329717

HH-Flywheel, assg-8328045

.JJ-Bolt, s-24NF-2 x 1%x--732840

KK-Dowel, tapered-804367

LL-Seal, oil, upper and lower, rear main bearing-7372560

MM-Plate, rear mounting-8328047

NN-Bearing, two halves, rear, main lower-7371169

PP-Pin, dowel, bearing-7371226

QQ-Camshaft-8329698

RR-Pin, dowel, bearing-7371229

SS-Bearing, two halves, center, main-

7371225

TT-Bearing, two halves connecting rod-5701528

UU--Jet, oil, timing gear-7372557

VV-Pin, dowel, bearing-7371229

WW-Pan, oil-7371278

XX-Crankshaft-7744463

YP-Bearing, two halves, front main-

7371170

ZZ-Gear, crankshaft drive-7741415

AB-Spacer,

7741414 crankshaft drive gear-

AC-Slinger, oil, crankshaft-7371161

AD-Seal, oil, front-7375028

Al&-Shield, fan and generator drkve pulley-7371376

AF-Key, woodruff, 3/le x s-124549

AG-Key, woodruff, %a x l-124552

AH-Washer, lock, ‘,&-inch-l36857

AJ-Key, woodruff, %a x s-124549

Figure 9.--Continued

27

28

Figure 10. Engine assembly-end sectional view.

RA PD 181021

support, prevents the leakage of oil from the rear end of the cylinder block. Leakage of oil from the front end of the cylinder block is controlled by the crankshaft oil slinger (AC), and the front oil seal

(AD) installed in the timing gear cover (G). The oil seal in the cover bears against the hub of the fan and generator drive pulley (A). c. Camshaft

The camshaft is supported at four places in the cylinder block. Only the front support is fitted with a replaceable bushing type bearing (C). A camshaft thrust plate (D) bolted to the front of the cylinder block takes the end thrust of the camshaft. The camshaft actuates the fuel and vacuum pump and the intake and exhaust valve tappets (V and W) by means of integral lobes forged into the shaft proper. Actuation of the distributor (D, fig. 10) is by means of an integral worm gear located at the approximate center of the camshaft.

The crankshaft drive gear (ZZ) and the camshaft driven gear (.I) are installed on the front end of the crankshaft and the camshaft respectively. These two gears are frequently referred to as the “timing gears”. The camshaft driven g ‘;:r

(J) is secured on the front end of the camshaft by means of a cap screw (F) and a plain washer (E). The crankshaft drive gear is secured on the front end of the crankshaft by a nut (B) threaded onto the front end of the crankshaft and also holding the fan and generator drive pulley (A), the crankshaft oil slinger (AC), and the crankshaft drive gear spacer (AB). The timing gear cover (G) incloses the timing gear and provides the mounting for the crankshaft front oil seal (AD).

10). The T-slot aluminum piston (U) is fitted with three rings

; two compression rings (R and

S) , and one oil control ring The t,op groove serves as an in-

A-Strainer,

B-Gage, oil-7036578 oil level, with cap, assy-

8328406

C-Starter,

D-Distributor,

E-Carburetor, assy-8328132 with coil, assy-7358569 assy-8329774

F-Lock, intake valve spring retainer-

7371238

N-Head,

P-Cover,

S-Ring, cylinder-8328474 exhaust set-7371146) compression-( set-7371146) valve ment-7371237

Q-Pump,

R-Ring, oil, assy-7376907 compression-(part compart- of ring part of ring

G-Arm, rocker LH-8329710 T-Ring, oil control-(part of ring

H-Retainer, intake valve spring- set-7371146)

J-Seal,

8329683

U-Piston, oil, intake valve spring re-

V-Pin, tainer--8329694 with pin, assy-7372873 piston-(part of piston, with

K-Spring, intake valve-8329695 W-Rod, pin, assy-7372873) connecting-7743752

L--Guide, intake valve-8329691

M-Valve, intake-8329697

X-Bearing, two rod-5701528 halves, connecting

Figure

IO.--Continued

sulator to protect the three rings below it from the heat generated in the combustion chamber. The upper end of the connecting rod

(W) is connected to the piston by means of the piston pin

(V) .

The lower end is bolted around the crankshaft, with a replaceable connecting rod two-halves bearing (X) installed between the connecting rod and the crankshaft. f. Exhawt Valves and Related Parts (fig. 9). The exhaust valves,

(M) which operate in the exhaust valve guides (EE) in the cylinder block

(FF)

are actuated by the camshaft (QQ,) ) through the exhaust valve tappets (V) . Adjustment of exhaust valves is accomplished by means of the exhaust valve adjusting screw (T) threaded into the upper end of the exhaust valve tappets. An exhaust valve rotator cap (S), installed between the lower end of the exhaust valve and the adjusting screw in the tappet, fits loosely on the end of the exhaust valve.

On each lift, or opening stroke of a tappet, the tappet first pushes the rotator cap through nominal clearance (par. 8’7c(2) (a) ).

The upper end of the rotator cap then contacts the exhaust valve spring ret&ner locks (P) which in turn pushes up on the exhaust valve spring retainer (R) and the exhaust valve spring

(N)

With the spring load thus removed from t.he valve, the valve is free to rotate a slight amount each time it is lifted from its seat in the cylinder block. g. Ink&e Valves and Related Parts (fig. 10). The intake valves

(M) operate in intake valve guides (L) in the cylinder head (N) and are actuated by means of rocker arms (h below). The rocker arms are actuated by the intake valve push rods (GG, fig. 9)) and the intake valve tappets (W, fig. 9).

The intake valve springs (K), the intake valve spring retainers (H) and the intake valve spring retainer locks

(F) make up the remainder of the valve operating parts.

An intake valve spring retainer oil seal (J), which encircles the upper end of the intake valve between the valve locks and the upper end of the valve guide, controls the leakage of oil past the valve stem and along the valve guide.

h. Rocker Arms and Related Parts (fig. 9).

The rocker arms

(BB) and their related parts are mounted on the top of the cylinder head and inclosed by the rocker arm cover (CC). The rocker arm shaft supported in four rocker arm shaft brackets

(Y) ,

carries the rocker arms (BB) and the rocker arm shaft springs

The intake valves adjusting screws (2) and locknuts (AA) provide the means for adjusting the intake valves (par. 114). i. FZyzuheeZ (fig. 9). The flywheel assembly (HH) is attached to the rear end of the crankshaft by means of two tapered dowels

(KK) and four standard bolts

(JJ) . j.

Engine Front

and Rear Mounting Plates (fig. 9). The front mounting plate (H) and the rear mounting plate (MM), bolted to

30

their respective ends of the engine, inclose and seal the ends of the cylinder block

(FF)

The front plate provides the mounting surface for the attachment of the front mounting support cushion and the rear plate forms the mounting surface for the flywheel housing.

Tc. Oil Pan and Fan and Generator Drive Pulley Xhield (fig. 9).

The oil pan (VW), in addition to serving as a reservoir for the engine oil, also serves as an engine base. A permanently attached sheet metal plate extending the full length of the pan reinforces it and protects the underside against damage from contact with solid objects which may be encountered in rough terrain.

In a like manner, the fan and generator drive pulley shield extending forward from the front end of the engine, gives protection to the fan and generator drive pulley (A) mounted on the front end of the crankshaft.

1. Water Pump (fig. 9). The water pump assembly (K), bolted to the front end of the engine, circulates the coolant through the vehicle cooling system. During the warmup period, however, and before the water temperature thermostat (I,), mounted in the cylinder head, opens, a small percentage of the coolant circulates only within the cylinder head and cylinder block through the bypass hose, to provide a rapid warmup. m. Information

on Accessories.

For operating or construction details of the accessory assemblies or subassemblies which are furnished with the engine refer to TM 9-804A, or to the paragraphs within this manual that apply.

22.

11) a. Lubrication of the engine is by means of a force feed, continuous circulating system. A planetary gear type oil pump is located on the left side of the engine and driven by the integral gear on the camshaft. Oil is drawn into the circulating system through a floating type oil strainer. b. This floating type oil strainer does not permit water or dirt to be picked up and sent through the engine bearings because the oil is drawn horizontally from the top level of the oil, leaving any dirt and water in the bottom of the oil pan. Oil pressure is maintained under any and all driving or climatic conditions. c. Oil is forced to the crankshaft and the camshaft bearings through drilled passages in the cylinder block and to the connecting rod bearings through drilled passages in the crankshaft.

d.

An oil jet, threaded into a hole in the front of the cylinder block, provides a positive spray lubrication to the timing gears. e. Oil sprayed from a drilled hole in the end of each connecting rod lubricates the cylinder walls, the pistons, the piston pins, the exhaust valve mechanism, and the intake and exhaust valve tappets.

31

Figure 11. Engine lubrication. sysasm. f.

The intake valve mechanism and rocker arm shaft parts are also lubricated by the engine lubrication system. They receive lubrication through an external oil line which conducts the oil from the oil gallery in the cylinder block to an oil passage in the cylinder head.

A drilled hole in the center of the rocker arm shaft support mates with the oil passage in the cylinder head to form the path through which oil is forced to the hollow rocker arm shaft.

The oil fills the rocker arm shaft and is fed to each of the rocker arms through holes provided in the rocker arm shaft. The returning oil drains from the cylinder head to its lowest part and finally to the oil pan through the intake valve push rod openings. g. The pressure under which the oil is supplied to the bearings and other parts of the engine, is controlled by a pressure regulator or relief valve located in the side of the oil pump.

The valve is set to maintain a pressure of 30 to 35 spi at a vehicle speed of approximately

32

30 mph. At idling engine speed pressure is approximately 10 psi with clean warm oil. h. An oil filter is included in the lubrication system to maintain the oil free from sludge, etc., between oil changes. A combination oil filler pipe can and bayonet type gage, installed in the oil filler pipe, provides the means for determining the oil level. in. to 1

Because of the obvious impossibility of describing in detail all of the various kinds of wear or damage or conditions of dirt, fouling, or foreign material deposits that might be discovered in the operation of rebuilding the engine, the cleaning inspection and repair paragraphs in this publication are limited to the description of the normal or common operations. Except in the cases where these specific procedures are given, t,he mechanic is expected to exercise his good judgment or to consult a higher authority when or if unusual conditions or difficulties are encountered during the performance of the cleaning, inspection, and repair operations. a. Cleanliness of personnel, tools, and surroundings is a funda- mental requirement where repair operations of a mechanical nature are carried on.

This is particularly true of areas where engines are to be repaired or rebuilt. All of the information and instructions con- tained in this publication are given on the assumption that these conditions prevail in the working area. Engine repairs, except for those of an emergency nature, should never be attempted under any other conditions. b. Use dry-cleaning solvent, volatile mineral spirits, or high pressure steam, whichever is available, for all cleaning operations. Use compressed air to dry the parts.

324309 0 - 55 - 3

33

c. When preparing to rebuild or repair an engine assembly, scrape, or wire brush all accumulations of dirt or road mud from external surface of the assembly.

Note and mark, by scratching the metal parts with a sharp pointed tool, any moist oil spots or unusually heavy accumulations of oil-soaked road mud, for they are good clues to the location of small cracks or holes which might escape notice in a visual inspection. Do not, however, confuse these accumulations with those that result from leaking gaskets or oil seals.

d.

After marking any questionable areas for later and more thorough inspection, complete the external cleaning operation with steam cleaning equipment or by hand brushing, using volatile mineral spirits as a cleaning agent.

Total immersion in a dip tank is also approved, provided the cleaning agent is dry-cleaning solvent or volatile mineral spirits.

26. Cleaning Component Parts After Disassembly

a. If other approved facilities are not available, all parts must be cleaned by hand using bristle brushes having the correct shape and of the proper size for the job to be done; i. e., round brushes for internal bores; square or rectangular hand brushes for flat or external surfaces. Scrub each individual part except ball or roller bearings.

Note.

Bearings require special handling.

Refer to TM 37465 or TB ORD

438, and clean, inspect, and prepare for use all ball and roller bearings used in these assemblies according to the instructions given therein. b.

Clean a.11 parts of hardened oil, lacquer deposits, and carbon.

Wire brushes, either hand wielded or power driven, may be used for this purpose provided there is no possibility of damaging finished surfaces. Otherwise, the parts must be permitted to soak in solvent until the foreign material is loosened. c. Remove all gaskets or parts of gaskets from gasket surfaces, using a putty knife or other suitable scraper. Be careful to avoid scratching or gouging the surface metal. cd. Rinse or flush the parts in clean dry-cleaning solvent or volatile mineral spirits. Even though the dirt or foreign matter is loosened by the cleaning action, it must be completely washed away by flushing.

This is a mandatory operation on parts that have undergone repair operations which required them to be ground, honed, or lapped. Use solvent under pressure to force-flush repaired parts. In the absence of such facilities, however, the parts may be rinsed by immersing them in a container of clean dry-cleaning solvent or volatile mineral spirits and then sloshing them about vigorously either manually or by some improvised mechanical means. Dry the parts with compressed air blasts.

34

27. Inspection Procedures a.

28. Repair Procedures a.

29. Handling After Inspection and Repair a.

flush

d.

Figure 12. aesembliee and mounting f fwIn t &?n&,. parts, bracket8 and

A-Insulator, brace-7375175

B-Nut, lockwasher, %-24NF-2-

8328482

C-Strap, ground-7371311

D-Washer,

178551 lock, int-est-teeth, 3/ IN-

E-Bolt, 3/8-24XF-3 x l-181637

F-Insulator, brace-7375175

G-Brace, adjusting, belt tension-

7X76388

H--Support, generator mounting-

7375389

J-Xut, s-16 SC-Z-134566

K-Washer,

L-Washer, lock, :‘/x-inch-120382 plain, it& ID-120395

&I-Washer, plain, 17& ID-120396

N-Bolt, generator-WO-633949

P-Bolt, generator-\VO-633949

Q-Washer, plain, 1%~ ID-120396

R-Washer, plain, is& ID-120395

S--Washer, lock, 3/8-inch-120382

T--Nut, :&-16NC-2-134566

U-Support, starter-8328133

V-Screw, cap, lockwasher, 5&18NC-3 x y4-451975

W-Screw, cap, lockwasher, 3/s-16NC-

2A x a&-451976

X-Washer, plain, :s-inch446363

Y-Starter, assy-8328132

Z-Nut, 9/s-24NF-2-120369

AA-Gasket,

BB-Washer,

CC-Screw, cap, +13NC-2

120126 starter, assy-WO-804396 lock, l/-inch-l20384 x lx--

DD-Generator,

EE-Bolt, assy-7374750 gS-16NC-2 x 1423571

FF-Washer, plain, gS-inch-120394

GG-Screw, cap, a&-16NC-2 x 7/-

WO-633949

HH-Washer, lock, a@rch-120382

JJ-Unit, sending, oil pressure, assy-

7728856

KK-Xut, lockwasher, %-28NC-2-

8329685

12.-Continued

LL-Stud

MM-Unit, sending, water temperature, assy-7389566

KS-Washer, plain, %-inch-l20392

I’P-Bolt

QQ-Support, sending unit, oil pressure-8329686

RR-Nut

SS-Bolt, s/16-24NF-2 x 3/4--120741

TT--Filter, oil, assy-WO-802147

UU-Screw, cap, IA-2OSC-2 x s--

805772

VV-Distributor, assy-WO-806329

W&-Stud,

24NF-2 s/,-16NC-2 (e/,6)

( 5h ) x it/lo--111318

XX-Insulator,

YY-Hose, carburetor-8329828 vent-WO-806357

ZZ-Pipe, air intake, assy-WO-809246

AB-Hose, carburetor to air cleaner pipe-8329646

AC-Hook,

AD-Screw, lifting-8328396 cap, 7/16-14XC-2 x 4%-

8329678

AE-Cable, spark plug, assy-8328449

AF-Screw, cap, %e-14NC-2 x 4l/-

8329677

AG-Bracket,

8328422 mounting, oil filter7

AH---Nut, lockwasher, 5&,-24NF-2-

804976

AJ-Carburetor,

AK-Nut, assy-8329774 a&-24NF-2-120369

AL-Nut,

AM-Washer,

+‘a--24NF-2-120369 lock, s-inch-120382

AN-Pump,

AP-Clamp, water, assy-7372806 hose, l-inch-502913

A&-Screw, cap, lockwasher, xe-18NC-

2 x rh--7372812

AR-Screw, cap, lockwasher, 5,/le-18NC-

2 x 2$$-7372813

AS-Bolt, adjusting brace-WO-A1468

AT-Nut, l$&-inch-7697864

AU-Pulley, fan and generator drive-

7372558

AT’--Key, woodruff, %a x 3/4--124549

37

Instructions for removing these accessories are furnished in TM 9-

804A and therefore are not repeated herein. When preparing to remove the accessory assemblies, set the engine assembly upright on a suitable stand or work bench, blocking it securely to prevent damage to the assembly or injury to personnel.

6. Remove accessories from the engine according to the instructions furnished in TM 9-804A. During removal of the accessories, dis- connect and remove the connecting fuel, vacuum, oil, and vent lines as instructed in paragraph 31k.

Accessories to be removed are as follovvs

:

Carburetor

Distributor

Generator

Starter

Oil Filter

Fan and Generator Drive Belts

Oil pressure Sending Unit

Water Pump

Fuel Pump

Spark Plugs

Clutch

RAPD 181024

Figure 13. Engine acccssorg assemblies fittings-Zcft and mounting rear view. parts, brackets, and

38

A-Screw,

cap,

"/1~-18XC-2xll/ls-

HII-Screw, fuel pump-WO-800741

7324841

B-Washer, lock, 5/la-inch-120638

JJ-Spring, return, accelerator pedal-

8329764

C--Clutch, with cover, assy-120638

D-Disk, driven, clutch-8328127

KK-Line, flexible, oil filter inlet, assy-

8328409

E-Elbow,

F-Line,

90 deg, ?/-inch-137421 fuel pump to carburetor-

LL-Line, flexible, fuel pump inlet-

WO-806172

JIM-Stud, ;&16AYC-2 x 3/s-24NF-3 s

G-Line,

J-Pan, oil, assy-i371278

K-Gasket,

L-Plug,

N-Line,

P-Line,

Q-Line,

WO-806065 oil pressure-WO-807700

H-Line, oil, sending unit, assy-

8::28407 oil pan drain plug-

WO-639979 drain, oil pan, 7h-inch-

WO-639979 rent-WO-807846

N-Tee, inv flared tube, 1/4-inch-178910 tee to windshield wiper-

WO-807843 vent, crankcase-806339

R-Line, vent, metering valve to tee-

WO-807846

122058 l’/i-7372581

S&-Gasket,

630299

PI’-Screw,

QQ-Washer,

RR-Bellcrank,

8329766

SS-Washer, ventilator body-WO- cap, special-WO-646093 plain, se-in.-120393 lower, accelerator- plain, 5/ls-in-120393

TT-Pin, cotter, %e x 1/2-in.-112726

UU-Rod,

VV-Stud, accelerator

8329765

Ys-16NU2 bellcrank link-

(l/2) x 3/-24NF-

3 ( 7/ ) x l:g-8329733

WW--Manifold,

XX-Gasket, exhaust-8329699

S-Line, distributor to windshield wiper

TY-Bracket, fitting-WO-806420

8329768

T-Gasket, end, exhaust manifold-

WO-648795

ZZ-Pin,

Cotter, &, x

%-inch-l12726

AB-Washer, accelerator bellcrank- plain, 11/5s ID, ‘4is OD-

U-Gasket, center, exhaust manifold-

WO-6489%

120393

AC--Spring, accelerator bellcrank-

V-Elbow,

W-Support,

90 deg, l/s-inch-444038 dual control-WO-806449

8:129770

AD-Bellcrank, upper, accelerator-

X-Screw, cap, lockwasher, :c/-lS,\rC-

WO-806478

2 x ~/s-7346875

AE-Rod, throttle-8329763

Y-Gasket, fuel pump-WO-638737

AF-Plug, spark, assy-8357724

Z-Spacer, fuel pumpWO-800361

AG-Hose, vent-WO-X07400

AH-Gage, oil level, assy--8328406

AA-Nut, self-locking, $Y-24SF-3-

503354

AJ-Elbow, vent

BB-Pump, fuel, assy-WO-805727

AK-Screw, cap, lockwasher, %‘/lc-l8NC-

2 x 11/423;,64

CC-Washer, rectangular, 0.406 ID-

\VO-805842

AL-Spacer, oil tiller pipe bracket-

8329694

DI)-Washer, lock, vi’/1G-inch-l20214

AM-Bracket, support, oil filler pipe-

EE-Washer, rectangular, 0.406 ID-

7368276

WO-X03542

AS-Pipe, oil filler, assy- 8329683

FF-Washer,

GG-Screw, lock, 5/1a-inch-120214 cap, 5/1o-lSNC-2 x 17/s-

AI’-Tee, s-in.444132

AQ-Flywheel, assy--8328045

AR--St& annular, l-4 Mhl-160189 ys-24SF-2-120369

Figure

lS.-Continuetl

39

bellcrank (RR) off the exhaust valve spring compartment cover stud. Remove the accelerator bellcrank spring (AC) from the upper bellcrank shaft.

(3) Complete the disassembly of the accelerator linkage parts by removing the cotter pins from the ends of the accelerator bellcrank link rod

(4) Remove the cylinder head cap screw, which secures the upper accelerator bellcrank bracket (YY) to the cylinder head, and remove the bellcrank bracket. m. Remove Ventilation Valves and Related Parts (fig. 13). Re- move the cap screw (PI’) and ventilator body gasket (NN) securing the crankcase vent body and related parts (fig. 115) to the exhaust valve spring compartment cover and to the cylinder block. Remove the crankcase vent body and the engine ventilation system parts threaded to it. Refer to paragraph 138 for disassembly instructions for these parts.

Note.

At this point in the disassembly operation, the engine should be mounted in a suitable engine repair stand. Where practicable, modify or adapt existing basy shop repair stands as necessary to accommodate the engine. If engine repair stands are unavailable, take care to perform the following operations in a manner designed to protect personnel against harm and the engine and its parts against damage.

a.

Remove the oil pan drain plug and gasket (K and L, fig. 13) and drain the oil pan. Remove the two nuts (V, fig. 70) from the rocker arm cover studs (fig. 14). From the front stud, remove three spark plug cable clips (U, fig. 70) and the copper rocker arm cover stud gasket (T, fig. ‘70). From the rear stud remove one spark plug cable clip and the copper gasket. Remove the rocker arm cover (S, fig. 70) and rocker arm cover gasket (X, fig. ‘70).

b.

Unscrew and remove the two rocker arm cover studs (fig. 14) from the rocker arm shaft brackets at either end of the rocker arm assembly. Invert the studs and install them in the same openings, screwing them down to a snug fit. Remove the nuts from the rocker arm shaft bracket studs, and lift the rocker arm assembly up and off the studs. Lift the intake valve push rods out of the cylinder block.

Note.

The studs are installed inverted to enable the rocker arm assemblies and their related parts to be removed as one unit. The studs must be installed to keep the rocker arm shaft springs from expanding and causing the end pieces to be pushed off the rocker shaft when the assembly is removed from the cylinder head. To avoid any possibility of the end of the stud damaging the rocker arm shaft, install the studs just tight enough to bind the brackets to the shaft. a. Remove the crankcase to cylinder head oil line (D, fig. 5) by disconnecting the line fittings from the inverted flared tube connector

42

(fig. 15) in the cylinder head and from the elbow in the lower section of the cylinder block.

43

b. Remove the remaining cylinder head cap screws and plain washers

(fig.

Caution:

One cylinder head cap screw (fig. 15) is located inside the intake manifold and is removed by inserting a wrench into the carburetor opening in the cylinder head. Do not fail to remove this cap screw before attempting to remove the cylinder head. Remove the cylinder head and gasket.

34.

Remove Fan and Generator Drive Pulley Shield and Oil Pan

Remove the six lockwasher cap screws which secure the fan and generator drive pulley shield (fig. the front underside of the engine, and remove the shield.

Remove the fan and generator drive pulley shield spacers and gaskets (fig. 17) and the remaining lockwasher cap screws which secure the oil pan to the cylinder block.

Remove the oil pan.

35. Remove Oil Strainer

(fig. 18)

Remove the two lockwasher cap screws which secure the oil strainer to the bottom of the cylinder block. Remove the oil strainer.

LOCK

Location

36. Remove Fan and Generator Drive Pulley

(fig. 16)

Unscrew the nut which secures fan and generator drive pulley on the front end of the crankshaft. Using a standard remover, remove the fan and generator drive pulley.

37. Remove Timing Gear Cover

Remove the four bolts, lockwasher nuts and studs (fig. 17) securing the timing gear cover to the front end of the engine. Remove the cover, the fan and generator pulley woodruff key (AF, fig. 9)) the crankshaft oil slinger (AC, fig. 9) and the crankshaft drive gear spacer (AB, fig. 9) from the front end of the crankshaft.

38. Remove Camshaft Driven Gear

Remove the cap screw (F, fig. 9) and the plain washer (E, fig. 9) securing the camshaft driven gear (J, fig. 9) on the front end of the camshaft. Using gear puller 41-P-29564 (fig. 19)) pull the camshaft driven gear from the front end of the camshaft. Remove the camshaft gear woodruff key (AJ, fig. 9).

bearing and its half bearing (TT, fig.

9).

Push the piston and connecting rod into the cylinder far enough to permit the half bearing to be removed from the connecting rod.

Note.

The pistons and connecting rods may be removed at this time through the top of the cylinder block, or they may be allowed to remain in the cylinder block and removed through the bottom of the block after the crankshaft has been removed (par. 48). If the pistons and connecting rods are to be removed through the top of the block, use a cylinder ridge reamer to remove the ridge from the tops of the cylinder bores before removing the pistons. Wad cloth into the bores, on top of the pistons, to prevent the metal chips from becoming lodged between the piston and the cylinder walls.

After the pistons and connecting rods are removed from the engine, assemble the lower half of the connecting rod to the upper half so that these parts will remain together until they are assembled in the engine.

48.

Slide the crankshaft thrust washer and the end play adjusting shims off the front end of the crankshaft (fig.

73).

Note.

There may be one or two shims, the actual number varying between engines.

Pull the two pieces of rear main bearing cap packing (fig. 18) up and out of their position between the bearing cap and the cylinder block.

Remove the cap screws and lockwashers securing the main bearing caps to the cylinder block. Remove the bearing caps with the half main bearings in the caps and lift. the crankshaft (B) out of the cylinder block. Remove the half main bearings from the bearing caps and the half main bearings from the cylinder block. Remove the bearing dowel pins (J), one each from the center and the rear main bearing caps (G and L), and one each from the front, center, and rear main bearing bores in the cylinder block.

Remove the upper half of the rear main bearing oil seal (E) from the cylinder block and the lower half from the oil seal groove in the rear main bearing cap.

49.

24)

Remove the intake and exhaust valve tappets from the bottom of the cylinder block.

Remove the two pipe plugs (fig. 26) from the left outside surface of the cylinder block.

Remove the two countersunk-head pipe plugs

(fig. 26)) one from each end of the block. Remove the slotted-head-

52

Figwe 2.5. Removing main bearing caps and bearings.

the square-head pipe plug (fig. 27) from the tapped opening just below the oil pump intake passage inside the cylinder block.

6. Insert a 24-inch length of $&inch bar stock into the camshaft bore in the cylinder block and drive against the bar to dislodge the expansion plug (fig. 27) from its seat in the rear end of the cylinder block. c. Check the inside dimension of the front camshaft bushing type bearing (fig. 26). If the dimension does not exceed 2.1880 inch, the bearing need not be removed. If removal of the bearing is necessary, use the improvised camshaft front bearing remover and replacer

(fig. 32) and drive the bearing out of the cylinder block.

53

181037

Figure $6.

a!. Pierce the centers of the two expansion plugs (fig. 31) with a sharp chisel, and pry the plugs out of the cylinder block.

51.

Note. Before performing the operations covered in this paragraph, refer to the general instructions given in paragraphs 24 through 29 relative to the cleaning, inspection, and repair of engine parts. a. Cleaning.

(1) Scrape and remove all accumulations of rust or foreign material from the water passages in the cylinder block.

Note.

If the water passages are heavily coated with rust or clogged with foreign material, refer to TM 9-2858 for methods of removing these substances.

(2) Clean the cylinder block main oil gallery (fig. 27) and the smaller oil passages in the cylinder block using round wire brushes slightly larger in diameter than the passages. Force flush the passages using cleaning fluid under pressure. b. Inspection and Repair.

(1) Inspect the top of the cylinder block for cracks or other damage which would make the block unfit for use. Check the tapped holes for rough or damaged threads and, if necessary, clean the threads by running the proper size tap into the holes. Remove any broken stud ends using a tool designed for this purpose.

(2)

Check the cylinder bores to see that none are scored, scratched or otherwise damaged so badly that the block is unfit for use.

If the ridge was not previously removed from the top of the cylinder bores (par. 47) remove the ridge with a ridge

(3)

reamer. Use extreme care not to undercut bore.

Check the dimensions of the cylinder bores with a cylinder bore gage. If the bores do not conform in all dimensions to those given in the repair and rebuild standards (par.

142a), they must be rebored to the next oversize.

Note:

Pistons are furnished in standard, 0.020, 0.030, and 0.040 inch oversize.

(4)

(5)

If the cylinder bores are not worn beyond the dimensions given in the repair and rebuild standards, but the walls of the bores are glazed, use the finishing hone to remove the glaze.

Remove the exhaust valve guides using the driver only of valve guide remover and replacer 41-R-2379-25 (fig. 28) to drive the guides downward from the top of the cylinder block and into the exhaust valve spring compartment. Start the new valve guides, blunt (non-tapered) end first,, into the valve guide bore in top of the cylinde% block. Slide the

55

Figwe

%3. Removing ezhawll valve

guide8 using ?-mover and replacer

thicker of the two flat adapters of the remover and replacer onto the end of the driver and drive the guides into the block until the adapter seats against the top of the cylinder block. When properly positioned, the top (tapered) end of the guide is exactly 1 inch below the level of the top of the block (fig. 29)

_ Run a 3/g-inch reamer (fig. 38) through the guides after they have been correctly positioned.

(6)

Use a valve seat grinding tool to grind the exhaust valve seats in the cylinder block just enough to true the seats and to remove pitted or burned areas. Maintain the width of the seats at three thirty-seconds of an inch and not wider than one-eighth of an inch. Upon completion of the valve seat grinding operation, check the valve seats for concentricity. Total, out-of-round of the valve seat, must not exceed 0.902 inch.

(7) Repair or replace the exhaust valves as instructed in paragraph 87, and then lap them to a perfect seat in the cylinder block exhaust valve seats.

(8) Force flush the exhaust valves and the cylinder block with cleaning fluid under pressure, or high pressure steam, to

Figure 29. Intake and exhauet valve guides installed--sectional view.

remove all metallic particles resulting from the reboring, reaming, and grinding operations.

52. Assembly

(fig. 30) a.

Coat the sealing edges of the expansion plug recesses in the qliuder block WAU. y’-“” type gasket cement and install the two

57

D

E

F

J

K-PLUG,

Caution:

c.

Caution:

Figure

31.

Installing ecupmsiora plugs.

d. If necessary, replace the camshaft front bushing type bearing

(par. 50~)) using the improvised camshaft front bearing remover and replacer (fig. 32). Slide the bearing onto the arbor of the remover and replacer, notched end first.

Aline the oil hole in the bearing with the oil hole in the bore in the cylinder block and drive the bearing into the bore until the front end of the bearing is flush with the front surface of the cylinder block.

Figure 32. Installing Camshaft front bearing.

e. Stake the bearing in place using an ll&-inch drift punch inserted into the fuel pump opening in the side of the block and centered in the oil hole in the front camshaft bushing type bearing (fig. 33).

Drive against the punch to cause the bearing metal to be driven into the oil hole in the cylinder block.

Make sure the oil hole is open and clear after performing this operation.

It is not necessary to line bore the bearing after installation.

Remove the three water temperature thermostat housing lockwasher cap screws (fig. 15).

Remove the t,hermostat housing and the housing gasket.

Remove the water temperature thermostat from the housing. b. Unscrew and remove the water pump bypass hose nipple (fig. 15) from the cylinder head. c. Unscrew and remove inverted flared tube connector (fig. 15).

Unscrew and.remove the three square-head pipe plugs (fig. 15).

Figure 33. i3taking camhalt front bearing.

Note.

54b(5).

Note.

Note. follow

24

“T’

I t

Figure 34. Removing intuke valve.

(2) Run a s/s-inch round wire brush through the intake valve guides.

(3) Clean the intake valves on a wire wheel, making sure that all carbon is removed from the top and the underside

of

the valve heads and that all gum and varnish deposits are removed from the valve stems.

(4) Wire brush and clean the valve springs, the valve spring retainers, and the valve spring retainer locks.

6.

(1)

(2)

Inspect the cylinder head for cracks, deep gouges on the finished surfaces, or other damage which would make the cylinder head unfit for use. Inspect all tapped openings and ma,rk for repair (c below) any damaged threads or broken stud ends.

Replace any worn, pitted, or corroded valves that cannot be cleaned with a wire brush. Replace any valves whose seats are pitted, burned, or corroded so badly that they cannot be cleaned with a light cut on the valve refacing tool (c(2) below).

Visually inspect the valve stems for marks of scoring or abrasion, and replace the valves if such marks are present. Replace any valves with bent stems. (Bent valve stems will become immediately apparent when the valve is mounted in the valve refacing machine

(c2(2) below). Check the diameter of the valve stem at two

(3) or three places along the length of the stem with a micrometer.

If any of the measurements are less than those specified in repair and rebuild standards (par. 149a), replace the valve.

Visually examine the springs and replace any springs v+-hich are deformed or obviously damaged.

Measure the overall free length of the springs and replace any that do not measure la& inch. Check each valve spring in valve spring tester (fig. 35). If the tester dial indicator registers less than ‘70 psi when the spring is compressed to

11+& inch, the sp ring must be replaced.

Note.

Exhaust and intake valve springs look alike, but are different. They must not be interchanged.

(4)

Normally there is very little wear of the intake valve spring retainers or the retainer locks and these parts can usually be used again. However, they must be visually inspected and replaced if they are found to be deformed or damaged. Replace all of the intake valve spring retainer oil seals.

Fipwe

35.

Checking spring.

64

(5) Intie vclZve gzlicies. Although there is usually very little wear of the intake valve guides, each guide must be carefully checked to make sure it is within the tolerances given in the repair and rebuild standards (par. The most practical method of checking the amount of clearance between the valve stem and the guide is to insert a new valve into the guide and move the valve from side to side noting the amount of clearance by the use of a dial indicator suit- ably mounted. If the clearance is found to be excessive, replace the guide (c(1) (6) below). c. Repair.

(1)

C@uZer head. them out or extracting with a tool designed for this purpose. Run a tap into the threaded holes to clean rough or damaged threads.

(6)

If any of the intake valve guides are to be replaced (b (5) above), drive the guides out of the cylinder head using

41-R-2379-25

(fig. 36))

Check the dimensions of the valve guide boree as specified in repair and rebuild standards (par. 144~).

(c) To install the intake valve guides, start the tapered end of the guide into position from the bottom of the cyIinder head. Using the remover and replacer 41-R-2379-25

(driver and intake valve guide adapter) (fig. 37) drive the valve guides into the head until the adapter seats against the cylinder head. When properly positioned, the end of the guide is just flush with the end of the valve guide bore in the cylinder head (fig. 29).

Figure $6. Rtmwing intake valve guide using rmmwr~and replacer

41-RZS79-25.

(4

(4

Run a 3/8-inch reamer through each intake valve guide after completion of the installation (fig. 38). Use care to keep the reamer perpendicular to the head.

Using a valve reseating tool, grind the valve seats in the head at an angle of 45“ to the axia of the valve stem, just enough to true the seats and to remove imperfections.

Maintain the width of the seat at three thirty-seconds of an inch but not wider than one-eighth of an inch.

After grinding the seats, check for concentricity. The total out-of-round of the valve seat must not exceed 0.002 inch. Regrind the seat, if necessary, to bring it within this

324309 0 - 55 - $

65

Figure Instulbing intake valve guide using remwver and replacer

41-3-2.379-25.

(fj Reface or replace the intake valves as instructed in (2) below and then lap them in the cylinder head intake valve seats.

1ntaAe Valves. Using a valve refacing tool, grind the seat area of the intake valves to a 4.5degree angle. Remove only enough metal to clean the seat and eliminate pits and burned areas. If it is necessary to remove so much metal

“1

66

Figure 38. Reaming intake ualve guide.

If the stem of an intake ralre is bent, it will be apparent when the ralre is clanWed in the refac’ing machine. Discard such ralvrs and replace with new ones.

Exhaust and intake valve springs look alike but are different. They m,ust not be interchanged. c. b.

67

-

d

A -Nipple, hose, water pump bypass- S-Screw, adjusting, intake valve-

8328480

8329718

B-Thermostat, water temperature- T-Lock, intake valve string retainer-

7348571

7371238

C-Gasket, thermostat housing-

U-Seal, oil, retainer, intake valve

8328458

D-Housing, thermostat-8328459 spring-8829694

V-Retainer, intake valve spring-

E-Screw, cap, lockwasher, %a--18NC-2 x rh-7372812

8329893

W-Spring, intake valv+8329895

F-Bracket, rocker arm shaft-8329712 X-Spring, rocker arm shaft-8329721

G-Washer, lock int-teeth, so-inch- Y-Arm, rocker, RH, assy-8329711

188538

H-Stud, rocker arm cover, sjs-24NF-

Z-Screw, cap, so-14NG2 x ll+&-

8328474

2-8329714 AA-Plug, pipe, sq-hd, ~-inch-219190

J-Stud, rocker arm shaft bracket- BB-Connector, inv flared tube, x-

8329879

K-Nut, lock, +24NC-2-7744472

-Plug, inch-137405 pipe, sq-hd, l&inch-108868

L-Plug, rocker arm shaft-W&648897

M-Shaft, rocker arm, with plugs,

DD-Screw, cap, xs-14NG2 x 4y*-

8329877

EE-Washer, plain-8329880 assy-8329720

N-Screw, lock, rocker arm shaft- FF-Plug, pipe, sltd-hdls, jg-inch-

8329719

845256

P-Screw, cap, The-14NC-2 x 4%-

GG-Rod, push, intake valve-8329717

8329878

HH-Guide, intake valve-8329691

Q-Nut, lock, ‘&&%NF-Z-l24920

JJ-Valve, intake-8%%97

R-Arm, rocker, LH, assy-8829710

KK-Head, cylinder-8328474

Figure 39.-Continued

Ftgwe &.I. Znstallhg intake valve springe.

c. Insert a screwdriver under the edge of the rocker arm shaft plugs

(fig. at each end of the rocker arm shaft, and pry the plugs out of the shaft.

d. Remove the intake valve adjusting screw locknuts from each of the rocker arm intake valve adjusting screws. Remove the screws from the rocker arms.

Figure 41. Disassembling rocker am

57.

Note.

Cleaning. Run a round wire brush through the bore of the rocker arm shaft, and clean out the drilled oil holes.

Clean out the oil holes in the rocker arm shaft brackets, and the oil holes and oil grooves in the bores of the rocker arm. b.

Inspection and Repair.

(1)

Rocker arm shaft. Replace the shaft if there are scores 01 abrasion marks at any point along the length of the shaft.

Measure the diameter of the shaft at the areas which form the rocker arm bearing points. Replace the shaft if it shows wear beyond the minimum diameter specified in repair and

70

(2) rebuild standards (par. 145). Check the shaft for alinement in a fixture designed for this type of service or by rolling the shaft across a smooth level surface. If the shaft will not roll freely, or if it rolls with a bumping motion, the shaft is out of alinement and must be replaced.

Measure the bores and the widths of the rocker arms and replace the arms if the dimensions do not. conform to those specified in repair and rebuild standards (par. 145). Inspect the threads in the adjusting scre.w hole in the rocker arm and if necessary clean with a properly sized tap. Replace the adjusting screw locknut the adjusting screw if either part is damaged or deformed.

(3) Rocker Measure the bore in the bracket and replace the bracket if the dimension exceeds that given in repair and rebuild standards (par. 145). Inspect the threads in the tapped hole in the top of the bracket and if necessary clean with a properly sized tap. If either side of the bracket is worn or scored replace the bracket.

58.

39) a. Install the two rocker arm shaft plugs (L), one in each end of the rocker arm shaft Slide two rocker arm shaft brackets (F) ont.o the rocker arm shaft. Aline the t.apped holes in the brackets with the drilled holes in the top of the rocker arm shaft and install the rocker arm shaft lock screws (N), making sure the points of the screws enter the drilled holes in the shaft.

Screw the intake valve adjusting screws (fig. 41) into the rocker arm and install the 5/,s-24NF-2 locknuts (Q,).

Note. The rocker arms are paired: that is, two of the arms are angled to the right and two are angled to the left. One of. each type is used on each end of the rocker arm shaft.

Slide one of the rocker arms onto the shaft so that the intake valve adjusting screw (S) in the rocker arm is on the same side of the rocker arm shaft as the mounting hole in the bracket and also so that the adjusting screw end of the. rocker arm angles away from the bracket. c. Install a rocker arm shaft spring (X) on the shaft against the rocker arm. Install the second rocker arm on the shaft in the same manner as in c above, except that the.adjusting screw end of the arm is to be angled toward the center rocker arm bracket (fig. 41).

Refer to the note in above. a?. Install a rocker arm shaft bracket on the end of the shaft so that the worn side of the bracket (par. is facing away from

71

the rocker arm. Temporarily secure the bracket in place by installing a rocker arm cover stud (H) upside down (par. 326) in the tapped opening in the top of the support. e. Assemble the parts on the opposite end of the rocker arm shaft repeating c and d above. a. Remove the two compression rings, the oil control ring and the oil control ring expander from the piston.

Do not remove the bolts from the lower end of the connecting rod unless they are damaged.

6. Clamp the connecting rod and piston assembly in a bench vise and remove the piston pin lock bolt and lockwasher (fig. 42).

&%. Location pirrton pin lo&

bolt.

c. Drive the piston pin out of the piston and connecting rod, wing the improvised piston pin remover and replacer (fig;-48).

Note.

To avoid the possibility of mushrooming the end of the pin, which might occur if the driving force were applied to the end of the pin, the piston pin tool must be inserted into the bore of the pin so that the force is exerted against the shoulder in the bore of the pi&on pin.

72

Note. a. Cleaning.

(1)

(2)

b. impectim

(1)

4.9.

and Repair. connecting rod 0U m-au hole.

;

(2)

(3)

on

147b).

73

74

131055

Figure 44.

Check&g

width

09 piston ring groove%

(4) Check the dimensions and the alinement of the piston pin bores in the piston and the connecting rod and replace the piston or the connecting rod if the wear or misalinement is so great that it cannot be eliminated by line boring 0.003 inch oversize.

Not?.

Piston pins are available in 0.003 inch oversize for service use.

(5)

Within manufacturing tolerances, pistons and cylinder block piston bores vary in size by a fraction of a thousandth of an inch. Since this is true, in order to obtain the most satisfactory running clearance between a piston and a cylinder, the cylinder must be fitted with a piston that is oversize approximately the same fraction of a thousandth inch that the bore is oversize; or vice versa. Fitting pistons to cylinders is a selective, or trial and error operation

; that is, if the first piston does not meet the standard ( (c) below) others must be tried until the correct clearance is obtained ( (d) below).

Fit pistons to cylinders (fig. 45) as follows

:

(a) Slide a piston pin into the bore of the piston to serve as a finger gripping surface.

(6) Attach a O.OOS-inch feeler gage, s/4-inch wide, and 10 to

12 inches long t.o the spring tension scale.

(c)

Lower the full length of the 0.003-inch feeler gage (fig. 45) into one of the cylinders of the previously rebuilt cylinder block. Lower the full length of the piston (upside down) into the same bore and so positioned that the feeler gage is directly opposite the T-slot in the piston. Pull up on the spring tension scale and note the reading on the indicator as the feeler is withdrawn from the cylinder bore.

If a reading of from 5 to 10 pounds is obtained, the piston is satisfactory for use in that bore. If a reading of less

(4 than 5 pounds is obtained, the piston is too loose; if more than 10 pounds, the piston is too tight.

If either of the latter readings is obtained, try the piston in the next bore.

Continue in this manner until all cylinder bores are properly fitted, replacing any pistons which cannot be fitted.

Note.

The piston Ming operation is generally begun at one end of the cylinder block and carried through each bore in turn to the opposite end of the block. To simplify the subsequent assembly of

Fitting pistons to oylindm.

(6)

Measure the diameter of the piston pin and replace the pin if the dimensions do not conform to specifications given in repair and rebuild standards (par. 14’703.

(7)

Use a connecting rod alining fixture to check the alinement of the rod (repair and rebuild standards (par. 146) ) and an approved procedure to straighten those found to be out of alinement. Replace connecting rods that cannot be satisfactorily straightened.

76

F+gswe 46. ConaeoC(nq rod4 at wunk8haft--hwtaZ~ed view.

The assembly operation is described for one assembly. Assemble the remaining three assemblies by following the same series of operations as given for the one assembly. b, Clamp the connecting rod (C) in a bench vise approximately three inches from the piston pin end. Note the cylinder identifying number stamped on the side of the rod (fig. 48) and select the piston with the corresponding number (par. 60b (7) ) . c.

Start the piston pin into the piston with the lock bolt groove in the piston pin facing the bottom of the piston. Assemble the piston and connecting rod with the T-slot in the piston on the side of the rod opposite the oil spray hole in the lower end of the rod.

Aline the piston pin bores in the rod and the piston, and holding the connecting rod in the center of the piston so that the lock bolt groove in the piston pin will be in line with the lock bolt hole in the rod, drive the pin into position using the improvised piston pin remover and replacer

(G3.43)

* d.

Install the piston pin lock bolt and lockwasher (fig. 42).

Select a new set of rings and check the end gaps of the rings as follows

:

(1) Insert one of the rings selected into one of the cylinder bores.

Using the piston (held upside down) fitted to that cylinder as a plunger, force the ring down into the cylinder the full length of the piston. Check the gap between the ends of the ring with a feeler gage (fig. 49),

(2) If the gap is less than 0.008 to 0.013 inch, remove the ring and file the ends of the ring with a fine cut file until the correct gap is obtained. If the gap is greater than that specified, remove the ring and use the next oversize ring set.

Repeat this procedure on each of the three piston rings and upon completion of the operation install the set of rings on the piston as instructed in

f

below. f. Install the piston rings on the pistons using a piston ring applier as follows

:

(1) Install the oil regulating ring expander in the lower ring groove by hand (applier not required).

(2) Install the oil regulating ring (slotted ring) in the lowest ring groove, and position the ring so that its gap is on the opposite side of the piston from the ends of the ring expander.

(3) Install the two compression rings on the piston so that the grooves on the inner edges of the rings face up (toward the top of the piston).

( flg. must

4

d

Figure

50.

Piston kg8

inatalkd

on pi&m.

Remove the exhaust valve adjusting screw from the end of the exhaust valve tappet. The intake valve tappet, being one piece (fig. 51) is subject only to the cleaning and inspection operations.

Before

Clectlting. Clean and inspect the intake and exhaust valve tappets for damage. b. In.s~cGn. and

(1) Check the threads and the fit of the exhaust valve adjusting screw in the exhaust valve tappets (fig. 51). The fit of a screw should be such that a wrench is required to turn it into or out of the tappet. Replace the worn part, either the screw or the tappet, or both, if there is looseness between the parts.

(2) Check the clearance of the tappets in their bores in the cylinder block (repair and rebuild standards (par. 1426)

) .

If there is excessive clearance between the bore and the tappet, try new unused tappet in the bore. If the clearance is still

I

, .:q excessive it indicates affected to accommodate an oversize tappet (0.004 inch oversize) in the particular tappet bore.

Section IX. REBUILD OF CRANKSHAFT

64. Cleaning

Note.

Before performing any of the operations given in this section, refer to the general instructions given in paragraphs 24 through 29, relative to the cleaning, inspection, and repair of engine parts.

Clean the crankshaft, taking particular care to clean the drilled oil passages of sludge or gum deposits.

65.

Inspection and Repair

If the crankshaft is replaced, the flywheel must be Atted to the new crankshaft (par. 70~). b. c.

143a)

) . check the amount of wear or the extent of out-of-roundness of the crankshaft bearing and connecting rod bearing journals (repair and rebuild standards (par. 143b and c)

) .

If the journals are unevenly worn, out-of-round, or tapered, the crankshaft must be ground (d below) to an undersize. c$. When necessary, the crankshaft may be ground and fitted with undersize bearings. In general, the crankshaft should not be ground to exceed 0.030 inch undersize.

66. Cleaning

Note.

Section X. REBUILD OF CAMSHAFT

Clean the camshaft as required.

67. Inspection and Repair

a. Zmpection.

Examine the camshaft gear teeth for damage. If teeth are damaged, replace the gear. Mount camshaft on centers or on

V-blocks and check for runout (repair and rebuild standards (par. l&a)

) .

Use a micrometer to measure the amount of wear of the camshaft bearing journals (repair and rebuild standards (par. 148b) ) . b. Rep&r. The camshaft cannot be repaired. If it has been damaged or if the journals are worn beyond limits, it must be replaced.

Section Xl. REBUILD OF FLYWHEEL ASSEMBLY

68. Cleaning

Note.

engine parts.

Clean the flywheel a,nd ring gear assembly.

69.

Inspection

a. If the friction face of the flywheel is scored or worn so badly that it cannot be corrected by refacing, replace the flywheel and flywheel ring gear assembly (fig. 52). If any of the mounting holes are misshapen or elongated, replace the flywheel. b. Measure the inside diameter of the clutch pilot bearing and replace the bearing (par. 70b) if the dimension exceeds 0.623 inch. c. If any of the teeth on the flywheel ring gear are broken, badly chipped or snubbed, or excessively worn, replace th6 ring gear (par.

70).

70. Repair

a. If the inner ends of the flywheel ring gear teeth are only slightly bured or snubbed, remove the burs and reshape the teeth using a small abrasive wheel. If, however, the teeth are broken, cracked or seriously bured, replace the ring gear as follows:

82

(1)

Figure 52. Flywheel assem bly-dianssembled view.

(2)

accommodate the straight dowel bolts (fig. 52) furnished with the replacement flywheel or crankshaft as follows:

(1) Assemble the flywheel and ring gear assembly to the crankshaft with the four 3/8-24NF-2 x 15/3s bolts, the 3/8-24NF-

2 nuts, and the ys-inch external-teeth lockwashers. Tighten the nuts securely.

(2) Drill the tapered dowel holes with a s5Js4-inch drill. Ream the holes with a s/,e-inch straight reamer. Remove the four bolts, nuts and lockwashers and remove flywheel from the cranksha.ft. to permit installation of the parts in the engine assembly.

53)

Remove the cotter pin from the oil strainer support and remove the oil strainer assembly.

Note. performing any operations given in a. Cleam&g. Clean the oil strainer parts of sludge or gum deposits.

b. Inspection amd Repah.

(1) Inspect the screen in the oil strainer assembly and replace if tears or punctures are found. Replace the oil strainer assembly if the screen has deteriorated to the point where it is no longer resilient or springy when flexed in the hands.

(2) Slide the outlet end of the strainer assembly into the inlet end of the oil strainer support and test for freeness of the parts. If either part is worn or distorted so much that the parts catch or bind, the part at fault must be replaced.

Insert the outlet end of the oil strainer assembly into the inlet end of the oil strainer support and secure in place by installing the l/s x 11/4 cotter pin in the support.

b.

Check the assembly to make sure there is no binding of the strainer in the support.

84

Figure 53. Oil strainer assembly-dieaasemble& dew.

Pull the water pump bearing retaining spring (fig. 54) out of the slot in the body of the water pump. b. Clamp the water pump in a bench vise and remove the water pump impeller (figs. 55 and 58) using puller 41-P-2958-65.

G. Lift the water pump seal and the seal washer off the end of the water pump shaft assembly. o?. Turn the assembly over and clamp the vise jaws on the body of the pump. Pull the fan and the water pump pulley from the end of the water pump shaft assembly, using puller 41-P-2908-240 and wrench

41-W-3248-900 (fig. 56). e. Tap against the impeller end of the shaft, using a soft-faced hammer, to drive the bearing and shaft assembly out of the water pump body.

FSgure 54. Water pump assembly.

I

86

Figure 55. Z&moving water pump impeller.

Figure 56. Removing fan and water pump pulley using pu11er--~1-P-2908-~~0.

f. Do not remove either the pipe plug or the hose nipple (fig. 54) from the water pump body unless they are damaged.

Note.

Before performing any of the operations given in this section, refer to the general instructions given in paragraphs 24 through 29, relative to the cleaning, inspection, and repair of engine parts. a.

Cleaning.

Clean the water pump body and water pump parts of rust and foreign material. b. Inspection.

(1)

The water pump shaft with bearing assembly is lubricated and sealed at the time it is manufactured. If the shaft is loose in the bearing, has end play, or binds and does not turn freely, the entire assembly must be replaced.

(2)

Inspect the seal washer seat inside the water pump body and if it is found to be rough or scored, reface the seat (c below). c. Repair. When necessary the seal washer seat on the inside of the water pump body (fig. 57) may be refaced to eliminate score marks or rough spots. Use refacer 41-R-2329-700 and follow the instructions furnished with the tool. a7

Early models were equipped with seal washer 7372811. Use preferred seal washer WO-MOOO3, if available. c. is

Figwe 58.

Section XIV. REBUILD OF OIL PUMP ASSEMBLY

77. Disassembly a.

Use an abrasive wheel or a file to cut off eit,her end of the oil pump drive gear pin (fig. 59). Drive the pin out of the gear, using a ya4-inch drift punch. Remove the gear from the end of the shaft. b. Remove the three cap screws securing the oil pump body cover

(fig. 59) to the oil pump body. Remove the cover and gasket. c. Remove the outer rotor (fig. 61) and the inner rotor with shaft assembly from the oil pump body.

\

Figure

59. Oil pum.~ assembly.

d. Back the pressure relief valve spring retainer (fig. 59) out of the oil pump body and remove the retainer gasket, the shim, the pressure relief valve spring, and the pressure relief valve.

78. Cleaning, Inspection, and Repair

C’leaning. Thoroughly clean all parts of the oil pump assembly giving particular attention to the oil pump body internal passages. b.

Inspection

(1) Reject any parts that are cracked, broken, or obviously worn.

(2) Inspect the inner rotor with shaft assembly for damage to the slot in the end of the shaft, replacing the rotor with shaft assembly if the slot is burred or distorted in any way.

90

Inspect the inner surface of the oil pump body cover for scoring or rough spots.

If such faults are present but only to a minor degree, remove them with a hand hone or crocus cloth. If the wver is seriously scored, replace the cover.

Check the cover for distortion using a straightedge and gage feeler (fig. 60).

The cover must be flat and true to O.OOl- inch. If a feeler gage thicker than OAOl-inch can be inserted between the straightedge and t,he cover, the cover must, be replaced.

Figure 60. Checking oil purmp body cover for distortion.

(5)

Insert the oil pump outer rotor and the inner rotor with the shaft into the oil pump body with bushing. Check the clearance between the outer rotor and the oil pump body with a feeler gage (fig. 61). If the clearance exceeds 0.012-inch, replace the oil pump body with bushing.

(6)

Position the two rotors so that the lobe of the inner rotor is entered as far as possible into one of the notches of the outer rotor (fig. 62).

With the rotors held in this position, insert a feeler gage between the opposite inner rotor lobe and the curved section of the outer rotor and gage the clearance. If the clearance exceeds O.OlO-inch, replace both rotors.

91

(7)

Measure the length of both rotors, and discard them if either one exceeds the length of the other by more than O.OOl-inch.

(8) The free length of the pressure relief valve spring (N, fig.

63) should be 1.640-inches.

Compress the spring to l$$s inches in the valve spring tester (fig. 35). If the tester dial indicator reads less than 9+$ psi, install one oil pressure relief valve spring shim (M, fig. 63) between the base of the tester and the spring. Again compress to l& inches and note reading. If necessary, add another shim.

If more than two shims are required to obtain a reading or 9l/2 psi, replace the spring. outer rotor (D) and the inner rotor with shaft, as-

Figure 6% Qheoking clearance between inmer a*ld outer oil pump rotor.%

securing it in place with the three I/,-20NC-2 x s/s lockwasher cap screws (A).

Note.

Tighten the cap screws to normal tension. b. With the oil pump body and cover assembled in this manner

(less gasket), grasp the end of the shaft, and attempt to turn it.

Note.

The shaft should be immovable. Remove the cover, coat both sides of the cover gasket and the threads of the attaching cap screws with plastic typegasket cement and install the gasket and the cover. Again attempt to turn the shaft by hand.

The shaft should now turn freely

; thus proving that the end clearance of the rotors is less than O.OOP- inch (the thickness of the gasket when compressed) which is satisfactory. c. If the shaft can be turned when the cover but not the gasket is installed, try a new body cover, body, or both until the proper end clearance is attained.

Install the oil pump drive gear on the end of the shaft, tapping it toward the oil pump body until the pin hole in the gear is alined with the pin hole in the shaft.

Insert the drive gear pin

(J) about half way into pin hole.

Note.

pwmp

’

2

’

3

Check the clearance between the inner edge of the gear and the end of the body using a feeler gage.

There should be from 0.020 to 0.030- inch clearance at this point.

If the clearance exceeds the maximum of 0.030-inch, replace the gear or the body with bearing, whichever part is worn. When the correct clearance is attained, tap the drive gear pin completely through the shaft and the gear, and peen the ends to secure the pin in place. e. If a new inner rotor with shaft is being used, install the gear and tap it forward toward the oil pump body until there is only 0.020 to 0.030-inch clearance between the end of the body and the face of the gear. Clamp the gear and the shaft in this position, and using t,he hole in the gear as a guide for the drill, drill a Y&-inch hole through the shaft.

Install a new drive gear pin through the gear and shaft and peen the ends to secure it in place. f. Install the oil pressure relief valve spring

(N) ,

the pressure relief valve spring shim or shims (M) , a new pressure relief valve spring retainer gasket

(L) ,

and the pressure relief valve spring retainer (K) in the opening in the side of the oil pump body. Install shims in accordance with paragraph 78b (8).

34)

Remove the four socket-head cap screws and copper gaskets securing the rear mounting plate support to the rear mounting plate and remove the support.

Note.

b.

Clean the rear mounting plate and the support.

&pa&.

(1) Replace the rear mounting plate if any of the mounting holes are elongated, or if the plate bent or warped.

(2) Check the tapped holes in the reinforcing bars and square nuts welded to the mounting plate, running a tap through them, if necessary to clean any rough or damaged threads.

(3) Examine the rear mounting plate support and replace if the rubber, originally bonded to the support, has become loosened or has deteriorated.

(4) Replace the copper gaskets.

95

F&we 64. Rear mountin# plate a48emb&l_disa88embted v&w.

Assemble the rear mounting plate support with the engine rear mounting plate using the new copper gaskets under the heads of the four 1/,-20NG2 x 1/2 socket-head cap screws. Tighten the cap screws only finger tight at this time.

Press or drive the crankshaft front oil seal out of the timing gear cover.

84.

Note. Before performing

C&w&g. Clean the timing gear cover. b

Inqzwction and Repair.

(1) the crankshaft front oil seal.

96

Beplace the cover if the cover is dented or warped out

of

shape.

Examine the bolting flange of the cover for distortion

or

stretching of the metal around the attaching bolt holes. If necessary, smooth out the rough areas of the flange following the procedures given in paragraph 89b and shown in figure 69.

85.

65)

Press the crankshaft front oil seal into the timing gear cover with the protruding leather edge of the seal facing the rear of the cover.

Section XVII. performing any of the operations given in this section,

refer to the

general instructions given in paragraphs 24 through 29 relative to the

clerning, inspection, and repair of engine parts.

324309 0 - 55 - 7

97

Perform the same cleaning operations on the exhaust valves and their related parts as were performed on the intake valves and their related parts (par. 54~~). b. Inspection.

(1) Euhu~t uaZve.9. Make the same inspection checks on the exhaust valves as were made on the intake valves (par.

543(2)).

(2)

Make the same inspection checks on the exhaust valve springs as were made on the intake valve

) , The test standards for the exhaust valve springs are as follows: Free length to be not less than

21/2-inches. Compression pressure to be not less than 50-psi when compressed to 27h4-inch

; nor less than 116-psi when compressed to 13/4-inch (fig. 35).

Note. c.

(1)

Inspect the parts for evidence of uneven wear and obvious damage or faults. If one valve spring retainer lock of a valve is damaged or worn, both locks of the valve must be replaced.

Using a valve refacing tool, grind the seat area of the exhaust valves to an angle of 45”. Remove only enough metal to clean the seat and eliminate pitted or burned areas.

If it is necessary to remove so much metal from the face of the valve that the thickness of the edge of the valve head is reduced to less than +&-inch, replace the valve.

Replace any valves with bent stems, or valves which do not conform to the repair and rebuild standards (par.

150a).

98

Lap the exhaust valves in the exhaust valve seats in the cylinder block as instructed in paragraph 51b (6).

(2) Check:

The rotator cap used between the exhaust valve adjusting screw and the end of the exhaust valve provides the means whereby the exhaust valve is momentarily freed and allowed to rotate slightly each time it is lifted off its seat

in the cylinder block. In order for the parts to operate

0.004-inch (fig. 66) clearance between the end of the exhaust valve and the rotator cap.

(b) Check the exhaust valve to exhaust valve rotator cap clearances using kit 41-K-84-15 (fig. 66).

1.

Stand the exhaust valve upright on the valve head. Lower the collar 41-C-2482-15 (fig. 66) over the valve stem

I-

I

I5

/

I

I

Figure 66. Kit-&-K-8&15 in posittvn on edwust valve.

copyright 1999

and install the exhaust valve spring retainer and retainer locks on the end of the valve. Slide the collar up against the spring retainer, and lock the collar in this position by tightening the collar thumb screw. Turn the upper half of the collar to the right as far as possible to take up any slack remaining between the assembled parts. d. Adjust the thimble of gage 41-Q-234275 so that the “0” mark on the thimble is alined with the mark scribed along

99

the length of the body of the gage. Loosen the gags thumb screw and set the gage over the end of the valve with the lower edge of the gage resting on the valve spring retainer locks. Press down on top of the center pin and tighten the gage thumb screw.

3. Set the exhaust valve rotator cap on top of the gage with the end of the gage center pin entered in the hole in the cap. While holding the assembled parts cradled in one hand, and pressing on the top of the exhaust valve rotator

Checking exhaust valve to rotator cap clearance with kit-_41-E-Q-15.

cap (fig. 67) with one finger, turn the gage thimble one complete revolution to the left. Slowly turn the thimble back to the right until the top of the thimble contacts the lower edge of the rotator cap and note the reading opposite the scribe mark on the body of the gage.

/L. A reading in excess of 0.004 inch to the right of the “0” mark indicates that there is too much clearance. To reduce the clearance, grind or lap the rim of the rotator cap as necessary to bring the clearance within the specified limits. A reading of any amount to the left of the

“0” mark indicates that there is not enough clearance.

To increase the clearance, grind or lap the end of the exhaust valve as necessary to bring the clearance up to the specified limits.

6. When the correct clearance is attained, remove the gage and collar from the valve and keep the valve, the rotator cap, the retainer lock and the retainer together until the specified limits.

Figure 68. h’xhaust matifold and attaching parts.

88. Exhaust Manifold a.

Insp&ion.

Replace the exhaust manifold (fig. 68) if broken or cracked. Check

for

cracks around the mounting holes and exhaust ports. Lay manifold on flat surface and check alinement of gasket surfaces. If manifold is broken, cracked or warped, it must be replaced. b.

Repair.

No repairs to the exhaust manifold are possible, replace if it is broken or damaged.

Remove the oil pan drain plug

(fig. 69) from t.he side of the oil pan. Replace the oil pan drain plug gasket. Install the 7/s-inch drain plug. b. Repair. Inspect the bolting flange of the oil pan for distortion or stretching of the met.al around the attaching bolt holes.

If such faults are present, clamp a piece of bar stock approximately 11/h x 5/rs x

Figure 69. Straightming bolting flange of

oil pun.

12 (fig. 69) in a bench vise and, using t.he bar stock as an anvil, flatten any distorted areas to a smooth level surface. Replace the oil pan if it is deeply dented, distorted, or out of shape.

90.

Always replace the camshaft driven gear. The driven gear is fibre and the crackshaft drive gear is steel. Because of this difference in materials, the driven gear absorbs whatever wear occurs between the gears and is usually the only one of the two that requires replacement.

However, if inspection reveals the crankshaft drive gear to be damaged, or if the woodruff key slot in the bore of the gear is distorted or mis-shapen, replace the drive gear also.

102

Unless the fan belts are in exceptionally good condition, replace fan belts.

Replace the engine front mounting support cushions if the rubber has become loosened from the steel plates to which it was originally bonded, or if the rubber has deteriorated and has become soft and spoWY*

All other engine parts not specifically covered in the above rebuild sections must be individually cleaned and inspected and judged as to their fitness for further use. Unless a part, no matter how small or minor, can be repaired or reworked so that it is restored to its original size or shape it must be replaced.

Standard parts, such as bolts or cap screws, on which the corners have been rounded, or the threads roughened, or flattened, must be replaced.

70 and 71) a. Mount the cylinder block in an engine repair stand (par. 30).

If an engine repair stand is not available, perform, the following assembly operations in a manner designed to protect the engine or engine parts against damage and personnel against injury. b.

Turn the engine upside down so that the bottom of the engine is facing up. Beginning at the rear end of the cylinder block, install the intake and exhaust valve tappets in the tappet bores in the cylinder block in the following order: One exhaust valve tappet, two intake valve tappets, two exhaust valve tappets, two intake valve tappets and one exhaust valve tappet. c. Carefully, so as not to damage or score the camshaft front bearing, insert the camshaft into the camshaft bore of the cylinder block.

Note.

Do not allow the rear end of the camshaft to strike sharply against the expansion plug (flg. 27) installed in the rear end of the bore.

d.

Install the camshaft thrust plate (fig. 24) on the front end of the cylinder block and secure in place with two 3/s-16NC-2 x 3/4 lock washer cap screws.

Tighten the cap screws to a torque of 20 to 26 pound-feet. Slide the camshaft thrust plate spacer onto the end of the camshaft with the beveled inner edge of the spacer facing the cylinder block.

103

A-Nut, lock washer, s-m-2

B-Cover, timing gear--7372576

C-Screw, cap, %e-14NC-3 x l%-122260

D-Washer, lock, es&teeth, 7&-inch-136857

E-Washer, plain-7741406

F-Key, woodruff, se x %--124549

G--Gear, camshaft driven-7741419

H-Cushion, front mounting support-

8328391

J-Plate, front mounting-7372578

K-Nut, “huglock”, +20NF-2B-442832

L-Bolt, +24NF-3 x s/,-WO-123520

M-Rod, push, intake valve-8329717

N-Gasket, cylinder head-28463

P-Head, cylinder, assy (see flg. 39)

Q-Screw, cap, v,&-14NG2 x 11?4e-8328474

R-Arm, rocker, assy (see flg. 39)

S-Cover, rocker arm-8329713

T-Gasket, rocker arm cover stud-WC)-

51875

U-Clip, spark plug cable-WC&8072010

V-Nut, 5&j+%NF-%l2@3%3

W-Clip, spark plug cabl~WO-8@72020

X-Gasket, rocker arm cover--8329716

Y-Nut, lock, s-24-7744472

Z-Screw, cap, %e-l4NG2 x 4?4-832Q677

M-Washer, plain-

BB-Line, oil, crankcase to cylinder head, assy--8328408

CC-Screw, cap, lock washer, l/b-2ONO2 x

1~-W0+00226

DD-Clip, 3/ie-inch-WG645539

EE-Flywheel, assy-f%Z3045

FF-Nut, 9$-24NF-2-12036Q

GG-Washer, lock, ext-teeth, ?&inch-

13E4@Q

HH-Nut, gS-24NF-2-120389

JJ-Washer, lock, %-inch-l38489

KK-Plate, rear mounting-8328047

LL-Gasket, special-A226080

MM-Screw, cap, Ye-18NG3 x $/a-l22007

NN-Gasket, cylinder block to rear mounting plate-3328049

PP-Gasket, special-A226080

&Q-Screw, cap, se-24NF-3 x ~-I20213

RR-Bolt, 9$-24NF-2 x 394-7371700

S&-Gasket, oil strainer support-7371267

TT-Screw, cap, lock washer, %g18NG3 x

Q/4-451975

UU-Strainer, oil, assy-7036578

Figure 70. Engine aaeembly-diea88embled

tielo No. 1.

W--Giasket, oil pan-W_

WW--Screw, cap, lock washer, 9$s-lSNG2 x

%-8328411

XX-Pan, oil-7371278

YY-Gasket, spacer, pulley shield-WC&

6701

LZ-Spacer, fan and drive pulley shield-

7372559

AB-Screw, cap, lock washer, qe--l8NG2 x

1$$*63

AC-Shield, fan and generator drive pulley-7371376

AD-Key, woodruff, so x l-124552

BE-Key, woodruff, se x $/a-l24549

AF-Gasket, cylinder block to mounting plate-7741427

AG-Stud, gS-li3NG2 (se) x 9$-24NF-2

( q$ ) x 119&3-103197

AH-Gear, crankshaft drive7741415

AJ-Screw, cap, lock washer, 9$-24NF-3 I

Qh--12.3520

AK-Spacer, camshaft drive gear-7741414

AL-Slinger, oil, crankshaft-7371161

AM-Gasket, timing gear cover-7371159

Figure 71. Wng6n.e aeeemblydisaaeembled

iUP0 181082

95. Install Main Bearing Halves in Cylinder Block

(fig* 72) a.

Install one half of the rear bearing oil seal in the seal groove in the rear end of the cylinder block.

6. Install the bearing dowel pins in the bearing dowel pin holes in the cylinder block, making sure the pins are installed with the small diameter projecting into the bore. c. Install the main bearing halves in the cylinder block as follows:

(1) Install the bearing half with the double oil groove and the flanged sides in the front bearing support.

A-Gasket, exhaust valve spring compartment cover stud-WO-5187.5

B-Stud, exhaust valve spring compartment cover-806348

C-Cover, exhaust valve spring compartment-7371237

D-Gasket, valve spring compartment cover-WO-630305

E-Cap, rotator,

7375023 exhaust

F-Lock, exhaust valve spring retainer-7375033

G-Retainer, exhaust valve spring-

7375034

H-Spring, exhaust valve-7371235

J-Bearing, bushing type, camshaft front-7744319

K-Jet, oil, timing gear-7372557

L-Camshaft-8329698

M-Plate, camshaft thrust-7351413

N-Spacer, camshaft thrust plate-

7741407

P-Screw, cap, lock washer, s-lSNC-2 x 3/4423569

Q-Block, cylinder, assy-7412658

R-Guide, exhaust valve-8328126

S-Valve, exhaust-7375035

T-Bearing, half, connecting rod-

5701528

U-Rod, connecting-7743751

V--Piston, w/pin, assy-7373873

W-Cock, tee handle, drain-103647

X-Seal, oil, crankshaft rear bearing-

7372560

Y-Screw, adjusting, exhaust valve-

7371258

%-Tappet, intake valve--W&800550

AA-Tappet, exhaust valve-7372585

BB-Pin, dowel, bearing-7371229

CC-Bearing,

7371167 half, front, main-

DD-Bearing,

7371173 half, center, main-

EE-Bearing, half, rear, main-7371165

FF-Crankshaft-7744473

GG-Bearing, half, rear, main-7371169

HH-Bearing, half, center, main-

7371225

JJ-Bearing, half, front, main-7371171

KK-Packing, rear bearing cap-

7371281

LI.--Cap, main bearing, rear-WC)-

737236

MM-Washer, lock, Yz in.-120384

NN-Screw, cap, main bearing cap

7371227

PP-Cap, main bearing, center-WO-

630288

QQ-Nut, s-24NF-3-7744472

RR-Nut, jam, s-%107823

SS-Cap, main bearing, front-WO-

630285

TT-Screw, cap, lock washer, %-lSNC-

3 x l-122017

UU-Screw, cap, lock washer, %a-

18NG3 x 2$&--8328399

VV-Pump, oil, assy-7376907

WW-Gasket, oil pump to cylinder block-7372587

XX-Shim, adjusting crankshaft end play, 0.002 thk-7371226

YY-Washer, thrust, crankshaft-

7371160

Figure 71.-Continued

Figure 7% Installing crankehaft bearings and dowel pine.

the be

Note.

6. &and the crankshaft upright on the rear (flanged) end on a clean solid surface. Install three 0.002-inch crankshaft end play adjusting shims (fig. 73) and the crankshaft thrust washer on the front end of the crankshaft.

Install the thrust washer so that the inner beveled edge faces the rear end of the crankshaft.

Note.

The installation of the O.OOSinch shim thickness facilitates the subsequent adjustment of the crankshaft end play (par. 107).

Figure 73. Crankshaft end play adjusting

Install the 3/ls x 1 crankshaft drive gear woodruiI key (fig. 78) in the longer of the two key slots on the front end of the crankshaft.

Install the crankshaft drive gear on the front end of the crankshaft with the timing mark “0” facing out, away from the cylinder block.

Aline the keyway in the gear, with the key installed in the shaft, and drive or press the gear onto the crankshs ft and firmly against the thrust washer.

d.

Insert the four 3/8-24NF-2 x

1 5i:r fiywheel bolts and the two tapered dowels (fig. 52) in the fly whet:1 bolt holes in the flange on the rear of the crankshaft.

Note.

If flywheel or crankshQt has been replaced and flywheel and crankshaft holes have been bored and reamed, use dowel bolts in place of tapered dowels. e.

Carefully lower the crankshaft onto the bearlhgs in the cylinder block.

f. Assemble main bearing halves in the main bearing caps as follows

:

(1) Insert the other half of the rear bearing oil seal (fig. 74)) a bearing dowel pin with the small diameter projecting into the bore, and the other half of the rear main bearing in the rear main bearing cap. Note that both halves of the rear main bearing have double oil grooves and non-flanged sides.

110

Figure 74. installing main bearing halves in main bear-if&g caps.

(2) Insert a bearing dowel pin, with the small diameter of the pin projecting into the bore, and the other half of the center main bearing into the center main bearing cap. Note that both halves of the center main bearing have a single oil groove and non-flanged sides.

(3)

Insert the other half of the front main bearing into the front main bearing cap.

Note that no dowel pin is used in

this cap. Also note that the bearing has flanged sides and a double oil groove.

Note.

Because it is possible to incorrectly install this bearing,

take

particular care to see that the bearing is installed in the cap with the narrower of the two oil grooves nearer the front edge of the cap.

If this bearing is not properly installed, the oil grooves in the two halves of the bearing will not match at the parting line and will cause the premature failure of the bearing.

g. Lightly coat both ends of both halves of the rear bearing oil seal and both sides of the crankshaft rear main bearing cap (fig. 74) with plastic type gasket cement and install the bearing cap in the cylinder block. Coat both pieces of the rear bearing cap packing with plastic type gasket cement and insert the packing into the holes on

Installing rear bearing oap.

either side of the rear bearing cap (fig. 75). The ends of the packing should protrude approximately one-fourth of an inch. Do not cut them off because when the oil pan is installed, it forces the packing further into the holes to effectively seal this area against oil leaks. h. Secure the rear bearing cap in place with two &inch lockwashers

(fig. 75) and two rear bearing cap screws. Tap the bearing cap to aline the matching marks on the bearing cap with those on the cylinder block. Tighten the cap screws to 65 to

70

pound-feet torque.

97. Check Running Clearance of Main Bearings

a. Thread the ll/,6-inch nut (fig. 17) onto the front end of the crankshaft. Using a socket wrench fitted over the nut as a crank,

111

check the clearance between the main bearings and the crank&aft as follows

:

(1)

With the bearing cap tightened to the specified torque (par. 96h), and using hand pressure only, turn the crankshaft through two complete revolutions. The crankshaft should turn freely without effort. If the crankshaft is immovable or if force is required to turn it, the bearing is too thick and must be replaced. In this event remove the cap and both halves of the bearing, and measure the dimensions of the journal to determine the bearing size required. Install a new bearing

(both halves) and recheck as above.

_ (BEARING, HALF. REAR

BRASS SHIM STOCK,

f

3/4 X l-1 /4 X 0.001IN

I

RAP0 l8lWJP

112

Figure 76. Checking rear main beariw for under&e.

(2) Check

If the crankshaft turns freely, remove the bearing cap with its half bearing. Cut a piece of brass shim stock s-inch wide, 11/4- inches long, and 0.002 thick (fig. 76).

Note. After cutting the shim stock, feather the edges on a honing stone to avoid the possibility of a rough edge scratching the surface of the bearing.

Lay the piece of shim stock on the crankshaft bearing journal and replace the cap and half bearing. Install the lock washers and the cap screws and tighten the screws to 65 to 70 pound-feet of torque. Again attempt to turn the crankshaft.

The crankshaft should now turn with a noticeable dragging action. If the crankshaft turns freely and without effort, the bearing is too thin and must be replaced.

In this event.

Do above operation. fall to remove the shim stock upon completion of the

It is essential for the flanged sides of both halves of the front main bearing to be in perfect allnement when the front main bearing cap is tightened for the last time after completion of operations a(l) and (2) above. Allne these surfacet3 by using a screwdriver or other suitable pry-bar (fig. 87) to force the crankshaft forward so the thrust face (fig. 74) of the crankshaft ie held firmly against. the flanged edge of the upper half of the front main bearing.

Install and tighten the front main bearing cap, lightly tapping the cap back- ward to force the flanged side of the bearing against the thrust face of the crankshaft as the cap tightening operation progresses.

98. install Front Mounting Plate a.

Coat

1y16

b. Coat both sides of the mounting plate to cylinder block gasket with liquid type gasket cement and install the gasket over the mounting plate studs. Install the front mounting plate and secure in place with two 3/,-24NF-2 lock washer nuts (fig. 78) and three a/8-16NC-3 x

37 lock washer cap screws. Coat the threads of cap screws with plastic type gasket cement before installing.

99.

Install Camshaft Driven Gear

a. Install the 3/ls x 3/4 camshaft. driven gear woodruff key (fig. 78) in the key slot in front end of the camshaft.

RAPD 181089

Figwe

78.

Installing camshaft driven gear.

b. With the woodruff key in the camshaft and the key slot in the camshaft driven gear (fig. ‘78) in alinement, start the camshaft driven gear onto the camshaft with the wide hub of the gear facing out, away from the cylinder block.

Turn the camshaft or the crankshaft as necessary to bring the timing marks “0” (figs. ‘73 and 80) in both gears together. Slide the %a-inch external teeth lock washer (fig.

79) and the 15/32 ID x l$& OD plain washer onto the 7/,a-14NG3 x ll/s cap screw and thread the cap screw into the front end of the camshaft. Tighten the cap screw to 30 to 40 pound-feet torque, pressing the gear onto the front end of the camshaft in the process.

Note.

Do not drive the gear onto the camshaft.

!?A

Install the timing gear oil jet (fig. 79) in the tapped hole in front of the cylinder block.

Position the oil hole in the side of the oil jet so that it will direct the oil stream against the camshaft driven gear just ahead of the point of its engagement with the crankshaft drive gear.

When installing the oil pump assembly the following facts should be borne in mind.

(1) The oil pump is driven from the camshaft by means of a worm (spiral) gear.

The distributor, in turn, is driven by

Figure

7’9. Crankshaft drive and camshaft driven gears (timing gears).

the oil pump by means of a tang on the end of the distributor shaft which engages a slot in the end of the oil pump shaft.

(2) Because the tang and the slot are both machined off center, the two shafts can be meshed in only one position.

(3) Since t,he position of the distributor shaft determines the

“timing” of the engine, and since the position of the distributor shaft is determined by the position of the oil pump shaft, the position of the oil pump shaft wit,h respect to the camshaft is critical. b. Turn the crankshaft as necessary to bring the timing marks “0” on the crankshaft drive and camshaft -driven gears together (fig. 79).

c. Coat both sides of the oil pump to cylinder block gasket with liquid type gasket cement and install the gasket on the pump. Start the oil pump drive shaft into the opening in the left side of the cylinder block with the mounting holes in the body of the pump in alinement with the mounting holes in the cylinder block. d. Insert a long blade screwdriver (fig. 80) into the distributor shaft opening on the opposite side of the block and engage the end of the oil pump shaft.

Turn the shaft so that the slot is positioned at what would be the rough equivalent of the nine thirty position on a clock face (fig. 81), with the wider edge of the slot on top

(nearer the top of the cylinder block).

Figure 80. Innstalling oil pump assembly. e.

Remove the screwdriver and, looking down the distributor shaft hole, observe the position of the slot in the end of the oil pump shaft to make certain it is properly positioned. Replace the screwdriver and, while turning the screwdriver clockwise to guide the oil pump drive shaft gear into engagement with the camshaft spiral gear, press against the oil pump to force it into its final position.

f.

Remove the screwdriver and again observe the position of the slot. If the installation was properly made, the slot will be in the position roughly equivalent to the eleven o’clock position on a clock

116

face (fig. 81) with the wider edge of the slot still on the top side. slot is improperly positioned, remove the oil pump assembly and repeat operations and e above. g. Coat the threads of the cap screws with plastic type gasket cement and secure the oil pump in place with two s/,e-18NG3 x 21/ lock washer cap screws (fig. 18) installed through the body of the oil pump and into the cylinder block, and one 5/,,-18NC-3 x 1 lock washer cap screw (fig. 18) installed through the oil pump mounting

Lange and into the cylinder block.

. . .- _ _. _. -

81. Initial positiona of oil

Coat both sides of the rear mounting plate with plastic type gasket cement and install the gasket and the rear mounting plate on the rear end of the cylinder block. Temporarily install loosely one ys-24NF-2 x 7/s bolt (fig. 21) in each side of the cylinder block to hold the plate in position.

(fig. 83)

Install the flywheel assembly on the bolts previously installed in crankshaft mounting flange and secure in place with six s/s-inch external teeth lock washers and 3/,-24NF-2 nuts.

Note.

Install the connecting rod bearing (two halves) in a connecting rod. Spread a light coat of engine oil on the bearing.

F,igure Installing rear mounting plate.

118

Figure 83. Installing fluwsheel assem.bly.

b. Thoroughly lubricate the piston rings with engine oil and compress the piston rings with a ring compressing tool. c. Turn the crankshaft so that the crankpin of the piston about to be installed is at bottom center. Matching the piston and connecting rod to the cylinder bore to which it was fitted (par. 60b (5)

) , start the piston into the top of the cylinder block (fig. 84) so that the narrow side of the connecting rod offset is adjacent to the nearest main bearing (fig. 46). When correctly positioned, the side of the lr-

Figure

84.

Installing pistons and comeoting

connecting rod stamped with the cylinder identifying number is on the camshaft side of the engine (fig. 84). Use the handle end of a hammer to tap the piston through the ring compressing tool and down two or three inches into the cylinder.

d.

Reach up from the bottom of the cylinder block and pull the end of the connecting rod down over the crankshaft journal. Install the cap and half bearing on the rod half of the rod and the bearing, numbered side of cap to numbered side of rod, and secure..in place with

119

e.

Do install the %-24NF

f.

this time.

) .

1

CAP, EXHAUST VALVE;

ROTAt7375032,

Pipwe 85. In&&hag eshmst

valmx~ and related parts.

Exhaust and intake valve springs look alike but are different. They must not be interchanged.

106. Adiust Exhaust Valve

6.

107. Adjust Crankshaft End Play a.

) .

(

AB,

(AC, fig.

the fan and generator drive pulley (A, fig. 9)) and the 11/rs-inch nut,

(B, fig. 9) on the front end of the crankshaft. Do not install the fan and generator drive pulley woodruff key (AF, fig. 9). Tighten the l%,-inch nut. Insert a screwdriver or other suitable pry-bar between the center main bearing support and the crankshaft number two counterweight (fig. 87) and pry the crankshaft forward. Insert a feeler gage between the crankshaft thrust washer and the flanged edge of the front main bearing and measure the crankshaft end play.

This clearance must be between 0.004- and 0.006-inch (repair and rebuild standards (par. 143~)

) .

Figure 87. Gaging cranhxhaft end plag.

b. If the clearance is less than O.OWinch, carefully gage the actual amount of clearance. Remove the ll/rs-inch nut, the fan and generator drive pulley, the crankshaft oil slinger, and the crankshaft drive gear spacer. Use puller 41-P-2956-4 (fig, 19) to pull the crankshaft drive gear forward on the shaft about one inch. Reach into the space between the crankshaft thrust washer (fig. 88) and crankshaft front bearing with a pair of thin-nose pliers and grasp one of the crankshaft end play adjusting shims. Jerk the shim to tear it and release it from the crankshaft. If the removal of addi- tional shims is necessary, they may be removed in the same manner.

(Total shim thickness to be removed is determined by subtracting the actual clearance from the desired clearance of from 0.004 to

0.006-inch).

G.

If the above operations were carefully performed, no rechecking is necessary. However, if there is any doubt as to t,he accuracy of the adjustment, recheck as instructed above. Remove the ll/,a-inch nut and the fan and generator drive pulley when the crankshaft end play has been properly adjusted. s

Removing a. Install the 3/1s x s/ fan and generator drive pulley Woodruff key (AG, fig. 9) in the key slot on the front end of the crankshaft.

b.

Coat both sides of the timing gear cover gasket (AM, fig. 70) with liquid type gasket cement and install the cover and the gasket on the front end of the engine.

Secure the cover in place with three s/s-24NF-3 x 3, bolts (fig. 89) and one s/s-24NF-3 x 1 bolt. Use eight s/s-24NF-3 lock washer nuts, four of which are used on the previously installed studs.

Do not tighten the nuts until the fan and generator drire pulley has been installed (par. 109).

123

a. Aline the keyway in the fan and generator drive pulley with the

Woodruff key installed in the crankshaft.

Drive the fan and generator drive pulley onto the crankshaft and secure it in place with the ll/ls-inch nut. Insert a block of wood between one of the counter- weights on the crankshaft and the side of the cylinder block to prevent the crankshaft from turning when tightening the nut. b. Tighten the eight timing gear cover nuts.

110. a. Install the two dowel bolts one on either side of t,he engine (figs.

21 and 22)) to serve as locating dowels for the engine rear mounting plate.

Install two ,5/,a-18NC-3 x 3/ cap screws (fig. 90) and two copper gaskets to attach the rear mounting support to the underside the cylinder block. Tighten the screws to 12-17 pound-feet torque.

12A

c. Tighten the I/-2ONC--2 x 1/ socket-head cap screws (fig. 90) attaching the rear mounting plate support to the rear mounting plate. d. Coat both sides of the oil strainer support gasket (fig. plastic type gasket cement and install the gasket and the oil strainer assembly in position on the underside of the cylinder block.

Use two yls-18NC-2 x 3/4 lock washer ca.p screws to secure the oil strainer in place. e. Coat both sides of the oil pan gasket (fig. 91) with liquid type gasket cement. Loosely attach the oil pan and gasket to the bottom the cylinder block with fourteen 5/is-18NG2 x 6/s lock washer installed in the side and rear mounting holes.

Do not install cap screws in the front holes. f. Center a fan and generator drive pulley shield spacer gasket

(fig. 17) and a pulley shield spacer over each of the oil pan front mounting holes.

Install the fan and generator drive pulley shield

(fig. 91) on top of the spacers with the squared side of the shield on the oil pump side of the engine.

Secure the shield in place with six 5/la--lBNC-2 x 11/s lock washer cap screws. Tighten the pulley shield cap screws and the oil pan cap screws to 12-17 pound feet. torque.

111.

Coat both sides of the water pump to cylinder block gasket (fig.

92) with plastic type gasket cement. Install the water pump and gasket on the front end of the engine using one 5/,,-lBNC-2 x 2%

125

blu.

lock washer cap screw and three 5/1a-l8NC-2 x 7/ lock washer cap screws to secure the water pump in place. Tighten cap screws to

12-17 pound feet torque.

112. Install Cylinder Head a.

Center the cylinder head gasket on the top of the cylinder block.

Set the cylinder head in place on the gasket. and install the ten

7&a-14NC-2 x 41/4 cap screws and the ten plain washers in the locations shown in figure 15.

6. Using the same size cap screws, but no washers, install the upper bellcrank accelerator bracket (fig. 98) and the oil filter mounting bracket, installing cap screw in the front mounting hole only of the oil filter bracket.

.Center a plain washer (fig. 93) on the cylinder head mounting hole, just to the rear of the carburetor mounting flange, and set the mounting feet of the engine lifting hook on the washer and on the rear end of the oil filter mounting bracket.

Secure the hook in place using two 7/,a-14NC-2 x 45/a cap screws. d. Install the 7/1a-14NC-2 x cap screw (fig. 15) in the cylinder head mounting hole at the bottom of the carburetor inlet opening. e. Tighten all cap screws to 60 65 pound-feet torque in the sequence shown in figure 94. f. Install the two 3/s-16NC-2 (?$a) x +&-24NF-2 (5/R) x lll/le studs

(fig. 93) in the tapped openings on either side of the carburetor mounting boss.

127

Figure 94. Cyt4&m head cap aw’eu, tightening sequence.

Lower the intake valve push rods, ball end first, through the cylinder head and cylinder block, seating the ball ends of the rods into the cupped ends of the intake valve tappets. b. Install the rocker arms and shaft assembly on the four rocker arm shaft bracket studs (fig. 14). Remove the two temporarily installed rocker cover studs (par. 58e). Using one yie-inch internal teeth lock washer (fig. 95) between each stud and rocker arm shaft bracket, install the studs so that the short threaded ends enter the tapped holes in the brackets.

Install four 3/-24NC-2 lock nuts on the rocker arm shaft bracket studs. Tighten the nuts to 30 to

36 pound-feet torque.

&24NF-2-8329714

128

F@ure 95. Inetatling rooker arm cover 8tUd8.

Turning the crankshaft as necessary to bring each intake valve in turn to the fully closed position, adjust the rocker arm to intake valve clearance to 0.018- to 0.020-inch (repair and rebuild standards

(par. 149a) ) .

6.

Adjust the clearance by loosening the intake valve adjusting screw lock nut (fig. 96) and turning the adjusting screw in or out to close or open the gap between the end of the intake valve and the rocker arm. Turn the screw clockwise to close the gap and counter- clockwise to open the gap. the gap is adjusted so that a 0.01%

Figure

96. inch feeler gage can be inserted with only a light feeling of resistance, hold the adjusting screw in that position and tighten the lock nut.

Check the gap after locking the screw to make sure that the gap is unchanged.

Install the crankcase to cylinder head oil line y/,e-inch clip on the rear end of the engine.

Use a 1/,-20NC-2 x 1/2 lockwasher cap screw attach the clip to the engine. b. Install the crankcase to cylinder head oil line 90’ elbow (P) in the cylinder block. Install the crankcase to cylinder head oil line (K)

c.

d.

(E) .

Figure 97. Left aide view of mgine partially assembled.

Coat both sides of the exhaust valve spring compartment cover gasket (D) with plastic type gasket cement and install the exhaust valve spring compartment cover (FF) and the gasket. Install the, exhaust valve spring compartment cover special stud (T) using a stud gasket (U) between the shoulder

011 the stud and the cover.

Slide the accelerator lower bellcrank (R) onto the exhaust valve spring compartment cover special stud (T) so the projecting hub of the b’ellcrank faces out. Install an 1’/3a ID, l$$e OD plain washer

(AA) and a 1/1a x $4 cotter pin (S) on the end of the stud to secure the bellcrank in place.

6. Slide the accelerator bellcrank spring (CC) onto the shaft of the accelerator upper bellcrank (.JJ) and insert the shaft into the accelerator upper bellcrank bracket (J) attached to the cylinder head. Install an r+& ID, 1?i6 OD plain washer (X) and a l/s x 1,

A-Line, flexible, oil filter inlet, assy- T-Stud, special, exhaust valve spring

8328469 compartment cover-WO-866348

B-Loom, split, 3/le x l-WO-A17445

C-clip, gie-inch-197839

U-Gasket, exhaust valve spring compartment cover stud-WO-51875

D-Gasket, exhaust valve spring com- V-Stud, a&-l6 x l’,&-WO309143 partment cover-W0639305 W-Pin, cotter, $&j x r&-l12726

E-Clamp, hose, rf&-inch (water pump X-Washer, plain, rr/5a ID, Ii& OD- bypass) -502913

126393

F-Tube, water pump bypass, assy- Y-Clip, 3/10-inch-W0645539

7372962

Z-Rod, accelerator bellcrank link-

G-Rod, throttle-8329763

8329765

H-Connector, se-inch-137464

AA-Washer, plain, I!/32 ID, r1/6 OD-

J-Bracket, accelerator upper bellcrank-8329768

K-Line, oil, crankcase to cylinder head, assy-8328408

L--Screw, rap, lockwasher, Y,-ZONC-

120393

BB-Stud, s-16NC-2 (se) x 3/s-

24NF-2 (5/s ) x 2yS-WO-A564

CC-Spring,

8329770 accelerator bellcrank-

2 x y%-WO-899226

M-Line, oil, sending unit, assy-

8328497

N-Elbow, 90 deg-13742’1

P-Elbow, 90 deg-137420

Q-Spring, return, accelerator pedal-

8329764

R-Bellcrank, accelerator, lower-

8329766

S-Pin, cotter, 1/46 x l/l-l12726

DD-Stud, 3Js-16NS (IL

(7/s

) x %-24NF

) x 13/,-w0-866860

EE-Stud, 3/s-16NC-2 (%6) K-24NF-

2 (6/s) x 2%-WO-A564

FF-Cover, exhaust valve spring compartment-WO-807707

GG-Elbow, 90 deg-444038

HH-Stud, s-16 x lr&-WO-300143

JJ-Bellcrank, accelerator,

WO-805478 upper-

Figure

97.--Continued

131

d.

i32

fuel

119. Install Fuel Pump Assembly a..

Before installing the fuel pump, turn the camshaft (by turning the crankshaft) to bring the low side of the fuel pump actuating cam directly opposite the fuel pump mounting hole. b. Coat both sides of the two fuel pump gaskets (fig. 98) with plastic type gasket cement. Assemble a yi/,,-inch lockwasher and the 0.406

ID rectangular washer onto the 5/,,-18NC-2 x 17s cap screw. As- semble identical parts on the fuel pump cap screw and coat the threads of the cap screws with plastic type gasket cement. Insert the cap screws through the bolting flange of the pump as shown in figure 98.

,%ssemble a fuel pump gasket, the fuel pump spacer and the second fuel pump gasket onto the cap screws as shown in figure 98, and install the fuel pump on the engine.

120. Install lower Crankcase Vent Control Valve and Related

Parts

Coat both sides of the crankcase vent body gasket (U) with plastic type gasket cement. Secure the gasket and the lower crankcase vent control valve (G) and its related parts (fig. 115) to the engine using the crankcase vent body c.ap screw (W) and a copper gasket (V) to secure the crankcase vent body (L) to the exhaust valve spring compartment cover and to the cylinder block.

121. Install Fuel and Vent lines

(fig.

99) a.

Connect the fuel pump inlet flexible line (D) and the fuel pump to carburetor line (E) to the fuel pump

71.

Install the ball check connector (C) in the elbow installed in the center section of the fuel pump. Connect the pressure line (B) to the ball check connector. Inst.all t,he ?$e x 1 split loom (P) over the pressure line and insert the line behind the clip welded to the exhaust valve spring compartment cover. c. Connect the crankcase vent line (F, fig. 105 and CC, fig. 4) to the

+&inch tee, in the intake manifold securing the line in place, by installing the s/is-inch crankcase vent line clip (DD, fig. 4) under the head of the bottom water pump attaching cap screw. Snap the 0.031 OD double clips (J, fig. 105) over the crankcase vent line and the fuel pump to carburetor lines at the approximate locations shown in figure

105. d. Connect the vent line (metering valve to vacuum pump) to the tee on the end of the crankcase vent metering valve (H) and to the elbow in the lower section of the fuel pump assembly e. Install the yia-inch special connector (R) in the side opening of the r/-inch inverted flared tube tee (S) and attach the distributor vent line (Q), windshield wiper line (T) , and the vent line (A) to the

?33

A-Line, vent

B-Line, pressure-WO-8@770u

C-Connector, ball check-7375063

D-Line, flexible, fuel pump inlet-

M-Screw,

cap, lock washer-_Ya-20NC-

2 x ‘h WO-800226

N-Clip, ss-inch-120522

P--Loom, split, %s x l-WO-A17445 wO-806172

E-Line, fuel pump to carburetor-

832f639

F-Line, vent metering valve to vacuum

Q-Line, vent distributor to windshield wiper tee-WCMO6420

R---Con=. special,

se-inch-WO- pump

S-Tee, N-inch, inv flared tube-178910

G-Valve, vent control, lower crank- T-Line,;;g windshield wiper- case-7410836

H-Valve, metering, vent, crankcase-

5336400

J-Support, dual control-WO-808449

K-Screw, cap, lock washer, $$-16NC-2 x s-7346875

L-Body, vent, crankcase-73712m

U-Gask;,9rnkcase vent body-WO-

V-Gasket, cop-WO-51875

W-Screw, cap, crankcase

vent body- wo-045093

X-Pump, fuel, assy-WO-805727

Figure 99. Installation

details of lines afnd ptting8. left side of engine.

tee Connect the opposite end of the vent line (A) to the elbow in the lower section of the fuel pump. Install the 3/ls x 1 split loom

(P) and the s6-inch clip (N) on the distributor to windshield wiper tee vent line

(Q) and attach the clip loosely to t,he rear of the cylinder block with a 1/4-20NC-2 x 1/2 lock washer cap screw

Install the exhaust manifold gaskets (fig. 100) and the exhaust manifold over the studs.

Install a 13j2 ID, 13/1s OD, plain washer on the center stud only.

Lift the vent line (A, fig. 99) slightly and slide

134

Figure 100. Tightening exhaust

munifold

stud Izute.

123. Install Clutch a.

:

135

F~P.M-~ 101. w/.faoings and hub assembly.

136

Figure 102. pressure plate w/cover a8sWbly.

(1)

When the gage is held in the position shown in figure 103, a correct setting is indicated when the end of the gage is against the web of the pressure plate and the outer edge of the release lever is just touching the front edge of the cutout section of the tool.

(2)

Check each of the three levers individually and make sure that all of the levers are within 27/,,-inch, plus or minus

0.005-inch.

(3) If necessary to adjust the levers, remove the pressure plate release lever clip (fig. 104) and loosen the adjusting cap screw lock nut. Turn the adjusting screw in or out as necessary to bring :he end of the pressure plate release lever withill the specified clearance. Replace t,he release lever clips upon completion of the adjusting operation.

105) a. If the engine assembly operation was begun with the cylinder block mounted in an engine overhaul stand, the engine must be removed from the stand at this point and placed upright on a suitable bench or stand.

Note. These bolts and bolt holex are machined to close tolerance. They provide the means whereby the clutch housing, to which the transmission is attached, is brought into correct alinement with the rear face of the engine. If dithculty is encountered in installing the dowel bolts, loosen the two cap screws which secure the engine rear mountin g support plate to the underside of the engine (fig. 90). This will allow the rear mounting plate to move slightly and permit the dowel bolts to be installed. Tighten the rear mounting plate support attaching cap screws after the dowel bolts have been installed. c.

d.

(L) .

E

Installation. detail8 of lines cind fittingsl-ight

aide

of engine.

plastic type gasket cement and install the unit in the tapped opening in the right side of the cylinder head. f. Install the two oil pressure sending unit support studs (N) in the cylinder block. Install the support on the studs and secure in place with two I/-28NF-2 lock washer nuts (P).

Install the oil pressure sending unit (B) in the support and connect the sending unit oil line

(M, fig. 97) to the sending unit. g. Install the oil filter assembly (TT, fig. 12) using two 5/,e-24NF-

2 x bolts and two 5/1e-24NF-2 lock washer nuts to connect the filter to the filter support.

Connect the oil filter inlet flexible line (A, fig.

97) to the inlet opening of oil filter.

Connect the oil filter outlet flexible line (T, fig. 3) to the outlet connection of oil filter and to the connector welded to the timing gear cover.

Note.

h. Install the engine front mounting support cushions (H, fig. 70) one on each side of the engine front mounting plate, using l/s-20NF-

2B “Huglock” nuts (K, fig. 70) to secure the cushions in place. i. Install the engine ground strap (C, fig.

12)

on the front mounting plate. Use a 3/8-24NF-3 x 1 bolt, two 3/8-inch external tooth lock washers (one on either side of the strap) and a s/s-24NF-3 lock washer nut to secure the ground strap in place. j. Install the distributor; before installing the distributor, however, check the position of the groove in the end of the oil pump drive shaft. If the groove in the end of the oil pump drive shaft is not in the “final” position shown in figure 81, turn the crankshaft as necessary to cause the oil pump shaft to move to the correct position.

(1) To install the distributor, remove the distributor cover screws and remove the cover from the distributor. Install the distributor in the engine, guiding the distributor drive shaft into the drive shaft hole in the cylinder block. If the tang on the end of the distributor drive shaft does not engage the groove in the end of the oil pump drive shaft, hold the body of the distributor and turn the distributor rotor until engagement of the shafts is completed.

(2) Install the 1/-20NC-2 x 5/8 cap screw (VU, fig. 12) and the

1/4-inch plain washer (NN, fig. 12) to secure the distributor in place.

(3) When the distributor has been secured in place, the distributor rotor should be in the position as shown in figure

106

(No. 1 cylinder firing position).

(4) Connect the distributor to withshield wiper tee vent line

(M, fig. 111) to the distributor and install the distributor cover. k. Install the carburetor insulator (XX, fig. 12) and the carburetor studs and secure in place with two a&24NF-2 nuts. Connect the fuel pump to carburetor line (G, fig. 105) to the carburetor inlet connection. Install the carburetor to air cleaner pipe hose (AB, fig. 12) on the carburetor, and connect the air intake pipe vent line

(H, fig. 111) and the distributor to air intake pipe vent line to their respective connectors. Connect the vent hose (K, fig. 3) oil filler pipe

(J, fig. 3). Connect the throttle rod (G, fig. 97) to the carburetor throttle shaft.

1. Install the generator mounting support (H, fig. 12) and the belt tension adjusting brace (G, fig. 12) on the right side of the engine using the adjusting brace bolt (AS, fig. 12), a s/8-&h lock washer

(AM, fig. 12) and a s/s-24NF-2 nut (AL, fig. 12) to secure the adjust-

?a

n.

Figure 106. Number one JIrixg position of distributor rotor.

over the rocker arm parts and install the rocker arm cover (S, fig. ‘70) and the gasket in place on the cylinder head.

Install a rocker arm cover stud gasket (T, fig. 70) on each of the rocker arm cover studs.

On the front stud, install one spark plug cable clip (W, fig. ‘70) and two spark plug cable clips (U, fig. ‘70) in the relative order as shown.

On the rear stud, install one spark plug cable clip (U, fig. 70). Secure the clips and the rocker arm cover in place with two 5/,,-24NF-2 nuts. p. Connect the vent hose (R, fig. 3) to the oil filler pipe (J, fig. 3) and to the rocker arm cover elbow (R, fig. 6).

Install the oil level gage and cap (Q, fig. 3) into the oil filler pipe. q. Install the spark plug annular gaskets and spark plugs (XX and

AF, fig. 13). Connect the spark plug cable assemblies (AE, fig. 12) to the spark plugs and to the distributor terminals in the order shown

J, K, L, M, figure 5. Snap the cables under the clips installed on the rocker arm cover attaching studs.

Section XIX. ENGINE RUN-IN TESTS AND ADJUSTME.NTS

125. Preparation for Run-In

Install the engine in a dynamometer or a test stand. Pre-oil the engine by forcing oil under pressure into the oil system to insure adequate lubrication of all parts until the oil pump supply reaches them. If pre-oiling equipment is not available, fill the engine oil pan with OE-10 engine oil to the “full” mark on the oil level gage.

126. Engine Run-In

A rebuilt engine will be started and run-in in accordance with instructions given in TB ORD 215. b. Run the engine for 15 minutes at 1,000 rpm, no load, to warm engine. Stop the engine and make adjustments (1) through (5) below

:

(1) Adjust distributor breaker point gap to 0.020-inch. Refer to TM g-8048 for procedure.

(2) Sdjust ignition timing. Refer to TM g-8048 for procedure.

(3) Remove the spark plug cables and the rocker arm cover and check the cylinder head attaching cap screws and rocker arm shaft bracket stud nuts.

If necessary, tighten the cylinder head cap screws to 60-70 pound-feet torque and the rocker arm shaft bracket nuts to 30-36 pound-feet torque.

(4) Recheck and, if necessary, adjust the intake valve clearance

(par. 114). Replace rocker arm cover and spark plug cables

(par. 1240 and p).

(5)

Start engine and adjust carburetor idle adjusting screw for an engine speed of 600 rpm as directed in TM 9-804A.

142

Section I. DESCRIPTION AND DATA

127. Description

The Borg and Beck clutch assembly is a single plate dry disk, automotive type, composed of two major units

; the pressure plate with cover assembly and the driven disk with facings and hub assembly

(fig. 107).

Figure 107.

Major

unit8

of

143

128. Data

Type---___-------_-----___---_----____--_--_--______----__

Torque capacity________________-____---------_____-_____-_____----

Clutch disk w/facings and hub assembly :

Make_----_____-__--____-_______-__--_---_--_--___-_____

Singledryplate

144lb-ft

Borg and Beck

Facing quantity and material_____-_-___----_-____-__ Two molded asbestos

Facing diameter inside______________-_____-----_--_-___--________ 5%in

Facing diameter outside_--_______-_--_---_------___---__--_______

Facing tl~ickness--______________---..-____----____-_---_---_-___

@.&in

0.138-in

Pressure plate w/cover assembly :

Make___________________________---______--__-__---------_-__--Auburn

Number springs_______________--_-_-___--_---___-----_--__-___--- 6

180 lb

Section II. DISASSEMBLY OF PRESSURE PLATE WITH COVER

ASSEMBLY

129. Remove Pressure Plate Cover From Pressure Plate a.

b. Exert a moderate amount of pressure on the section of round stock to depress the release levers. Remove the pressure plate release lever clips (L, fig. 109) from the ends of the levers. c. Remove the adjusting screw, lock nut, and plain washer (fig. 108) from the pressure plate. Hold a steady pressure on the levers until all three cap screws are removed.

Release the applied pressure slowly, and remove the pressure plate with/cover assembly from the arbor press when the springs have expanded to their full free length.

E

Remove the pressure plate spring cups (F, fig. log), pressure springs (G, fig. 109), auxiliary pressure springs (H, fig. log), and auxiliary pressure spring retainers from the pressure plate (D,

fig. 109).

Inspect the pressure plate release levers and if they are found to be worn or damaged, or if the pressure plate lever pivot pin is loose, cut off one end of the pivot pin with an abrasive wheel and drive the pin out of the plate. Remove lever.

Section III. CLEANING, INSPECTION, AND REPAIR OF

CLUTCH ASSEMBLY

131. Cleaning

Before performing any of the operations given in this section, refer to the general instructions given in paragraphs 24 through 29, relative to the cleaning, inspection, and repair of engine parts.

Clean all parts of the clutch assembly thoroughly.

132. Inspection and Repair

(fig.

109) a. Replace the pressure plate (D) if the plate is worn unevenly, scored, ridged, or burned.

Replace the plate if the face of the plate shows radial cracks. b. Replace any worn or damaged pressure plate release levers

(K) .

Replace the pressure plate cover (E) if the cover is warped or distorted. c. Inspect the driven disk, with hub assembly (R) and replace the disk if it is distorted or warped. d. If the driven disk facings (A and C) are worn thin, torn, oil soaked, burned, or highly glazed, drill out the tubular rivets (R) and replace the facings. When installing the new facings turn the smooth (non-grooved) sides of the facings to the disk. Install the

9/s4 diameter, 13/64 long, flat head tubular rivets (R) so that heads of alternate rivets are on the same side of the disk. e. Replace any damaged or deformed pressure plate spring cups (F) or auxiliary pressure spring retainers

(M) . f.

Place each pressure spring (G) in a tester (fig. 35) and compress the spring to lyis-inches. If the indicator reads less than 180 pounds, replace the spring.

Place each auxiliary pressure spring (H) in the tester and compress the spring to ls3/6,-inches. If the indicator reads less than 60 pounds, replace the spring.

Section IV. ASSEMBLY OF PRESSURE PLATE WITH COVER

ASSEMBLY

133. Install Pressure Plate Release levers

(fig.

109)

If the pressure plate release levers (K) were removed from the pressure plate cover

(E) , install the levers and pressure plate release lever pivot pins (J) and rivet the pivot pins in place. Make certain the levers work freely on the pins.

134. Install Pressure Plate Cover on Pressure Plate

(fig.

109) a. Set the pressure plate (D) on the flat bed of the arbor press

(fig. 108) and position the pressure plate cover (E) over the plate.

Lift the release levers so that they stand straight up. b. Install the three pressure plate spring cups (F) in the cover with the indentations in the

cups

facing the center of the cover. c. Install a pressure spring (G) and an auxiliary pressure spring

(H) (auxiliary pressure spring centered in the pressure spring) in each pressure plate spring cup

(F) .

Install an auxiliary pressure spring retainer (M) on top of each auxiliary pressure spring.

d.

Drop the levers over the ends of the springs, and center a piece of 2$.+inch diameter, 3-inch long round stock on the levers (fig. 108).

Exert a moderate pressure on the levers with the arbor press and secure the pressure plate cover to the pressure plate with a 9/3a ID, 1 OD, plain washer (Q) I/-28NF-2 x 7s adjusting screw (N)

; and a

I/,-28NF-2 lock nut (P) installed under each of the pressure release levers (fig. 108). e. Install the pressure plate release lever clips (L) by engaging the slotted underside of the clips under the heads of the adjusting screws

(N) , and then snapping the clips into place over the ends of the pressure plate release levers

Section I. DESCRIPTION AND OPERATION

135. Description a.

Ventilation of internal combustion engines is necessary to prevent harmful condensation, to relieve internal pressures set up by the action of rapidly moving parts, and to rid the crankcase section of volatile vapors. Sections requiring ventilation are usually vented directly to the atmosphere through suitable openings or vents. b. As described in paragraphs

4f and

206, this particular Model

MD engine is of waterproof construction. Because it is waterproof, or watertight, it is also airtight. Therefore, the method used to ventilate the engine is not according to usual practice. Disregard this chapter when working on engines not equipped with the underwater ventilating system. c. The usual method of ventilating is impractical because of the necessity of keeping the engine watertight when submerged. Thus, the Model MD engine utilizes a separate ventilating system having a single inlet connected to the engine air inlet system and a single outlet connected to the engine intake manifold. The ventilating air theu passes through the combustion chambers and out through exhaust system. The system, made up of tubes, hoses, valves, etc. intercon- nects all the points requiring ventilation. Two other units that require ventilation, the carburetor and the distributor (fig. ill), are vented independently of the engine ventilation system (d below). a?. The carburetor and the distributor are vented in the following manner :

(1)

C’arburetor ventilatiun.

The upper section of the carburetor must be open to atmospheric pressure to maintain a balanced condition in all parts of the carburetor. Therefore, the carburetor is vented by means of the vent line (H, fig. 111) which is connected to the top of t.he carburetor and to the air intake pipe.

(2)

Dhtltributor ventilation.

The distributor is vented by means of two lines: First, the distributor to windshield wiper tee vent line (M, fig. 111) connected to the underside of the distributor and to a 3/la-inch inverted flared tube special

148

MEDIA, INC.

COPY RIGHT 1999

E

F

J

A

V

W

Figure 110. Engine ventilating systent.

WO-800226

Figure 111.

Carburetor and distributor vent system.

connector. Second, the distributor to air intake pipe assembly vent line (K, fig. 111) connected to the upper side of the distributor and to the air intake pipe assembly. The ss-inch special connector is used in the distributor vent line to re- strict the distributor vent line to 0.040-inch. This restriction limits the amount of vacuum in t,he distributor to a predetermined value regardless of t,he engine speed. e. Another series of tubes and fittings connects the transfer case and the clutch housing with the center section of the fuel pump and through that to the crankcase section of the engine (par. 1376).

Althou,gh not used to ventilate the engine, this series of tubes is con- sidered part of the engine ventilating syst)em because it is through these tubes that the clutch housing, the transmission, and the transfer case are pressurized, and thus protected, against the entry of water during underwater operation.

110) a. When the engine is running, the vacuum created in t.he engine intake manifold and the vacuum booster section of the fuel pump (C) draws fresh air into the ventilating system through the upper crankcase vent control valve (L) attached to the air intake pipe assembly

(J, fig. 111). The flow of air is then through the 90” elbow (M) , the nipple (N), and the vent hose (K) to the oil filler pipe. From the oil filler pipe, the air passes through the vent hose

(J) ,

and the elbow

(H) to the rocker arm cover mounted on the cylinder head. From the area inclosed by the rocker arm cover, the air passes downward into the cylinder block or crankcase, through the intake valve push rod openings. The air leaves the cylinder block through the series of closely assembled parts which include the lower crankcase vent control valve (BB) and the metering valve The air is then exhausted into the engine intake manifold through the vent line connector (P) , and I/-inch tee flared tube

(Q) .

From the air intake manifold the air is drawn into the cylinders, burned, and then exhausted into the engine exhaust The vent line (Z) connects the vacuum booster section of the fuel pump to the engine ventilating system to insure a constant vacuum in the engine ventilating system regardless of the engine speed. b. When the vehicle is in over-land service, the two vent control valves, (L and BB) , are open and play no part in the ventilating system. The metering valve however, operates to automatically controI or limit the amount of vacuum developed within the engine vehtilating system to a predetermined value regardless of the en&e speed, as follows

:

151

(1)

Figure 112.

Sectional view

of

ventilating system metering valve.

(2)

37. Operation (Underwater Service)

(fig.

BB) .

Nota.

This does not include the vent system of the carburetor and the distributor which are vented independently of the engine (par. 135d).

Note.

There is no direct pressure line connection to the transmission case because there is a common internal opening between the transmission and the transfer case through which the pressure reaches the transmission.

Figure 11.9. Scetional view of fuel pump assembly.

\////

Note.

Figure

Bull check

connector-sectional view.

(2) From the fuel pump the pressure path is to the clutch housing through the 90” elbow (B), the 3/,,-inch ball check connector (A), the pressure line (X), the yr6-inch inverted flared tube tee (W), the pressure line (S), the 3/,,-inch inverted flared tube elbow (T) , and the tranfer case vent

The ball check connector is normally in the closed position and only opens when the engine internal pressure builds up above atmospheric pressure and forces the ball away from its seat in the connector. d. When the vehicle emerges from water, the operator removes the pipe plug (V) f rom the bottom of the clutch housing and opens the two vent control valves (L and BB) and thereby makes the engine ventilating system again operative.

Section II. REBUILD OF ENGINE VENTILATING SYSTEM

138. Disassembly of Ventilating System

(fig.

115) a. In the process of disassembling the engine, the ventilating system is disassembled and almost completely broken down into its individual parts.

The only parts that. remain to be disassembled are the upper and lower crankcase vent control valves (L and BB, fig.

110)) the metering valve (E, fig. 110)) and the, ball check connector

(A, fig. 110). The metering valve and the lower crankcase vent control valve are separated as follows :

(1)

Back the reducing elbow (A) off the t,hreaded end of the metering valve seat

(B)

Remove the metering valve by unscrewing the metering valve base (E) from the pipe nipple

(F).

(2) Unscrew and separate the crankcase vent body (M) from the street elbow (L). Separate the street elbows (L) and (K) and remove elbow (K) from the nipple (J). Do not remove pipe nipple (J) , reducing pipe bushing (H) or pipe nipple (F) f ram the lower crankcase vent control body (G) unless the parts are damaged. b. Disassemble the metering valve by unscrewing t’he metering valve base (E) from the metering valve seat (B) and lift the metering valve (D) and the met,ering valve spring (C) from the seat. c. Disassemble the lower crankcase vent control valve as follows:

(1) Remove the lock nut (S) , the lock washer (R) and the lower crankcase vent control valve lever (V) from the end of the lower crankcase vent control valve sleeve (N). Full the cotter pin (X) from the end of the lower crankcase vent control valve swivel pin (U) and remove the pin and flat washer (W) from the lever.

P

V

Figure 115. Ventilating system parts (edmust valve spring compartment cover to intake manifold line).

d.

m-m

130

e. Remove the ball check connector from the fuel pump and disassemble connector (fig. 114) as follows:

(1) Back the connector seat out of the connector body.

(2) Remove the ball check and ball check spring from the connector body.

Note.

Ven.tilating system parts (air inlet pipe to rocker arriv cover).

a. Clean all parts of the engine ventilating system. b. Normally there is no wear of the parts of the ventilating system.

The parts need only be inspected for damage and to make sure that all holes and openings are open and clear. Any damaged part or parts with rough threads must be replaced.

115) a. Figures 115 and 116 show the relative location of the various parts of the ventilating system.

Use these illustrations as a guide when assembling the ventilating system.

157

b. When assembling the parts of the ball check connector (fig. 114) screw the seat into the connector body until the end of the seat is just flush with the end of the connector body.

Clamp the connector in a bench vise and using a small, sharp punch, tap lightly against the inside edges of the connector body opposite the slot in the end of the seat, and wedge a little of the connector body metal into the slot.

Note.

Take care not to damage the threads on either piece. These pieces are brass and only a very light tap is required to satisfactorily perform the operation. c.

Assemble the lower crankcase vent control valve as follows:

(1) Insert the lower crankcase vent control valve sleeve (N) into the lower crankcase vent control valve body (G).

In- stall new lower crankcase vent control valve packing (P) over the end of the sleeve and secure in place with the vent control valve packing nut (Q). Tighten the packing nut until the sleeve is seated firmly in the valve body.

(2) Install the lower crankcase vent control valve lever (V) on the end of the sleeve (N) and secure in place with the lock washer (R) and lock nut (S). Install the swivel pin

(U) in the end of the lever and secure in place by installing the flat washer (W) and l/is x 3/s cotter pin (X). d. The upper crankcase vent control valve is identical to the lower crankcase vent control valve and is to be assembled by following the instructions given in c above. e. Assemble the metering valve (D) as follows :

(1) Install the metering valve spring (C) and the metering valve

(D) in the metering valve seat (B) with the conical end of the valve facing the externally threaded end of the seat.

(2) Coat the external threads of the metering valve base (E) with plastic type gasket cement and seat.

9w the base into the f. Assemble the metering valve and the vent control valve together and to the other related lower crankcase ventilating system parts in the order shown in figure 115. Coat the external threads of all parts with plastic type gasket cement before assembling them together. g. Coat the external threads of the upper crankcase vent system related parts (fi g. 116) with plastic type gasket cement and install the 90” elbow in the vent control upper crankcase valve. Install the coupling in the elbow and complete the operation by assembling the vent control valve to the air intake pipe.

158

141. General

The repair and rebuild standards included herein give the minimum, maximum, and key clearances of new or rebuilt parts as well as wear limits which indicate that point to which a part or parts may be worn before replacement, in order to receive maximum service with minimum replacement. Normally, all parts which have not been worn beyond the dimensions shown in the “Wear Limits” column or damaged from corrosion will be approved for service.

142. Cylinder Block

(pars. 50 and 51)

(All dimensions in inches unless otherwise noted.) a. Piston Bores.

Fig. Ref. letter

117 x

M

U

Max

Point of measwcment

Diameter at top of ring travel-_____--

Rebore for next oversize at___--_____ taper________________________-

Out of round_______________________

and fit8 of new partr

Minimam

Mazimzlm

WtXV limita

3. 125 3. 127

Diameter at bottom of ring travel_ _ _ _ _ 3. 125

3. 127

Piston to block clearance____________ 0. 0021 0. 0029

______ ______

______ __---_

0.0003 0.0005

3. I37

3.129

0. 005

0. 005

0. 010

0.003

6. Value Tappet Bores.

118

A

B

Diameter of tappet bore_________-___ 0.625

0. 626

Tappet to block clearance_ _ _ _ _ _ _ _ _ _ _ 0.0005 0. 002

Rebore for oversize at--_-----_____-_ ______ ______

Note. Valve tappets are available in 0.004-inch oversize.

c. Exhaust V&e Guide Bores.

119 B Diameter__________________________

0.

6295

0. 003

0. 003

0. 655 0. 656 __----

d. E&a& Valve Seats.

119 E Exhaust valve seat angle___________.. 45’

____ __ ___--. e.

Camshaft Bores.

117 J

N

P

Front bushing type bearing__________

2. 1870 2. 1880 ______

Front intermediate.__-__-___-_____-

2. 1250 2. 1260 ______

Rear intermediate___________-_____-

Rear__________-___________________

2. 0625 2.0635

1.6250 1.6260

____ ._

__--__

159

160

Figure and measurement.

324309 0 - 55 - 11

standards measurement.

measurement.

143. Crankshaft

Crankshaft.

Ftg. Ref. letter

117 _ _

F

Sizes and fits oj new parts

Point

measurement

Run-out-(crankshaft points D and A). suspended at

F:nd plag___.__ ..__ _~ . .._.. ~___.. .

0. 004 0. 006

wear limits

0.001 b. MixIn Bearing dournuls.

117 D B A Diameter___~___~.____~_~~.~_--~..~

E Bearing to journal clearance_. _ _ . . . .

2. 332

0.001

D B A Regrind for next undersize at _ . _ _ _. .

D B A Maximum out of round_____~~_~__~_

D B A Masimum taper- . . ______..~___~

2. 3340

0. 002

2. 3930

0. 001 t.0

0. 0025

2. 3330

0. 001

0.001 c.

Connecting Rod Bearing Journals.

117 G

H

G

G

G

Diameter~_~__~_____~___---._---._-

Bearing to journal clearance_. _ _ ~. . _

Regrind for next undersize at _ _ _ _ _

Masimumout.ofround_.__.~.__.~..

Maximum taper__.___~.__...._

1. 9370 1. 9385

0. 001 0. 002

1. 9367

0. 002

1. !3367

0. 002

__ 0.002

144. Cylinder Head

54)

a. Intake Valve Guide Bores.

Fig.

Ref. letter

119 G

Point of measurement

Diameter of bore.. _

_ .

. _ _ _. . _ b.

Intake Valve Seats.

119 F

Valve seat, angle_. _ _.

_ _.

_

. _. . .

.

---___

and fits

parts of nezu

Minimum Maximum

0. 655

0. 656

W&IT

limits

._._._

145. Rocker Arm Assembly

Fig.

120

117

121

ReJ. letter

F

E z

A

B

57)

Point of measurement

Sizes and Jits of new

----__ parts

Minimum Maximum

Wear

limits

Diameter of bore in rocker arm shaft 0. 7445

0. 7455 _ __ . . _ bracket.

Bore to shaft clearance__._-. q:,,

_ _______

0. 0005 0. 002

___--_

Diameter of rocker arm shaft_ _ _ _ _ _ _ _ 0. 7435 0. 7440

. . _ -

Diameter of internal bore of rocker

0. 7445 0. 7450 . .

~. _ arm.

Widthofrockerarm______--___..-.. 1.000 __.___ .._.__

31 lb1 .

R~+,& and &dd standards point8 of measuTement.

117 d.

Piston

of nw w

V

Point of measurement

Dian~eter-~~~~_~-----. _.__~_________

Minimum

0. 8117 0. 8119 to piston clearance _._. ~. _

_ .

. _ 0. 0001. 0. 0005

Piston pins are available in 0.003-inch oversize.

001

RA PD 181134 measurement. 125. Repair and rebuild standard

148. Camshaft

Cam.shaft.

Sizes anzaftt; of new meacurrmcnt

--__---

Minimum Maximum limits

124 __~__ _ Runout (camshaft supported at A and _. . . ._ . . . ._ 0. 001

K

0.

Camshaft gear to thrust plate clearance_ 0. 004 0.006 0.004

‘b.

Bearing Journal Diameters.

124 A

B

C

D

Front________~______~_~_----~.~----

Front intermediate________-----_~---

Rear intermediate________--------~--

Rear_____..~~___~~~____...---_._.-

2.1855 2.186 2. 182

2. 1215 2. 1225 2. 121

2. 0590 2. 0600 2. 0585

1. 6225 1. 623 1. 621 c.

117 L

R

Q to Journal Clearances.

Front_____~.__~~_..~~~__...~-. _ . _ 0. 001

Front intermediate______~~~__---~~~- 0. 0025

0. 0025

0. 0045

0. 004

0. 004

Rear intermediate_______~~----~-..~-

Itear____~_____~_~_~___~-----~~~~--

0. 0025

_...~_

0. 0045

___...

0. 004

.~__~.

Figure 124. Repair and rebuild standards

149. Intake Valve

Fig. Ref. letter

119

120

Sizes an~z$; of new

Point of measurement

I__--

Minimum Maximum

Wear limits

Seatangle___________________-_____ -..___-

45” ____-_

Diameter stem________-____________

Valve to arm clearance__-_____

0. 3733 0.3738

0.018 0.020

0.369

____-- b.

Intake

120 B

C

A

Inside diameter-______-___-________ 0. 3745 0. 3755 0. 3785

Valve to guide clearance_____________ 0. 0007 0. 0022 0. 095

Outside diameter_________--________ 0. 6565 0. 6575 ______

150. Exhaust Valve

and

Fig. Ref. letter

119

118

D c

D b.

Point of measurement

Sizes and fia of new

part8

-----

Minimum Maximum

Wea7 limits

Seatangle_________________________

Diameter stem___--_-_________-____

45’

0.371

____-_

0. 372

__---_

0. 3685

Valve cap to tappet clearance_ _ _ _ _ _ _ _ 0. 016

0.017

Valve to valve cap clearance_________

0.000 0.004

_-----

0.005

B

Inside diameter-_. _________________ 0. 3745 0. 3755 0. 3785

Valve to guide clearance_____________ 0. 0025 0.0045 0. 0105

Outside diameter___________________ 0. 6565 0. 6575 ____-_

151.

Oil Pump

Fig. Ref. letter

125 D

A

C

B

Sizes a7aa.f oj new

Paint meaawsment

-___---

Minimum M&mum

WelV limit8

Outer rotor lobe to inner rotor lobe

0.0005 0. 006 0. 010 clearance.

Outer rotor to pump body clearance_ _

0. 005 0.010 0.012

Free length of plunger spring_______-- ______ 1. 640

____-_

Plunger spring length when load of 9% 1. 064

__--_- ___--- lb applied.

End of body to end of drive gear teeth-_ 0. 020

0.030 _-----

Pigure

I.%

RA i’D 181136

152. Torque Specifications

Camshaft gear to camshaft, bolt____________-_____-________

Camshaft thrust plate bolts, 4 cylinder_____________________

Connecting rod cap bolt nut, VI/,-inch___________--_--__-____

Cylinder head screws___-_-_______-_____________-___-______

Exhaustmanifold___--__-__________________-______-_______

Flywheel to crankshaft__--__-_-_____-_____-_________--___-

Generator (bracket)_____-____-_-_-_-_-___-_-_-__-__--__-_

Main bearing caps___________________________--_______--_-

Oil pan screws to cylinder block___-___-_______________-_---

Piston pin lock bolts, 3/s-inch_________-_______-_-__-_____-_

Rocker arm bracket to head nut____-_-_____--____-________

Spark plugs to cylinder head---___________________________

Starter______________-__-______-____-_____________________

Water outlet elbow to cylinder head_________________---____

Water pump to cylinder block____-_____-_-_________-___-___

3040

20-26

50-55

60-70

29-35

3541

25-35

65-75

12-17

3541

30-36

26-30

20-25

20-25

12-17

169

Special Regulations in the series, SR 110-l-1, ORD 1, and

FM 21-8, and SB 9-l should be consulted frequently for lat.est changes or revisions of references given in this appendix and for new publications relating to materiel covered in this maaual.

The following supply manuals of the Department of the Army supply manual pertain to this materiel

Land Mines and Components

:

Demolition Explosives ORD 3 SNL R-7 and Related Items; Ammunition for Simulated

Artillery, Booby Trap, Hand Grenade, and Land

Mine Fire. b.

Antifriction Bearings and Related Items______________

Cleaners, Preservatives, Lubricants, Recoil Fluids,

ORD 5 SNL H-12

ORD 3 SNL K-l

Special Oils, and Related Maintenance Materials.

Electrical ~‘ittings____________---_________________-__

Items of Soldering, Metallizing, Brazing, and Welding

0R.D 5 SNL H-4

ORD 3 SNL K-2

Materials; Gases and Related Items.

Lubricating Equipment, Accessories, and Related Dis- ORD

(*)

SNL K-3 gensers.

Lubricating Fittings, Oil Filters, and Oil Filter Ele- ORD 5 SNL H-16 ments.

Major Items and Major Combinations of Group G______ ORD 3 SNL G-l

Miscellaneous Hardware_-------------------------__- ORD 5 SNL H-2

Oil Seals______--_______---_-----------__----------_

Pipe and Hose Fittings____________--_-__--__----___-

Standard Hardware_______---------_-____--------____

Truck, Utility, Ya-ton 4 x 4 M38A1________________-_--_

ORD5 SNLH-13

ORD 5 SNL H-6

ORD 5 SNL H-l

ORD 8 SNL GZ58

The following forms pertain to this materiel :

DA Form 9-1, Material Inspection Tag

DA Form 9-3, Processing Record for Storage and Shipment (Tag)

DA Form 94, Vehicular Storage and Servicing Record (Card)

(*) se&ion

DA Form 9-68, Spot Check Inspection Report for Wheeled and Half-

Track Vehicles

DA Form 9-69, Spot Check Inspection Report for all Full-Track and

Tank-Like Wheeled Vehicles

DA Form 9-71, Locator and Inventory Control Card

DA Form 9-72, Ordnance Stock Record Card

DA Form 9-76, Request for Work Order

DA Form 9-7’7, Job Order Register

DA Form 9-78, Job Order

DA Form 9-79, Parts Requisition

DA Form 9-80, Job Order File

DA Form 9-81, Exchange Part or Unit Identification Tag

DA Form 447, Turn-In Slip

DA Form 460, Preventive Maintenance Roster

DA Form 461, Preventive Maintenance Se.rvice and Inspection for

Wheeled and Half-Track Vehicles

DA Form 462, Preventive Maintenance Service and Inspection for

Full-Track Vehicles

DA Form 446, Issue Slip

DA Form 468, Unsatisfactory Equipment Report

DA Form 378, MWO and Major Unit Assembly Replacement

Record-Organizational Equipment File

DA Form 811, Work Request and Job Order

DA Form 811-1, Work Request and Hand Receipt

DA Form ,865, Work Order

DA Form 866, Consolidation of Parts

DA Form 867, Status of Modification Work Order

DD Form 6, Report of Damaged or Improper Shipment

DD Form 31’7, Preventive Maintenance Service Due (Sticker)

00 Form 5825, Artillery Gun Book

4.

Other Publications

The following publications contain information pertinent to this materiel and associated equipment :

a. Garwuflage.

Camouflage, Basic Principle_----_______-___-----___-----

Camouffage

of

Vehicles--__--_---_______-_---__---______

FM 5-20

FM 5-20B

6.

Decontam,ination.

Decontamination _________________________-___--____-__ TM 3-220

Defense Against Chemical Attack______________-_-_-_-_- FM 21-40

C.

Destruction to Prevent Enemy Use.

Explosives and Demolitions____-___________-__---____-__ FH 5-25

Ordnance Service in the Field___________-______________- FM 9-5

d. General.

Accident Reporting___________---__-____--__-___--_--_-__ SR 385-1040

Cooling Systems

:

Vehicles and Powered Ground Equipment_ TM 9-2858

i7i

Inspection of Ordnance Materiel in the Hands of Troops ___ TM 9-1199

Military Vehicles______________________-_______-________ TM 9-2869

Motor Vehicles________-____-__--_____________--_____-__ AR 769-105

Ordnance Maintenance and General Supply in the Field__-_ FM 9-10

Precautions in Handling Gasoline__-__________-___---____ AR 859-20

Prevention of Motor Vehicle Accidents----__---_________ SR 385-1551

Principles of Automotive Vehicles_____---__--______-___. TM 9-2796

Storage Batteries, Lead-Acid Type__________________-_--. TM 9-2857

Unsatisfactory Equipment Report_____________--___--___ SR 799-45-5 e.

Repair and Rebuild.

Abrasives, Cleaning, Preserving, Sealing, Adhesive, and Re- TM 9-850 lated Materials Issued for Ordnance Materiel.

Carburetors (Carter)__________________________________ TM 9-1826A

Electrical Equipment (Auto-Lite) _______________________ TM 9-1825B

Electrical Equipment (Delco-Remy)_____________________ TM 9-8627

Fuel Pumps________________________-_---___-_____-____ TM 9-1828A

Hand, Measuring, and Power Tools_----------______--___ TM 19-590

Instruction Guide: Care and Maintenance of Ball and Roller TM 37-265

Bearings.

Lubrication _________________________-_______-_________. TM 9-2835

Maintenance and Care of Hand Tools_________________--- TM 9-867

Maintenance Responsibilities and Shop Operation____--- AR 75&5

Ordnance Expenditure for Repair of Transport Vehicles___ SR 759-139-5

Modification of Ordnance Materiel____----__--__-----___ SB 9-38

Painting Instructions for Field Use____________--_--,___--- TM 9-2851

Preparation of Ordnance Materiel for Deep-Water Fording- TM l&2853

Processing and Reconditioning of Antifriction Bearings__ TB ORD 438

Tactical Motor Vehicle Inspections and Preventive Main-

TM 9-2810 tenance Services.

Wheeled and Half-Track Vehicles, Trailers, and Towed TB 9-2835-12

Artillery

:

Lubrication of Wheel Bearings. ya-ton, 4 x 4, Utility Truck, M38Al__________________-___ ‘TM 9-894A

f. Shipment and Stand-By or Long-Term Storage.

Army Shipping Document_______________---_____________

Instruction Guide : Ordnance Packaging and Shipping

(Posts, Camps, and Stations).

Marking of Oversea Supply________-_____--_______-_--__

Military Standard-Marking of Shipments______________

Ordnance Storage and Shipment Chart-Group G________

Preservation, Packaging, and Packing of Military Supplies and Equipment.

TM 38-705

TM 32854

SR 746-30-5

MILSTD-129 1

TB SOSSC-G

TM 38-230

Processing of Motor Vehicles and Related Unboxed Ma- teriel for Shipment and Storage.

Processing of Unboxed and Uncrated Equipment for Over- sea Shipment.

Protection of Ordnance General Supplines in Open Storage-

Standards for Oversea Shipment and Domestic Issue of

SB 9-4

AR 74730

TB ORD 379

TB ORD 385

Ordnance Materiel Other than Ammunition and Army

Aircraft.

Report of Damaged or Improper Shipment______________ SR 745-45-5

Accessories:

Installation______-__--_-__-___--____-_-_______--______

Removal_____________-_____--____-___--____--________

Accidents, reports of_____________.____-__-_--____-_________

Arm, rocker:

Inspection and repair________________-_--__._--________

Installation________-________--_____-___-_____-__-___-_

Removal_____________--__-___--____-___--____-_._____

Bearing, connecting rod:

Check clearance_-_-_--__-_____--________--____--______

Installation_________________--__.___-_--____--______-_

Re~noval_______________--________._____---___--__--__

Bearing, crankshaft. (See Bearing, main.)

Bearing, front, camshaft:

Inspection__________-----_____--___.-_--____--______-_

Installation________-__--__-_--_-__--______-_____-----_

Removal_______________-_-___-___.___-_--__-_______-_

Bearing, main:

Checkclearance___________-___--____-_--____-_______-_

Installation of lower halves_____________--____--._____-_

Installation of upper halves______________-.__-_-_.-_---_

Removal______________--_____-_____-_--____--______-_

Bearing, pilot, clutch:

Installation_________-___-_____-___.__________-______._

Removal____________.--__-_--____--_______-____-_---_

Bearing, water pump shaft. (See Shaft, w/bearing, water pump.)

Belt, fan and generator drive:

Inspection__________-___-_-_---_____-_--_._-____-_---_

Installation______-_--_--__-_---__._-__--___-____-_.--_

Removal_____._______---_-_---_____-_--___---._-_-_-_

Belt tension adjusting brace. (See Brace, adjusting, belt tension.)

Block, cylinder:

Asse~nbly___________-_---_-_-_-_..__-_--_.___-__-_-_-_

Cleaning_______________-_____-_____-_--__~_--______-_

Disassembly________________-_-_____-_--__~___._-_-_-_

Inspection__________-_--_.-___-_____-_--._.__-._-.-_-_

Body, oil pump. (See Pump, oil.)

Body, water pump. (See Pump, water.)

Brace, adjusting. belt tension:

Installation___________________.___--.-_.--~_-_--------

Removal_____________________-___--.-__.--._._--------

Bracket, shaft, rocker arm:

Inspectionandrepair________---___--_- _______ _ ._.___-_

Installation_________-_____-___-_..--____.__-__._._-_-_

Removal_______--__-_-___-_______--_-_____-____-_-_-_

Parapraph

124

30

3

57

58

56

104

104

47

50

52

50

97

96

95

48

70

70

91

124

30

52

51

50

51

124

31

57

58

56

103

137

36

137

40

70

71

67

173

52

57

52

111

108

107

52

82

82

PQlC

137

36

6

70

71

67

117

117

51

57

55

52

55

Camshaft:

Cleanir~g_____________---_---~~----_----_----__--.__-_

Inspection._______.__.._-_._.--____-___-_..__-_._--_.-

Instsllation______.____.-.__._-_.___-..______.-__.--___

Removal___~___._.___.--_.-.--.._.-...-__._.-_._---.-

Camshaft driven gear. (See Gear, camshaft driven.)

Camshaft front bearing. (See Bearing, front camshaft.)

Camshaft thrust plate. (See Plate, thrust, camshaft.)

Carburetor:

Installation_____.~~~_..~-__..~-._.--_..~_..~--_.~~--..

Removal_____________---------_---------~------------

Cleaning

:

General_____________---__----------_----------.-.----

Procedure_-____---~_--~-----~~-----_----~----_-------

Clutch:

Clip, pressure plate release lever:

Installation________-_----------------.~----_----_~

Removal___..~____~____---__.--__..__..~~-...~._.

Cover, pressure plate:

Assembly_________~___._~~-__.-~_....__._._..._._.

Disassembly_______~__~~_____~___._~_..__~_..___..

Inspection~~__________~~_________.~~_...___...~_._.

Installation___~~_____________~___.___._.____~~___.

Removal_____________-----_-~--_.~~-_..---.-~--_.

Cup, spring, pressure plate:

Inspection__________-_....-_..-~_....____.~.......

Installation__~_____________.___~_____._____.____..

Removal____~_________-_.__--~----------.------_-

Data______._____~____---_..-_-__._~-..._....._..._.__

Description__________-----..---__.-~-._~__.._~-..._._.

Disk, driven:

Inspection_~_________--~-----.---.~~-_...~-._~~...

Installation________-------.--------.-.-~---_----_-

Removal_____________-~-----~---_---_..~~-_..-...

Repair-_____~~~__--__---~.----------_~~---_~~--_~

Facing, driven disk

:

Inspection_____~_..__--~--~_----------_~~---..~___.

Installation___________.~__________~~__..____..~_..

Removal____~_~_.__~____--.---------_~_.--_~~~._.

Lever, release pressure plate:

Adjustment___~~____~._~_____~___.~___~.~__...._.._

Inspection____-____ ~_____~______.___~~~____.~~_..

Installation___~~____~_-~--~------_~ __..~~__...___

Removal____~~~___.~._.__~--~----~~-_..-~-.~~~...

Pin, pivot, release lever:

Installation.._ _._._ ~_.____~~_._.__~_._~~_.___~_...

Ile~noval______~_____-_~~~---~~~-_.~~....~__...._.

Plate, pressure w/cover assembly

:

66

67

94

46

Pap

82

82

103

51

124

30

24

25

137

36

33

33

132

133

132

123

132

133

130

133

130

132

133

129

128

127

132

123

30

132

134

129

133

130

132

133

129

146

146

144

144

143

146

135

36

146

147

144

146

145

146

146

144 i46

146

146

135

146

146

145

146

145

174

Clutch-Continued.

Retainer, spring, auxiliary pressure:

Inspection_____________-__-____-__--___-_.__--___-

Installation______________-_____-_---___-___-_-___-

Removal______________-______--__--__-_--__--_-__

Spring, pressure:

Inspection_____________-_-__--__._--__--_-__--___-

Installation___________________--__--_-__--__-._-_-

Removal_____________.-_-__-__-_-_-__-_--__--___-

Spring, pressure auxiliary:

Inspection_.__________-___________________________

Installation___________-_____--___-_-___-_________-

Removal____________________---__--___-_-__--___-

Clutch pilot, bearing. (See Bearing, pilot clutch.)

Connecting rod. (See Rod, connecting.)

Connecting rod bearings. (See Bearing, connecting rod.)

Connector, ball check:

Assembly___________________--_______-_________-______

Cleaning_____________----_.__-___---_--_-__--__--__--

Disassembly__________________________________________

Inspection____________--______-~_-_-__--__--_-_-______

Installatio.l__ _____________________--___-__-__-_-______

Operation____________________________________________

Removal__~________.__-___-_-__----__--__--_-_-______

Cover, body, oil pump. (See Pump, oil.)

Cover, exhaust valve spring compartment:

Installation___________________________________________

Removal..___________--_____--___--_-_____________-__

Cover, pressure plate. (See Clutch.)

Cover, rocker arm:

Installation___________________________--__--___-______

Removal_____________-___________-___--___-___-______

Cover, timing gear:

Assembly____________________________________.-_______

Cleaning____.~________________________________-_------

Disassembly__________________-___-__---___-______--__

Inspection and repair______________--_-_-___-___-__-___

Installation________-__--____-_-_-__-_-_-___-______--__

Removal________________________________.________--__

Crankshaft:

Cleaning____________---____---_--_-_-__________------

Inspection____________--__-_-_-_---_----_._-_.____---_

Installation________-_---__-_---_----_---______-___----

Removal_____________--__-_---_--------__________----

Repair______________--_____---__-___-_.______-_------

Crankshaft front oil seal. (See Seal, oil, front.)

Crankshaft main bearing. (See Bearing, main.)

Crankshaft rear oil seal. (See Seal, oil, rear main bearing.)

Crankshaft thrust washer. (See Washer, thrust, crankshaft.)

Cup, spring, pressure plate. (See Clutch.)

Cushion, support, front mounting:

Inspection___________-______--__--__________---_------

Installation___________--__________-__--__________-----

Removal__________________---__--___________--_------

Cylinder block. (See Block, cylinder.)

Cylinder head. (See Head, cylinder.)

132

133

129

132

133

129

132

133

129

Page

146

146

144

146

146

144

146

146

144

140

139

138

139

121

137

138

116

44

124

32

85

84

83

84

108

37

64

65

96

48

65

137

42

97

96

96

96

123

45

81

81

108

52

81

157

157

155

157

133

153

155

131

48

92

124

40

103

137

47

175

Data, engine and clutch assembly___________________________

Description, engine and clutch assembly__________-_______-___

Disk, driven, clutch. (See Clutch.)

Distributor:

Installation___________________________________________

Removal_____________________________________________

Dowel pin, main bearing.

(See Pin, dowel, main bearing.)

Paragraph

5

4

124

30

107 End play, crankshaft, adjust___________--______-________-___

Engine :

Adjustments__________________________________________

Construction__________________________________________

Data______________________________________________--_

Description____________________-_--__________________-

Disassembly into subassemblies-_--________-____-_______

Lubrication system____________________________________

Operation____________________________________________

Run-in test________________--____-_______-____________

Engine ground strap. (See Strap, engine ground.)

Equipment, unsatisfactory, reports of________________________

Exhaust manifold. (See Manifold, exhaust.)

Exhaust valve parts:

Cap, rotator:

Adjust cap to valve clearance_______________________

Cleaning_____________________________--___-______

Inspection___________________-_-___-_--____-______

Installation_______________________________________

Removal______________________---_________-______

Guide :

Installation_______________________________________

Removal--__________________-________-___________

Lock, retainer:

Cleaning________________-_-_____________-________

Inspection________________________________________

Installation____________-_-_______________-_____-__

Removal_________-__________-_--____--______---__

Retainer, spring:

Cleaning______________________---_______-___-_--_

Inspection_____________---____________---__----_-_

Installation_________________.________-_---___-_--_

Removal______________________-_-_____-_-_____--_

Spring:

Cleaning____________--_-__----____----_-__--_____

Inspection._.____________________________-_____-__

Installation________________--_-_-__--_-____--_____

Removal____ ____ ________________________-.______

Tappet:

Cleaning______________________-_-___________-_--_

Inspection___________--_-__--_-____--_-_____-_-___

Instalation_______________________________________

Removal..________________________________________

Valve:

Adjust cap to valve clearance-_-__-____--_-__-_--_-_

Adjustclearance_______________________________-_-_

Cleaning____________----___-_-____--_______-_____

3

87

86

87

105

45

51

51

86

87

105

45

86

87

105

45

86

87

105

45

62

63

94

49

87

106

86

126

21

23

20

30

22

21

126

176

Pagr

16

7

98

97

98

120

49

55

55

97

98

120

49

97

98

120

49

97

98

120

49

80

80

103

52

98

121

97

137

26

121

142

25

33

25

36

31

25

142

6

Exhaust valve parts-Continued

Valve-Continued

Inspection________________________________________

Installation___________________________________-___

Removal_________________________________________

Repair_____________-___-_________________________

PWlpaph

87

105

45

87

Facing, disk, driven. (See Clutch.)

Fan and generator drive belt.

(See Belt, fan.)

Fan and generator drive pulley.

(See Pulley, fan and generator drive.)

Fan and water pump pulley. (See Pulley, fan and water pump.)

Filter, oil:

Installation____________________________-______________

Removal____________________-________________________

Flywheel:

Dowel,bolt______________-__-_________________________

Dowel, tapered____--________________--__--____________

124

30

70

70

70

Drill for dowel bolts________________________________-__

Gear, ring:

Installation____________-__________________________

Removal_____________-_____-_____________________

Inspection____-______________-___________-____________

Installation__________________-_______-__--_________-__

Removal_____________________________________________

Repair____________-________-________-___-____--___-__

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70

69

103

41

70

Forms_______________-______--_________-___-______________

3

Front mounting plate. (See Plate, mounting, front.)

Fuel lines. (See Lines, fuel.)

Gear, camshaft driven:

Inspection______________-____________________-________

Installation______________________-____________________

Removal___________________________________-_________

Gear, crankshaft drive:

Inspection and repair____-_________-___________________

Installation___________________________________--__-___

RemovaI_____________________________________--______

Gear, drive, oil pump.

(See Pump, oil.)

Generator:

Installation___________________________________________

Removal_____________________________________________

Guide, valve, intake. (See Intake valve parts.)

Head, cylinder:

Assembly_____________________________________________

Cleaning_____________________________________________

Disassembly________________________________________-__

Inspection________________________-___________________

Instalbtion___________________________________________

Removal__________..__________________________________

Repair_______________________________________________

Hook, lifting engine:

Installation___________________________________________

Removal__________.______________________________-.____

90

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38

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96

39

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30

55

54

53

54

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31

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98

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47

Impeller, water pump. (See Pump, water.)

Inspection:

General______________-----____________-_--_-________.

Procedure___________------________________--_________

Intake valve parts:

Guide:

Inspection__________-_-_-__________-_-_----_-_____

Installation_______________________________________

Removal_____________---___________.______----_-_

Lock:

Cleaning_________________________________________

Inspection__________---_-____-_-_-_--__--_---_-_-_

Installation_________-_-_--_-___-----_--_---_-_-_-_

Removal__________________________________-_-_-_-

Retainer:

Cleaning____________----___. _____________________

Inspection__.___________________________.__-_-_-_-

Installation_________-_-__-_-_----_-_-_-_-___-_____

Removal_____________---________-_-_---_---------

Seal, oil, retainer:

Installation________-_-_-___________-.-_-_-_-_-----

Removal---_------_-_-_--_-_------_-_-_-_-_-_-_-_

Spring:

Cleaning____________----____-_-_-_-_---_-----_-_-

Inspection__________--_--________-_-_---_-_-_-_-_-

Installation________------_.____-_-_-_----_--_-_-_-

Removal_________.________________________-______

Tappet:

Cleaning____________-_-___.____.________-_-___-__

Inspection__________-_-__-_-_----------_-_-_-_-_-_

Installation_________-_-__-_-_----_---_-___-_-_-_-_

Removal__________________-_-_-_-_-_----__---_-_-

Valve

:

Adjustclearance________________-_---_-_-________--

Cleaning.__.________----________________-_-_-_-_-

Inspection__________-----________________---_-_-_-

Installation~______________________________________

Removal.________________________________________

Repair._________________-_-_-_-_-_-_---____--_-_-

Paragraph

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53

Jet, oil, timing gear:

Installation___________________________________________

Removal_________________________--------_------_-__-

Lever, release, pressure plate. (See Clutch.)

Lifting hook. (See Hook, lifting, engine.)

Line, fuel:

Installation________--------__________________-_-_-_-_-

Removal_____________________________________________

Line, oil:

Installation____________________-----_--_-_-_-_____-___

Removal.____________---________-_-___---------------

Line, vacuum:

Installation________-----_____-_-_-_-_-----------------

Removal..________________-_--------_-_-_-___-___-___

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Lines, vent:

Instsllation-_____-__--__--_-_______---_---_-___---__--

Removal_________-__-______--______--__--______--__--

Linkage, throttle:

Instsllation_____--____--__--_____-____--___-----___-__

Removal_________-__-___-___-______--__--_______-____

Maintenance allocation

:

Depot_____-____--__----__--_____---__--___-___---__--

Field___________--__----___-_____-_-__---__-____--_.--

Manifold, exhaust:

Inspection____________--__--_____----_---_____----_---

Installation______-__--_---_--______---_---______--~---

Removal________-__--__--_---____--__--_______---_--_

Mark, matching, rear bearing cap--~.._._-___-_______---_--_

Mark,timing______________-_____--__--._____--______-__--

Material, unsatisfactory reports of.__--_--_______--_________-

Oil filler pipe.

(See Pipe, oil filler .)

Oil filter support. (See Support, oil filter.)

Oil lines. (See Line, oil.)

Oil pan. (See Pan, oil.)

Oil pressure sending unit support. ing unit.)

(See Support, pressure send-

Oil pump. (See Pump, oil.)

Oil seal, rear main bearing.

(See Seal, oil, rear main bearing.)

Oil strainer.

(See Strainer, oil.)

Packing, rear main bearing:

Installation__________________-______-___-______-______

Removal_______________-____________________-_________

Pan, oil:

Cleaning_____________________-_-___-___--____---_--__

Inspection and repair____-___--__-___-___--____--__--__

Installation_____________-___--______-_________--______

Removal__-____--__---_-_---_____--___-____--______--

I’arts____-________________---__--____-__-___--_-__--______

Parts, standard:

Inspection and repair____-___----____-___--___---______

Pin, dowel, main bearing:

Installation in bearing cap____--__-__--_----__---_--_

Installation in cylinder block_______________.__--______-_

Removal___________--._-___--____--__--____--________

Pin, oil pump drive gear. (See Pump, oil.)

Pin, piston:

Inspection______________-_____---___-_______-_--______

Installation_________--__-_-_--____--__--.___--__._____

Removal_______________-___--__-___-.--_______-______

Pin, pivot, release lever.

(See Clutch.)

Pipe, oil filler:

Installation__________-__-___--____~-__--____--________

Removal_______--__--__-_-______---_-_________.____-.

Piston:

Checking clearance of____-__---___---_---___---______-.

Cleaning___________________---_-_-_-_--__._----_____.

Inspection_____________.-_._---_-_-____-___._.___

Selective fitting of________________---.--___--____-___-.

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Piston and connecting rod assembly:

Assembly____________-______-____-_-____---____._-_--_

Cleaning__________________--____--_-____----____-_-__

Disassembly_______________--___-----___---_-____-----

Installation______._._______-__-__-_- ._________________

Removal__________.____--.____-_____-_-__.____-______

Piston pin. (See Pin, piston.)

Plate, mounting front:

Inspection__________._._.__----____-_-_-.__----____--_

Installation_________~___-___---______-_____-_--___.-_-

Removal__________________--_-__----_-_..--_-__._-_---

Plate, mounting, rear:

Assembly_~___________.____--_-__-_-----___-_---__._._

Cleaning__________________--_-__-_-----_-_-----______

Disassembly________________-___-_-_-____----____-_-_-

Inspection and repair______________-_-_-__-_--_-_______

Installatio~~______._________--_-__-_-----.__-_---____._

Removal_________________________-_-____----_-__-_-_-

Plate, pressure. (See Clutch.)

Plate, thrust, camshaft:

I~~stallatio~~_____________________---_-___--_--_-__-_-_-

Removal________________________----____-_--_-______-

Plugs, spark. (See Spark plugs.)

Pulley, fan and generator drive:

Installation______________.____________________________

Removal____________________-_-_______-____._.-______

Pulley, fan and water pump. (See Pump, water.)

Pump, fuel:

Installation___________-_________-----_-______-_-______

Removal______________-___--_-____-_-_-___________.__

Pump, oil:

Assembly__________________________-___-__________-___

Body:

Cleaning____________________----_-________-______

Inspection___________________-_-_-_-______________

Cover, body:

Cleaning____________-_-____-________-___-_-______

Inspection________________-____-_-_-__________-_-_

Installation__________________________________--_-_

Removal_________________-____-_-_-__________-_-_

Disassembly__________________-__-_-__-___________-___

Gear, drive:

Cleaning____________-_-_____--_-_-____-__________

Inspection_____________-________-_____._________-_

Installation___________--______-_-_-____-_-_-______

Removal____________________-_-______________-_-._

Installation________-_-_-____-_-____-_-_-_________--_-_

Pin drive gear:

Installation_________________-_-_-____-_____-___.__

Removal_________________-____-_-_-__________-_--

Removal___________________-_-____-_-___________--_--

Retainer, relief valve spring:

Cleaning___.________-_-______-_-_-__-_____-______

Inspection___________________-_-______________-___

Installation____________-_____-____________________

Removal______________-_____-___-_-__________-_-_

180

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Pump, oil-Continued

Rotor. inner, w/shaft:

Clesning_________________-____________-_____-____

Inspection____________--_______-_-___-_____-__--_-

Installation_________-_--____-__-_____-__-__-__--_-

Removal_________--_-____--_-_________-_____-____

Rotor, outer:

Cleaning___________--_-____-__-_____-__--_-___-__

Inspection__________--_-__-_--_____-____--_____-__

Installation_________-_---___-_--_-______-__-__-___

Removal___-_______--______--_____-_--__-________

Shaft, drive. (See Rotor, inner w/shaft.)

Shim, pressure relief valve:

Installation________-______-__-____________________

Removal_________-_--__-___-__-___-___-_-________

Spring, pressure relief valve:

Cleaning_____________--______-____-_---_-___-_-__

Inspection__________-__--_________________________

Installation_________--_--___-__-___-___-__________

Removal_____________-___________--__-__-___-____

Valve, relief, pressure:

Cleaning___________-_---_____-___--___-_-___-____

Inspection__________--__-___-__-__________________

Installation_________-___-_____--__--___-_-___-____

Removal___________-_---______-___-__--_-________

Pump, water :

Assembly_____--_______-___________________-__________

Bearing. (See Shaft, w/bearing.)

Body:

Cleaning_____________________-________-__________

Inspection__________----_______-__-_____--___-____

Repair___________________________________________

Disassembly_____._________________-__________________

Impeller :

Cleaning_________________________________________

Inspection______________..___-___-_-____-___--_____

Installation_______-____________-_-________________

Removal___-_____________________________________

Installation___________________________________________

Pulley :

Installation_________________-______-______________

Removal_____________________________________-_--

Removal________________---__-__________________-____

Seal:

Inatallstion__________--_-_-___-___-_______-_____--

Removal___________________-______-___-_-______-_

Shaft, w/bearing:

Inspection__________--_________--_________________

Installation________-_________-__________________--

Removal___-_________-______________-____________

Spring, retaining bearing:

Installation__________-________--__________________

Removal________________-__--___________________-

Washer, seal:

Cleaning______________________-_______-__________

Paragraph

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Pump, water-Continued

Washer, seal-Continued

Ins~ection_________________________---_-_--_-_-_-_

Installation________--_--_____-_------_____________

Removal_________________________________________

Rear main bea.ring packing.

(See Packing, rear main bearing.)

Records_.___________________________________-_-__-_-_____

Repair

:

General.____________--_-__________---_--_____________

Procedures___________----_-______________--_-_________

Reports_____________-_-_-_---_____________-_--__--_______

Retainer, spring, auxiliary pressure. (See Clutch.)

Ring, compression:

Gapsetting____________________________________-_--_-_

Installation_________-_-__________-_-_-________________

Removal._________________________________-_-__------

Ring, oil control:

Gap setting_____________--_-___________-_-_-_----_--__

Installation__________________________..________________

Removal__.________._----_________-_---------__-_-___

Rocker arm. (See Arm, rocker.)

Rocker arm and shaft assembly:

Assembly_____________________________________________

Disassembly__________________________________________

Installation-_-----_____.._ .___________________--_--_--_

Removal_____________--_--_________--------------_---

Rocker arm cover. (See Cover, rocker arm.)

Rocker arm shaft. (See Shaft, rocker arm.)

Rocker arm shaft bracket.

(See Bracket, shaft, rocker arm.)

Rocker arm shaft spring. (See Spring, rocker arm shaft.)

Rod, connecting:

Assemble to piston______________.__-------.-----------_

Cleaning____________--_---._._.___._._._._._._._._._.

Disassemble from piston--_--. . . _. . . _ __. _. _. . . _. _. _. _. _.

Inspection andrepair_____________________________~____

Rotor, inner, oil pump. (See Pump, oil.)

Rotor, outer, oil pump.

(See Pump, oil.)

Paragraph

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28

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Seal, oil, front:

Installation_________________._.._._._._.___._._._._._.

Removal_____________-----___..__.________.__-____-_.

Seal, oil, rear main bearing:

Installation________--_------_._._._._.___-__________._

Removal_____________-----_...__._._._._._..____._.__

Seal, water pump. (See Pump, water.)

Sending unit, oil pressure. (See Unit, sending oil pressure.)

Sending unit, water temperature. temperature.)

(See Unit, sending, water

Shaft, rocker arm:

Inspection___________---_-__.______._._._~_.-----~----

Installation________---------_._.___._._._.__........_.

Removal_____________-----._.___..._._____._.-~_~__-~

Shaft, w/bearing, water pump.

Shaft, w/inner rotor.

(See Pump, water.)

(See Pump, oil.)

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72

Shield, fan and generator drive pulley:

Insta~ation________--_---__------__.___---_.-_----__--

Removal__________--_---._-_---______---__.-__---_.--

Shim, adjusting, crankshaft and play:

Installation______--._._._--_____--___._~---____-_---_-

Removal_______---__..__--____---_____---_.-__----_--

Shim, oil pump pressure relieve valve.

(See Pump, oil.)

Slinger, crankshaft, oil:

Insta~ation________--__---_-__---____-_--__.-__--.____

Removal________--__._-----___---_.___---__-._---__--

Spacer, camshaft, thrust plate:

Installation_______-______---.._----____----_-__---__--

Removal_________-___.__--_____---_.__----_-___--__-_

Spacer, gear, drive, crankshaft:

Installation______________-_____--__.__---___-__---_.__

Removal__________--__---_-__--_____---____----___.__

Spark plugs:

Installation________--__---.-_-_-_____-_-_.___---_____.

Removal______________---_-___---_____--____---______

Spring, oil pump pressure relief valve.

Spring, pressure, auxiliary. (See Clutch.)

(See Pump, oil.)

Spring, pressure, clutch. (See Clutch.)

Spring, rocker arm shaft:

Installation__________.__---____--____---_____-________

Removal_______________._-._____--_____-___-_---_____

Standard parts. (See Parts, standard.)

Starter:

Installation_____________---____--____--__.___-________

Removal___.__________._--._____-_____--_____--_____.

Strainer, oil:

Assembly______________.__-______--____--____-_-______

Cleaning________________________--.___--__.----__.___

Disassembly_____--._.___--__._--__.__-__ ____ __ .______

Inspection_______--______--____-____________---__.____

Installation_-_.---_-___--__-_---_____-_____-______-__-

Removal__________-___-----__--_____-_____-_____-----

Strap, ground:

Installation________-_.__--_-___--____--____-.-____-__.

Removal_________-____._--______--____---__-_--_._._.

Support, mounting, generator:

Installation______--____._-______--__.__-_____-____-__-

Removal_______--_-___--__-__--_____-_._________-----

Paragraph

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Support, oil filter:

Installation______--_.__--__-__---_.__--.___._____--_-.

Remov~l_______----.._---_-_---_____--._______._--_--

Support, oil pressure sending unit:

Installation_______-____._---___--__._--____._-___--__.

Removal______________._--___----__._-_._--._-

Support, rear mounting plate:

Cleaning_____________._~_...____._-.._._----._--._-..

Inspection

and

Installation______--._~_._._._._._._-_____----__---_-__

Removal________--._..__._____-___-_____----__--~_-__

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Support, starter:

Instsllation___________________________________________

Removal_________________________-___________________

Test,engine______________________________________________

Throttle linkage. (See Linkage, throttle.)

Timing gear. (See Gear, camshaft driven, and Gear, crankshaft drive.)

Timing gear cover. (See Cover timing gear.)

Tools :

Common, and equipment_______________________________

Specid_______________________________________________

Troubleshooting:

Carbon, excessive______________________________________

Compression, low______________________________________

General______________________________________________

Ignition______________________________________________

Oilconsumption,excesaive________________-_-___________

Procedures____________________________________________

BrWWWh pooc

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142

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9

18

10

12

15

19

11

17

17

24

28

22

23

24

21

Underwater ventilating system.

(See Ventilating system.)

Unit, sending, oil pressure:

Installation____________________________________-_--~__

Removal________________________ _____________________

Unit, sending, water temperature:

Installation___________________________________________

Rsmoval_____________________________________________

Vacuum line. (See Line, vacuum.)

Valve, metering:

Assembly______________________________-______________

Cleaning__________________________-__________________

Descripfion___________________________________________

Disessembly__________________________________________

Inspection____________________________________________

Tnstallation___________________________________________

Removal_____________________________________________

Valve, pressure relief, oil pump.

(See Pump, oil.)

Valve, vent control, lower crankcase:

ARsembly._____________________.______________________

Cleaning_,___________________________.~_______.______

Disassembly-________ _________________________________

Operation over-land service_____________________________

Operation underwater service___________________________

Inspection____________________________________________

Installation___________________________________________

Removal_____________________________________________

Valve, vent control, upper crankcase:

Assembly______________________.._____________________

Cleaning____. __________________________________________

Disassembly_. ___________________________________-_____

Operation over-land service________________..____________

Operation underwater service______________________. ____

Inspection____________________________________________

Installation_________________.. ________________________

Removai_..___________________________________________

Vent line. (See Lines, vent.)

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DEPARTMENT

DEPARTMENT

TM !b8015-1

TO 38Y2-‘7-2

Cl

OF THE ARMY TECHNICAL MANUAL

OF THE AIR FORCE TECHNICAL ORDER

ENGINE (WILLYS-OVERLAND MODEL MD) AND CLUTCH

FOR S-TON 4 x 4 UTILITY TRUCK M38Al AND %-TON

4 x 4 FRONT LINE AMBULANCE Ml70

TM 9-8015-l

TO 38Y2-7-2

DEPARTMENTSOFTHEARMY

AND THE AIR FORCE

TM 9-8O&l/TO 19-75B-21,s March 1954, is changed as follows:

The title is changed to read-

ENGINE (WILLYS-OVERLAND M 0 D E L MD) AND

CLUTCH FOR X-TON 4 x 4 UTILITY TRUCK M38A.1

AND

IA-TON 4 x 4 FRONT LINE AMBULANCE Ml70

1.

Scope

* *

* * b.

*This manzal eontaizs * * * utility truck M38Al

and the IA-ton

4 x 4 front line ambulance M170.

The appendix contains * * * to the materiel.

* *

* * * * *

5. Data

*

Used*in vehicle*models_*_______~38Al ana* M170.

* * *

*

*

*

*

*

Repair

* *

*

*

* o.

*If the old ** * * crankshaft as follows

:

(1) Assemble the flywheel * * * the nuts securely. Refer to

* paragraph 152 for torque specifications.

* * * * * *

92.1 Fan

and Generator

Drive Pulley

(added) a. Inspect the fan and generator drive pulley (AU, fig. 12), and if pulley inside flanges shows signs of having separated at the hub, repair as outlined in 6 below. b.

(1) Locate the centers for three holes on the pulley so that they will be on a circle 23/4 inches in diameter, the center of which lies on the centerline of the pulley. Space the holes so that they will be 120” apart.

2

Caution: Absolute accuracy of spacing ia necessary to prevent throwing the pulley out of balance.

(2) Drill three l/a-inch holes at the locations indicated in (1) above.

(8) Rivet securely with three l/a x 7/le flat-head steel rivets.

*

(pars. 60 and 61)

* * b. (Superseded) Rings.

*

* * *

3%~

Ref. ktter Point of mcaaursmen4 Minimum Maximum Wear limb

123 C

B

Thickness of compression rings (2) __ 0. 0930 0. 0935 _ _ _ _ _ _ _

Thickness of oil ring (l)___________ 0. 186 0. 1865 _______

122 _____ Top ring to groove clearance__ _ _ _ __ 0.002 0.0035 0. 005

Center ring to groove clearance_ _ _ _ 0. 0015 0. 0030 0. 0045

Bottom ring to groove clearance____ 0.001 0.0025 0.0045

Ring gap in cylinder block_________ 0. 007 0. 023 0. 040

[Aa 451.2 (23 Mar 55) ]

OFFIOIAL:

JOHN A. KLEIN,

Major

OF THEI ARMY

AND THH Am

M. B. RIDGWAY,

General,

OFFICIAL:

E. E. TORO,

CokmeZ,

Active Amy:

Tee Svc,

DA (1)

Ord Bd (2)

CONARC (3)

Army AA Comd (2)

OS Maj Comd (5)

OS Base Comd (2)

Log Comd (3)

MDW (1)

Armies (3)

Mil DIst (1)

Ord Proc Dist (10)

MAAG (1)

Mil Msn (1)

Units organized under following TOE’s :

9-12A, Hq & Hq Co, Maint &

Sup Co Ammo (1)

9-17, Ammo Co, Army (1)

945A, Sp Wpn Spt or Depot

Corps (2)

Div (2)

Ord Gp (2)

Ord Bn (2)

Ord Co (2)

Ft & cp (2)

Gen & Br Svc Sch (2)

Ord Sch (50)

PMST Ord ROTC units (1)

Bn (1)

9-46A, Hq & Hq Det, Sp

Wpns Spt or Depot Bn (1)

947A, Sp Wpns Spt pot co (1)

or

De-

9-49, Sp Wpns Dir Spt Co

(1)

9-578, Fld Sup Co (1)

9-229, ORD GM Dir Spt Co

Gen Depots (2)

Ord Set, Gen Depots (5)

Ord Depots (10)

POD (2)

OS Sup Agencies (1)

ORD PG (10)

(1)

9-347, Ord Tire Rebuild Co

(1)

9-367, Sup Depot Co (1)

9-387, Ammo Depot Co (1)

Ord Arsenals (6)

NO: Same as Active Army except allowance is one copy to each unit.

USAR:

None.

For explanation of abbreviations used, see SR 320-50-l.

Willys-Overland MD engine, clutch, M38A1 utility truck Technical manual

ORDNANCE MAtNTENANCE: ENGINE (WIUYS-OVERLAND

MODEL MD) AND CLUTCH FOR ‘/‘i-TON 4 x 4 UTILITY

TRUCK

M38Al

CarPTEa

7464 LAWA$TER PIKE

SUITE 321

HOCKISSIN, DE 19707

Caution:

52. Assembly

(fig. 30) a.

Caution:

Caution:

“T’

147b).

* d.

b. Inspection amd Repah.

b.

(L) ,

of

or

refer to the

clerning, inspection, and repair of engine parts.

88. Exhaust Manifold a.

d.

95. Install Main Bearing Halves in Cylinder Block

(fig* 72) a.

the be

d.

98. install Front Mounting Plate a.

123. Install Clutch a.

Section I. DESCRIPTION AND OPERATION

135. Description a.

MEDIA, INC.

COPY RIGHT 1999

148. Camshaft

and the IA-ton

4 x 4 front line ambulance M170.

5. Data

*

*

Repair

* *

*

*

* o.

92.1 Fan

Drive Pulley

Key Features

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Engines 1949-1952 Master

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Frequently Answers and Questions

What type of engine is the Willys Overland MD?

How does the MD engine operate underwater?

What is the purpose of the engine ventilating system?

How is the MD engine lubricated?

**(fig* 72) a.**