DEPARTMENT OF THE ARMY

TECHNICAL MANUAL
DEPARTMENT OF THE AIR
FORCE TECHNICAL ORDER

6-CYLINDER, HORIZONTALLY
OPPOSED, AIR-COOLED
GASOLINE ENGINE
(CONTINENTAL MODEL AO-895-4)

DEPARTMENTS OF THE ARMY AND THE AIR FORCE

MARCH 1953

TM H755BB
CJ
TECHNICAL MANUAL

6-CYLINDEJR, HORIZONTALLY OPPOSED,

AIR-COOLED GASOLINE ENGINE
(CONTINENTAL MODEL AO-895-4)
TM 9-1755BB

HEADQUARTERS,
DEPARTMENT OF THE ARMY

CHANGES No. 2

WASHINGTON 25, D.C., 11 December 1959

TM 9-1755BB, 23 March 1953, is changed as follows:

82. Oil Pressure Control Valve
*
*
*
*

e. Assembly,
*
*
*
*
*
*
*
(2) Place the spring * * * the valve spring. It is set for 60-70
psi using engine oil SAE 50 at 180 F. If the desired * * *
check new readings.
127. Oil Pressure

.Oil pressure can * * * pressure control valve. If pressure is too

'jjifa adjust it to 60-70 psi, using engine oil SAE 50 at 180 F., by
adding up to three plain washers in the cap.
148. Cylinders
*
*

b. (Superseded) Cylinder Bore.

Fig. No.

Point of mtaturtmenl

Ref.Ltr.

Sizet andfit*
o/ntv parti Wear Unit

Bore diameter 1 inch from bottom of skirt 5. 7460

to
(bottom of ring travel).
5.7490
Bore diameter opposite center of barrel 5. 7425
to
fins.
5. 7455
Bore diameter at top of cylinder barrel.. 5. 7380
to
5.7410
Maximum out-of-round of cylinder bore. 0. 0010
*
*
*
*
*
*
[AG 412.5 (20 Oct 59)]

122.....

BB

XAOO 319&B Dec.

520482 69

5. 7590
5. 7550
5. 7537
0. 0050
*

By Order of Witter M. Brucker, Secretary of the Army:

Official:

v.

L. L. LEMNITZEB,
^ United States Army,
Ctief of Staff.

Major Genera^ United State* Army,

The Adjutant General
Distribution:
Active Army:
Tech Stf, DA (1) except CofOrd
(H)
Ord Bd (2)
USCONARC (3)
US ARADCOM (2)
OS Maj Comd (2)
OS Ba*s Comd (2X
Log Comd (3)
" MUW (1)
Annies (3) except'first US Army
(5)
Corps (2)
Div (2)
Ord Gp (2)
Ord Bn (2) except TOE 9-45,
9-375 (none)
Ord Co (2) except 1TOE 9-12,
9-17, 9-46, 9-47, 9-57, 9-229,
9-347, 9-367, 9-376, 9-377,
9-387 (none)
Fort Belvoir (7)
Fort Bragg (2)
Fort Hood (7)
Fort Bliss <9)
Fort Sill (6)
Fort Sam Houston (7)
Svc CpUegesr. (2)
Br Svc Sch (2) except USA Ord
Sch (50)
PMSTSr DJv Ord Units (1)
Ord Ammo Comd (1)
NO: State AG (3).
USAR: None.
'
For explanation of abbreviations used, see

Gen Dep (2)

Ord Sec, Gen Dep (5)
.Ord Dep (10) except Black Hills,
Savanna (5), Tooele (4), Sierra,
Umatilla & Wingate (3), Sioux
(2), Rossford (12), Anniston
(18)
Port of Emb (OS) (2)
Trans Terminal Comd (2)
Army Terminals (2)
OS Sup Agcy (1)
Fid Comd, Def Atomic Spt Agcy
(1)
OrdPG(lO)
Ord Arsenals (5) except Benicia
(45),'Rock Island (12), Frankford (10), Joliet (4), Lake City
(3), Ravenna & Springfield (2),
Radford (1), Raritan (535,
Frankford (30)
;
USA Corps (Res) (1)
Ord Proc Dist (1) except New
York (5), Philadelphia (4),
St. Louis (3), Cleveland (2),
Chicago (none)
MAAG (Belgium) (2)
Ord Tk Autmv Comd (55)
JBUSMC (2)
JUSMAG (Greece) (2)
Units organized under following
TOE: 29-55 (2)
AR520-50.

TAQO 3199B
.S. teVIRHNENT FKINTIHS OFriCtt !

TM 9-1755BBITO 19-100AD-1

6-CYLINDER, HORIZONTALLY OPPOSED

AIR-COOLED, GASOLINE ENGINE
(CONTINENTAL MODEL AO-895-4)

United States Government Printing Office

Washington : 1953

Tki manual '* correct to 3 November

DEPARTMENTS OF THE ARMY

AND THE AIR FORCE
WASHINGTON 25, D. C., S3 March 1953
TM 9-1755BB/TO 19-10OAD-1 is published for the information
and guidance of ajl concerned.
TAG 412.5 (13Xov52)]
BY ORDER OF THE SECRETARIES OF THE ARMY AND THE

OFFICIAL:
1VM. E. BERGIN
Major General, USA
The Adjutant General

J. LAWTON COLLINS
Chief of Staff, United States Army

OFFICIAL:
K. E. THIEB AUD
Colonel, VSAF
Air Adjutant General

HOYT S. VANDENBERG
Chief of Staff, United States A ir
Force

DISTRIBUTION :
Active Army:
Tech Svc (1) ; Tech Svc Bd (2); AFF (2); AA Comd (2);
OS Maj Comd (10); Base Comd (2); MDW (3); Log
Comd (5); A (10); CHQ (2); Div (2); Regt 9 (2);
Bn 9 (2); CO 9 (2); FT (2); Sch (5) except 9 (50);
PMS & T 9 (1); Gen Dep (2); Dep 9 (10); POE (5),
OSD (2); PRGR 9 (10); Ars 9 (10) ; Proc Dist 9 (10) ;
MilDist (3).
NG: Same as Active Army except one copy to each unit.
A rmy Reserve: Same as Active Army except one copy to each unit.
For explanation of distribution formula, see SR 310-90-1.

CONTENTS

CHAPTER 1. INTRODUCTION

PmtnUu

Page

Section I. Genenl....................................
//. Description and data___....___......_.....

1-3
4-6

5
7

CHAPTER S. PARTS, SPECIAL TOOLS, AND EQUIPMENT

FOR FIELD AND DEPOT MAINTENANCE-...

7-10

11

11,12
13,14

24
25

15-33
34-36

33
48

37-55
56-59
6O-62
63-65
66-68
69,70

53
72
108
114
125
130

71-73
74,75
76-78
79-81
82-101
102-126
127-129
130-133

137
144
151
154
162
198
234
235

CHAPTERS. HYDRAULIC GOVERNOR------------------- 134-137

239

6. REPAIR AND REBUILD STANDARDS------------ 138-163

246

APPENDIX REFERENCES--.-.-.-.----------...------------ .......

311

INDEX............................ _-_ _.. ....... ------

315

3. TROUBLE SHOOTING
Section/. General--..-....-----.-_---_-------.----.
//. Engine.-----------.--.--..------------.-CHAPTER 4. ENGINE
Seetionl. Description and data._------------------II. Preparation of engine for rebuild.-__--._-.///. Disassembly of stripped engine into subassemblies.-------------..-------------7V. Rebuild of accessory case---.-----.----.---.
V. Rebuild of camshafts and drives.-_.-.--._-..
V7. Rebuild of cylinders. ---_----------_._-VII. Rebuild of pistons, pins, and rings _--_--.__.F//7. Rebuild of crankcase...-_-...---------.._-IX. Rebuild of crankshaft and connecting rod
assembly...............................
X. Rebuild of oil pumps..___...._........._..
XI. Rebuild of cooling fan and fan clutch assembly.
X/7. Rebuild of throttle linkage ..------------XIII. Rebuild of miscellaneous parts._ _..--..-.-.
XIV. Assembly of engine from subassemblies.......
XV. Tests and adjustments.._--..----.--.---.-XVI. Run-in test..--.-----------.--------------

FUEL FILTER
ASSY

THROTTLE LINKAGE
CROSS SHAFT

Figure 1. Engine-right-front view.

COOLING FAN OUTLET

HOUSING ASSY

RA PD 188837

OIL COOLER
ASSY

CRANKCASE OIL
PAN ASSY

FILLER PIPE ASSY

CRANKCASE OIL

Figure 2.

Engineleft-rear

OIL COOLER
ASSY

RAPD 18883?

Figures.

Enginefront view (accessory cud).

HEAT CONTROL
UNIT HOUSING
ASSY
HEAT CONTROL
VAIVE ASSY

CRAMKCASf ENGINE
LIFTING fYf

RA PO 188840
4.

Eny'iiicrmr r/Vjr (fli/irlio I <nil).

CHAPTER 1
INTRODUCTION
Section I. GENERAL
1. Scop*
it. (1) These instructions are published for the information and
guidance of |>ersonnel resjxmsible for field and depot maintenance
procedures for the Continental (J-fylinder hori/ontally-opj>osed aircooled, gasoline engine, Model AO-X'J5-4, Instructions contained in
this nmmial are based on the engine as installed in the armored
infantry vehicle TlMKl. They include information on maintenance
which is beyond the scope of the tools, equipment, or supplies nor
mally available to using organizations. This manual does not contain
information which is intended primarily for the usinjj organization,
since such information is available to ordance maintenance personnel
in the pertinent oj>erator's technical manuals or Held manuals.
(2) This first edition is being published in advance of complete
technical review by all concerned. Any errors or omissions
will l>e brought to the attention of Chief of Ordnance, Wash
ington 2:, I). ('., ATTENTION: ORDFM-Pub.
b. This manual contains a description of and procedure for removal,
disassembly, inspection, repair, rebuild, and assembly of the stripped
engine. The appendix contains a list of current references, including
supply catalogs, technical manuals, and other available publications
applicable to the materiel.
c. TM S)-7f>5B, and any other operator's manual covering materiel
in which this engine is installed, contains operating and lubricating
instructions for the materiel and contains all maintenance operations
allocated to using organizations in performing maintenance work
within their sco|>e.
d. TM 9-1826B contains service information on the Stromberg
carburetor.
<?. TM 9-18^8A contains service information on the fuel pump and
fuel filter.
/. TM fM82f>C contains service information on the Eclipse-Pioneer
generator and starter.

g. TM 9-1825E contains service information on the BendixScintilla magnetos.

2. Field and Depot Maintenance Allocation
The publication of instructions for complete disassembly and re
build is not to be construed as authority for the performance by field
maintenance units of those functions which are restricted to depots
and arsenals. In general, the prescribed maintenance responsibilities
will apply as reflected in the allocation of maintenance parts listed
in the appropriate columns of the current OKI) 8 supply catalogs
pertaining to vehicles using this engine. Instructions for depot main
tenance are to be used by maintenance companies in the field only
when the tactical situation makes the repair functions imperative.
Supply of parts listed in the depot guide column of ORD 8 supply
catalogs will be made to field maintenance only when the emergency
nature of the maintenance to be performed has been certified by a
responsible officer of the requisitioning organization and upon express
authorization by the chief of the service concerned.
3. Forms, Records, and Reports
(t. General. Responsibility for the proper execution of forms, rec
ords, and reports rests upon the officers of all units maintaining this
equipment. However, the value of accurate records must be fully
appreciated by all persons responsible for their compilation, main
tenance, and use. Records, reports, and authorized forms are nor
mally utilized to indicate the type, quantity, and condition of materiel
to be inspected, to be repaired, or to be used in repair. Properly
executed forms convey authorization and serve as records for repair
or replacement of matexiel in the hands of troops and for delivery of
materiel requiring further repair to ordnance shops in arsenals, depots,
etc. The forms, records, and reports establish the work required, the
progress of the work within the shops, and the status of the materiel
upon completion of its repair.
6. Authorized Forms. The forms generally applicable to vinits
maintaining this equipment are listed in the appendix. No forms
other than those approved for the Department of the Army will be
used. For current and complete listing of all forms, refer to current
SR 310-20-6. Additional forms applicable to the using personnel
are listed in the operator's manual. For instructions on use of these
forms, refer to FM 9-10.
c. Field Reports of Accidents. The reports necessary to comply
with the requirements of the Army safety program are prescribed in
detail in the SR 385-10-40 series of special regulations. These re-

ports are required whenever accidents involving injury to personnel

or damage to materiel occur.
d. Report of Unxatix factory Equipment or Material*. Any sugges
tions for improvement in design and maintenance or equipment, safe
ty and efficiency of operation, or pertaining to the application of pre
scribed petroleum fuels, lubricants, and/or preserving materials, will
be reported through technical channels as prescribed in SR 700-45 5
to the Chief of Ordance, Washington 25, I). C., ATTN: ORDFM,
using DA Form 4(58, Unsatisfactory Equipment Report. Such sug
gestions are encouraged in order that other organizations may bene
fit,
Note. Do not report all failures that occur. Report only REPEATED or
RECURRENT failures or malfunctions which indicate unsatisfactory design
or material. However, reports will always be made in the event'that exception
ally costly equipment is involved. See also SR 700-45-5 and the printed in
structions on DA Form 468.

Section II. DESCRIPTION AND DATA

4. Description
a. The Continental engine (fig. 1) , Model AO-895-4, is a 6-cylinder
horizontally opposed, four-cycle, air-cooled, gasoline engine with over
head valves. The cylinder assemblies are individually replaceable
units. They have the valve rocker assemblies in the head, and are
arranged in two banks of 3 cylinders each, with a separate camshaft
to actuate the valves of each band. A mechanically driven fan,
located on the top of the engine, is provided to circulate air around
the cylinders for cooling. Baffles are mounted on the cylinders to
direct the air flow. An accessory case provides a means for mounting
and driving the engine accessories. A mechanical type fuel pump,
actuated by an engine-driven eccentric cam, is mounted on the right
(1-3-5) side of the accessory case.
b. A conventional, double-venturi, down-draft carburetor is
mounted on top of the jacketed cast iron hotspot intake manifold
housing. The jacket passage of the housing is connected to the
exhaust manifolds. Exhaust gases, moving through the jacket pass
age, are controlled by a vacuum controlled valve. Air is drawn
through the carburetor and the carbureted mixture is heated as it
passes through the jacketed hotspot intake manifold housing into
the intake manifolds located on each bank of cylinders.
c. Dual ignition (fig. 103) is provided by two magnetos, each one
igniting six spark plugs. The inner magneto fires the accessory-end
spark plug in each cylinder. The outer magneto fires the flywheelend spark plug of each cylinder. An ignition harness connects each

magneto to its spark plugs. The magnetos and ignition harness are
waterproof and shielded to prevent radio interference.

d. The engine is lubricated by a forced-feed system utilizing two

pumps. One pump is a dual unit consisting of a scavenger and pres
sure oil pump (fig. 11). The other pump is a separate scavenger pump.
Together, the dual unit and the separate scavenger pump supply oil to
the lubricating system. The dual pump is mounted on the lower side
of the crankcase. The scavenger pump of the dual unit transfers oil
from the flywheel end of the oil pan to the reservoir of the pressure
pump through the scavenger pump suction line (fig. 11). The separate
scavenger pump transfers oil from the accessory case sump to the pres
sure pump reservoir through the scavenger oil pump outlet line (fig.
11). With scavenger pumps constantly transferring oil from both ends
of the engine, the pressure pump is assured an adequate supply of oil
at all times. In normal operation, the oil passes from the pressure
pump through passages in the crankcase and accessory case to the oil
control housing. It then passes through external oil lines to the exter
nal oil cooler and returns to the engine through the oil control hous
ing and the oil filter. The oil flow as shown in figure 12 is controlled
by four valves. An oil pressure control valve (fig. 12), an oil filter by
pass valve (fig. 12), and an oil cooler by-pass valve are all located in
the oil control housing (fig. 42). The fourth valve, an oil cooler by
pass valve (thermostatic), located on the oil cooler, regulates oil tem
perature.
e. A generator and a starter are mounted on opposite sides of the
accessory case.
5. Engine Nomenclature

In this manual, the following terms will be used to identify the lo

cation of parts and assemblies:
a. The ends of the engine will be called the "accessory end" or
"front" and the "flywheel end" (fig. 4) or "rear/'
b. As viewed from the accessory end toward the flywheel end, the
side to the right will be called the "right (1-3-5) side" and the side
to the left will be called the "left (2-4-6) side." Beginning at the
accessory end, the right bank of cylinders is numbered 1-3-5 and the
left bank is numbered 2-4-6.
<?. Starting from the accessory end, the main bearings are numbered
from 1 to 4 and the halves are identified with markings "1-3-5R side"
and "2-4-6L side."
d. Cylinders, pistons, connecting rods, and connecting rod bearings
are marked with their respective cylinder number locations.
e. The hotspot intake manifold housing side of the accessory case
will be called "front" and the crankcase side will be called "rear."
8

6. Tabulated Data
Crank-haft rotation.__ clockwise, viewed from
front (accessory end).
Cylinder arrangement._____. Individual cylinders in
a horizontally-opposed
position.
Cylinder cooling. air supplied by one
integral fan.
Drive from crankshaft..____________ direct
Dry weight complete with flywheel and all accessories_______ 1-.856 Ib
Firing order....______________ 1-&4-2-5-4
Horsepower (gross)--______.____________ 375 bhp at 2.800
rpni.
Horsepower (net) (at tW) F. and 29.92 in.-Hg as
engine is installed in T18B1 vehicle) __________ 300 bhp at 2,400 rpm
Induction system_________________ naturally aspirated
Make and type.._________________ Continental, 6-cylinder,

four-cycle, air-cooled,
horizontally-opposed,
gasoline engine.
Model___________________________._ AO-S95-4
Number of camshafts_____________.__ 2
Number of'cylinders_____________________...______ 6
Numbering of cylinders from accessory case toward flywheel end:
Right aide (as viewed from accessory end)______________ 1, 3, 5
Left side (as viewed from accessory end)._____________ 2, 4, 6

Oil pan capacity____________ 11 gal

Output of oil pumps (SAE 50 oil at 180 F. and 90 psi) :

Scavenger and pressure oil pump (dual unit) (at 2,800 rpm) :
Pressure oil pump________________________ 29.7 gpm
Scavenger oil pump._____________________ 27.4 gpm
Accessory case scavenger oil pump_______________ 27.4 gpm
Overall dimensions (including flywheel assembly) :
Length_-_________________________________ 49.24 in.
Width_________________________________.___ 50.72 in.
Height___________________________________ 36.98 in.
Torque (gross)_____________________ 845 Ib-ft at 2,000 rpm
Torque (net) (at 60 F. and 29.92 in.-Hg as engine
is installed in T18E1 vehicle) _______________ 720 Ib-ft at 2,000 rpm

CHAPTER 2
PARTS, SPECIAL TOOLS, AND EQUIPMENT FOR FIELD
AND DEPOT MAINTENANCE
7. General
Tools and equipment and maintenance parts over and above those
available to the using organization are supplied to ordnance field
maintenance units and depots for maintaining, repairing, and/or
rebuilding the materiel.
8. Parts
Maintenance parts listed in Department of the Army Supply Cata
log ORD 8 SNL G-260 which is the authority for requisitioning re
placements. Parts not listed in the ORD 8 catalog, but required by
depot shops in rebuild operations, may be requisitioned from the list
ing in the corresponding ORD 9 catalog and will be supplied if avail
able. Requisitions for ORD 9 parts will contain a complete justifi
cation of requirements.
9. Common Tools and Equipment
Standard and commonly used tools and equipment having general
application to this materiel are listed in ORD 0 SNL J-8, Section 16;
ORD 6 SNL J-9, Sections 3 and 8; and ORD 6 SNL J-10, Section 4
and authorized for issue by T/A and T/O & E. They are not spe
cifically identified in this manual.
10. Special Tools and Equipment
The special tools and equipment tabulated in table I will be listed
in a section of Department of the Army Supply Catalog ORD 6 SNL
J-16. This tabulation contains only those special tools and equip
ment 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.

11

*/oo|

fc f 1

IN.41-P-

Figure 5.

Special tools and

Q WRENCH, STARTER JAW BRG NUTll-W-545^15.

P STRAP, CRANKCASE TIE ROD, LGH 5% IN.

N SLING, LIFTING41-8-3829-720.

LEYE, LIFTING, CRANKCASKil-E-015-350.

MPROTECTOR, CONNECTING ROD. LGH 8

HREPLACER, GUIDE (EXHAUST VALVE)41-R-2300-475.

JREPLACER, GUIDE (INTAKE VALVE)41-U-2390-4S2.
KCOMPRESSOR, VALVE SPRING, CAST CONSTRUCTION
41-C-2550-28.

13^6 IN.^l-R-2378-570.

FGAGE AND COMPRESSOR, PISTON RING41-G-534-50.

GREMOVER AND REPLACER, PISTON RING, ID 6 IN.. LGH

10-IX. LONGil-W-871-80.

IN. OPNG. 10%-IN. LONGtl-W-1893-400.

DWRENCH. CRANKSHAFT DAMPER COUNTERWEIGHT
PIN41-W-870-50.
EWRENCH, CROWFOOT, OPEN END. L HDL. 2%2-IN. OPNG.

IN.41-W-872-710.
CWREXCH. OI'EX EXI>. OO DK<; AX<JLE, S<JLE EXl>. 1..TU.V

SQ-DRIVE, DBLE-HEX, SIZE OF OPNG %-IN.. LGH 21

IN.41-W-872-715.
BWRENCH, CYL HOLD-DOWN NUT. SGLE-HD BOX. V:

AWRENCH, CYL HOLD-DOWN NUT, SGLE-HI) KOX. Mt IN.

S'Q-DRIVE. DBLE-HEX. SIZE OF OPNG % IN.. UJH

HOI (INTAKE). D1AM TAPEKS FROM O.-MW TO O.4^

IX., LUH IS5* IN.41-11-2254-552.
YREAMER. FINISHING. VALVE GUIDE VAlA'E STEM
HOLE (INTAKE), DIAM TAPERS FROM 0.485 TO 0.500
IN.. U5H 13% IN.41-H-2254-505.
/.HANDLE. REMOVER AND REPLACER. DIAM OF SHK
1 IX.. LGH l.H% IX.II-H-lJWB-TilO.
AAUKMOVKR. GUIDE (EXHAUST VALVE), DIAM 0.557
AND 0.74S IX.. IAJH 22 IN.41-R-3S71-aO.
HB RKMOVKR. GUIDE (INTAKE VALVE). DIAM 045tfi AXD
(1.071) IN.. LGH 22 IN.41-11-2871:*.-..

OJi62 IN.. LGH 13% IN.ll-R-2254-520.

X-RKAMER, HOUGHING, VALVK GUIDE VALVE STEM

O.fWO IX.. LGH IS'H IN.ll-R-2254-570.

W REAMER. FINISHING. VALVE GUIDE VALVE STEM
HOLE (EXHAUST), DlAM TAPERS FROM 0%57 TO

1SNF-3I1-R-2S7H-57A.
V-REAMER. ROUGHINCi. VALVE GUIDE VAl.VK 8TB1I
HOLE (KXHAUST), D1AM TAPERS FROM 0.550 TO

OING8 1.655 X 1.915. LUH 6^ IN-II-W-3727-33.

TWRENCH. AIX'ESSORY DRIVE GEAR HUB NUTll-W43O-275.
UItBMOVER AXD REPLACEK. PLUG. T HDL, THI % IN.-

217-<iUO.
8WRENCH. TUBULAR. DBLE ENI*. HEX. SIZE OF HEX

1CIIOU>ER, STARTER DRIVE ADAPTER AND JAWll-H-

puo rjooj

750.

Figure 6.

-W-

-W-

15H6-399.
BBWRENCH, INSERT (ROSAN). %-20 TO %-16-41-W1536-402.
(V WRENCH, INSERT (BORAX). %-18TO 1-1441-W-1586410.
DDTOOL, INSERTING, HELMXHLl

1236-396.
AA WRENCH, INSERT (ROSAN I. 'i-2O TO %-18ll-W-

X-WRENCH. INSERT (ROSAN). %-24 TO %-20ll-W-

1536-391.
Y WRENCH. INSERT (ROSAN). *H-24 TO

X WRENCH, INSERT (ROSAN), *H-18 TO

770.
V DRIVER. INSERT (ROSAN). r *-18 TO 1-1441-P-2967785.
W WRENCH, INSERT (RC8AN), H-28 TO %-I641-W-

765.
U DRIVER. INSERT (ROSAN), Vi-20 TO %-16I1-IV2967-

755.
8DRIVKB. INSERT ( ROSAN >, %-'2i TO ^-a*-41-D-287700.
T DRIVER, INSERT (ROSAN I, %-30 Tl> %-18ll-D-2987-

7.YJ.
K DRIVER. INSERT (ROSAN), <H-24 TO %-20U-IMBMT-

Q DRIVER. INSERT (ROSAN), 'He-lH TO %-13-I>-2867-

Special toolt and. equipmentContinued.

KBUSHING, PILOT (INTAKE VALVE GUIDE)41-B-2181175.

LBUSHING. PILOT (EXHAUST VALVE GUIDE)41-B2181-150.
MREPLACER, OIL SEAL, OD 2.120 IN., LGH l%e IN.41-R2392-995.
NWRENCH, CROWFOOT, %-IN. OPNG, 10-IN. LONG41-W2390-50.
PDRIVER, INSERT (RO8AN), Vi-28 TO %-1641-D-2967-

GTOOL, EXTRACTING, HELI-COIL41-T-3092-350.

HLIGHT, MAGNETO TIMING41-L-1439.
JWRENCH, ENGINE TURNING, LGH 3^ IN.--I1-W-906-180.

HDL, 10-IN. LGHll-W-871-32.

FGAGE, THKNS, VALVE TAPPET ADJ. NO. OF LEAVES
441-G-415-375.

1.255-IN. OPNG, 4-IN. LONG41-W-871-90.

EWRENCH, CROWFOOT, % IN. OPNG, S'He-IN- OFFSET

APULLER, CRANKCASK SECTION REMOVING41-P-2906280.

BPULLER, SCREW, THREADED %-16NC-2, 9-IN. LONG,
2%-IX. HI>LI1-1*-2OX-O.
CSCREW, PULLER, THD % IN. 20NF-2 FOR 5% IN., LGH
OVERALL 6% IN.41-S-1044-125.
DWRENCH, CROWFOOT, OPEN END, ^4-IN. SQ-DRIVE,

FIXTURE SIT, REAMING-41-F-ZW185

REMOVER (KIT) INSERT (VAIVE SIAT) - 41*2371-4*5

RA PO 155878

Figure 7.

16

Special tool* and equipment.

STAND
41-S-4942-20

RAW)
Figure 8.

Special tooh and equipment.

17

41-A-26-670

Identifying Number

1 Fixture, reaming, assv .

1 Reamer

Consisting of:
1 Box............ ...

41-C-2559-28

COMPRESSOR, valve spring, cast con

struction.
CRADLE ASSEMBLY, engine stand,
assy, univ.
DRIVER, insert (Rosan), J4-28 to %-16._
DRIVER, insert (Rosan), Me-18 to K-13.
DRIVER, insert (Rosan), % 8-24 to % 6-2Q_
DRIVER, insert (Rosan), %-24 to ^-20 _.
DRIVER, insert (Rosan), fte-20 to %-18_DRIVER, insert (Rosan), ft-20 to #-16. _
DRIVER, insert (Rosan), H-18 to 1-14.. _
EYE, lifting, crank case
FIXTURE SET, reaming..
4 1-B- 1624-600
41-F-2997-280
41-R-491-200

41-D-2967-750
41-D-2967-752
41-D-2967-755
41-D-2967-760
41-D-2967-765
41-D-2967-770
41-D-2967-785
41-E-615-350
41-F-2997-185

41-C-2674-125

41-B-2181-175

BUSHING, pilot (intake valve guide)

K, 6

L, 6

P, 6
Q,6
R,6
8,6
T, 6
U, 6
V,6
L, 5, 27
7

K, 5, 51

Fig.

Ruferonoes

04

64

57
57
57
57
57
57
57
55, 103
88

63,65

Par.

Hold engine for repair and inspection.

Used w/STAND 41-S-4942-20.
Installing "Rosan" insert locking rings.
Installing "Rosan" insert locking rings.
Installing "Rosan" insert locking rings.
Installing "Rosan" insert locking rings.
Installing "Rosan" insert locking rings.
Installing "Rosan" insert locking rings.
Installing "Rosan" insert locking rings.
Lifting halves of crankcase.
Reaming crankshaft and flywheel dowel
pinholes.

4 l-R- 2254-552.
Removing and installing valve springs.

2254-505 and REAMER, roughing

Use

Adapt engine stand cradle to stand.

Used w/CRADLE 41-C-2674-125.
Used w/REAMER, finishing 41-R2254-520 and REAMER, roughing
41-R-2254-570.
Used w/REAMER, finishing 41-R-

Special Tools and Equipment for Field and Depot Maintenance

BUSHING, pilot (exhaust valve guide). _. 41-B-2181-150

ADAPTER, engine stand cradle

Item

Table I.

_ _ .

7950244

_..._____,_ 7950655

._

41-P-2908-60

PULLER, screw, threaded, %-l6NC-2,

0.557 to 0.562 in., Igh 13% in.

9 in. long, 2%-in. handle.

REAMER, finishing, valve guide valve
stem hole (exhaust), diam tapers from
41-R-2254-520

41-P-2906-280

PULLER, crankcase section removing

(three required).

41-P-2839-535

PROTECTOR, connecting rod, Igh 8 in. .

Line, gasoline .
7950242
LIGHT, magneto timing ........... ... 41-L-1439

Hose, primer.

Hose, gasoline

Cable, generator field

7950238
. _ 7950239
Cable, starter _ _
...
.
7950241
Cable, junction box, .._
. .
7950240
Cable, ground
....__
. _ _ 7950243
Hose, gasoline
_ .
7950654

Cable, generator armature.

KIT, extension harness and fuel linesConsisting of:

7950041

W, 5

B, 6, 33

A, 6, 26

H, 6
M, 5, 23

R, 5, 36

shk 1 in., Igh 13% in.

HOLDER, starter drive adapter and jaw.. 4 l-H-2 197-600

F, 6, 89, 90
Z,5

4 l-G-4 15-375

F, 5, 55, 86

41-H-1396-510

GAGE, thkns, valve tappet adj, No. of

leaves 4.
HANDLE, remover and replacer, diam of

GAGE AND COMPRESSOR, piston ring. 41-G-534-50

64

49, 56

54, 56, 58

109
52, 103, 105

58

108, 109

67, 105

Reaming exhaust valve guide.

Removing starter drive adapter, crankcase oil pan, and flywheel damper.

Protecting craukcase when cylinders are

removed.
Removing power take-off drive adapter,
accessory case cover, accessory case
diaphragm, fan drive housing, and
magneto drive housing adapter.

Timing engine.

Holding starter drive adapter and jaw.

Used w/WRENCH 41-W-545-15.
Extend harness and fuel lines for operat^
ing engine and transmission with ve
hicle controls when removed from
vehicle.

Used w/REPLACER 41-R-2392-995.

Gaging piston ring gap and installing

piston.
Setting valve rocker clearance.

41-R-2254-552

0.550 to 0.560 in., Igh 13% in.

REAMER, roughing valve guide valve

0.488 to 0.498 in., Igh 13% in.

REMOVER and REPLACER, piston
ring, ID 6 in., Igh l33/io in.
REMOVER and REPLACER, plug, T
hdl, thd % in.-18NF-3.
REMOVER, guide (exhaust valve), diam
0.557 and 0.743 in., Igh 22 in.
REMOVER, guide (intake valve), diam
0.495 and 0.679 in., Igh 22 in.
REMOVER KIT, valve seat inserts.
Consisting of:
1 Box........_.----.--.----.-..1 Remover. ___.._.------.-------REPLACER, guide (exhaust valve)
REPLACER, guide (intake valve)......

stem hole (intake), diam tapers from

AA, 5, 48

41-R-2371-20

7, 50

H, 5, 49
J, 5, 49

41-R-2371-465
41-B-1641-500
41-R-2371-425
41-R-2390-475
41-R-2390-482

BB, 5, 48

U, 5, 19

41-R-2378-575

41-R-2371-35

G, 5, 53

41-R-2378-570

X, 5

V,5

41-R-2254-570

stem hole (exhaust), diam tapers from

Y, 5

Fi(t.

References

41-11-2254-505

Identifying Number

64

64

64

64
64

22, 64

64

64

47, 109

66, 68

Par.

Use

Installing exhaust valve guides.

Installing intake valve guides.

serts.

Removing and installing valve seat in-

Removing intake valve guides.

Removing and installing camshaft drive

shafts and oil transfer plugs.
Removing exhaust valve guides.

Removing and installing piston rings.

Reaming intake valve guide.

Reaming exhaust valve guide.

Reaming intake valve guide.

Special Tools and Equipment for Field and Depot Maintenanc

eContinued

REAMER, finishing, valve guide valve

stem hole (intake), diam tapers from
0.495 to 0.500 in., Igh 13Ji in.
REAMER, roughing, valve guide valve

Item

Table I.

X, 5. 28

41-S-3829-720

41-W-871-80

41-W-871-90

E, 5

D, 6

D, 5, 60

T, 5, 30

41-T-3582-101
41-T-3583-101
41-T-3584-101
41-W-430-275
41-W-870-50

0,6
DD, 6

TOOL, extracting, heli-coil ..-..---.... 41-T-3092-350

TOOL, inserting, heli-coil -------4 l-T-32 17-753

TOOL SET, field maintenance. _.-._____

3d echelon . .
_ __
______ ^
4th echelon .
_
- _
5th echelon..
WRENCH, accessory drive gear hub
bearing nut.
WRENCH, crankshaft -damper counter
weight pin.
WRENCH, crowfoot, open end, %-in sqdrive, 1.255-in. opng, 4-in. long.
WRENCH, crowfoot, open end, L hdl,
2%2-in. opng, 10-in. long.

P5, 23, 27

RH 7950188
7950201
41-S-4982-600

LH 7950187

41-S-4942-20

STRAP, crankcase tie rod, Igh 5'Ju in..-. 41-S-5906-300

STAND, engine overhaul, coinp. -_-__..

Consisting of:
1 Support assembly . . _ ....._.
1 Support assemblv _
-.--.-..
1 Pipe, support
------STAND, package unit, transporting--

SLING, lifting (engine and transmission) - . 41-S-3832-22

8

C, 6

41-S-1044-125

1H.

SCREW, puller, thd ft in.-20XF-2 for

5% in., Igh overall 6% in.
SLING, lifting (crankshaft) .............

M, 6

41-11-2392-995

REPLACER, oil seal (magneto drive

driven shaft gears), OD 2.120 in., Igh

108

14

71,73

56, 59

52, 69, 103,

105
64
64

35, 49, 55,

103

55, 103

53

58

Turning camshaft drive housing pack

ing nut.

Turning accessory drive gear hub bear

ing nut.
Removing and installing crankshaft
damper counterweight pins.
Turning engine at vertical fan drive
shaft.

Transporting engine and transmission,

or engine only.
Protecting crankcase cylinder pads when
cylinders are removed.
Extracting heli-coil inserts.
Inserting heli-coil inserts.
Basic special tool sets for Continental
engine ADS-895 series.

Lifting crankshaft and crankshaft as

sembly.
Lifting engine and transmission, or en
gine only.
Hold engine during repair and rebuild.

Installing oil seals in generator drive

adapter and magneto drive housing
adapter.
Removing flywheel.

K>

_. . _

4 1-W- 1593-600

41-W-1536-390
41-W-1536-391
41-W-1536-393

WRENCH, open end, 60 deg angle, sgle

end, 1.505-in. opng, 10%-in. long.

WRENCH, insert (Rosan), %-28 to #-16. WRENCH, insert (Rosan),^ 6-18 to J4-13
WRENCH, insert (Rosan), ^ 6-24 to yt 20.
WRENCH, insert (Rosan), %-24 to fc-20. .
WRENCH, insert (Rosan), yie-20 to %-\BWRENCH, insert (Rosan), V$r-20 to %-16
WRENCH, insert (Rosan), #-18 to 1-14
WRENCH, spark plug dbl end, tubr,
curved offset, 12 pt, # 6 in. opngs.

41-W-1536-410
41-W-3297-50

4 1-W-l 536-396
41-W-1536-399
4 1-W-l 536-402

41-W-906-130

41-W-872-715

41-W-872-710

WRENCH, engine turning, Igh 3#-in

box, ya-in. sq-drive, dble-hex, size of

opng %-in., Igh 21 %-in.

WRENCH, cyl hold-down nut, sgle-hd

box, J^-in. sq-drive, dble-hex, size of

opng %-in. Igh 21 %-in.

WRENCH, cyl hold-down nut, sgle-hd

41-W-2390-50

41-W-871-62

Identifying Number

Z, 6
AA, 6
BB, 6
CC, 6
100

W, 6
X, 6
Y, 6

C, 5

J, 6

A, 5

B, 5, 22

N, 6

E, 6, 13

Fift.

52

52'

56, 59

36, 121

Par.

57
57
57
57
36, 121

57
57
57

131
36, 123

107, 109,

14, 52, 105,

References

Installing
Installing
Installing
Installing
Installing

"Rosan" inserts.
"Rosan" inserts.
"Rosan" inserts.
"Rosan" inserts.
or holding spark plugs.

Installing "Rosan" inserts.

Installing "Rosan" insert*.
Installing "Rosan" inserts.

Turning oil cooler line nuts.

Turning engine at flywheel.

Turning crankcase cross bolt nut.

Removing and installing sending units

and switches.
Turning cylinder barrel nut.

Turning ignition harness nut.

Use

-- ,__. ____

Special Tools and Equipment for Field and Depot MaintenanceContinued

WRENCH, crowfoot, #-in. opng, 3# 6-in.

offset hdl, 10-in. Ig.
WRENCH, crowfoot, %-in. opng, 10-in.
long.
O
*

..

I torn

Table I.

0*

41-W-545-15
41-W-3727-33

WRENCH, starter jaw brg nut.

WRENCH, tubular, dble end, hex, size of

hex opngs 1.655 x 1.915, Igh 6# in.
S, 5, 15

Q, 5, 36
36, 59, 56

58
Turning starter jaw bearing retaining
nut. (Used with holder 41-H-2197600).
Removing and installing oil control
valves.

CHAPTER 3
TROUBLE SHOOTING
A'o/c. Information in this chapter is for use of ordnance maintenance person
nel in conjunction with and as a suppleuu-nt to the trouble shooting section In the
pertinent operator's manual. It provides the continuation of instructions where
a remedy in the operator's manual refers to ordnance maintenance personnel for
corrective action.

Section I. GENERAL
11. Purpose
Operation of a deadlined vehicle without a preliminary examina
tion can cause further damage to a disabled engine and possible injury
to personnel. By careful inspection and trouble shooting such damage
and injury can be avoided and, in addition, the causes of faulty opera
tion of a vehicle or engine can often be determined without extensive
disassembly.
12. General Instructions and Procedures
This chapter contains inspection and trouble shooting procedures
to be performed while a disabled engine is mounted in the vehicle and
after it has been removed.
a. The inspections made while the engine 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 engine.
b. The trouble shooting performed while the engine is mounted in
the vehicle is that which is beyond the normal scope of organizational
maintenance. Check the trouble shooting section of TM 9-755B, or
any other pertinent operator's manual, then proceed as outlined in
this chapter. These trouble shooting operations are used to determine
if the fault can be remedied without removing the engine from the
vehicle and also, when subsequent removal is necessary, to indicate
when repair can be made without complete disassembly of the engine.
c. Inspection after the engine is removed from the vehicle is per
formed to verify the diagnosis made when the engine was in the
vehicle, to uncover further defects, or to determine faults if the engine
alone is received by the ordnance establishment. This inspection is
particularly important in the last case because it often is the only
means of determining the trouble without completely disassembling
the engine.
24

d. Trouble shooting a disabled engine after it has been removed

from the 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.
Section II. ENGINE
13. General
Most engine troubles actually are accessory troubles. Xormally the
jjertinent operator's manual will cover trouble shooting of all engine
accessories while mounted on the engine. This section covers only
those troubles which can develop within the engine itself.
14. Detailed Procedures
a. Seizure of Part*. When an engine cannot be turned over by
hand or with the starter, seizure of parts or hydrostatic lock (o below)
is the cause. Refer also to paragraph 131 for additional information
on hydrostatic lock. It is difficult to isolate or "spot" seizure because
the power section and the accessory case are connected by a splined
shaft which can only be removed when these two assemblies are
separated. It is therefore necessary to determine if seizure is in the
power section or the accessory case by checking gear backlash. Using
engine turning wrench M-W-906-130 ((J), fig. 6), rock crankshaft
forward and backward to see if there is any movement. If there is
no movement, investigate for hydrostatic lock, frozen pistons, or
seized bearings in the power section. If there is normal movement,
seizure is probably in the accessory case. Using engine turning wrench
41-W-871-90, turn the engine at the fan drive vertical shaft forward
and backward and note movement of gear trains in the accessory
case. If wrench 41-W-871-90 is not available, a wrench adapter
(fig. 9) made to fit the power take-off drive shaft may be used. Re
move camshaft gear housing covers and check gear movement for
backlash. By a systematic elimination of accessory case drives, the
seizure may be traced to the main accessory gear train. Remove the
accessory case (par. 51) and perform the necessary repairs.
Caution: P^xercise great care in deciding what inspection and re
pairs must be performed. Parts in the nonseized section may be
strained or bent and require replacement, or presence of chips may re
quire a complete teardown and cleaning of the engine lubricating
system.
b. Gear Failures. Gear and drive shaft failures generally can be
isolated by a systematic check of the affected gear train. Methods
of locating these failed gears are covered under the individual systems.
25

Uear failure repairs frequently can be confined to replacement of the

damaged parts.
Caution: Exercise great care in deciding what repairs must he
inacie. Disassembly and cleaning of part or ail of the engine nmy be

NOTE-. WRENCH ADAPTER IS SPLINED

TO FIT POWER TAKE-OfF DRIVE SHAFT

FUU FIUE7 0.026

APPROXIMATE RADIUS
.0785
CIRCULAR WIDTH

POWER TAKE-OFF DRIVE

SHAFT SPUNE

Figure 9.
26

Turning enpine with tcrcnch and adapter.

RA P0 188812

necessary due to chip** getting into the engine lubricating system or

moving parts.
c. ^foie. Engine noises can be caused by worn, broken, or im
properly adjusted parts ((4) below) and by lack of lubrication
(/ below). Ability to isolate trouble causing a noise is a matter of
experience. When noise occurs, shut the engine down immediately for
investigation. Some of the more common noises and their causes are:
(1) (frindiny Noi*r. Turn the engine by hand. If it is some
what tight and the grinding persists, a bushing or bearing
jxrolwbly in failing. Refer to a above.
(2) tiharp Tappiny .VoiV. A defective valve rocker or incorrect
valve clearance will produce this sound. Start the engine
and listen through a short piece of pipe pressed against
the rocker covers. The tapping from the defective unit will
be much sharjter and louder than from the others.
(3) Heavy clattering at *pe?dti below MO rpni. This noise is
caused by the counterweights of the crankshaft vibration
damper and is a normal noise. It will disappear at higher
speeds.
(4) Knyine knocking.

Caused by:

(a) Too much radial clearance. Worn or cracked main and

connecting rod bearings.
(b) Too much crankshaft end play. Thrust flanges on bearing
worn.
(c) Too much connecting rod end play. Thrust faces worn.
(d) Sprung or bent connecting rods.
(I. ly nit ion Sy*tem.
(1) Preliminary instruction*. Most ignition system defects are
covered in the pertinent operator's manual. However, fail
ure or seizure of one or more gears in the magneto drive
train would cause either or both magnetos on the engine to
stop turning.
(2) Procedure. Remove the magnetos (par. 36^) and rotate
the engine with the turning wrench 41-W-906-130 ((T),
fig. 6). If the engine will not rotate, refer to a above. If
one magneto driven idler bevel gear fails to rotate, the gear
must be damaged. If both driven gears fail to rotate, see
whether the other accessories rotate and use the following
procedure:
(a) Other accessorial do not rotate. Remove accessory case
(par. 51) and locate the damaged gears or shaft. Before
repairing damage, refer to b above.
(b) Other accessories turn. Remove the magneto drive hous
ing cover (par. 5Sd) and inspect the gears. Rotate the
27

engine and see whether the magneto drive idler bevel gear
((HH), fig. 40) is turning with the magneto driven bevel
gear with integral shaft ((DD), fig. 40). If the driven
bevel gear with integral shaft does not rotate, remove the
accessory case (par. 51) and inspect for failure in the
accessory case gear train. Before repairing or replacing
damaged gear, refer to b above.
e. Fuel System,
(1) Preliminary instructions. Most fuel system defects are
covered in the pertinent operator's manual. A failure in
the gear train will result in nonoperation of the fuel pump.
(2) Procedure (fig. 41). Remove the fuel pump (par. 36/)
from its adapter. Inspect the fuel pump bevel gear (T) and
see if it rotates with the engine, with other accessories, and
the governor. If the gear does not rotate, remove the fuel
pump drive adapter assembly (AA) (par. 58e) lift out the
gear and look for gear failure. If the gears are not dam
aged, see whether the fuel pump and governor drive bevel
gear (BB) rotates. If not, remove the camshaft drive hous
ing (par. 56e) and check for gear failure. If failure is still
not found, remove the accessory case (par. 51) and check
the accessory gear train. Refer to b above.
/. Air Intake Manifolds and Valve*.
(1) Preliminary instructions. Difficulties are covered in the
pertinent operator's manual and the methods of locating
them are listed below. First check for obstructions or bad
leaks in the induction system.
(2) Procedure. Remove the valve rocker covers (par. 45) and
examine the camshafts and rockers for damage. Follow
whichever of the following conditions applies.
(a) Camshaft damaged. If the camshaft is damaged, do
whichever of the following applies.
/. Camshaft bearing or journal damaged. Repair or replace
damaged component.
2. Camshaft lobe damaged. Repair lobe or replace damaged
camshaft. Inspect rocker roller for freedom of rotation
and damage. Replace any defective rocker.
3. Camshaft broken. Replace with new camshaft.
(b) Valve rocker damaged. Replace the damaged rocker as
sembly. Inspect the corresponding camshaft lobe for
damage, and repair or replace camshaft, as necessary.
Check for a stuck valve ((e) below) and for clogged
lubricating passages to the rocker roller, if frozen.

28

(c) Valve stuck. Turn the engine with the turning wrench
41-W-906-130 ((J), fig. 6), and observe if all valves open
and close satisfactorily. Check compression (p below).
If any valves are stuck open, it will be readily apparent.
Remove the cylinder (par. 52) and make the necessary re
pairs and parts replacement. A stuck valve often will
damage the rocker and sometimes the camshaft. Inspect
the rocker and camshaft to the limits specified in repair
and rebuild standards (pars. 146,147, and 160).
(d) No damage visible. Turn the engine with the turning
wrench 41-W-906-130 ((J), fig. 6) and observe whether
the camshafts rotate. If they do not, remove the camshaft
gear housing covers (par. 47) and examine the gears for
damage. If they are all right, remove the camshaft drive
shafts (par. 47) and inspect for damage. If the drive
shafts are all right, remove the accessory case (par. 51)
and locate the damaged gears. Before repairing or re
placing damaged gears, refer to b above.
g. Starting System.'
(1) Preliminary instructions. Most defects are covered in the
pertinent operator's manual. Other difficulties are failure
or seizure in the gear train.
(2) Procedures. Turn the engine with the turning wrench 41W-906-130 ((J), fig. 6). If it cannot be turned, refer to a
above. If it turns, attempt to crank engine with starter.
If the entire engine does not crank, remove the starter (par.
36d) and starter drive assembly (par. 56A) from the accessory
case and examine accessory case for damage to the starter
gears. If defective gears are indicated, remove the accessory
case (par. 51) and locate the damaged gear. Before repair
ing or replacing any gear, refer to b above.

h. Engine Low in Power. Stop engine and proceed as in p below.

If that is not the cause, trouble shoot as outlined in the pertinent opera
tor's manual and in <?, d, e, and / above.
i. Engine Misfires and Runs Rough. Trouble shoot as outlined in
the pertinent operator's manual and in c, d, e, and / above.
j. Engine Fails to Start. Refer to pertinent operator's manual and
to d, e, and / above.
k. One Bank of Cylinders Fails to Fire. Proceed as in i above.
I. Engine Lubrication System, Defective.
(1) Preliminary instructions. One cause of bearing failures
is the presence of dirt, sand, or metallic particles in the oil
resulting from valve grinds or cylinder reconditioning.
Make the checks outlined in the pertinent operator's manual.
If the trouble is not isolated, proceed as in (2) below.
241130 0533

29

(2) Procedures.

(a) Oil Low Pressure. A defective oil pressure control valve

or foreign material under the valve seat will cause oil low
pressure. Repair valve (par. 82). Obstructed oil galleries,
oil pump screens, or oil pumps; or burned out main, rod, or
camshaft bearings could also cause this condition. If the
obstructing material in the oil gallery is something that
might be circulated through the engine, rebuild the en
tire engine; otherwise, remove the obstruction. If worn
parts are the cause, rebuild the engine. One or both oil
pumps may not be operating properly or oil supply may
be low. This is another cause of oil low pressure. Check
the pumps for security of mounting and for impeller wear
and defective internal parts. Replace pumps if necessary.
Also, check for damaged internal oil lines, for crankshaft
oil plug defects, and for defective "O" ring gaskets on oil
transfer lines. Check oil supply.
(b) Excessive oil eonfrum-ption. Make a careful diagnosis to
determine whether a complete engine rebuild is necessary
or an overhaul of only one cylinder, piston ring, or piston
is required. Excessive oil consumption may be caused by:
1. Badly worn connecting rod or main or camshaft bearings.
This allows too much oil leakage or throw-off from the
end of the bearings.
2. External oil leaks at the front and rear main bearings.
Faulty bearing or oil seals lead to this condition.
3. Defective piston rings or worn cylinder walls.
(c) Oil high temperature. Common trouble such as improper
ignition timing, lean carburetor mixtures, off-specification
fuel, dirty oil filter and oil coolers, or defective control
valves should be thoroughly investigated. Other causes
of oil high temperature could be restrictions or defects in
the oil cooling or engine cooling system or the oil circu
lating system, high oil flow due to a damaged crankshaft
oil plug, broken internal main oil lines, defective bearings,
etc. Inspect for cooling fan damage (n below), for oil
pump defects-((a) above), and for damaged or worn
bearings and oil seals. Replace worn or defective parts.
(d) Oil high pressure. Oil high pressures normally result
from oil low temperatures, high viscosity oil, clogged oil
filter, or defective or improper setting of the oil pressure
control valve. A restriction in the oil passages, or burned
bearings and bushings could cause this condition. If the
obstructing material in the oil passages is something which
might be circulated through the engine, a complete clean-

30

ing and rebuild will be required. If burned or damaged

parts are the cause, rebuild the engine.
m. Generating System. If tests in the pertinent operator's manual
do not isolate the trouble, see whether the generator drive bevel gear
turns when the engine is cranked. If it does not turn, remove it for in
spection. If damaged, repair or replace (par. 580). If the gear is all
right, remove the accessory case (par. 51) and inspect for failure in the
accessory gear train. Before repairing or replacing any damaged
gears, refer to b above.
n. Cooling Fan and Clutch.
(1) Preliminary instructions. Most cooling system defects are
covered in the pertinent operator's manual. A failure in the
fan drive gear train will result in nonoperation of the fan
and lead to cylinder and engine oil high temperatures.
(2) Procedures. Remove the cooling fan outlet vane housing
assembly ((B), fig. 17) and examine the fan rotor for dam
age. Note if the rotor is free to turn in the fan rotor hous
ing. Turn the engine with the turning wrench 41-W-906-130
((J), fig. 6). If the engine will not turn, refer to a above.
If the fan rotor does not rotate, see if other accessories rotate
and use the following procedure:
(a) Other accessories do not rotate. Remove the accessory case
(par. 51) and locate the damaged gears or shaft. Before
repairing damage, refer to b above.
(b) Other accessories rotate. Remove the fan and clutch as
sembly and see if the fan drive vertical shaft rotates. If
the shaft does not rotate, remove the fan drive oil seal
housing-(par. 54Z>) and. fan drive vertical shaft bearing
housing (par. 54c ) from the crankcase flange and examine
the bevel gears and shafts. If these gears do not rotate,
the failure is in the accessory case. Remove the accessory
case (par. 51) and locate the damaged gears or shafts. If
the fan drive shaft does rotate, the failure is in the cool
ing fan and fan clutch assembly (fig. 67).
(c) failure of cooling fa/n and fan clutch assembly. Dis
assemble the cooling fan and fan clutch assembly (par. 76)
and examine the bearings. Examine the friction disk and
pressure plate. If failure is in the bearings, friction disk,
or pressure plate, examine all parts carefully, as the ex
cessive heat generated by these failures may affect re
lated parts. If failure is not in the bearings, disk, or
plate, examine clutch balls and springs. Inspect clutch
drive hub, fan rotor and adapter, and both parts of clutch
housings.

o. Hydrostatic Lock. Hydrostatic lock can be detected by re

moving one spark plug from each cylinder and noting if there is any
evidence of gasoline in the cylinders. If there is no liquid present
and the crankshaft cannot be rocked back and forth with the engine
turning wrench 41-W-906-130 ((J), fig. 6), look for seized pistons
or bearings (a above). If .there is gasoline present, rotate the crank
shaft with the ignition switch in the "OFF" position, to displace the
liquid. Turn the engine over several times to be certain that all
liquid is removed and that no internal parts have been damaged.
It is possible to damage connecting rods, pistons, and cylinders by
attempting to start an engine in the hydrostatieally locked condi
tion. Ins{>ect for damaged parts. Refer to paragraph 131 for ad
ditional information on hydrostatic lock.
p. C&mprexxion Pre*xure at Cranking Speed. Compression pres
sure at cranking speed should be between 90 ?.nd 110 psi with a dif
ference of not more than 15 psi between cylinders. Low or widely
varying pressures can he caused by burned, warped, or stuck valves,
or by worn piston rings or cylinders. Remove valve rocker covers
(par. 45) and inspect for stuck valves (/ (2) (c) above). If valves
are not defective, disassemble and inspect cylinder (pars. 63 and 64)
smd piston (pars. (5(5 and (>7). Repair or replace worn or defective
pa rts.

32

CHAPTER 4
ENGINE
Section I. DESCRIPTION AND DATA
15. Lubrication System
a. Two positive displacement pumps supply oil to the lubricating
system. One is a scavenger and pressure oil pump (dual unit) (fig.
11) and the other is an accessory case scavenger oil pump. The scav
enger and pressure oil pump is inclosed in a single housing and is
secured to a machined mounting pad located on the lower web of
No. 2 main bearing (fig. 57) in the crankcase. The oil for the pressure
pump is entirely inclosed in a pressure pump reservoir formed by
the oil pun partitions and the baffle plate assembly (fig. 96). The
scavenger pump, or top half of this dual unit, transfers oil from
the flywheel end of the oil pan to the pressure pump reservoir. The
separate accessory case scavenger oil pump (fig. 11), located on a
machined pad on the lower side of the accessory case, transfers oil
from the accessory case oil sump assembly ((P), fig. 73) to the pres
sure pump i-eservoir. The two scavenger pumps constantly transfer
oil from both ends of the engine. This assures the pressure pump
an adequate supply of oil when the vehicle is on grades. In normal
operation, the oil passes from the pressure pump outlet (fig. 10)
through passages in the crankcase and accessory case to the oil control
housing assembly ((B), fig. 31). It then passes through external
lines to the engine oil cooler (fig. 12) and returns to the inlet of the
oil control housing and to the accessory case. Oil flow is controlled
by four valves as shown in figure 12. The oil pressure control valve
assembly, the oil filter by-pass valve assembly, and the oil cooler by
pass valve assembly ((H), (J), and (K), fig. 42) are located in the
oil control housing. A fourth valve, the oil cooler thermostatic by
pass valve assembly ((A), fig. 79), is located on the engine oil cooler.
ft. The oil cooler thermostatic by-pass valve assembly ((A), fig. 79)
permits oil to by-pass the oil coolers whenever oil temperature is below
185 F. The valve also opens to by-pass oil whenever there is a pres
sure differential greater than 60 psi. Normally, the valve is open to

TOWER TAKE-OFF

TO CAMSHAFT)
LEFT (2-44) SIDE)'

MAGNETO Dl

MAGNETOS

MAIN

DRIVE

OIL LOW PRESSURE

WARNING LIGHT
SENDING SWITCH

HIGH TEMPERATURE
WARNING LIGHT
SENDING SWITCH

OIL HIGH PRESSURE GAGE

SENDING UNIT
MAIN OIL
PASSAGE
LEFT (2-4-6)

^CONTROL VALVE

OIL FILTER
BY-PASS VALV1
/ OIL PRESSURE

Figure 10.

Oil flow chart.

PUMP

SCAVENGER ON.

RAPO IM9S2

SCAVENGER OIL PUMP

SUCTION UNE

OPEN

VALVE CLOSED

ON. COOLER lY-f ASS

VALVE (THKMOSTATK)

PRESSURE OIL
PUMP OUTLET

SCAVENGER AND
PRESSURE OH. PUMP
(DUAL UNIT)

SCAVENGER OIL
PUMP OUTLET LINE
SCAVENGER OIL
PUMP OUTLET UNE,

ACCESSORY CASE

CAMSHAFT
RIGHT (1-3-5) SIDE

MAIN OIL PASSAGE

RIGHT (1-3-5) SIDE

SPRAY LUBRICATION
OF EXHAUST VALVE

ACCESSORY CASE
(SPILL LINE
TO GOVERNOR

OIL COOLER
BY-PASS VALVE

CML COOLH

Figure 11. Oil pumps and .linesboth oil pans removed.

by-pass. As oil temperature increases, the valve closes. This forces

oil to circulate through the oil cooler and enter the oil control housing
and the engine oil filter. If oil temperature is above 185 F, and a
pressure differential greater than 60 psi is built up, the valve opens.
c. The oil pressure control valve assembly ((H), fig. 42) maintains
desired oil pressure in the oil cooler and engine oil passages by by
passing excess oil through a relief opening to the sump. Limited
adjustment of the valve is possible (pars. 82 and 127). Excess oil
is by-passed directly to the accessory case sump (fig. 12) through the
accessory case spill line.
d. The oil filter by-pass valve assembly ((J), fig. 42) is a springbalanced type valve. Should the filter become obstructed, the valve
will open when a differential of 50 psi is reached and oil will be
delivered directly to the engine through the oil pressure control valve.
e. The oil cooler by-pass valve assembly ((K), fig. 42) is a springbalanced type valve and by-passes oil in the control housing when
there is a restriction in the engine oil cooler or external lines. Nor
mally closed, it opens under a pressure differential of 50 psi.
/. Direct pump pressure is carried through a large drilled passage
from the outlet side of the pressure oil pump, through the crankcase
and accessory case, to the oil control housing (fig. 10) on the top
corner of the accessory case, right (1-&-5) side. Drilled passages
provide lubrication to the accessory case bearings and to the main
oil passages in each side of the crankcase. Drilled passages through
the crankcase webs supply oil to the main bearings. Oil passages
from each crankshaft journal provide lubrication to the connecting
rod journals and bearings. Cylinder bores, piston rings, and piston
pins are lubricated by oil thrown from the connecting rods.
ff. Connecting passages in the accessory case supply oil to the hollow
camshafts through drilled passages in the camshaft drive shafts.
Drilled holes in each camshaft journal convey oil through connecting
passages to the rocker shafts, rocker bearings, and rollers. Throw-off
oil lubricates the intake valve stems. Lubrication is supplied to the
exhaust valve stems by oil streams from drilled passages in the cam
shaft bearings.
h. External oil-drain manifold sections ((B), (C), and (R),
fig. 98) return oil from the cylinder heads (valve rocker boxes) and
camshaft gear housing assemblies ((N), fig. 45 and (P), fig. 46) to
the oil pan and accessory case sump.
16. Hydraulic Governor

The hydraulic governor (figs. 108 and 109) maintains engine speed
below predetermined limits regardless of engine load. Refer to para
graph 134 for additional description of the hydraulic governor.
36

FROM ACCESSORY)
CASE SUMPJ

ACCESSORY CASE
SCAVENGER OIL PUMP

TO RESERVOIR

PRESSURE PUMP

TEMPERATURE GREATER THAN 185 DEC F

VALVE OPENS AT 60 PSI
DIFFERENTIAL PRESSURE

(THERMOSTATIC) VALVE CLOSES AT

OIL COOLER BY-PASS VALVE

Figure 1%.

Oil flow diagram.

TO RESERVOIR

.
^
! (FROM FLYWHEEL
- SCREEN -""(END OF OIL PAN

OIL FILTER

TO CRANKCASE SUMP

H-H-H

~| ENGINE BEARINGS

OIL PRESSURE CONTROL

VALVE VALVE MAINTAINS
60-70 PSI AT
ENGINE BEARINGS

RAPD 186762

TO ACCESSORY CASE SUMP

OIL FILTER BY-PASS

VALVE VALVE OPENS
AT 50 PSI
DIFFERENTIAL PRESSURE

SCAVENGER PUMP

SCAVENGER AND PRESSURE

OIL PUMP (DUAL UNIT)

AT 50 PSI
DIFFERENTIAL PRESSURE

OIL COOLER BY-PASS

VALVE VALVE OPENS

ENGINE
OIL COOLER
(EXTERNAL)

17. Crankcas* and Oil Pan

a. The crankcase is a two-piece aluminum-alloy casting. The two
halves, right (1-3-5) side and left (2-4-6) side (fig. 57), are split
vertically along the center of the four main bearings to allow for
installing the crankshaft. The halves are bolted together. There
are 12 special long crankcase cross bolts ((H), fig. 58) through the
four transverse main bearing webs. The bolts are shouldered at three
points to prevent bearing misalinement. Eight of these bolts protrude
through holes in the cylinder mounting flanges on both cylinder
banks and help secure the cylinders to the crankcase. There are also
three special crankcase alinement dowel-type bolts ((AC), fig. 58)
which help secure the two crankcase halves and prevent misalinement
of the main bearings. The two banks of horizontally-opposed cyl
inders are mounted on machined pads on each crankcase half (fig. 57).
The engine cooling fan and fan clutch assembly (fig. 67J are mounted
on the centrally located flanged portion of the crankcase.
b. An oil passage is cored into each half of the crankcase casting.
Passages also are drilled through the crankcase webs to the main
bearings. Additional passages also supply oil to the oil control hous
ing (fig. 10), accessory case, and cooling fan drive shaft housing.
c. The crankcase oil pan with studs assembly ((F), fig. 73) is an
aluminum-alloy casting. It is partitioned to form a reservoir for the
pressure pump. A plate incloses the top of the reservoir and is sealed
to the pump body with an 4tO" ring gasket, to prevent splashing of oil
and entrance of air. The accessory case oil sump assembly ( (P), fig.
73) is an aluminum-alloy casting without baffles and is bolted to the
accessory case and the crankcase oil pan (fig. 73).
18. Main Bearings

The four replaceable main bearings (fig. 57) are of the split-pre
cision type. They are steel-backed and faced with a special bearing
alloy. The No. 3 bearing is double-flanged with bearing metal to take
any crankshaft thrust and to control crankshaft end play. The bear
ing halves are identical. Each has a tang at the joint to prevent ro
tation in the crankcase bore. The oil holes drilled through the bear
ings register with an oil groove cut in the bearing bore of the crankcase. The bearing faces have annular grooves which register with
the oil holes in the crankshaft journals.

19. Crankshaft
a. The crankshaft (fig. 59) is a steel forging. It has four main
bearing journals, six crankpins (in pairs), and an integrally-forged
flange on one end for mounting the flywheel. Crankpin pairs are
38

positioned 120 degrees apart with the crankpins of each pair 180
apart.
b. All crankpin and main hearing journals are bored to reduce
weight. Oil holes are drilled at an angle to connect the main bear
ing journals and the crankpin journals. The diagonally drilled holes
are connected with steel crankshaft oil tubes (fig. 59). Oil is conveyed
from the main bearing journals through the crank cheeks, to the crankpins and to the connecting rod bearings. A pressed-in crankshaft oil
slinger (fig. 59) is located in the No. 1 main-bearing journal bore of
the crankshaft to pick up oil thrown by the No. 1 rod and provide
lubrication for the spline of the accessory drive shaft ((Z), fig. 35).
c. The crankshaft and the flywheel are individually balanced,
statically and dynamically, by the manufacturer.
d. A flanged hub is permanently installed on the accessory end of
the crankshaft for mounting the pendulum-type vibration damper
which reduces crankshaft vibrations. The crankshaft vibration
damper consists of four wedge-shaped damper counterweights ((D),
fig. 64). Each counterweight is suspended on two counterweight pins
supported in holes in the flanged hub. Two of the counterweights
are suspended on solid counterweight pins ((C), fig. 64) while the
remaining two counterweights are suspended by male counterweight
pins ((H), fig. 64), female counterweight pins ((K), fig. 64), and pin
bushings ((J), fig. 64).
e. The flywheel has a torsion damper hub through which the trans
mission shaft is driven. The damper consists of an internally splined
damper hub ((B), fig. 24) mounted on a plate which is spring-driven
by the flywheel. The damper reduces torsional shock on the trans
mission input shaft.
20. Connecting Rods and Bearings
(fig. 56)

Connecting rods are "F'-section type, with tapered shanks. They

are machined from steel forgings. Bronze piston pin bearings are
pressed into the small end of each connecting rod. The bearings are
diamond-bored to finished size after being assembled in the connect
ing rods. There are two diagonal oil grooves in the inner diameter
of the bearing. Oil enters a well, drilled in the small end of the
connecting rod, and follows annular grooves to lubricate piston pin
bearing, piston pin, and piston pin boss. Connecting rod bearings
are of the split-precision type, steel-backed with a special bearing
alloy face. Bearing halves are identical and are prevented from turn
ing in the rod bores by means of a tang on the split face of each half.

21. Pistons, Pins, and Rings

56)
a. Pistons are of the cast-aluminum solid-skirt type. The piston
skirt is cam ground and tapered (when cold) to provide accurate fit
in the cylinder at operating temperature. The pistons are reinforced
with piston pin bosses which extend to the crown of the piston.
b. Pistons have four rings. The top two rings are compression
rings, and the third and fourth rings are oil control rings. The com
pression rings are chrome-faced.
c. Piston pins are tubular and full-floating. Domed aluminum
plugs are inserted in each end of the piston pin to center the pin and
to prevent scoring or damage to the cylinder wall.
22. Cylinders and Valves
(fig. 52)
a. Each cylinder assembly (D) is a separate unit. The cylinder
barrel is an alloy-steel shell around which an aluminum muff is cast,
finned for air-cooling. A finned cast-aluminum cylinder head, in
ternally threaded, engages extenial threads on the cylinder barrel.
The assembly is made permanent by shrinkage fit. The intake and
exhaust valve (seat) inserts (C) and (QQ) are installed in machined
recesses in the head by heating the cylinder head and cooling the in
serts. The inserts may be removed for replacement by using a special
remover kit 41-R-:W71M>f> (fig. 7) supplied for that purpose (par.
64). Intake and exhaust valve guides (M) and (GO) are bronze and
are replaceable. An outer extension of the cylinder head forms a
recess, or rocker box. in which the outer, intermediate, and inner valve
springs (CO), (I)D). and (E*E), valve rockers (T), and valve rocker
shafts (S) are located. The cylinders are arranged in two banks,
numbered 1-3-5 and 2-4-0 from the accessory end. Flanges, contain
ing 14 stud holes, mount each cylinder to the crankcase.
b. One aluminum camshaft bearing cap (R) and one valve rocker
shaft bracket (U) in each cylinder hold the rocker shafts and valve
rockers. The cap and bracket are dowelled and bolted to the cylinder
head, and the camshaft bearing is bored with the cap in place. There
fore, caps are not interchangeable and must remain as part of the
cylinder assembly. Counterbores in the rocker box walls and covers
accommodate the camshaft intercylinder connectors (fig. 21).
c. The valve stems extend into the rocker boxes. Three springs (a
above) compressed between intake and exhaust valve spring retainers
(P) and (BB) and secured to the valve stem by split, cone-shaped
spring retainer locks (Q) , hold the valves to their seats. The exhaust
valves (RR) are sodium-filled and have a positive valve rotator which
serves as the lower valve spring seat. A valve clearance adjusting
40

screw assembly (fig. 74), with a flat swivel pusher pad, is mounted in
one end of the valve .rocker.
d. Forged steel valve rockers with valve rocker roller cam followers
are used. The valve rocker rollers (fig. 74) are hardened and honed
to provide an extremely smooth and permanent wearing surface. The
rollers operate on small bronze roller hubs (fig. 74). Hollow rocker
shafts (S) and drilled passages in the valve rockers convey oil to all
moving parts. The rockers are fitted with bronze valve rocker bear
ings (fig. 74) containing annular grooves for oil pick-up.
e. Valve rocker covers (fig. *2) are not. entirely interchangeable.
End valve rocker covers are machined and tapped for the attachment
of the camshaft gear housing assemblies (( X), fig. 45 and (P), fig. 46)
and end rocker box covering plates ((T), fig. 45 and (L), fig. 46).
Intermediate cylinder valve rocker covers (V) are not so machined.
End covers are interchangeable. Intermediate covers also may be
interchanged.
23. Camshaft
a. A hollow steel camshaft ((D), fig. 45 and (NN), fig. 46) is
mounted on each bank of cylinders. The hollow passage lessens the
weight of the shaft and also provides an oil passage for pressure
lubrication to the valve parts. Tubular intercylinder connectors (fig.
21) inclose the camshaft between cylinders. They are clamped in
place by valve rocker covers (fig. '2) and sealed by "O" ring gaskets.
b. Each camshaft is driven separately by bevel gears in the acces
sory case. The horizontal, vernier-type, splined camshaft drive shaft
((M), fig. 45 and (Q), fig. 46), connecting the drive and driven gears,
can be removed to permit separate rotation of the camshaft for engine
timing purposes. Regardless of gear positions, splines will mate at
some point of insertion.
24. Accessory Case

a. The camshafts, cooling fan (fig;. 67), scavenger and pressure oil
pump (dual unit) (fig. 11), and all engine accessories are driven by a
series of gear trains entirely inclosed in the accessory case. The ac
cessory drive gear ((V), fig. 29 and (T), fig. 35) is driven through
the splined accessory drive shaft ((Z), fig. 35) from the crankshaft
and meshes with the following gears to drive the various gear trains:
(1) The power take-off drive gear ((W), fig. 29 and (H), fig. 35)
drives the generator, starter, accessory case scavenger oil
pump, and the scavenger and pressure oil pump (dual unit).
The starter driven bevel gear ((X), fig. 29 and (G), fig.
35) is attached to the power take-off drive gear and meshes
with the starter drive bevel gear ((Y), fig. 29 and (R),
41

fig. 37), which drives the scavenger oil pump bevel gear
((Z), fig. 29 and (A), fig. 66). The generator driven bevel
gear ((DD), fig. 29 and (G), fig. 39) is driven by the gen
erator drive bevel gear ((EE), fig. 29 and (J), fig. 39),
which meshes with the power take-on* drive gear. The
scavenger and pressure oil pump (dual unit) is driven by
the splined scavenger and pressure oil pump drive shaft
((Z), fig. 6,5) from the internally splined power take-off
drive shaft ((AA), fig. 29 and (V), fig. 34).
(2) The camshaft drive idler gears ((IT), fig. 29 and (K), fig.
85) drive the governor, fuel pump, and camshafts. The fuel
pump bevel gear ((S), fig. 29 and (T), fig. 41) is driven by
the fuel pump and governor drive bevel gear ((T), fig. 29
and (BB), fig. 41), which is splined to the camshaft drive
shaft ((Q), fig. *29, (M), fig. 45, and (Q), fig. 46). The
governor bevel gear ((R), fig. 29 and (S), fig. 41) is driven
by the fuel pump bevel gear.
(3) The accessory drive idler gear ((LL), fig. 29 and (U), fig. .
o5) drives the engine cooling fan and magnetos. The mag
neto drive bevel gear ((MM), fig. 29 and (V), fig. 35) is
splined to the accessory drive idler gear and drives the two
magneto gears (HH), fig. 29 and (K), fig. 40) through the
magneto driven idler bevel gear (GG), fig. 29 and (L), fig.
40), the magneto drive idler bevel gear ((FF), fig. 29, and
(HH), fig. 40), the spark advance governor assembly ((JJ),
fig. 29 and (W), fig. 40), and the magneto driven bevel gear
with integral shaft ((KK), fig. ^9 and (DD), fig. 40).
2>. The accessory-case-to-crankcase flange contains two locating
dowel pins and three oil transfer tubes. The drive connection between
the crankshaft and the accessory case gear train (a above) is installed
when the accessory case is assembled to the crankcase.
c. The accessory case also accommodates the oil filter assembly
( (A), fig. 31), accessory case breather adapter with lifting eye assem
bly ((G), fig. 31), and the oil control housing assembly ((B), fig. 31).
Where gear loads require, bearings are supported by bronze bearing
liners. Drilled passages in the case permit pressure lubrication to
all bearings.
25. Induction SystemHotspot Control

a. A carburetor is mounted on top of a jacketed, cast-iron hotspot

intake manifold housing assembly ((P), fig. 104), which is attached
to intake manifolds on each bank of cylinders. An intake manifold
balance tube ((M), fig. 97), to counteract surge, connects the two
intake manifolds between No. 5 and 6 cylinders. A carbureted mixture
heating system is provided for cold-weather starting of the engine.
42

Hot exhaust gases are passed through the hotspot intake manifold
housing, heating the mixture as it passes through the housing and
into the intake manifolds. The gases are controlled by the vacuum
heat control assembly (fig. 76). The unit is located on the outlet
flange of the right (1-3-5) side exhaust manifold assembly ((C),
fig. 104), at the rear of the engine. High manifold vacuum actuates
the unit through a heat control-to-intake manifold flexible line ((W),
fig. 76) leading to the No. 5 intake manifold section. Vacuum is
high when the engine is starting. As a result, a heat control dia
phragm ((EE), fig. 76) in the unit is activated, operating the heat
control valve shaft rod assembly ((FF), fig. 76) which closes the
butterfly valve in the heat control valve assembly ((J), fig. 76).
When the valve is closed, passage of the hot exhaust gases from the
right (1-3-5) side exhaust manifold is restricted. Instead, the gases
are forced into the hotspot inlet tube assembly ((L), fig. 104) and
then into the hotspot intake manifold housing, then through the
hotspot outlet tube assembly ((A), fig. 104), and discharged into the
left (2-46) side exhaust manifold assembly ((B),fig. 104). Asengine
speed increases, manifold vacuum decreases. The spring-loaded
diaphragm then returns to its normal position, opening the butterfly
valve, and allows the exhaust gases to escape through the right
(1-3-5) side exhaust manifold assembly. This stops any further
preheating of the fuel mixture, since preheating is undesirable after
the engine reaches normal operating temperature.
b. A heat control thermostat assembly ((Q), fig. 76) is incorporated
in the vacuum heat control unit to prevent preheating when the
engine is already warm before starting. Under this condition, the
thermostat expands, offsetting the effect of high manifold vacuum
which occurs at low engine speed. Thus, the thermostat keeps the
butterfly valve open when the engine is warm, regardless of engine
speed, allowing the exhaust gases to escape without preheating the
fuel mixture.
26. Crankcase Breathing System
a. The crankcase breathing system is a completely closed system.
It enables the inside of the engine to be ventilated at all times and
makes it possible to submerge the engine without water getting in.
b. The intake manifold vacuum is used to circulate air through the
crankcase and accessory case. A carburetor-to-flame arrester line
((S), fig. 105), originating at the carburetor, leads to the crankcase oil filler pipe through the flame arrester assembly ((P), fig. 105)
and the flame arrester-to-filler pipe line ((L), fig. 105). The flame
arrestor is provided to eliminate any possibility of flame flash-back
in the fuel system. A crankcase-to-oil filler pipe line ((W), fig. 105)
also connects the oil filler pipe to the crankcase.
43

ff. Two external breather tubes (fig. 95) are also attached to a tri
angular accessory case breather tube adapter (fig. 95) on the top
of the accessory case, and connect two air-metering valves ( (P), fig.
78) through 90-degree elbows, which are located in the front of the
hotspot intake manifold housing assembly ((S), fig. 78). Tims,
crankcase air is circulated from the fresh air inlet at the carburetor,
through the crankcase, out at the top of the accessory case, and into
the hotspot intake manifold housing. Cylinder blow-by gases are
also carried from the accessory case to the hotspot intake manifold
through the same two lines.
d. The function of the air-metering valves, on the hotspot in
take manifold housing, is to restrict the flow of blow-by-gases and ven
tilation air into the manifold at idling and low engine speeds, so as
not to disturb the carbureted mixture ratio. Passage of only a small
amount of air is required at these conditions as cylinder blow-by is
low. The vacuum in the'manifold is high under law speed conditions.
This lifts a plunger in the valves causing a restriction of air flow.
Xhe manifold vacuum is low when the engine is running at high speed
and full load conditions, and the volume of cylinder blow-by gases is
high. This requires a larger opening through the valves in order to
pass the increased volume of air and gases to the intake manifold.
Thus, the plungers in the valves drop down of their owi) weight and
open the valve for free flow when there is low vacuum and are lifted
by high vacuum to restrict the flow when free passage is not desired.
27. Cooling System
Aluminum muffs are molded to the steel cylinder barrels and ma
chined to provide air-cooling fins for the cylinders. The aluminum
cylinder heads contain cast cooling fins for air-cooling. Cylinder air
deflectors (fig. 88) direct air flow across .the cylinders. The tops of
the cylinders are shrouded to house an air-cooling suction fan (fig.
67), which is mounted on a fan drive vertical shaft (fig. 75). This
cast aluminum fan is statically balanced by the manufacturer. The
fan drive vertical shaft (fig. 75) is driven by bevel gears housed in
the top of the crankcase. The bevel gears are driven by a fan drive
horizontal shaft (fig. 75) from the accessory case gear train. The
fan draws cooling air from the underside of the cylinder through the
cylinder fins and discharges the hot air vertically from the shroud.
The engine and transmission oil coolers ((J), fig. 79) are mounted on
the shroud above the cylinders. A- portion of the air exhausted by the
cooling fan is drawrn through these coolers and keeps the oil at the de
sired operating temperature.

44

28. Fuel System

(fig. 106)
a. An ac, type BF, fuel pump assembly (W) and an ac fuel filter as
sembly (CC) are mounted on the accessory end of the engine to supply
clean fuel to the carburetor. Flexible lines carry fuel from the filter
to the pump and carburetor.
b. The Stromberg Model NA-Y5G-3 carburetor (Q) is especially
designed for use on ordnance engines.
c. A Bendix, type EF, fuel primer filter assembly ((R), fig. 99) is
mounted on the accessory end of the engine to supply clean fuel for
the primer system. Fuel enters the filter under pressure from a pump
in the vehicle and is carried to each cylinder head by external lines.
Fuel enters the cylinder through spray-type primer line nozzle as
semblies ((C), fig. 99). The primer system was designed for use only
during engine starting.
29. Ignition System
a. Two Bendix-Scintilla, type S6LN-32, magnetos (fig. 102) are
mounted at the top left corner of the accessory case. They are con
nected to two spark-plugs in each cylinder by a radio-shielded hightension ignition harness. The entire ignition system is ventilated,
radio-shielded, and waterproofed. Each magneto fires six spark
plugs. The inner (right) magneto fires the accessory end plug of
each cylinder and the outer (left) fires the flywheel end plug of each
cylinder.
b. The magneto drive gear train contains an American-Bosch type,
spark advance governor assembly ((W), fig. 40). A preset control of
the governor provides for a 15-degree spark advance during the 1,500
to 2,450 rprn engine speed range.
c. A Bendix-Scintilla, single-spark, waterproof booster coil, with
a radio interference filter (fig. 102), is used for starting the engine.
The coil is energized by a 24-volt storage battery. It provides starting
impulses for the inner (right) magneto during the cranking of the
engine, when the magnetos are not being turned fast enough to
produce adequate voltage. The coil delivers a single spark at each
opening of the magneto contact points, rather than a flow of sparks
as delivered by the conventional induction vibrator-type booster coil.
The coil is connected to the ground connection of the inner magneto
through a waterproof, radio-shielded cable. The other magneto
ground connection is connected through a similar cable to the radio
interference filter unit.
d. Intake manifold vacuum is used to provide forced-air circula
tion, within the inclosed waterproof magnetos and ignition harness, to
carry away condensation. A carburetor-to-magneto flexible line (fig.
241130 O534

45

102) connects the air-inlet side of the carburetor to the top of the inner
magneto. Another line connects the magnetos together. An ignition
harness-to-intake manifold flexible line ((P), fig. 101) extends from
the flywheel ends of the ignition harness to cylinder No. 5 and 6
manifold sections ((B) and (R), fig. 98). By utilizing the vacuum
in the intake manifolds, fresh air is drawn from the air-inlet side
of the carburetor, through the magnetos and the inside of the igni
tion harness, into the intake manifolds. The flow of air is controlled
by the size of the orifice holes in the various units and by the amount
of vacuum in the intake manifold.
30. Starter
a. The Eclipse-Pioneer Model 36-E16-1A starter assembly ((N),
fig. 43) (800 Ib-ft capacity) is a 24-volt, dc, waterproof unit, consisting
of a motor section and a gear section.
b. The Jack and Heintz Model JRD-30 starter, optional with the
Eclipse starter, is essentially the same, except that it is fitted with
a quick-disconnect mounting attachment. The quick-disconnect fea
ture consists of a worm drive attaching device, operated by a small
pinion which is readily accessible. A lock keeps the small pinion
from turning or working loose.
31. Generator
The Eclipse-Pioneer Model 30EOO-3A generator assembly (A, fig.
43) is a 150 ampere, 28.5 volt, dc unit, as generally used for energy in
24-volt electrical systems.
32. Sending Unit and Switches
An ac electrical oil high pressure gage sending unit ((M), fig. 31),
an oil low pressure warning light sending switch ((E), fig. 31), and
a high temperature warning light sending switch ((H), fig 31) are
located in the main oil passage at the top of the accessory case.
a. Oil Low Pressure Warning Light Sending Switch. This oil
pressure type sealed unit is internally constructed and calibrated so
that electrical contact points close when the oil pressure in the main
oil line of the engine falls to 30psi, thereby closing the circuit and
causing a warning light mounted in the vehicle to light.
6. Oil High Pressure Gage Sending Unit. This sealed electrical
oil high pressure gage sending unit is ruggedly constructed and con
sists of a threaded plate to which are crimped a diaphragm, a radially
notched spring, and an overload guard plate. The unit is connected
to an electric gage located in the vehicle.
c. High Temperature Warning Light Sending /Stjdtch. This sealed
electrical unit is wernally constructed and calibrated so that elec46

trical contact points close when the oil temperature in the main oil
line of the engine reaches 245 5 F., therehy closing the circuit,
and causing a warning light mounted in the vehicle to light.

33. Tabulated Data

Number
Accessories:
1
Booster coil- - ____-__________ __
1
Carlmretors _..- _____ ______ -___
1
Fuel filter----- __-___._.____________________
1
Fuel pump.____.-_____ _____ _____ __ _ ._
1
Generator ______ __.____ ____ ___
1
Governor .______________________________
1
High temperature warning light sending switch-____
2
Magnetos.- ___ _-__ _________ - _______
1
Oil cooler----__-_-________________________
1
Oil filter____________________________.._______
1
Oil high pressure gage sending unit-_-_--_-______________
1
Oil low pressure warning light sending switch___-_________
1
Primer filter_____-_____________________________
12
Spark plugs- ___.____.___
1
Starter--___________-___________________________
Accessory drive ratios:
Camshaft____________________________ 0.5crankshaft speed
Cooling fan ______ ___________________ 1.40crankshaft speed
Fuel punip_______________________ 0.81 crankshaft speed
Generator_____________________..____ 2.60crankshaft speed
Governor--_____________________ 1.10crankshaft speed
Magnetos _____-_____________________ 0.5 crankshaft speed,
counterclockwise as
viewed from .above.
Power take-off_____________________ 1.0 crankshaft speed
Starter _________-________________ 0.91 crankshaft speed
Tachometer drive_____________-________ 0.5 crankshaft speed
Camshaft rotation____________________ counterclockwise viewed
from accessory end
Compression ratio ___-_____________________ ____ 6.5:1
Cooling fan rotation______________________- clockwise viewed from
above engine
Cylinder bore________________________________ 5.75 in.
Engine idle speed_________________________________ 650 rpm
Engine main oil line pressure
(SAE 50 oil at 180 F.) _____________________ 70-80 psi at 2,800 rpm
35 psi min at idle.
Engine speed (governor)_________________ 2,950 rpm max at no load
2,800 rpm min at full load.
Firing order__________________________________ 1-6-3-2-5-4
Generator charging rate______________-_ 150 amps, 28.5 v
Ignition timing___________________ automatic advance, set 10 deg
before top center.
Intake manifold pressure_________________ 2628 in-Hg at 2,800 rpm.
Dry, absolute_____________________ 1112 in.-Hg at idle 650 rpm.
Piston displacement _________________________________ 895.9 cu in.
Piston stroke____________________________________ 5.75 in.

47

Sparlc plug gap_________.____ 0,011 to 0.014 In.

Valve clearance (cold engine) :
Intake_________ ________._ -_______________ 0.007 in.
Exhaust___________________.-__________ 0.020 in. (0.014 in.
under roller).
Valve events (with cold engine) :
Intake opens.,______________.__----___ 40 deg before top center
Intake closes._____.__--_-___.__ ______ 84 deg after bottom center
Exhaust opens_____ ______________________ 08 deg before bottom center
Exhaust closes.______._______--,_______ 32 deg after top center
Intake remains ope________-------- -________. ____ 304 deg
Exhaust remains open, _-__-__-_----- __ ____________ 280 deg
Valve lift____________ ______-______-,__._ 0.4053 in.
Valve timing setting--- --- -- - -------_______ intake closes 50 deg after
bottom center with
0.100-inch clearance.

Section II. PREPARATION OF ENGINE FOR REBUILD

34. General
a. Engines removed from veliicles for rebuild must be thoroughly
cleaned, drained, and stripped of accessories. Refer to pertinent op
erator's technical manuals for procedures on removal of the engine
from vehicles.
b. Send the accessories to proper department for inspection and
rebuild.
35. Cleaning and Draining
a. Cleaning. Mount the engine on the engine stand -41-S-4942-20
(fi<j. 8). Thoroughly clean all parts and outer surfaces before at
tempting any repair or rebuild operations. Make certain no foreign
matter -enters the working parts of the engine or its accessories.
Close or cover all openings. Wash the engine, using water under
pressure to remove as much mud and dirt as possible. Remove re
maining grease and dirt, using a stiff brush and dry-cleaning solvent
or volatile mineral spirits.
b. Draining. Break locking wires. Drain oil by removing plugs
in accessory case sump, oil filter housing in the accessory case, and
the crankcase oil pan. Remove oil filter assembly (par. 36).
36. Removal of Accessories

a. Carburetor.
Note. The carburetor can be removed within the hotspot intake manifold
housing as a subassembly (par. 50).

(1) At the carburetor, disconnect the fuel pump-to-carburetor

flexible line assembly ((K), fig. 106) from the pump, the
carburetor-to-magneto flexible line assembly from the inner
48

(right) magneto, and the carburetor-to-flame arrestor line

((S), fig. 105).
(2) Disconnect the cross shaft-to-control rod turnbuckle assem
bly at the carburetor by removing cotter pin, slotted nut,
plain washer, and drilled-for-cotter-pin bolt from the righthand-thread rod-end ball bearing ((AA), fig. 69).
(3) Remove four jam nuts, plain nuts, and plain washers holding
the carburetor to the hotspot intake manifold housing assem
bly ((S), h'g. 78). Lift off carburetor. Discard carburetorto-housing gasket ((T), fig. 78) and check carburetor mount
ing spacer ((U), fig. 78) for reuse.
b. Fuel Filter, Primer Filter, and Oil Filter.
(1) Fuel filter (fig. 10(5). Disconnect fuel filter-to-fuel pump
flexible line assembly (AA). Remove nuts holding fuel fil
ter bracket (A) to accessory case. Lift off filter and bracket.
(2) Primer filter (fig. 99). Disconnect primer lines to No. 1 and
3 cylinders. Remove jam nuts and plain nuts holding the
filter mounting bracket (S) to the left (2-46) side cam
shaft gear housing cover. Lift off filter and bracket.
(3) Oil flter. Remove the oil filter assembly ((A), fig. 31)
from its housing in the accessory case by removing the jam
nuts, plain nuts, and plain washers. Pull the filter from the
housing by the handle provided for this purpose. Discard
gasket.
Ignition Harnesft.

(1) Disconnect spark plug leads at spark plugs. Use crowfoot

wrench 41-W-871-62 (fig. 13) to detach shielding nut. Use
crowfoot wrench 41-W-329750 (fig. 100) to hold spark plug.
(2) Vent lines can be removed with the harness when discon
nected from the intake manifolds. Remove clamps holding
harness to accessory case.
(3) Disconnect adapters at magnetos by removing holding screws.
Lift off adapters.
(4) The harness is supported by ignition harness clip assemblies
((W), fig. 101) secured with bolts located on each side of the
engine on cylinders No. 1 and 5, and No. 2 and 6. The harness
is also held to the booster coil and filter assembly bracket
(fig. 102) by magneto cable closed cushioned clip ((C), fig.
101) ; to bracket ((J), fig. 101) by ignition harness clip ((L),
fig. 101) ; and to fuel filter-to-fuel pump flexible line assem
bly ((AA), fig. 106) by closed cushioned line clip ((BB),
fig. 106). Remove bolts. Remove harness with vent lines
attached.
Note. Spark plugs may be left in the cylinders until cylinders are
to be removed from the crankcase (par. 52).
49

WRENCH41-W-871-62

Figure 13. Disconnecting spark plug leads.

d. Starter (fig. 14).

(1) Jack and Heintz. Depress locking plate with wrench and
loosen worm gear bolt. Lift starter from adapter.
(2) Eclipse pioneer. Remove locking wire and adapter ring bolt.
Remove starter by jarring it loose with the hands.
e. Generator (fig. 43). The generator is mounted on six studs fixed
in a generator drive assembly (F), which is bolted to the accessory
case. Remove jam nuts, plain nuts, and washers. Withdraw ger<
tor from the drive assembly. Use care not to damage the splined end
of the generator shaft as it is removed from the drive assembly.
/. Fuel Pump (fig. 106). The fuel pump need not be removed until
the accessory case has been taken off the engine. Disconnect fuel
pump-to-carburetor flexible line assembly (K), fuel filter-to-fuel pump
flexible line assembly (AA), and fuel pump-to-breather line flexible
line assembly (Z). Remove jam nuts, plain nuts, and washers holding
fuel pump to its mounting adapter (fig. 41). Remove pump. Dis
card gasket.
50

Figure 14.

Removing starter.

g. Magnetos and Booster Coil (fig. 102).

(1) Remove cables between the booster coil with filter assembly
and magnetos.
(2) Remove magneto-to-magneto flexible line assembly.
(3) Remove two mounting nuts and washers from each magneto
and lift the magnetos from the magneto drive housing
adapter ((G), fig. 40). Discard gasket.
(4) Remove round-head screws and lock washers holding booster
coil to mounting bracket. Remove coil.
h. Governor (fig. 108).
(1) Disconnect the control shaft-to-governor right- and left-hand
thread rod assembly ((N), fig. 68) from governor rocker
arm ((Z),fig. 109).
(2) Remove three jam nuts, plain nuts, and plain washers. Lift
the governor from the camshaft drive housing. Remove the
drive shaft with balls, upper race, and thrust bearing assem
bly, Discard gasket.
Note. The governor may be left in place and removed when the
accessory case is disassembled (par. 56).

i. Oil Control Housing Valves. Remove the oil filter by-pass, oil
pressure control, and oil cooler by-pass valves with special wrench
41-W-^3727-33 (fig. 15).
Note. The oil control housing valves may be removed at the time the oil
control housing is removed from the accessory case (par. 560).

;'. Oil Coolers.

Note. The oil coolers are bolted to the engine shroud and can be removed
with the shroud.

(1) Oil coolers with shroud. Disconnect and remove the engine
oil cooler inlet line assembly ((W), fig. 79). Use wrench
41-W-1593-600 ((C), fig. 5). Disconnect engine oil cooleroutlet line assembly ((U), fig. 79) at the oil control housing.
Remove shroud (par. 37) and lift shroud and oil cooler as
sembly (fig. 16) from the engine as an assembly.
(2) Oil coolers from shroud (fig. 17). Disconnect engine and
transmission oil cooler lines at coolers. Remove cotter pin,
slotted nut, and washer holding oil cooler seal hose lower
bracket (L) to the shroud and remove the bracket and oil
cooler seal lower hose (S). Remove drilled hex-head bolt
((L), fig. 79) and lift oil cooler assembly from the engine.

52

Fifjure 15.

Removing valves from oil control housing.

Section III. DISASSEMBLY OF STRIPPED ENGINE INTO

SUBASSEMBLIES
37. Removal of Engine Shroud and Oil Cooler Assembly

(% 17)

The main shroud assembly is secured to the engine at each cylinder

head with studs, cotter pins, slotted nuts, and washers; at each corner
of the crankcase with fan rotor housing supports and drilled hex-head
bolts; at the flywheel end of the crankcase with one stud and selflocking nut; and at the accessory case with one stud and self-locking
nut. Remove the shroud in the following manner:
a. Remove the drilled-head screws and lock washers securing the
ilame arrester assembly ((P), fig. 105) to flame arrester support
bracket ((R), fig. 105) on the accessory case. Loosen the hose clamps
between the oil filler pipe with cap assembly ((BB), fig. 105) and
the crankcase-to-oil filler pipeline ( (W), fig. 105). Remove the clip
holding the fuel pump-to-breather line flexible line assembly ((Z),
fig. 106) to the flame arrestor-to-filler pipeline ((L), fig. 105). Dis
connect the fuel pump-to-breather line flexible line assembly at the
90-degree flared tube elbow ((M), fig. 105). Remove the two closed
cushioned line clips. ((J), fig. 105) holding the flame arrestor-to-filler
pipeline ((L), fig. 105) to the shroud and remove the line and flame
arrester assembly as a unit.
53

SHROUD AND OIL

ENGINE

SND
FAN ROTOR HOUSING
ACCESSORY END
PAN ROTOR HOUSING
SPA

CYUNDER SHROUD
STUD

Figure 16.

RAPD T88841

Shroud and oil cooler assembly removed from engine.

b. Remove 14 self-locking nuts (A) holding the cooling fan outlet

vane housing assembly (B) to the shroud and remove the housing.
c. Remove hex-head bolts with integral lock washer (X) holding
the left (2-4-6) side hotspot tube slot cover assembly (G) and the
right (1-3-5) side hotspot tube slot cover assembly (CC) to the
shroud. Remove the covers.
d. Remove the hex-head bolts with integral lock washers (X) hold
ing the right (1-3-5) side main shroud exhaust hole cover (AA), the
le^t (2-4-6) side main shroud exhaust hole cover (V), and the vacuum
heat control rod housing cover assembly (BB) to the shroud and
remove the covers.
e. Disengage the vacuum heat control support bracket ((AA), fig.
76) and the oil filler pipe bracket ((X), fig. 105). Remove the hexhead bolts with integral lock washers fastening these brackets to the
shroud.
/. Remove the right -(1-3-5) side flywheel and shroud assembly
(Z), the left (2-^M>) side flywheel end main shroud cover assembly
(U), and the right (1-3-5) side flywheel end main shroud cover assem
bly (Y) by removing the hex-head bolts with integral lock washers
holding them to the shroud.
g. Remove six cotter pins, slotted nuts, and plain washers holding
the oil cooler seal hose lower bracket (L) to the shroud and remove
the bracket and the oil cooler seal lower hose (S).
h. Remove cooling fan and fan clutch assembly (par. 38).
i. Remove four drilled hex-head bolts, two self-locking nuts, and
plain washers holding the fan rotor housing assembly (M) and main
shroud assembly to the engine. Disconnect oil cooler lines (par. 36).
Lift off the rotor housing and shroud and oil cooler assembly (fig. 16).
38. Removal of Cooling Fan and Fan Clutch Assembly
(fig- 67)
a. Remove the screws holding the fan rotor cover (C) to the fan
clutch outer (upper) housing (L). Remove the cover.
b. Remove the cotter pin and the slotted nut on the fan drive vertical
shaft (fig. 75). Remove the cooling fan and fan clutch as an assembly
by lifting it from the fan drive vertical shaft.
39. Removal of Crankcase Oil Filler Pipe and Breather Line
(fig. 105)
a>. Remove the clamps and breather line connection hoses (P) from
the crankcase-to-oil filler pipe line (W).
6. Remove the four drilled-head bolts (V) in the base flange of the
oil filler pipe with cap assembly (BB). Remove the pipe from the
oil pan. Discard oil filler pipe gasket (U).
55

RA PD 188845

Figure 11. Engine shroud assembl]/exploded view.

56

ANUT, SELF-LOCKING7039110.
BHOUSING, COOLING FAN OUTLET VANE, ASSY7403381.
CSHROUD, MAIN, ASSY8328921.
DNUT, SELF-LOCKINGCO-502644.
EWASHER, PLAIN7767318.
FHOLT, DLD-HEX-HDCO-520628.
GCOVER, HOTSPOT TUBE SLOT, LEFT (2-4-6) SIDE, ASSY7347786.
HWASHER, PLAIN502204.
JNUT, SLTD7703684.
KPIN, COTTER121223.
LBRACKET, OIL COOLER SEAL HOSE, LOWER7414506.
MHOUSING, FAN ROTOR, ASSY7376053.
NSTUD7403066.
pSUPPORT, ROTOR HOUSING8328918.
QSTUD7403503.
RSTUD7403067.
SHOSE, OIL COOLER SEAL, LOWER7403495.
TFASTENER, SHOULDERED, SHROUD SEAI,7347780.
UCOVER, MAIN SHROUD, LEFT (2-4-6) SIDE, FLYWHEEL END, ASSY8328923.
VCOVER, MAIN SHROUD EXHAUST HOLE, LEFT (2-4-6) SIDE8328922.
WNUT, SI'EED GRIP RETAINER7414564.
XBOLT, HEX-HD W/INT-LOCK WASHER7414584.
YCOVER, MAIN SHROUD, RIGHT (1-3-Ti) SIDE, FLYWHEEL END,
ASSY8329028.
ZSHROUD, FLYWHEEL END, RIGHT (1-3-5) SIDE, ASSY8329027.
AACOVER, MAIN SHROUD EXHAUST HOLE, RIGHT (1-3-5) SIDE8329026.
BBCOVER, HEAT CONTROL ROD HOUSING, ASSY8329029.
CCCOVER, HOTSPOT TUBE SLOT, RIGHT (1-3-5) SIDE, ASSY7347785.

Figure 17.Engine shroud assemblyexploded viewContinued.

57

40. Removal of Exhaust Manifold Sections, Hotspot Tubes,

and Vacuum Heat Control Valve Assembly
(fig. 104)

a. Disconnect the heat control-to-intake manifold flexible line ((W),

fig. 7t>) from the tee in the No. 5 cylinder intake manifold section.
Remove three drilled-head bolts ((H), fig. 7(>) holding vacuum heat
control valve assembly ((J), fig. 76) to the outlet flange of the right
(1-3-5) side exhaust manifold assembly (C). Remove the heat con
trol valve assembly. Discard gasket.
h. Remove plain brass nuts (X) holding the hotspot tubes to the
hotspot intake manifold housing assembly (P). Remove drilled hexhead bolts (J) and slotted brass nuts (G) holding the tubes to the
exhaust manifold flanges. Remove hotspot outlet tube assembly (A)
and hotspot inlet tube assembly (L). Discard gaskets.
c. Remove self-locking nuts (D) and plain washers (E) holding
the exhaust manifold flanges to the cylinders and remove the mani
folds. Discard gaskets.

41. Removal of Rocker Box and Camshaft Gear Housing Oil

Drain Manifold
(fig. 98)
b. Loosen all hose clamps (X). Remove all flange connection
bolts at the accessory case sump and at the oil pan. Remove manifold
section hose (A) and remove cylinder No. 1 oil drain line assembly (E)
sump end cylinder No. 1 oil drain line assembly (F), sump end cyl
inder No. 2 oil drain line assembly (G), cylinder No. 2 oil drain line
assembly (H), cylinder No. 5 oil drain line assembly (AA), and
cylinder No. 6 oil drain line assembly (S). Discard gaskets.
b. Remove manifold section bolt (Q), annular gasket (P), and
manifold section-to-cylinder head gasket (M) from cylinder No. 1,
2,3, and 4 manifold sections (C), cylinder No. 5 manifold section (B),
and cylinder No. 6 manifold section (R) attached to the cylinder
heads. Remove the sections as a unit from each bank of cylinders.
Discard gaskets.
c. Remove the manifold-to-oil pan adapter (U) from the oil pan.
Discard the gasket.

42. Removal of Intake Manifold, Balance Tube, and Connectors

(fig. 97)
a. Loosen hose clamps (B) at left (2-46) side and right (1-3-5)
side intake manifold connectors (A) and (X). Remove jam nuts and
plain nuts holding the intake manifold connectors to the hotspot in
take manifold housing. Remove the connectors and discard gaskets.
b. Loosen hose clamps (N) at the intake manifold balance tubecon58

nector tubes (H). Remove flange bolts holding connector tubes to

intake manifold assemblies and remove the connector tubes. Dis
card gaskets.
c. Remove all nuts holding the intake manifold sections to the cyl
inders and remove the sections as a unit from each bank of cylinders.
Discard gaskets.
d. Remove drilled hex-head bolts (DD) from the balance tube
flanges (K) holding the balance tube in the crankcase. Remove
flanges, hoses, and "O" ring gaskets. Slide tube out of crankcase.
Discard gaskets.
43. Removal of Throttle Linkage
a. Disconnect the control-shaft-to-cross-shaft link assembly ((X),
fig. 69) from the carburetor control cross shaft outer lever by remov
ing cotter pin, slotted nut, drilled hex-head bolt, and plan washers
holding the link to the lever. Remove three jam nuts ((U), fig. 68),
plain nuts ((V), fig. 68), and plain washers ((W), fig. 68) and remove
the governor control shaft support bracket ((E), fig. 68) and governor
linkage assembly from the mounting studs.
b. At the accessory case cover, remove the jam nuts, plain nuts, and
plain washers holding the cross shaft support bracket ((V), fig. 69)
on the cover studs.
c. Remove jam nuts, plain nuts, and plain washers holding left
(2-4-6) side camshaft gear housing cover assembly ((H), fig. 45) to
the camshaft gear housing assembly ( (N), fig. 45). Disconnect ac
cessory case right (1-3-5) side breather tube assembly (fig. 95) from
the accessory case breather tube adapter (fig. 95) at the top of the
accessory case.
d. Remove the cross shaft with the camshaft gear housing cover,
cros shaft support bracket, and control levers as a unit.
44. Removal of Cylinder Air Deflectors
(fig. 88)
a. Detach the four air deflector end springs (K) holding the No. 1
and 6 cylinder air deflectors (A) and the No. 2 and 5 cylinder air
deflectors (G) to the air deflector clamps (M). Remove cotter pins,
nuts, bolts, and air deflector spacers (E) holding the deflectors to
gether. Remove the four drilled-hex-head bolts (J) holding deflectors
to the cylinders.
& Remove the nuts and washers from the air deflectors hooks (L)
clamping the intermediate cylinder air deflectors (F) to the cylinders.
Remove No. 1 and 6 cylinder air deflectors (A) and No. 2 and 5
cylinder air deflectors (G) and air deflector clamps (M).
c. Remove the bolts holding the intercylinder baffles ((G), fig. 52)
to the cylinders. Remove the baffles.
59

d. Remove the intermediate cylinder air deflectors (F) from the

cylinder heads.

45. Removal of Valve Rocker Covers

All covers are secured to the cylinder heads by eight hex-head bolts
((W), fig. 52) and can be lifted off after removal of the bolts. Covers
on the No. 5 and 6 cylinders are bolted to the rocker box covering
plates ((T), fig. 45 and (L), fig. 46). Covers on the No. 1 and 2
cylinders are bolted to the camshaft gear housing assembly ((N), fig.
45 and (P), fig. 46). Remove the bolts; then lift off the covers.
Discard gaskets.

46. Removal of Primer Lines

(fig. 99)
Disconnect primer lines from all intercylinder primer line tube
tees (F). Remove jam nuts, plain nuts, and washers holding primer
line clip brackets (G) to the accessory case cover. Remove lines
carefully and put them where they will not be damaged.

47. Removal of Camshafts and Camshaft Gear Housing

a. Remove the camshaft drive shaft snap ring ((K), fig. 45) from
the camshaft drive bevel gear ((LL), fig. 45). Remove the oil transfer
outer plug ((L), fig. 45), using remover and replacer 41-R-2378-575
((U), fig. 5). With the same remover (fig. 19), remove the camshaft
drive shaft ((M), fig. 45) from the camshaft drive bevel gear.
b. To remove the right (1-3-5) side camshaft drive shaft, remove
camshaft gear housing cover ((U), fig. 46). Discard gaskets. Re
move the tachometer transmitter drive adapter ( (BB), fig. 46) by re
moving jam nuts, plain nuts, and washers. Discard adapter gasket.
Remove tachometer drive shaft ((Z), fig. 46). Remove the oil trans
fer outer plug and camshaft drive shaft as in a above.
c. Loosen valve rocker shaft bracket and camshaft bearing cap bolts
((Z), fig. 52) a few turns at a time until all are loose. Remove the
caps and brackets with valve rockers and shafts. These parts are
marked with identifying numbers corresponding to numbers on cyl
inders and must be installed in their original positions.
d. Remove the two hex-head bolts ((P), fig. 45 and (J), fig. 46)
and tab washers holding the camshaft gear housings to the cylinders.
Loosen the camshaft drive-shaft housing nut ((GG), fig. 45 and
(WW), fig. 46) at the accessory case. Remove the camshaft with
intercylinder connectors and camshaft gear housing (figs. 20 and 21)
as a unit.

60

{NTER-CYUND6R

Figure 18.

Figure 19.
241130 O535

>

Cylinder air deflectors ana baffles.

Removing camshaft drive shaft.

61

. To prevent loss or damage while handling the cylinders, install

the camshaft bearing caps and valve rocker shaft brackets in jxisiticms
from which they were removed.
48. Removal of Accessory Cast Sump and Scavenger Oil
Pump
(fig. 73)

a. Remove the four drilled hex-head bolts (V) and their washers,
16 jam nuts (8), plain nuts (T), and plain washers (U), holding the
sump to the accessory case and to the cmnkcase oil pan. Jar the
sump with a soft hammer to loosen it. Remove the sump. Discard
the gaskets.
b. Remove the safety wire and slotted nuts holding the accessory
case scavenger oil pump (fig. 11) to the accessory case, and lift off
the pump.

49. Removal of Crankcase Oil Pan

- 73)

Remove the 1(> jam nuts (L), plain nuts (K), and plain washers
(M), holding the oil pan to the crankcase flange. Loosen the remain
ing 22 nuts holding the oil pan to the crankcase. Jar the pan loose
with a soft hammer.
Note. It is more convenient to swing the engine stand 41-S-4M2-2O, bringing
the oil pan to the top. Remove it from the crankcase, using puller 41-I'~29<)K-tiO
(fig. 6).

Discard the gasket.

50. Removal of Hotspot Intake Manifold Housing and Acces

sory Case Breather Tubes
(fig. 78)

Note. If the carburetor was not removed previously (par. .SO), it can be re
moved with the hotspot intake manifold housing.

a. The accessory case right (1-3-5) side breather tube assembly

(fig. 95) was disconnected at the top during removal of cross shaft
assembly (par. 43). Disconnect the accessory case left (2-4-fi) side
breather tube assembly (fig. 95) at each end and the accessory case
right (1-3-5) side breather tube assembly at the 90-degree flared tube
elbow (Q) of the air metering valve assembly (P). Kemove the tubes.
ft. Remove plain brass nuts (V). plain washers (D), jam nuts (H),
plain nuts (J), and plain washers (K) ; remove the hotspot intake
manifold housing from its stud.

62

figure 20.

Camshaft and gt-ar houning remwrd from engine right (1-&-5) tide.

MANIFOLD,
LEFT (2-4-4) SJDC,
ASSY-

SECTION,
INTAKE. CYLINDER
7346554
CONNfCfOR,
INTER-CYLINDER
7744693

Figure 21.

MfO 188805

Removing vamshait and year housingleft (2-4-6) i4e.

51. Removal of Accessory Case

a. Remove locking wire and remove the six nuts from studs inside
the front web of the crankcase along the bottom flange.
6. Remove the jam nuts, plain nuts, and washers on the six studs
along the top flange of the accessory case on the crankcase side.
63

c. Remove the six jam nuts, plain nuts, and washers on the sides
of the case.
d. Loosen the hose clamps on the cooling fan drive horizontal shaft
hose nipple (fig. 75) along the top flange of the crankcase. Loosening
the hose nipple in the accessory case a few turns makes it easier to
remove later.
e. With a soft hammer, tap the accessory case lightly to free it.
Remove the case. Remove the accessory drive shaft ((Z), fig. 35),
the cooling fan drive horizontal shaft (fig. 25), and the pressure oil
pump drive shaft ((Z), fig. 65) as the accessory case is removed from
the crankcase.
/. Remove the oil spill line snap ring ((W), fig. 31) at the bottom
flange of the accessory case. Withdraw the spill line ((X), fig. 31).
g. Stand the accessory case on a suitable table or disassembly stand,
and secure to avoid damage to attached parts.
A. Remove the slotted nuts ((A) and (R), fig. 65) and the drilledhead bolt ((U), fig. 65) holding the pressure oil pump and lines to the
crankcase. Remove the pump and lines (fig. 11).
52. Removal of Cylinders
a. Remove all jam nuts and cotter pins from the cylinder hold-down
slotted and hex nuts ((PP) and (E),fig. 52).
&. Using a torque wrench in combination with wrench 41-W-872715 ((A), fig. 5) for larger nuts, and wrench 41-W-872-710 (fig. 22)
for smaller nuts, remove the cylinder hold-down nuts. Check and
record the torque required to break each nut loose. If the torque re
quired to break the smaller nuts (on studs) is less than 300 poundinches, the nut should be removed and mica-base antiseize compound
applied to the stud. Install the nut and tighten to 350 pound-inches.
If the nut does not tighten to this torque, the stud is stretching and
must be replaced (par. 57). If the torque required to break the larger
nuts (on cross bolts) is less than 650 pound-inches, the nuts should be
removed, antiseize compound applied, and the nut retightened to
750 pound-inches. If the nut does not tighten to this torque, the
cross bolt is stretching and must be replaced.
c. After loosening all nuts with the torque wrench, remove all but
two nuts on each cylinder. These nuts will hold the cylinders in posi
tion until they are removed from the crankcase.
d. Using engine turning wrench 41-W906-130 ((J), fig. 6), bring
the piston in No. 1 cylinder to top center and remove the two remain
ing nuts holding the cylinder to the crankcase. Loosen the cylinder
by. jarring it with the hand, and remove it by carefully pulling
straight out until it clears the mounting studs. Be careful to prevent
the connecting rod, cylinder, and piston from falling against the
cylinder mounting pad.
64

RA PO 1558W

Figure 22. Torquing cylinder hold-down nuts.

Note. Before removing the cylinder from the piston, place a connecting rod
protector 41-P~2839-.r>35 (tig. 23) on the rod to prevent possible damage to the
cylinder mounting pad. Remove the cylinder.

f. Support the piston and slide out the piston pin. Pull the piston
over the top of the connecting rod. If a carbon deposit makes it
difficult to remove the pin, tap it gently with a wooden dowel. Note
the position of the identifying number on the piston boss (marking on
the piston boss is normally to the accessory case end). Install the
piston pin in the piston.
Note. Pistons for No. 1 and 2 cylinders will be at top center together. There
fore, both cylinders can he removed without turning the engine. Also Nos. 3 and
4 pistons will be together and Nos. 5 and 6 pistons will be together. If the
crankshaft binds after some of the cylinders are removed, replace the slotted
nuts on the crankcase cross holts ((H). fijr. 58), using crankcase tie-rod straps
41-S-5906-300 (fig. 23) or large washers to protect the machined surfaces of
the cylinder mounting pads and tighten the nuts enough to release the crank
shaft binding.

/. Remove the remaining cylinders and pistons. Mark any cylin

der or piston if the location identifying number is not legible.

65

Figure 23. Crankcase cylinder pad. protectors,

53. Removal of Flywheel Torsion Damper and Torsion Damper

Hub
(fig. 24)

a. Remove the four drilled hex-head bolts (A) holding the splined
torsion damper hub (B) to the damper hub plate (H).
J. Remove the flywheel cover plate (C) from the flywheel with
dowel pins assembly (K) by removing the 12 self-locking, socket-head
bolts (R) which hold the cover plate to the flywheel. This plate can
usually be removed by tapping around its edges with a soft hammer.
Tapped holes are provided for pusher bolt, if it is difficult to remove.
The torsion damper ring (D) will come out with the cover plate.
c. Remove the torsion damper pressure plate (E) and the torsion
damper friction disk (F). Remove the splined torsion damper hub
(B), the torsion damper spring driven plate (G), damper hub plate
(H), the remaining torsion damper friction disk (F), and the torsion
damper spacer plate (J). Remove the drive springs (M) and the
drive spring seats (N) from the flywheel.
66

Figure 24. Flywheel and torsion damper assemblyexploded view.

JPLATE, SPACER, DAMPER7744784

KFLYWHEEL, W/DOWEL PINS, ASSY752U90
U-LOCK, FLYWHEEL BOLT7744783
MSPRING, DRIVE7744634
MSEAT, SPRING7744635
FBCH.T, DLD-HD7744627
ft-PIN, DOWEL7767363
1--BOLT. SELF-LOCKING, SOCtCET-HO7744640

RAPO I

d. Disengage the flywheel bolt locks (L). Remove the sii drilledhead flywheel bolts (P) from the crankshaft hub. Remove the fly
wheel from the crankshaft with puller screws 41-8-1044-125 ((C),
fig. 6).
<?. The flywheel and crankshaft carry identifying matching num
bers. The position of the flywheel on the crankshaft is located by one
dowel pin which is 3 degrees off the normal center line position.
Thus, the flywheel will be installed in its original position on the
locating dowels.
54. Removal of Cooling Fan Drive

a. Remove the cooling fan drive horizontal shaft (par. 51).

b. Remove the slotted nuts holding the fan drive oil seal housing
(fig. 75) to the crankcase. Remove the oil seal housing. Use puller
41-P-2906-280 ((A), fig. 6).
c. Lift the fan drive vertical shaft bearing housing (fig. 75) and
the fan drive vertical shaft (fig. 75) from the crankcase. Use puller
41-P-2906-280 (fig. 26). Discard "O" ring gaskets.
d. Remove the fan drive vertical shaft bevel gear and the fan drive
horizontal shaft bevel gear (fig. 75) from their bearing in the crankcase.

Figure 25. Removing fan drive horizontal shaft.

68

Figure 26. Removing fan drive bearing housing.

69

e. Keraove the fan drive horizontal shaft hose nipple (fig. 75) from
the fan drive horizontal shaft bevel gear bearing (fig. 75) in the crankcase.
/. Kemove the bolted fan tower plug: ((V), fig. 58), which faces
the flywheel end of the crankcase, from the bore in the crankcase.
55. Removal of Crankshaft Assembly
(fig. 58)
a. Kemove the lock bolt holding the fan drive horizontal shaft
bevel gear bearing (PP) in the crankcase opening. This bearing and
the fan drive vertical shaft bearing (UTJ) can be lifted out as the
crankcase halves are separated (e below).
6. Attach crankcase lifting eye 41-E-615-350 (fig. 27) to the
crankcase. Kemove the crankcase from the engine overhaul stand
41-S-4942-20 by removing the nuts holding the transmission adapter
to the stand. Place the engine, with oil pan flange down, on suitable
wooden blocks on a disassembly table.
c. Remove the 12 crankcase cross bolts (H) and the two special
dowel-type crankcase alinement bolts (AC) in the fly wheel end flange.

CRANKCASE, HALF,
IGHT SIDE7403360

Figure 27. Separating the crankcase halves.

70

and the one special dowel-type crankcase alinement bolt (SS) in

the top flange at the accessory end. Bolts can be driven out of the
case by using a soft brass drift and hammer. Remove the flywheel
end fan rotor housing spacer (DD) by removing two plain nuts and
washers.
d. Turn the crankcase over on the left (24-6) side and lay it on
wooden blocks, allowing the connecting rods to hang down.
e. Remove the remaining top flange and fan drive gear housing
nuts and bolts. Remove the safety wire, slotted nut (EE), and plain
washer (S) from the stud in the flywheel end diaphragm. Lift off
the top half (the right (1-8-5) side) of the crankcase. Do not let
connecting rods fall and nick flange surfaces. Lift out the cooling
fan ((rive gear horizontal and vertical bearings.
Note. The main bearing halves will normally remain in the crankcase. Do
not allow the halves to become damaged in disassembly.

/. Attach the crankshaft lifting sling 41-S-3829-720 (fig. 28).

Tie the connecting rods in a vertical position with twine or wire as
shown in figure 28. Raise the crankshaft and connecting rod assemSLINO41-5-3829-720

Figure 28. Lifting crankshaft and connecting rod assembly from crankcase.
71

bly high enough with a chain fall to remove the crankshaft main
bearings (fig. 57).
Note. Main bearings are etched at installation. When removing bearings,
see if the original marking on the back is legible, if not, renew the marking
with a grease pencil. Never mark a bearing with a metal Instrument.

g. Place the crankshaft and connecting rod assembly on wooden

"V" blocks fastened to a work bench so the crankshaft rests on the
two end main bearing journals.
h. Remove the connecting rod protectors from the crankcase cyl
inder pad studs. Place the crankcase halves on suitable wooden blocks
so the machined faces sire not damaged.
Section IV. REBUILD OF ACCESSORY CASE
56. Disassembly of Accessory Case
a. General. The disassembly steps given are in a practical order,
but the sequence given is not mandatory and-may be altered to suit
convenience. Figure 44 shows the accessory case assembled. Fig
ures 31, 34, and 35 show the exploded views of the accessory case. The
bronze bushing-type bearings in the accessory case must not be re
moved or replaced during engine disassembly or overhaul (par. 57&

(7)).

b. Remove Accessory Case Cover (fig. 78). Remove 17 jam nuts,

plain nuts, and washers holding the cover to the accessory case. Use
a soft hammer to jar the cover loose or use pullers 41-P-2906280 ((A).
fig. 6) (holes are provided for puller screws) and remove it from the
studs. Discard gasket.
c. Remove Accessory Case Diaphragm and Fan Drive Gear Outer
Bearing Liner Assembly (fig. 34).
(1) Remove the safety wire and drilled-hex-head bolts holding
the accessory case diaphragm (C) to the accessory case. Re
move the diaphragm. Use puller 41-P-2906-280 ((A), fig.
6), if necessary to loosen diaphragm from dowel pins.
(2) Remove the safety wire and six slotted nuts from the fan
drive gear outer bearing liner assembly, and remove the
assembly using puller 41-P-2906-280 ((A), fig. 6). The
liner assembly consists of the fan drive gear (H), the fan
drive gear roller bearings (G), and the fan drive gear outer
bearing liner (F).
, (3) Remove internal snap ring (D). Withdraw the fan drive
gear oil seal housing (K) and the fan drive gear oil seal (M)
as an assembly.
d. Remove Accessory Drive (rear.
(1) Remove the internal snap ring from the accessory drive
gear ((T),fig. 35).
72

*"

XX

^/

D-PRESSURE PUMP DRIVE IMPELLER WITH SHAFT

E-SCAVENGER PUMP DRIVEN IMPELLER
F-SCAVENDER PUMP DRIVE IMPELLER
OPRESSURE PUMP BEVEL GEAR
H-FAN DRIVE VERTICAL SHAFT BEVEL GEAR
J-FAN DRIVE VERTICAL SHAFT
K-FAN DRIVE HORIZONTAL SHAFT BEVEL GEAR
IFAN DRIVE HORIZONTAL SHAFT
M-FAN DRIVE GEAR
N-CAMSHAFT DRIVE DRIVEN IDLER BEVEL GEAR
P-CAMSHAFT DRIVE IDLER BEVEL GEAR
Q-CAMSHAFT DRIVE SHAFT
R-GOVERNOR BEVEL GEAR
S-FUEL PUMP BEVEL GEAR
T-FUEL PUMP AND GOVERNOR DRIVE BEVEL GEAR

C-PRESSURE PUMP DRIVEN IMPELLER

A-CAMSHAFT DRIVE BEVEL GEAR

B-CAMSHAFT BEVEL GEAR

Figure 29. Accessory case year train.

DO-GENERATOR DRIVEN BEVEL GEAR

H-GENERATOR DRIVE BEVEL GEAR
ff-MAGNETO DRIVE IDLER BEVEL GEAR
OO-MAGNETO DRIVEN IDLER BEVEL GEAR
HH-MAGNETO GEAR
JJ-SPARK ADVANCE GOVERNOR ASSEMBLY
KK-MAGNETO DRIVEN BEVEL GEAR WITH INTEGRAL SHAFT
UACCESSORY DRIVE IDLER GEAR
MM-MAGNETO DRIVE BEVEL GEAR
RA PD 188853

CC-SCAVENGER PUMP DRIVEN IMPELLER

X-STARTER DRIVEN BEVEL GEAR

Y-STARTER DRIVE BEVEL GEAR
Z-SCAVENGER OIL PUMP BEVEL GEAR
AA-POWER TAKE-OFF DRIVE SHAFT
U-SCAVENGER PUMP DRIVE IMPELLER

U-CAMSHAFT DRIVE IDLER GEAR

V-ACCESSORY DRIVE GEAR

W-FOWER TAKE-OFF DRIVE GEAR

UNtft. FAN DMVf

GEAR OUTER

WRENCH41-W-430-275

SHAFT, DRIVE.
POWER TAKE-OFF 7346504
ADAPTER, POWER
TAKE-OFF DRIVE 7403367

RA PD 188804
Figure SO.

Tightening accessory drive shaft 'bearing retaining nut.

(2) Bend up the tabs of the accessory drive gear bearing nut
lock ((S), fig. 34). Remove the accessory drive gear bearing
nut ((T), fig. 34), with wrench 41-W-430-275 (fig. 30), by
striking the tool handle sharply with a hammer.
(3) Pull the accessory drive gear ((T), fig. 85) and the accessory
drive gear bearing spacer ((R), fig. 35) through the small
accessory drive gear roller bearing ((R) , fig. 34) by tapping
it with a soft hammer. The inner and outer race large
accessory drive gear roller bearing ((S), fig. 35) will also
come out with the accessory drive gear. Remove the snap
ring ((Q), fig. 34) from the case and tap the bearing gently.
Remove it from the rear side of the accessory case.
e. Kemove Camshaft Drive Housings and Drive Gears.
(1) Remove the left (2-46) side camshaft drive housing assem
bly ((Z), fig. 45) by removing the four jam nuts, plain nuts,
and plain washers holding it to the accessory case. Lift the
housing from the studs. Discard the "O" ring gaskets.
74

(2) Bemove the camshaft drive idler bevel gear ((A), fig. 35),
the camshaft drive driven idler bevel gear ((B), fig. 35) with
the oil transfer inner plug ( (CC), fig. 45), and the camshaft
drive idler gear ((K), fig. 35), in this order, from the left
(2-4-6) side.
(3) Bemove the right (1-3-5) side camshaft drive housing
assembly ((D), fig. 46), which includes the governor and
fuel pump bevel and driven gears and the fuel pump drive
adapter assembly ((AA), fig. 41), by removing the four jam
nuts, plain nuts, and plain washers holding it to the accessory
case. Lift the housing assembly from the studs and discard
"0" ring gasket.
(4) Bemove the camshaft drive idler bevel gear ((A), fig. 35),
the camshaft drive driven idler bevel gear ((B), fig. 35),
with the oil transfer inner plug ((C), fig. 35) and the cam
shaft drive idler gear ((K), fig. 35), in this order, from the
right (1-3-5) side.
/. Remove Magneto Drfoe Housing Assembly and Drive (fig. 40).

(1) Remove the magneto drive housing assembly (fig. 32) by

removing the jam nuts, plain nuts, and plain washers hold
ing it to the accessory case. Lift the assembly from the
studs and discard the flat gasket and "O" ring gasket. Care
should be taken in removing assembly since the spark advance
governor coupling (V) and the spark advance governor
assembly (W) may come out at the same time.
(2) Remove the spark advance governor coupling (V) and the
spark advance governor assembly (W) from the magneto
driven bevel gear with integral shaft (DD).
(3) Remove the safety wire and slotted nuts and lift out the
magneto driven bevel gear with integral shaft (DD) and
driven bevel gear adapter (CC). It may be necessary to tap
the adapter gently with a soft hammer from inside the case
to remove it.
(4) Remove the accessory drive idler gear shaft pin bolt ((N),
fig. 35). Withdraw the accessory drive idler gear shaft
((Y), fig. 35) and lift out the accessory drive idler and mag
neto drive bevel gear assembly ((U) and (V), fig. 35).
g. Remove Oil Control Housing.
(1) Remove the engine and transmission cooler and control hous
ing inlet and outlet connectors ((M), fig. 79) by removing the
jam nuts, plain nuts, and plain washers holding the con
nectors to the control housing.
Note. If the oil control valves were not removed previously (par.
36), they should be loosened with wrench 41-W-3727-33 (fig. 15) be
fore the oil control housing is removed from the accessory case.
75

A-FILTER, OIL, ASSY7539861.

B-HOUSING, OIL CONTROL, ASSYCO-525434.
C-PLUG, DRAIN, MAGNKTIC7375426.
D-GASKBT, DRAIN PLUG105456.
ESWITCH, SENDING, OIL LOW PRESSURE WARNING LIGHT7321327.
FELBOW, PIPE7744713.
GADAPTER, BREATHER TUBE, W/LIFTING EYE, ASSY7376017.
H-SWITCH. SENDING, WARNING LIGHT, HIGH TEMPERATURE7346664.
JPLUG, PIPE7767337.
KELBOW, PIPE-7410085.
I,BUSHING, PIPE7410X>86.
MUNIT, SENDING, Oil. HIGH PRESSURE GAGE7321347.
NPLUG, PIPE7538990.
P-HOUSING, MAGNETO DRIVE, ASSY7403469.
Q-HOUSING, CAMSHAFT DRIVE, LEFT (2-4-6) SIDE74145O3.
RDRIVE, GENERATOR, ASSY7403467.
S-PLUG, PIPE7338670.
T-GASKET, ACCESSORY CASE TO CBANKCASE7346527.
U-GASKET, "O" RING501225.
VLINE, OUTLET, SCAVENGER OIL PUMP7375419.
WRING, SNAP7410378.
XLINE, SPILL7346642.
YGEAR, BEVEL, SCAVENGER OIL PUMP7372686.
Z-DRIVE, STARTER, ASSY7403476.
AAHOUSING, CAMSHAFT DRIVE, RIGHT (1-3-5) SIDE7414505.

Figure 31. Accessory case subassemblicsexploded view.

76

figure S2. Removing magneto drive housing and drive assembly.

(2) Remove the oil control housing assembly ((B), fig. 31 and
(A), fig. 42) by removing the safety wire, four jam nuts and
plain nuts, five drilled-head bolts, and nine plain washers.
Slide the housing off the studs. Discard the gasket.
h. Remove Starter Drive Assembly. Remove the starter drive as
sembly by removing the jam nuts, plain nuts, and plain washers hold
ing the assembly to the accessory case. Using puller 41-P-2908-60
(fig. 33), pull the starter mounting adapter from the studs. Discard
the "O" ring gasket.
i. Remove Generator Drive Assembly (fig. 31). Remove the gen
erator drive assembly (R), by removing the jam nuts, plain nuts,
and plain washers holding the assembly to the accessory case. Use
puller 41-P-2908-60 ((B), fig. 6) and remove the assembly from the
studs. Discard the "O" ring gasket.
;'. Remove Power Take-Of (fig. 34).
(1) Remove the power take-off drive cover (Z) by removing the
bolts and washers holding it to the accessory case. Tap the
cover gently with a soft hammer to loosen it on the gasket.
Discard the gasket.
(2) Remove the power take-off drive adapter (X) and power
take-off drive shaft (V) by tapping lightly with a soft ham
mer from the crankcase side. Remove the power take-off drive
gear ((H), fig. 35), the starter driven bevel gear ((G), fig.
241130 0836

77

35), and tue staner anven oevc* gwr mm uvrmj$ \\*/i f g.

85) as an assembly. Discard the "O" ring gasket.

k. Remove Aewtory Case Breather Tube Adapter <md Lifting Eyt
(fig. 31). Remove the safety wire awl three slotted nuts holding the
breather tube adapter and lifting eye assembly (G) to the accessory
case. Remove the assembly. Discard the gasket.
/. Remove lending tfiritehe* and Sending Unit (fig. 31). Using
crowfoot wrench 41-W-280O-50 ((N), fig. 6), remove the following
^ending unit and sending switches, including pipe elbows (F) and
(K) and pipe bushing (L):
(1) Oil high pressure gage sending unit (M).
(2) High temperature warning light sending switch (H).
(3) Oil low pressure warning light sending switch (E).
57. Cleaning, Inspection, and Repairs of Accessory Cose
a. Cleaning. Ordnance maintenance personnel must thoroughly
understand the importance of cleaning engine parts. Extreme care
and conscientious effort are required in all cleaning operations. The
presence of dirt or foreign substances is a constant threat to satisfac
tory engine operation. All parts must be cleaned before inspection,
after repair, and before assembly. After cleaning, nil parts should
be protected from dust and grit. The inner and outer surfaces of all
castings and all parts subject to oil lubrication must be cleaned with
dry-cleaning solvent or volatile mineral spirits. Particular attention
must be paid to all oil passages in both castings and machined parts.
When necessary, wire or probes must l>e used to break up nil sludge
or gum deposits and admit the cleaning solvent. Wash passages
thoroughly with cleaning solvent. Passages must be blown out with
compressed air to free them from all foreign particles. Passages and
openings can be checked for being open and clear as air passes through
them.
i. Inspection and Repair.
(1) Castings.

(a) Check the castings for cracks, paying particular attention

to areas adjacent to studs, pipe plugs, and Rosan inserts.
Cracks are frequently found at sharp comers and fillets.
Replace castings showing any evidence of cracks.
(b) Carefully examine all mating surfaces and mounting
flanges for nicks or deep scratches. Remove all burs or
raised metal with a fine mill file.
(c) Watch for local discolorations of mating flanges as they
often indicate persistent oil leaks. Test all such flanges
with a straightedge or on a surface plate. Parts with
warped flanges or mounting pads should be replaced.
78

RAPD 186760

Figure 33. Removing starter drive aemt>ly.

(d) Examine all pipe plug openings for torn or damaged

threads. Clean up threads with an old pipe tap so threads
are not cut oversize. If threads do not clean up, tap the
hole to the next larger size plug. Threads must be in good
condition to eliminate oil leakage.
(2) Rosan iwerts.
(a) Inspection. Inspect the Rosun lock thread screw inserts
in the aluminum castings for signs of looseness and galled
or pulled threads. Insert and lock ring must be 0.005 to
0.010 inch below top surface of parent material to avoid
any interference of mating surfaces. Replace any defec
tive inserts.
(b) Replacement of inserts.
1. To permit higher stresses in studs and bolts which are
set in aluminum castings, it is common practice to install
inserts of a stronger metal into which the studs or bolts
are threaded. Rosan inserts are screwed into the softer
castings until they are slightly below the surface. When
the insert is set, a lock ring, broached to fit the splined
79

end of the insert and coarse milled on the outer edge, is

driven into a counter bore. This lock ring prevents
any turning of the threaded insert. Various sizes of
Rosan insert drivel's and wrenches are listed in table I.
. To remove an insert, drill out the center with a drill slightly
smaller than the inner serrations, to the depth of the
lock ring. Back out the insert with a remover. The
insert will push the lock ring out.
J. Rosan insert wrenches are short hexagonal pieces having
an internal spline to fit the insert. Select the proper
size and turn the insert into the casting, slightly below
the surface. Place a new lock ring in position and center
it over the insert with the correct Rosan driver. Drive
the lock ring into the casting slightly below the surface
(0.005 to 0.010 in.).
(3) Studs.
(a) Damaged stud*. Inspect all studs for damaged threads.
Minor damage may be corrected with a standard thread
chaser. Studs with stripped threads, bent or loose studs,
or studs showing any evidence of stretching must be
replaced.
(b) Removing stud*. Back studs out slowly to avoid heating
and possible seizure. Broken studs, too short to be re
moved with a wrench, may be drilled and extracted with
a remover. If it is impossible to remove them by this
method, a piece of bar stock or a nut may be welded to the
stud. This method must be used with care to avoid damage
to the housing.
(c) Replacing studx.
1. Clean out tapped holes. Use an old tap if threads apI>eur to be in good condition. A new tap may cut over
size. Inspect the threads. If there is any indication of
stripped or damaged threads, or if the stud was removed
for looseness, retap the hole to the next larger oversize.
2. Oversize studs are supplied for replacement (table II).
Studs are marked on the housing end to indicate
whether they are standard or oversize (fig. 84). Check
the marking to be sure the replacement is of the proper
size. Be sure the correct end is threaded into the hous
ing. Note that the stud threads are of different size, the
coarser thread being the housing end.
3. A. small amount of mica-base antiseize compound should
be applied to the threads before installing studs. Drive
studs in slowly to prevent heating. Observe the setting
height as given on stud chart (table II).
80

4. When, from any cause, the tapped holes in castings are

damaged beyond salvage by oversize studs, fit them with
heli-coil inserts or Rosan inserts and install new studs
of the original size. For the method of installation and
removal of heli-coils, refer to paragraph 64. For method
of replacing Rosan inserts, refer to (2) above.
(4) (fear*. If magnaflux testing equipment is available, check
all gears by this method. Replace those in which cracks
are found. Examine all gear teeth for sharp fins or burs at
tooth corners and for galling or pitting on the tooth faces.
Gears which indicate wear on the gear teeth should be as
sembled in position in their mating bearings. With feeler
gages, check gear backlash between two meshing teeth.
Check all gears to the limits specified in repair and rebuild
standards (par. 140). Remove any slight nicks or burs from
gear teeth with a hard oil stone. Polish with crocus cloth,
wet in dry-cleaning solvent, or volatile mineral spirits.
Thoroughly clean the repaired parts before assembly.
(5) Spline*. Check all spline teeth for galling, chipping, and
wear. The fit with the mating part must be free of any
binding. Stone-off any slight rough spots or burs. Polish
with crocus cloth.
(6) Shafts. Check all shafts by magnaflux, if available. If
this equipment is not available, inspect all shafts with a
magnifying glass for cracks. If cracks are discovered, the
shaft must be replaced. Raised metal at nicks or scratches
should be stoned-off and polished with crocus cloth. Check
shaft to the limits specified in repair and rebuild standards
(par. 140).
(7) Bearings.
(a) Ball and roller type bearings. After bearings have been
cleaned thoroughly, spin them and check for audible evi
dence of roughness and wear. Check bearings for wear of
the inner and outer races by supporting the inner race and
torsionally checking the bearing for end clearance. Check
all bearings to the limits specified in repair and rebuild
standards (par. 140). Rough or worn bearings must be
replaced.
(&) Bushing type bearings.

1. Check all bearings carefully for looseness in the housing

and for evidence of heating. Heating is an indication
of insufficient lubrication. Examine the oil passages in
the accessory case and be sure they are clean. Loose or
damaged bearings are cause for the accessory case to be
rejected. These bearings cannot be successfully replaced
81

in the field as their centers must be held in alinement.

Check all bearings to the limits specified in repair and
rebuild standards (par. 140).
S. Cheek the thrust faces of bearings for wear and obvious
damage. The wear can be determined by the assembly
of the mating parts in their proper place, and by check
ing end play, using a feeler gage between the thrust
faces. Check all bearings to the limits specified in repair
and rebuild standards (par. 140).
(8) Oil paxxages and oil pfuffx. See that oil passages in the ac
cessory case are clean. There are pipe plugs in all passages
which can be removed, and the passages and openings can
be tested with air. It is important that all main passages
and passages to bushing-type bearings be open.
(9) Drive axxembliex and cover platen. Inspect all accessory
drive assembly and cover plate castings. Check for loose
or damaged drive assembly bearings. Replace drive assem
blies when either the bearing or drive is damaged. Use u
fine mill file to remove any raised metal resulting from nicks
or scratches on bearing areas.
58. Rebuild of Accessory Case Subassemblies
Note.
engine.

The accessory ease diaphragm is a nonfunctional part of the AO-895-4

a. Fan Drive Gear Bearing Liner Assembly (fig. 34).

(1) Disassembly.

(a) Remove both snap rings (D) from the fan drive gear outer
bearing liner (F) and press fan drive gear (H) and its
roller bearings from the liner.
(>) Press the fan drive gear roller hearings (G) from both
ends of the gear.
(<?) Remove snap ring (J) from the gear.

(2) Cleaning, inspection, and repair.

(a) Cleaning. Clean all parts thoroughly with dry-cleaning
solvent or volatile mineral spirits.
(6) Inspection. Inspect fan drive gear by magnaflux. If this
method is not available, inspect with a magnifying glass
for cracks. Cracked parts must be replaced. Examine
the gear for abrasions on tooth faces and for burs on tooth
corners. Examine bearings and replace any which appearto be defective. Inspect the fan drive gear oil seal. Note
if the sealing edge is worn, cracked, or too stiff to seal
properly. Replace the seal if there is doubt as to its serv
iceability. Check parts to the limits specified in repair
and rebuild standards (par. 140).
82

(c) Repair.
1, Minor scratches and abrasions can be removed with crocus
cloth, wet with dry-cleaning solvent or volatile mineral
spirits. Scratches of any kind are dangerous and may
lead to failure. If there is any doubt as to the service
ability of a part, replace it.
. Repair or replace Rosan inserts (par. 57).
(3) Assembly,
(a) Install snap ring (J) in fan drive gear (H).
(6) Press the fan drive gear roller bearings (G) on both ends
of the fan drive gear.
(c) Install both snap rings (D) in the fan drive gear outer
bearing liner (F).
(d) Install the fan drive gear and roller bearing assembly in
the bearing liner,
ft. Starter Drive Assembly (fig. 37).
Note. If the engine hag Jack and Heintz or Eclipse Pioneer quick-disconnect
starter adapters, the adapters must be removed before disassembling the starter
drive assembly. To remove the quick-disconnect adapter on the Jack and
Heintz assembly, remove the Mix special nuts holding it to the starter drive assem
bly. The Eclipse Pioneer adapter is removed by removing six plain washers,
plain nuts, and jam nuts holding it to the starter drive assembly.

(1) Disassembly.
(a) Slip holder 41-H-2197-600 (fig. 36) over the starter mount
ing studs engaging it to the starter jaw (H). Secure with
nuts. Clamp the holder in a vise. Remove cotter pin
(T) from the threaded end of the starter jaw.
(b) Remove the starter drive bevel gear retaining nut (S).
Remove the starter drive bevel gear (R) and its shim.
(c) Remove the starter jaw nut internal locking ring (P) from
the starter jaw bearing nut (N). Using wrench 41-W545-15 (fig. 36), unscrew the nut.
(d) Remove the holder from the adapter.
(e) Remove the six flat-head screws from the bearing liner (G).
Press the liner out of the starter drive adapter with studs
assembly (D).
(/) Press the starter jaw (H), starter jaw ball bearing (J),
starter jaw roller bearing (M), and the bearing inner and
outer spaces (L) and (K) from the liner.
(g) Press the starter jaw oil seal (F) from the liner.
(h) Remove "O" ring gasket (E) from its groove in the starter
drive adapter.
(2) Cleaning, inspection, and repair.
(a) Gleaning. Clean all parts thoroughly with dry-cleaning
solvent or volatile mineral spirits.
83

Figure S4.

Accessory casefront viewexploded view.

VSHAFT, DRIVE, POWER TAKE-OFF7346504.

WGASKET, "O" RING546881.
XADAPTER, POWER TAKE-OFF DRIVE7403367.
YGASKET,. COVER7346657.
ZCOVER, POWER TAKE-OFF DRIVE7346656.
AABOLT, DLD-HEX-HD7346712.

SLOCK, ACCESSORY DRIVE GEAR HEARING NUT7346507

.
TNUT, ACCESSORY DRIVE GEAR BEARING7346508.
URING, SNAP7414964.

7346677.

RBEARING, ROLLER, ACCESSORY DRIVE GEAR, SMALL

PGASKET, "O" RING501219.

QRING, SNAP583343.

Figure 84. Accessory casefront viewexploded viewContinued.

ABOLT, DLD-HEX-HD7416581.
BWASHER, PLAIN502245.
CDIAPHRAGM, ACCESSORY CASE, ASSY7403362.
DRING, SNAP7414962.
ENUT, SLTD225869.
FLINER, FAN DRIVE GEAR OUTER BEARING7403357.
GBEARING, ROLLER, FAN DRIVE GEAR712170.
HGEAR, FAN DRIVE7346501.
JRING, SNAP7414963.
KHOUSING, OIL SEAL, FAN DRIVE GEAR7403363.
LFIX, LOCATING, FAN DRIVE GEAR OIL SEAL HOUSING7338668.
MSEAL, OIL, FAN DRIVE GEAR7375410.
NCASE, ACCESSORY, ASSY7414504.

AGEAR, BEVEL, DRIVE IDLER, CAMSHAFT7346544.

BGEAR, BEVEL, DRIVEN IDLER, CAMSHAFT DRIVE 7375432.
CPLUG, OIL TRANSFER, INNEll7744669.
I>BEARING, BALL, STARTER DRIVEN BEVEL GEAR7346682.
ESHIM7346683.

F1BOLT, DLD-HEX-HD583762.

OGEAR, BEVEL, STARTER DRIVEN734654S.

HGEAR, DRIVE, POWER TAKE-OFF734B500.
J_NI:T, SLTD7703684.

KGEAR, IDLER. CAMSHAFT DRIVE7346547.

LCASE, ACCESSORY, ASSY7414504.
A ISPACER, FAN ROTOR HOUSING, ACCESSORY END83281)24.
XBOLT, PIN, IDLKRGKAIt SHA FT 7375435.
PWASHER, LOCK120214.
QRING, SNAP583313.
ItSPACER, BEARING, ACCESSORY DRIVE GEAR7346491.

SBEARING, ROLLER, ACCESSORY DRIVE GEAR, INNER AND OUTER

RACE, LARGE7346676.
TGEAR, ACCESSORY DRIVE7346526.
UGEAR, IDLER, ACCESSORY DRIVE7346549.
VGEAR, BEVEL, DRIVE, MAGNETO7346550.
WGEAR, BEVEL, DRIVEN, MAGNETO, W/INTEGRAL SHAFT7346538.
XBOLT, DLD-HEX-HD588598.
YSHAFT, ACCESSORY DRIVE IDLER GEAR7348546.
ZSHAFT. ACCESSORY DRIVE7346492.
Figure 35.

86

Accessory caserear viewexploded view.

(6) Inspection.
1. Inspect the gear and starter jaw by magnaflux or any other
available and suitable method. Look for cracks, nicks,
and burs on the teeth of the gear and splined end of the
starter jaw.
2. Examine the bearings and replace as required for con
tinued serviceability.
3. Examine the mounting studs and the starter drive
adapter self-locking nuts on the Jack and Heintz starter.
Mark any loose or damaged studs.
4. Check parts to the limits specified in repair and rebuild
standards (par. 141).
(c) Repair.
1. Minor scratches can be removed with crocus cloth, wet
with dry-cleaning solvent or volatile mineral spirits.
Minor burs on gear teeth can be removed in a like man
ner. However, signs of cracked teeth or other defects
are cause for replacement.
2. Replace studs (par. 57).
3. The starter jaw oil seal cannot be repaired and any sign
of failure is cause for replacement.
WRENCH 41-W-545-15

Figure 36.

Tightening starter jaw bearing retaining nut.

87

e
*

e
e
I

88

(3) Assembly (fig. 37).

(a) Press the starter jaw oil seal (F) in bearing liner (G) with
the solid face to the starter side and install new "O" ring
gasket (E) in its groove in the starter drive adapter.
(b) Press the liner in the drive adapter with studs assembly
(D) making certain the oil holes of the liner and adapter
are in alineinent. Use care to avoid damage to the "OM
ring gasket. Install the six flat-head screws (U) and stake
them in place.
(c) Press the starter jaw 1m 11 bearing (J), the liearing inner
and outer spacers (L) and (K), and the starter jaw roller
bearing (M) on the starter jaw (H). Center the outer
spacer between the bearings to eliminate interference when
the jaw and bearing assembly is inserted into the bearing
liner. Press the jaw assembly into the liner and adapter.
(d) Install holder 4l-H-2197-000 (fig. 36) on the adapter.
Clamp the holder in a vise.
(e) Install the starter jaw bearing nut (N) with wrench
41-W-545-15 (fig. H<>). Insert starter jaw nut internal
locking ring (P).
(/) Install the starter drive bevel gear shim (Q) and the
starter drive bevel gear (R) on the starter jaw.

SELECT SHIMS TO OBTAIN THIS

DIMENSION WHEN SIDE CLEARANCE
IN BEARINGS IS TAKEN UP IN
THRUST DIRECTION AS SHOWN

Figure S8.

4.249
RA PD 155912

Shimming starter drive bevel gear.

89

(g) Install the starter drive bevel gear retaining nut (S);
tighten and check the dimension shown in figure 38. Select
shims to obtain this dimension.
(A) Install cotter pin (T) in the bevel gear retaining nut.
(t) Remove the assembly from the holder.
c. Generator Drive Assembly (fig. 39).
(1) Disassembly,
(a) Remove the cotter pin, slotted nut, and plain washer from
the generator drive bevel gear shaft (K). Tap the shaft
gently with a soft hammer and remove the shaft and the
generator drive bevel gear (J).
(b) Remove safety wire, slotted nuts, and plain washers and
lift the generator drive bevel gear bracket (H) from the
drive adapter with bracket and studs assembly (C).
(c) Lift the generator driven bevel gear (G) from the adapter.
(d) Press the adapter oil seal (A) from the adapter.
(e) Remove pipe plugs (D) from the adapter, bracket, and
shaft.
(2) Cleaning, inspection, and repair.
(a) Cleaning. Clean all parts thoroughly in dry-cleaning sol
vent or volatile mineral spirits. Clean oil passages byflowing clean dry-cleaning solvent or volatile mineral spirits
through them. If necessary, use probes to dislodge sludge
deposits.
(b) Inspection.
1. Inspect gears and shaft by magnaflux or any^ other avail
able method. Look for cracked or burred gear teeth.
Examine the shaft for scratches or galling.
2. Inspect the adapter and bracket for casting defects,
cracks, and burs. Mark any loose or defective studs.
3. Examine the oil seal. Replace it if there is any doubt as
to its serviceability.
4. Check parts to the limits specified in repair and rebuild
standards (par. 142).
(c) Repair.
1. Replace the studs (par. 57).
2. Remove any minor burs or scratches with crocus cloth, wet
with dry-cleaning solvent or volatile mineral spirits.
Any signs of cracks are cause for part replacement.
3. The adapter oil seal cannot be repaired. Replace the seal
if it shows any sign of failure.
4- The drive adapter and drive bevel gear bracket are ma
chined as a unit. If either part is defective, replace both
parts.
90

(3) Assembly.
(a) Install pipe plugs (D) in the drive adapter with bracket
and studs assembly (C), the generator drive bevel gear
bracket (H), and generator drive bevel gear shaft (K)
respectively.
(6) Install the adapter oil seal (A) with replacer 41-R-2392995 ((M), fig. 6), keeping the flat face of the seal on the
generator side.
(c) Install driven bevel gear (G) in the adapter and install
drive bevel gear bracket (H) with four plain washers and
slotted nuts. Secure with safety wire.
(d) Place the generator drive bevel gear (J) on the generator
drive bevel gear shaft (K). Insert the shaft in the bracket.
Install plain washer (N) and the slotted shear nut (P).
Tighten and secure with cotter pin (Q). Rotate the gears
and note if they turn freely. Check gear backlash (par.
142).
d. Magneto Drive Housing (fig. 40).
(1) Disassembly.
(a) Remove the jam nuts, plain nuts, and plain washers from
the magneto drive housing cover (R) and the booster coil
and filter assembly mounting bracket (fig. 102). Remove
the bracket and cover. Discard the cover gasket and the
"O" ring gasket.
(6) Remove the magneto drive housing adapter (G) by re
moval of jam nuts, plain nuts, and plain washers holding
the adapter to the magneto drive housing (X). Remove
the adapter using puller 41-P-2906-280 ((A), fig. 6).
Discard the gasket. Lift out both magneto gears (K).
(c) Remove the cotter pins, slotted nuts, and plain washers
from the magneto driven idler bevel gear adapter (J).
Using puller 41-P-2906-28Q, lift out the adapter. Bemove the magneto driven idler bevel gear (L) and-the
magneto drive idler bevel gear (HH) through the cover
opening of the magneto drive housing (X).
(d) Remove pipe plug (GG) from the housing.
(2) Cleaning, inspection, and repair.
(a) Cleaning. Wash all parts in dry-cleaning solvent or vola
tile mineral spirits.
(b) Inspection.
1. Examine all mating surfaces of the housing and adapter
for nicks and scratches. Note if the edges of surfaces are
burred or contain high spots which will prevent proper
seating of mating parts. Examine castings for cracks.
91

Figure 99.

Generator drive assemblyexploded view.

r
'
SWASHER, PLAIN502204.
TNUT, PLAIN225854.
UNUT, JAM107823.

RSTUD7408075.

MWASHER, PLAIN502245.
NWASHER, PLAIN7372651.
PNUT, SHEAR, SLTD7846725.
QPIN, COTTER121222.

KSHAFT, DRIVE BEVEL GEAR7346535.

LNUT, SLTD225869.

Figure 39. Generator drive assemblyexploded viewContinued.

GGEAR, BEVEL, DRIVEN7346503.

HBRACKET, DRIVE BEVEL GEAR7403440.
JGEAR, BEVEL, DRIVE7346546.

FGASKET, "O" RING546884.

OADAPTER, DRIVE, W/BRACKET AND STUDS, ASSY

7403679.
DPLUG, PIPE7538990.
EGASKET, "O" RING501219.

ASEAL, OIL, ADAPTER500286.

BSTUD7403097.

A C

figure 40.

Magneto housing and drive astembtyexploded view.

KKSTUD7403071.

JJPIN, COTTER121223.

TSTUD7403501.
UNUT, SLTD225869.
VCOUPLING, SPARK ADVANCE GOVERNOR7346524.
W--OOVERNOR, SPARK ADVANCE, ASSY7767445.
XHOUSING, DRIVE7346516.
YSTUD7403068.
ZNUT, JAM107823.
AANUT, PLAIN225854.
BBWASHER, PLAIN502204.
CCADAPTER, DRIVEN BEVEL GEAR7346558.
DDGEAR, BEVEL, DRIVEN W/INTEGRAL SHAFT7346538.
EEGASKET, HOUSING7348753.
FFGASKET, "O" RING501219.
GGPLUG, PIPE7538990.
HHGEAR, BEVEL, IDLER, DRIVE7346520.

Figure 40. Magneto housing and drive assemblyexploded viewContinued.

SWASHER, PLAIN502245.

RCOVER, DRIVE HOUSING7346605.

KGEAR, MAGNETO7410051.
LGEAR, BEVEL, DRIVEN IDLER7346521.
MSTUD7403503.
NSTUD7403073.
PSTUD7403071.
QGASKET, COVER7346617.

GADAPTER, DRIVE HOUSING7346534.

HGASKET, DRIVE ADAPTER7346502.
JADAPTER, DRIVEN IDLER BEVEL GEAR7346552.

FSEAL, OIL, MAGNETO GEAR500048.

DMAGNETO, ASSY7403411.
EGASKET, MAGNETO7346513.

ANUT, JAM107822.
BNUT, PLAIN225853.
CWASHER, PLAIN7744766.

t. Examine gears for abrasions on tooth faces and burs on

tooth corners.
3. Inspect the gears and shaft by magnaflux. If this method
is not available, inspect them with a magnifying-glass
for cracks. Replace all cracked parts.
4. Inspect the oil seals. Note if the sealing edge is worn,
cracked, or too stiff to seal properly. Replace the seals
if there is any doubt of their serviceability.
5. Examine the governor spark advance assembly (W) and
note if the pins and stops are secure, if flyweights oper
ate freely, and if springs are cracked or broken. If any
unit has a defective part, replace with a new assembly.
0. Examine studs. Look for loose or damaged studs. Mark
any defective studs for replacement.
7. Check all parts to the limits specified in repair and rebuild
standards (par. 143).
(c) Repair.
1. Minor nicks and burs can be removed from castings with
a fine mill file. Bad mating surfaces are cause for re
placement.
#. Replace studs (par. 57).
3. Minor scratches on gears and shafts can be removed with
crocus cloth, wet with dry-cleaning solvent or volatile
mineral spirits. Replace any parts having scratches with
raised metal.
(3) Assembly (fig. 40).
(a) Install pipe plug (GO) in the magneto drive housing (X).
(b) Install the magneto drive idler bevel gear (HH) through
the cover opening of the housing.
(c) Install the magneto driven idler bevel gear (L). Install
the magneto driven idler bevel gear adapter (J) in place
on the holding studs by tapping it gently with a soft ham
mer. Secure with plain washers (S), slotted nuts (U),
and cotter pins (JJ). Make sure the gears turn freely
without binding.
(d) Install the two magneto gears (K) in the magneto drive
housing (X) with the interior splined hubs up (out).
() Install the magneto gear oil seals (F) in the magneto drive
housing adapter (G) with the flat face to the magneto
side. Use replacer 41-R-2392-995 ((M), fig. 6).
(/) Install the drive housing adapter assembly on the magneto
drive housing, using a new drive adapter gasket (H) and
secure with plain washers, plain nuts, and jam nuts.
(ff) Install the magneto drive housing cover (R), with a new
cover gasket (Q). Install the booster coil and filter as96

sembly bracket (fig. 102) on the larger studs. Secure

cover and bracket with plain washers (S), plain nuts (B),
and jam nuts (A).
e. Camshaft Drive Housing, Governor, and Fuel Pump Drive
(% 41).
(1) Disassembly.
(a) Remove the fuel pump drive adapter assembly (AA) by
taking off the jam nuts, plain nuts, and plain washers
holding it to the camshaft drive housing assembly (D).
Slide the adapter from the studs and discard "O" ring
gaskets (U) and (V).
(b) Remove the fuel pump bevel gear (T) from the adapter.
(c) Remove the governor bevel gear (S) from the camshaft
drive housing assembly (D). Remove the fuel pump and
governor drive bevel gear (BB).
(d) Remove two pipe plugs (E) from the fuel pump drive
adapter, and three pipe plugs (E) and (DD) from the cam
shaft drive housing.
(2) Cleaning, inspection, and repair.
(a) Cleaning. Clean all parts thoroughly in dry-cleaning
solvent or volatile mineral spirits. Clean oil passages
by flowing clean dry-cleaning solvent or volatile mineral
spirits through them. If necessary, use probes to dislodge
sludge deposits. Passages must be kept clean.
(b) Inspection and repair.
1. Look for cracks in the camshaft drive housing and the
fuel pump drive adapter. Use a strong light or the
latest inspection process available. Inspect mating
surfaces for nicks, scratches, and burs. Replace castings
in which cracks are found.
#. Inspect gears by magnaflux, if available, and examine
for abrasions and burs. Note any scoring or galling
on bearing surfaces. Replace cracked parts.
3. Check studs and replace any loose or damaged studs
(par. 57).
4. Examine the threaded pipe plug openings in the cast
ings. They must not be damaged or leaks will exist
after assembly. Repair or replace any plugs having
damaged threads.
5. Check all parts to the limits specified in repair and re
build standards (par. 144).
(3) Assembly.
(a) Install two pipe plugs (E) in the fuel pump drive adapter
assembly (AA), and three pipe plugs (E) and (DD) in
the camshaft drive housing assembly (D).
97

Figure 41-

Camshaft drive housinggovernor and fuel pump driveexploded vit-ir.

UGASKET, "O" RING501219.

AAADAPTER, FUEL PUMP DRIVE. ASSY7346591.

BB-GEAR, BEVEL, DRIVE, FUEL PUMP AND GOVERNOR
7346541.
CCSTUD7403501.
DDPLUG, PIPE7338670.
BEGASKET, "O" RING-501221.
GASKET, "O" RING501210.

ZSTUD7403101.

VGASKET, "O" RING546871.

WSTUD7403507.
XGASKET, FUEL PUMP7006868.
YPUMP, FUEL, ASSY7410094.

RSTUD7403502.
SGEAR, BEVEL, GOVERNOR7346542.
TGEAR, BEVEL, FUEL PUMP7346543.

Figure 41. Camshaft drive housinffgovernor and fuel pump driveexplod

ed vietrContinued.

MWASHER, PLAIN502204.
NNUT, PLAIN225854.
PNUT, JAM107823.
QSHAFT, CAMSHAFT DRIVE7346568.

LSTUD7403500.

KGOVERNOR, ENGINE, HYDRAULIC, ASSY7410402.

JNUT, JAM107822.

AGEAR, BEVEL, DRIVEN IDLER, CAMSHAFT7375432.

BPLUG, OIL TRANSFER, INNER7744669.
CGASKET, "O" RING646868.
DHOUSING, CAMSHAFT DRIVE, ASSY7414505.
EPLUG, PIPE7538890.
FGASKET, GOVERNOR7521260.
GWASHER, PLAIN502245.
HNUT, PLAIN225853.

(b) Install the fuel pump and governor drive bevel gear (BB)
in the camshaft drive housing.
(e) Install the governor bevel gear (S) in the camshaft drive
housing. Hold it in position from the governor side, as
the fuel pump drive adapter assembly (AA) with the fuel
pump bevel gear (T) is assembled to the camshaft drive
housing. Use new "0''ring gaskets (IT) and (V). Secure
with plain washers (G),plain nuts (H). and jam nuts (.1).
/. Oil Control Housing and Valve* (fig. 42).
(1) fHtiaxMenibly. Remove pipe plug (Q) from the oil control
housing assembly. Remove the oil control valves (par. 36*
and 560).
('2) Cleaning, inspection* and repair.

(a} Cleaning. Wash thoroughly with dry-cleaning solvent or

volatile mineral spirits. Clean oil passages by flowing clean
dry-cleaning fluid or volatile mineral spirits through them.
If necessary, use probes to dislodge sludge deposits. Re
move chips, dirt, and lapping compound from valves and
housing.
(b) Inspection.
L Check for loose or damaged studs and mark defective ones
for replacement.
2. Check the housing for cracks, damaged gasket surfaces,
torn threads in threaded openings, and worn or pitted
valve seats. Replace the housing if any cracks are noted.
(c) Repair.
/. Replace studs (par. 57).
2. Minor valve seat defects can be corrected by lapping. Re
place valve housings having damaged valve seats.
3. Minor scratches and burs on gasket surfaces can be removed
with an oil stone.
(3) Assembly.
(a) Install pipe plug (Q) in the oil control housing assembly
(A).
(b) Assemble the oil pressure control valve assembly (H), the
oil filter by-pass valve assembly (J), and the oil cooler by
pass valve assembly (K) with new gaskets. Install the
valves in the housing, only haiidtight, to prevent dirt from
entering the openings in the housing..
g. Power Take-0 fi Drive Gear Assembly.
(1) Disassembly.
(a) Remove safety wire, slotted nuts, and bolts holding the
starter driven bevel gear ((G), fig. 35) to the power takeoff drive gear ((H), fig. 35).
(b) Remove the starter driven bevel gear ball bearing ((D),
100

%. 35) and shim E), fig. U) from the starter driven

bevel gear ((G), fig. 35).
(c) Remove external snap ring ((U), fig. 34) from the power
take-off drive shaft ((V), fi#. 34).

RA PD 155916
AHOUSING, OIL CONTROL, ASSY7375872,
BWASHER, PLAJN~.;>02245.
CNUT, PLAIN-225853.
DNUT, JAM107822.
EGASKET, ANNULAR502801.
PWASHBR, PI*AIN502245.
GBOLT, DLD-HD7376120.
HVALVE, CONTROL, OIL PRESSURE, ASSY7521774.
J_VALVE, BY-PASS, OIL FILTER, ASSY7539486.
KVALVE, BY-PASS, OIL COOLER, ASSY-7375859.
LGASKET, ANNULAR583803.
MGASKET, ANNULAR583802.
NSTUD7403519.
I'GASKET, HOUSING-7346578.
QPLUG, PIPE 733S671.

figure 49.

Oil control Housinff and valvesexploded view.

101

(2) Cleaning, iimjHTtitm* and repair.

(a} Cleaning, (Mean all parts thoroughly with dry-cleaning
solvent or volatile mineral spirits.
(b) Impection and repair.
/. Inspect the gears and shaft by inagnatfux, if available.
If not, use a strong light and check the gears for cracks,
sharp fins, or hurs at tooth corners, and for galling or
pitting of tooth faces. Replace all gears showing such
defects.
2. Inspect the shaft for cracks, galling, sharp burs, and nicks
on splines. Check the spline for tit with its mating part.
Stone-off any slightly rough spots and polish with crocus
cloth wet with dry-cleaning solvent or volatile mineral
spirits. Replace the shaft, if any cracks are discovered.
3. Check the bushing-type bearings in the power take-off
drive adapter ((X), rt#. 34) for looseness and evidence
of overheating. Overheating is an indication of insuffi
cient lubrication. Examine the oil passage in the
adapter to be sure it is clean. Check bearings to the
limits specified in repair and rebuild standards (par.
145). Replace loose, damaged, or worn hearings.
4. Check the starter driven bevel ^rear ball bearing for freeness of hall rotation in races. Replace the bearing, if
there is any doubt as to its continued serviceability.
5. Check parts to the limits specified in repair and rebuild
standards (par. 141).
(3) Assembly.
(a) Install the external snap ring ( (U), fig. 34) on the power
take-off drive shaft ((V) , fig. 34).
(b) Assemble the starter driven bevel gear ((G), fig. 35) to the
power take-off drive gear ((H), fig. 35). Secure with
drilled hex-head bolts and slotted nuts ((F) and (J), fig.
35) and safety wire.
(c) Install the starter driven bevel gear ball bearing ((D), fig.
35) and shim ((E), fig. 35) in the starter driven bevel gear
((G), fig. 35) . Combined thickness of the shim and bear
ing outer race should total 0.594 to 0.596 inch. Select shims
to obtain this dimension.
h. Accessory Case Breather Tube Adapter and Lifting Eye ( fig. 95).
(1) Disassembly.
(a) Remove the cotter pin from the drilled flat-head lifting eye
pin. Remove the plain washer and the lifting eye spring
and withdraw the pin. Separate the accessory case lifting
eye from the accessory case breather tube adapter.
102

(b) Remove the flared tube elbows from the breather tube
adapter.
(2) 6fleaning, inspection, and repair.
(a) Cleaning. Clean all parts thoroughly with dry-cleaning
solvent or volatile mineral spirits.
(b) Inxjiection and repair.

1. Check the spring and replace it if there are signs of

weakness.
2. Examine the breather tube connector openings in the
adapter for torn or damaged threads. If the threads
are not serviceable, replace the adapter.
(3) Ansetnbly. Install the drilled flat-head lifting eye pin
through the accessory case lifting eye and the accessory case
breather tube adapter. Assemble the lifting eye spring on
the pin. Secure with plain washer and cotter pin. Install
the flared tube elbows in the adapter.
59. Assembly of Accessory Case From Subassemblies
a. General. The engine is a precision product. Consequently, the
repair and rebuild standards of its components have been fixed at
extremely close limits. Great care must be exercised in all phases of
the assembly operation to insure satisfactory engine performance.
General rules for assembly follow :
(1) Cleanliness is essential to all operations. Dirt and dust, even
in minute quantities, are abrasive. Protect assemblies from
wind-blown dust. Be sure that the ports have been cleaned
as specified; be sure they are kept clean. Hands must be
kept free from an accumulation of grease which collects dust
and grit. Dusty, grimy clothing cannot be worn during
assembly operations.
(2) Before assembly, coat all bearings, shafts, and contact sur
faces with the engine oil appropriate for the air temperature
range. This is to assure adequate lubrication of the parts
until pressure lubrication reaches them.
(3) Always use new gaskets on joints which confine oil. Annular
copper asbestos gaskets must never be reused. All "0" ring
gaskets should be replaced. Metal-cased oil seals, such as
those used in the magneto drive adapter, the generator drive
adapter, or the starter drive adapter, normally are long life
parts and may be reused, if in good condition. The contact
material, either leather or synthetic, must be pliable and show
no evidence of burning. Note also that in this type of seal,
a thin featheredge contacts the rotating part. If this edge
is destroyed, the seal is worthless.
103

(4) Always use plain washers under nuts on aluminum surfaces.

(5) Be especially careful to see that all bolts are secured with
jam nuts, tab washers, safety wire, or cotter pins as may be
specitied. Many engine failures are traced to neglect of this
simple precaution.
b. Assembly.
(1) Install pipe plugs ((.I). (N),aiui (S), fig. 31) in the acces
sory case.
(2) Install the fan drive gear oil seal ((M), fig 34) with fan
drive gear oil seal housing ((K), rig. 34), fiat side to the front
(accessory end) of the engine. Install the internal snap ring
((D), fig. 34).
(3) Install the power take-off drive gear ( (H), fig. 35) and the
the starter driven bevel gear ((G), fig. 35) us an assembly,
inserting the power take-off drive shaft ((V), fig. 34)
through the front of the accessory case.
(4) Install "O" ring gasket ((P), fig. 34) on the power takeoff drive adapter oil transfer tube, located on the accessory
case mounting pad for the adapter. Install "O" ring gasket
((W), fig. 34) on the power take-off drive adapter ((X),
fig. 34). Place the adapter over the power take-off drive
shaft ((V), fig. 34) and slide it into place in the accessory
case opening. Hold it in place with suitable washers and
bolts until the power take-off drive cover ((Z), fig. 34) is
installed at completion of engine assembly.
(5) Install the generator drive assembly ((F), fig. 43) with a
new "O" ring gasket ((G), fig. 43) and a new "O" ring
gasket ((H), fig. 43) on the generator drive assembly oil
transfer tube. Secure with plain washers, hex-head nuts, and
jam nuts ((D), (C),and (B), fig. 43).
(6) Install the starter drive assembly ((K), fig. 43) with a
new "O" ring gasket ((J), fig. 43). Secure with plain
washers, hex-head nuts, and jam nuts ((D), (C), and (B),
fig. 43).
(7) Install the accessory drive idler gear ((U), fig. 35) and the
magneto drive bevel gear ((V), fig. 35) as an assembly. In
sert the accessory drive idler gear shaft ((Y), fig. 35). Se
cure with idler gear shaft pin bolt ((N), fig. 35) and lock
washer ((P), fig. 35).
(8) Install, in the following order, both camshaft drive idler
gears ((K), fig. 35), both camshaft drive driven idler bevel
gears ((B), fig. 35), containing both camshaft oil transfer
inner plugs ((C), fig. 35) and both camshaft drive idler bevel
gears ((A),fig. 35).
104

Figure JfS.

RAPO 155917A

f/\\\ ' *

HGASKET, "O" RING-501219

JGASKET, "O" RING546891
KDRIVE, STARTER, ASSY7403476
L-ADAPTER, MOUNTING, STARTER7338594
MNUT, SELF-LOCKING, ADAPTER7338592
MSTARTER, ASSY7538988

Starter, generator, and drirc asgemblienexploded view.

, ASSY7727461
NUT, JAM107823
eNUT, HEX-HD225854
BWASHER, PLAIN-502204
*GASKET, GENERATOR AND STARTER7767382
f~~DRVE, GENERATOR, ASSY7403467
6A$KT. "O" RING-546884

(9) Install internal snap ring ((Q), fig. 34) in the ma in-accessory
drive bearing liner of the accessory case.
(10) Install the outer and inner race of the large accessory
drive gear roller bearing ((S), fig. 35) and the accessory
drive gear bearing spacer ((R), fig. 35) on the accessory drive
gear ((T), fig. 35). Install the drive gear in the accessory
case, meshing it with the power take-off drive gear ( (H), fig.
35), the camshaft drive idler gears ((K), fig. 35), the acces
sory drive idler gear ((U), fig. 35), and magneto drive bevel
gear ((V), fig. 35). Install the small accessory drive gear
roller bearing ( (R), fig. 34) by tapping it gently with a soft
hammer. Install the accessory drive gear bearing nut lock
((S), fig."34) and accessory drive gear bearing nut ((T),
fig. 34), using special wrench 4l-W-430-275 (fig. 30). Bend
the tangs of the nut lock into the slots of the nut. Install
the internal snap ring ((Q), fig. 35) in the accessory drive
gear ((T), fig. 35).
(11) The fan drive gear outer bearing liner assembly was as
sembled during rebuild of accessory case subassemblies (par.
58). Install the liner assembly in the accessory case, by
tapping gently with a soft hammer, meshing gear with acces
sory drive idler gear ((U), fig. 35). Secure the liner assem
bly with six plain washers and slotted nuts ((B) and (E),
fig. 34) and safety wire.
(12) Install accessory case diaphragm assembly ((C), fig. 34)
using a soft hammer to tap the diaphragm on the dowels.
Secure with six plain washers and drilled hex-head bolts
((B) and (A), fig. 34) and safety wire.
(13) Install left (2-4-6) side camshaft drive housing assembly
((Z), fig. 45), using a new "O" ring gasket ((BB), fig. 45),
by positioning the camshaft drive driven idler bevel gear
((DD), fig. 45) in the housing. Secure with plain washer,
plain nut, and jam nut ((Y), (X), and (W), fig. 45).
(14) Install right (1-3-5) side camshaft drive housing assembly
((D), fig. 46) with the governor and fuel pump drive, using
new "O" ring gaskets ((AC) and (AD), fig. 46) on the oil
transfer tube and a new "O" ring gasket ((C), fig. 46) on
the housing, by positioning the camshaft drive driven idler
bevel gear ((A), fig. 46) in the housing. Secure with plain
washer, plain nut, and jam nut ((ZZ), (YY), and (XX),
fig. 46). Turn the main drive gear by hand to see that all
gears of the gear train turn freely.
(15) Install the magneto driven bevel gear with integral shaft
((DD), fig. 40), meshing it with the magneto drive idler bevel
gear ((HH), fig. 40). Install the magneto driven bevel gear
106

adapter ((CC), fig. 40), keeping the large oil drain slot at the
bottom. Taj) gently with a shoft hammer to get it into
position on the studs. Secure with plain washer and slotted
nut ((S) and (II), fig. 40) and safety wire.
(16) Slide spark advance governor assembly ((W), fig. 40) and
spark advance governor coupling ((V), fig. 40) on the mag
neto driven bevel gear as an assembly. Mesh the coupling
on the spark advance governor drive pins. Install "O" ring
gasket ((FF), fig. 40) on the magneto drive housing oil
transfer tube, and install the magneto drive housing gasket
((EE), fig. 40). Position the magneto drive housing assem
bly over the shaft end of the magneto driven bevel gear and
studs of the accessory case. Mesh the internal splines of the
magneto drive idler bevel gear ((HH), fig. 40) with the
external splines of the spark advance governor coupling.
Secure with plain washer, plain nut, and jam nut (BB),
(AA), and (Z), fig. 40). Turn the gear train and check
for free rotation.
(17) Install accessory case cover ( (E), fig. 78), using a new "0"
ring gasket ((F), fig. 78), and secure it with plain washers,
plain nuts, and jam nuts ((K), (J), and (H), fig. 78).
(18) Install accessory case breather tube adapter and lifting eye
OIL CONTROL
HOUSING ASSEMBLY
ACCESSORY DRIVE
IDLER GEAR

CAMSHAFT DRIVE
HOUSING,
RIGHT SIDE

CAMSHAFT DRIVE
IDLER GEAR

MAGNETO
DRIVE,
HOUSING
ASSEMBLY

CAMSHAFT DRIVE
IDLER BEVEL GEAR

Fiyure 44. Accessory case assemblyrear view.

107

assembly ((U), tig. 31), using a new gasket, secure with

slotted nuts and safety wire.
(19) Install the oil control housing assembly ((B), fig. 31) with
a new housing; gasket ((P), fig. 42). Secure with nine plain
washers, four plain nuts, four jam nuts, five drilled-head
bolts, and safety wire as shown in figure 44. Using special
wrench 41-W8727-33 (fig. 15), tighten the control housing
valves and secure with safety wire.
(20) Install the oil lo\v pressure warning light sending switch
((E), fig. 31), the high temperature warning light sending
switch ((H), fig. 31), and the oil high pressure gage sending
unit ((M),fig. 31) with pipe elbows ((F) and (K),fig. 31)
and pipe bushing ((L), fig. 31) in the positions indicated in
figure 31. Use wrench 41-W-2390-50 ((N) fig. 6).
(31) Install the oil filter assembly (par. 126) and the magnetic
drain plug.
Section V. REBUILD OF CAMSHAFTS AND DRIVES
60. Disassembly of Camshafts and Drives
a. Remove valve rocker covers (par. 45). Remove camshaft drive
shafts and remove camshafts, camshaft gear housings, and intercyl
inder connectors from the engine as an assembly (par. 47). Remove
camshaft drive housings from .the accessory case (par. 56).
b. Remove the intercylinder connectors ((U), fig. 45 and (N), fig.
4(5) from the camshaft and discard the "O'' ring gaskets. Loosen the
drive shaft housing nuts ((GG), fig. 45 and (WW), fig. 46); remove
the drive shaft housing ((HH), fig. 45 and (W), fig. 46). Discard
the "O" ring gasket ((V), fig. 45 and (G), fig. 46).
c. Remove the jam nuts, plain nuts, and washers holding the drive
shaft support ( (JJ), fig. 45 and (UU), fig. 46) to the camshaft gear
housing assembly ((N), fig. 45 and (P), fig. 46). Remove the sup)>ort. Remove the camshaft drive bevel gear ((LL), fig. 45 and (SS),
fijr. 46) and discard the "O" ring gaskets. Remove the camshaft
assembly from the camshaft gear housing.
d. Place the camshaft assembly in a vise, using soft-jawed pro
tectors. Remove the locking wire and bolts and lift off the accessory
end oil-retaining cover ((B), fig. 45 and (Y), fig. 46) and the cam
shaft bevel gear ((C), fig. 45 and (X), fig. 46).
61. Cleaning, Inspection, and Repair of Camshafts and Drives
a. Cleaning. Clean all parts thoroughly with dry-cleaning solvent
or volatile mineral spirits.
b. Inspection and Repair.
( 1) Inspect castings, studs, gears, splines, shaft, and oil passages
(par. 57).
108

(2) Check the camshafts by magnaflux. If this equipment is

not available, examine them with a magnifying glass for
cracks. Replace cracked shafts. Examine the camshaft
lobes for scuffing and scoring. Light scuffing and scoring
can be cleaned up with a hard oil stone and polished with
crocus cloth. Clean raised metal from any small nicks and
abrasions elsewhere on the shaft with a hard oil stone and
crocus cloth. Check dimensions to the limits specified in
repair and rebuild standards (pars. 146 and 147). Severely
scuffed or scored shafts must be replaced.
(3) Check oil-transfer outer and inner plugs ((L) and (CC),
fig. 45 and (R) and (B), fig. 46). Adequate oil supply to
camshafts and cylinder heads depends upon the fit and con
dition of these plugs. See that oil passages are clean. Check
the plugs to the limits specified in repair and rebuild stand
ards (pars. 146 and 147).
62. Assembly of Camshafts and Drives

a. Camshafts and gear housings are right and left. The right
(1-3-5) side camshaft is shorter than the left (2-4-6) side because of
the staggered position-of the cylinders.
b. Attach the camshaft bevel gear ((C), fig. 45 and (X), fig. 46)
and the accessory end oil-retaining cover ((B), fig. 45 and (Y), fig.
46) to the camshaft with drilled-head bolts. Secure with locking
wire.
r. Install a new "O" ring gasket on the camshaft gear housing as
sembly ((N), fig. 45 and (P), fig. 46). Slide the camshaft into the
housing to seat large camshaft journal in its bearing. Be careful
not to nick or damage camshaft lobes or journal bearings during this
operation.
d. Install a new "O" ring gasket 011 the camshaft drive shaft sup
port ((JJ), fig. 45 and (UU), fig. 46). Insert the cam shaft drive
bevel gear ((LL), fig. 45 and (SS), fig. 46), in its support and install
the support on the camshaft gear housing. Secure with plain washers,
plain nuts, and jam nuts.
e. Install new ''O" ring gasket ((R), fig. 45 and (H), fig. 46) on intercylinder connectors ((U), fig. 45 and (N), fig. 46). Slip the con
nectors over the camshafts.
/. The camshaft drive housing assembly ((Z), fig. 45 and (D), fig.
4-6) was installed on the accessory case (par. 59). The camshaft drive
shaft housing ((HH), fig. 45 and (VV), fig. 46) is installed on the
drive shaft housing (par. 108). The camshaft, camshaft gear housing,
and intercylinder connectors are installed on the engine as an assembly
(par. 108).
241130 O538

109

Figure 45.

Camshaft and driveleft (2-4-6) sideexploded view.

*A PO 188025

ABOLT, DLD-HD7744685.

MMELBOW

LiLGEAR, BEVEL, CAMSHAFT DRIVE-7744888.

JJSUPPORT, DRIVE SHAFT7744673.

KKGASKET, "O" RING546864.

HHHOUSING, DRIVE SHAFT7346640.

FFPLUG, PIPE7338670.
GGNUT, DRIVE SHAFT HOUSING7744897.

EEGASKET, "O" RING501221.

7375432.

XNUT, PLAIN225854.
YWASHER, PLAIN502204.
ZHOUSING, CAMSHAFT DRIVE, ASSY7414503.
AAGASKET, "O" RING501219.
BBGASKET, "O" RING546863.
CCPLUG, OIL-TRANSFER, INNER7744669.
I)DGEAR, BEVEL, DRIVEN, IDLER. CAMSHAFT DRIVE

WNUT, JAM107823.

, HOSE, MALE PIPE END7346711.

TPLATE, COVERING, ROCKER BOX7346604.
NNSTUD7403501.
UCONNECTOR, INTERCYLINDER7744693.
PPSTUD7403501.
VGASKET, "O" RING501463.
Figure J^5. Camshaft and. drire-left (2-4-6) sideexploded rictr Continued.

SGASKET, COVER PLATE7744889.

BCOVER, OIL-RETAINING, ACCESSORY END7346702.

CGEAR, BEVEL, CAMSHAFT7744898.
DCAM SHAFT7346598.
ENUT, JAM107822.
FNUT, PLAIN225853.
GWASHER, PLAIN502245.
HCOVER, GEAR HOUSING, ASSY7414513.
JGASKET, COVER7348540.
KRING, SNAP7410379.
LPLUG, OIL-TRANSFER, OUTER7744853.
MSHAFT, CAMSHAFT DRIVE7346568.
NHOUSING, CAMSHAFT GEAR, ASSY7376029.
PBOLT, HEX-HD7744682.
QWASHER, TAB7744681.
RGASKET, "O" RING7539862.

Figure 46. Camshaft and driveright (1-5-5) aideexploded view.

fat

Figure 46.

TRANSMITTER

DRIVE

FFCOVER, TACHOMETER TRANSMITTER DRIVE7403615.

GONUT, JA M107821.
HHNUT, PI-AIN225851.
JJWASHER, PLAIN502266.
KKNUT, JAM107822.
LLNUT, PLAIN225853.
MMBOLT, DU)-HEX-HEAD 7744683.
NNCAMSHAFT7346659.
PPELBOW, HOSE, MALE PIPE END7346711.
QQSTUD7403501.
RRSTUD7403501.
SSGEAR, BEVEL, CAMSHAFT DRIVE7744X88.
TTGASKET, "O" RING546864.
UUSUPPORT, DRIVE SHAFT7744673.
WHOUSING, DRIVE SHAFT7346639.
WWNUT, DRIVE SHAFT HOUSING7744897.
XXNUT, JAM107823.
YY-NUT, PLAIN225854.
ZZWASHER, PLAIN502204.
ABPLUG, PIPE7338670.
ACGASKET, "O" RING501221.
ADGASKET, "O" RING501219.

COVER7767519.

CCSTUD7403212.
DDSEAL, OIL500241.
TACHOMETER
EEGASKET,

Camshaft and driveright (1-3-5) sideexploded viewContinued

YCOVER, OIL-RETAINING, ACCESSORY END7346702.

ZSHAFT, DRIVE, TACHOMETER TRANSMITTER7346602.
AAGASKET, ADAPTER7346634.
BBADAPTER, TACHOMETER TRANSMITTER DRIVE7346600.

XGEAR, BEVEL, CAMSHAFT7744898.

UCOVER, GEAR HOUSING7346588.

VWASHER, PLAIN502245.
WBOLT, DLD-HD7403158.

T-nGASKET, GEAR HOUSING COVER7346596.

RPLUG, OIL-TRANSFER, OUTER7744853.

SRING, SNAP7410379.

QSHAFT, CAMSHAFT DRIVE7346568.

PHOUSING, CAMSHAFT GEAR, ASSY7346589.

NCONNECTOR, INTERCYLINDER7744693.

LPLATE, COVERING, ROCKER BOX7744692.

MGASKET, COVERING PLATE7744889.

KWASHER, TAB7744681.

JBOLT, HEX-HD7744682.

HGASKET, "O" RING7539862.

DHOUSING, CAMSHAFT DRIVE, ASSY7414505.

EPLUG, PIPE7538990.
FGASKET, MOUNTING, GOVERNOR7521260.
GGASKET, "O" RING501463.

CGASKET, "O" RING546863.

AGEAR, BEVEL, DRIVEN, IDLER, CAMSHAFT DRIVE

7375432.
BPLUG, OIL-TRANSFER, INNER7744669.

Note. The camshaft drive shafts and the right (1-&-6) aide camshaft gear
housing cover are installed after timing the engine (par. 100). The left (2-4-6)
side camshaft gear housing cover is installed with the throttle linkage (par.
119).

The valve rocker box covering plates are installed (par. 110). The
tachometer drive shaft and adapter is installed (par. 109).
Section VI. REBUILD OF CYLINDERS
63. Disassembly of Cylinders
(fig. 52)

a. Remove spark plugs. Clean, inspect, and recondition as shown

in operator's manual.
6. The intermediate cylinder valve rocker cover (V) was removed
at engine disassembly (par. 45). Remove camshaft bearing cap (R)
and valve rocker shaft brackets (U). Note identification numbers
on bearing caps (par. 47).
<?. Place valve spring compressor 41-C-255928 (fig. 51) on the
cylinder head. Attach it in position over the exhaust valve, with
bolts from the bearing cap and rocker shaft bracket or other suitable
bolts. Screw in the spring depressor until the exhaust valve spring
retainer (BB) exposes the spring retainer lock (Q). Tap com
pressor lightly with a soft hammer if the lock tends to stick in the
valve stem groove. Remove the locks. Release compressor care
fully and remove the spring retainer, the three valve springs, the ex
haust valve rotator (FF), and the exhaust valve (RR). Position
spring compressor on the intake valve and remove parts as outlined
above.
d. Replace the bearing cap and valve rocker shaft bracket with
the valve rocker in their original position so they are not damaged or
lost.
e. Remove primer line nozzle assembly ((C), fig. 99) from
cylinders.
64. Cleaning, Inspection, and Repair

a. Cleaning.
(1) Parts. Clean all parts thoroughly with dry-cleaning solvent
or volatile mineral spirits.
(2) Combustion chamber. Remove heavy carbon deposits from
the combustion chamber with a conventional scraper or any
blunt tool which will not nick or scratch the surface. It is
necessary to remove only heavy deposits. Surfaces do not
have to be cleaned to a mirror finish.

114

b. Inspection.

(1) Oil pannage*. Check the oil passages in the camshaft bearing
cap, rocker shaft, and valve rocker assembly ((T) fig. 52).
Make certain they are clean an open. Small drilled holes
in the rockers supply oil to the valve rocker rollers (fig. 74).
A small drilled hole in the bearing cap supplies oil to ex
haust valves.
("2) Cylinder. Check the surface of the cylinder bore for deep
scratches, scoring, or pickup. Examine the joint between the
cylinder head and cylinder barrel for signs of pitting or
erosion. Examine the cylinder head for cracks or erosion
around the spark plug inserts, the valve seat inserts, and
valve guides. Inspect for broken fins on cylinder head. Re
place the cylinders if defective.
(3) Bore.
(a) Check bore dimensions to the limits specified in repair
and rebuild standards (par. 148). If the cylinder is to be
used with a new set of rings, the cylinder bore should be
roughed by hand with a fine abrasive cloth or stone. If
the cylinder has been rehoned, roughing is not necessary.
Note. After roughing the bore with abrasive cloth, wash the
cylinders thoroughly to remove abrasive.

(b) At room temperature cylinder bores are tapered slightly

so they will be essentially straight at engine operating
temperature.
(c) With the cylinder, at room temperature, take two measure
ments of bore diameters at top of ring travel: one measure
ment approximately parallel to the line of valves; the other
at 90 to the first measurement.
(d) Next, check the bore diameter at the flange end of the
cylinder, approximately parallel to the line of valves, at
the point of deepest ring wear. Make a second measure
ment at 90 to the line of valves, to the point of deepest
ring wear.
(4) Diagnosis.
(a) Check the cylinder bore taper by comparing the average
measurements of (3) (c) and (d) above. If the head end
. average is greater than the flange end, rehone the cylinder.
( b ) Compare the two measurements taken at the head end. If
the difference shows out-of-round more than 0.003 inch,
rehone the cylinder. If diameter at the head end is more
than 5.7537 inches after honing, replace the cylinder.
(5) Ring ridge. Check for ring ridge by carefully running a
finger over the cylinder wall. If a ridge can be felt at the
115

of ring travel, either at the top or bottom of cylinder, it

should be rehoned.
(6) Valve guide*. Inspect valve guides for looseness, cracks,
galling, erosion, or scuffing. Remove any carbon deposit in
the valve guide bores with crocus cloth and dry-cleaning sol
vent. Check bores to the limits specified in repair and re
build standards (par. 148). Replace if necessary (figs. 48
and 49).
(7) Valve (neat} insert*.
\ote. it i very important that valve (neat) inserts are seated
tightly in cylinder head. Inspect carefully for any signs of loosening.
Loose inserts must be removed and new ones installed (c (4) below).

(a) If inserts are not to be replaced, inspect the seats. Regrind (fig. 47) (par. 148), if any sign of pitting or burn
ing is found.
(6) Test the valve seat on the insert for imperfect seating.
Blue the face of valve (seat) insert with Prussian blue.
Install a perfect valve, and rotate it one-half turn on the
(seat) insert. If valve does not show perfect contact, regrind the seat on the insert.
(8) Valves, valve springs, and retainers.
(a) Check valves for evidence of imperfect seating. Heavy
discoloration, burning, erosion, or a carbon deposit on the
valve face is an indication of a warped valve. Light frost
ing or discoloration of the shiny valve face should not be
cause for replacement if the valve otherwise appears to
be in good condition. These minor discolorations usually
appear, as the valves begin to cool, after the engine is
stopped. Valves seat much better at operating tempera
tures than inspection of a cold valve indicates. Examine
valve stems and locking grooves for wear, scoring, pitting,
or other damage. Make certain that tips are not cracked
or damaged. Check stem diameters to the limits speci
fied in repair and rebuild standards (par. 148).
(&) Inspect valve springs for cracks, flaws, or other visible
evidence of failure. Check all springs for compression
to the limits specified in repair and rebuild standards
(par. 148).
(c) Check valve spring retainers and spring seats for wear
or signs of failure. Check the retainer lock. This lock
is in halves and wear may be noted by ridges left on the re
tainer between the halves. Check exhaust valve rotator.
The spring collar must turn freely when not loaded.
When loaded the rotor cap turns at least three degrees.
Replace all worn parts.
116

45 DEC 00 MIN BOTH

44 DEC 45 MIN SEATS

Figure 47.

Diagram of valve scat grinding.

45 DEC 15 MIN BOTH

VALVES

RA PD 155925

REGRIND ON THESE
LINES WHEN WIDTH Of
VALVE SEAT EXCEEDS 0.160
(GRIND TO KEEP SEAT
CENTERED ON VALVE FACf.)

(9) Camshaft bearings. Use a fine mill file to remove raised

metal from light scores or scratches in the camshaft bearings.
Check bearings to the limits specified in repair and rebuild
standards (par. 148).
(10) Heli-coil invert*. Inspect the heli-coil inserts for air de
flector mounting bolts in No. 1,2, 5, and 6 cylinders for signs
of looseness and galled or pulled threads., Replace any de
fective inserts.
c. Repair.
(1) Cylinder baire? /?/<*. Carefully straighten bent fins on the
barrel as close as possible to the original spacing. These fins
are soft and should not be destroyed. Replace cylinder if
loss of total fin area is more than 1 percent.
(2) Cylinder head fins. Replace cylinders with broken head fins
if defect is more than half the fin depth or more than 2 inches
long. A cylinder can be used if it has not more than three
acceptable defects. No two defects can be on adjacent fins
Defective areas shall be smoothly blended to eliminate sharp
corners. The depth of any blended fin must not be less than
50 percent of its original depth.
(3) Replace valve guides.
(a) To remove a valve guide, insert valve guide remover
41-R-2371-35 (for intake valve guides) or valve guide re
mover 41-R-2371-20 (for exhaust valve guides) (fig. 48)
Support the cylinder so that fins will
into the guide.
not be damaged. Drive the guide out of the cylinder head.
(6) Oversize valve guides (0.010 and 0.020 in.) are supplied
as replacements for loose guides. Check bore diameter in
cylinders to limits specified in repair and rebuild standards
(par. 148). Use suitable size guide for replacement.
(c) Valve guide replacers 41-R-2390-482 (for intake valve
guides) and 41-R-2390-475 (for exhaust valve guides)
'fig, 49) are provided for installing replacement guides.
To install a valve guide, pull the loose ferrule from end of
the replacer. Place valve guide over tool, entering the
short end of the guide into the hollow tool handle. Install
the ferrule to retain the guide. Enter the ferrule in the
bore for the valve guide and drive the guide to its seat.
Withdraw the replacer. Install the loose ferrule on the
tool.
(d) Roughing and finishing valve guide reamers and reamer
pilot bushings (fig. 5) are provided for conditioning re
placed guides.

118

REMOVERS - 414-2371-20
4 MI-2371-35

RA H) 155926

Figure 48.

Removing valve guide.

1. EfhaiMt valve guides. For exhaust valve guides, use pilot

bushing 41-B-2181-150 ((L), fig, 6), roughing reamer
41-R-2254-570, and finishing reamer 41-R-2254-520
((V)and(W),fig. 5).
2. Intake valve guide*. For intake valve guides, use pilot
bushing 41-B-2181-175 ((K), fig. B), roughing reamer
41-R-2254-552, and finishing reamer 41-R-2254-505
((X)and(Y),fig. 5).
(<?) To ream valve guides, insert the pilot bushing in the valve
(seat) insert. While an assistant holds the bushing in
place, rough and finish ream the guide to limits specified
in repair and rebuild standards (par. 148).
(4) Replace valve (seat} inserts.
(a) Remover kit 41-R-2371-465 (fig. 50) is used to remove and
replace valve seat inserts. The kit is a drawbar collet set,
modified to permit the use of CO2 (carbon dioxide) gas
which, upon expansion, gives the collet an extremely low
temperature. T\vo collets are provided, one for the intake
and one for exhaust valve (seat) insert.

119

- 41-H-239O-473
4M-2390-4W

Figure 49. Installing valve guide.

120

Figure 50. Removing valve {seat) inserts irith remover kit.

-41-C-2559-28

Figure 51.

Compressing valve springs.

121

K>

Figure 52.

/f

f>F

"*j^^f[r^\f r[ ^

Cylinder assemblyexploded view.

"-:.

fl

M
W

AGASKET, "O" RING170148.

Figure 52.

VVBOLT, HKX-HI>7H50195).

PPNUT, SLTD7338679.
QQINSERT (SEAT), EXHAUST VALVE7744609.
RRVALVE, EXHAUST7346481.

NNPIN, COTTER121224.

LLSTUD7403515.
MMSTUD7403097.

KKDEFLECTOR, AIR7376025.

JJNUT, SLTD7703684.

HHPIN, COTTER121223.

GGGUIDE, EXHAUST VALVE7348533.

FFROTATOR. EXHAUST VALVE7539838.

BBRETAINER, EXHAUST VALVE SPRING7539889.

CCSPRING, VALVE, OUTER7744799.
DEK-SPRING, VALVE, INTERMEDIATE7744800.
EESPRING VALVE, INNER7744789.

AAWASHER, PLAIN7767318.

ZBOLT, DLD-HEX-HD7346679.

YWASHER, PLAIN502245.

XWASHER, LOCK120214.

Cylinder assemblyexploded viewContinued.

TROCKER, VALVE, ASSY7410281.

UBRACKET, ROCKER SHAFT7403353.
VCOVER, VALVE ROCKER, INTERMEDIATE CYLINDER7375436.

SSHAFT, ROCKER7767322.

BVALVE, INTAKE7346482.
CINSERT (SEAT), INTAKE VALVE7744608.
DCYLINDER, ASSY7346610.
ENUT, HEX7767432.
FNUT, JAM107381.
GBAFFLE, INTERCYLINDER7376014.
HBOLT, HEX-HD7744736.
JWASHER, LOCK121621.
KSTUD7403071.
LNOZZLE, PRIMING7410158.
MGUIDE, INTAKE VALVE7346483.
NSEAT, INTAKE VALVE SPRING7744617.
PRETAINER, INTAKE VALVE SPRING7744798.
QLOCK, SPRING RETAINER7744610.
RCAP, CAMSHAFT BEARING7403352.

(6) To remove a valve (seat) insert, place the proper size

collect on the collect arbor. Screw the cone expander into
the arbor. Connect the hose furnished with the kit to a
COj cylinder. Arrange it so the quick-detachable fitting
may be attached to the extension tube of the collect without
delay. Heat the cylinder, in a furnace, to between 450
to 500 F.
Caution: Asbestos gloves always should be worn while
replacing inserts. Severe burns can result from heated
cylinders and from the low temperature of the tool.
If a furnace is not available, the insert part of the cylinder
may be heated with a blowtorch. When the cylinder is
heated, immediately insert the collect assembly into the
valve (seat) insert from the open end of cylinder. Seat
the collect and expand it to the limit by the handwheel.
Attach the hose fitting to the tube extending from the
cylinder head. Open C02 valve for 10 tp 15 seconds to
shrink the insert. Strike the extension on the gas fitting
with a hammer to dislodge the insert. Detach the gas
fitting. Withdraw the insert while still on the collect.
Figure 50 shows the arrangement for removal.
Note. Allow the cylinder to air-cool. Do not cool with water.

(c) Oversize valve (seat) inserts (0.010 and 0.020 in) are sup
plied as replacements for loose inserts. Check to the limits
specified in repair and rebuild standards (par. 148). Use
suitable insert for replacement.
(d) To replace a valve (seat) insert, heat the cylinder to 450
to 500 F. Place the insert on the collect, and turn the
handwheel to hold the insert in place. Attach the CO2
fitting and chill the insert. Detach the gas fitting, insert
the collect assembly, and seat the insert securely. Release
the collect and remove after the cylinder temperature has
approached normal by air-cooling.
Before refacing valve seats (fig. 47), be certain that grind
ing stones are true to a 45 angle. Using a valve seat
grinding tool, dress the seats. Check valve contact (6 (7)
above). When perfect contact is obtained, narrow the
seat width by grinding the surfaces and inner walls. Keep
the seat as near as possible to the center of the valve face.
Check valve contact again after seat width is obtained.
(,5) Replace heli-coil insert*. A heli-coil insert is a steel spiral
coil with a thread-shaped form ground on the inside and
outside of the coils. A tang at one end of the coil is used in
threading the insert into a threaded casting.
124

(a) Remove inserts. Insert the heli-coil extracting tool

41-T-3002-350 ((G), fig. 6) into the insert. Keeping a
constant pressure on the tool, turn counterclockwise until
the insert is removed.
( ft) Install inserts. Thread insert into the threaded guide of
inserting tool 41-T-3217-753 ((DD), fig. 6) by slowly
turning pilot until the insert is flush with the end of the
tool. Place pilot of the inserting tool in the threaded
hole in the cylinder casting, the face of the tool resting
solidly against the casting. Slowly turn the pilot clock
wise, causing the insert to enter the threaded casting, un
til no more resistance is felt. Remove inserting tool.
(c} Replace defective studs (par. 57) .
(d) Replace defective Rosan inserts (par. 57).
65. Assembly of Cylinders
52)
a. Install exhaust valve spring compressor 41-C-2559-28 (fig. 51)
on the cylinder head. Secure it in position with bolts from the cam
shaft bearing cap (R) and valve rocker shaft bracket (U) or other
suitable bolts. Insert the exhaust valve (RR) in its guide. Assemble
the exhaust valve rotator (FF) , three valve springs, and exhaust valve
spring retainer (BB). Compress the spring assembly sufficiently to
permit installation of spring retainer locks (Q) in valve stem groove.
Be certain that lock halves are in the groove in the valve stem. Re
lease compressor carefully until spring retainer is in position. Posi
tion compressor and install the intake valve, springs, and retainers in
similar manner. Be sure the exhaust valve rotators (FF) are assem
bled on exhaust valves only.
b. Install the bearing cap and valve rocker shaft bracket in their
original position.
c. All cylinders are marked on the rocker box contact flange, intake
side, showing original installation position. Replacement cylinders
must be marked similarly.
d. Install the primer line nozzle assembly ((C), fig. 99) in each
cylinder.
Section VII. REBUILD OF PISTONS, PINS, AND RINGS
66. Disassembly of Piston
a. Before pistons are washed, check to determine if all rings are
free in the ring grooves. Mark any sticking ring so that a detailed
inspection can be made later when ring is removed.
b. Remove rings with remover and replacer 41-R-2378-570 (fig. 53) .
Tag rings so that serviceable rings may be installed in their original
grooves.
241 130 O 53 9

125

Figure 53.

Installing pisivn ring.

67. Cleaning, Inspection, and Repair of Pistons, Pins, and

Rings
a. Cleaning.
(1) Clean the pistons and rings with carbon-remover solvent.
Scrape off remaining deposits. A broken piston ring makes
a good scraper to remove deposits from ring grooves. Be
careful not to scratch or gouge ring lands when scraping
off deposit. Be certain that oil drain holes in the oil rings
and in the oil ring grooves are clean. Carbon can be removed
with an undersized drill.
(2) Clean carbon deposits from piston pins and from piston pin
bores with crocus cloth wet with dry-cleaning solvent or
volatile mineral spirits.
b. Inspection.
(1) Examine piston pins for nicks, scratches, and wear. Using
a micrometer, check the diameter of piston pins. Replace
pins which are worn beyond the wear limits specified in re
pair and rebuild standards (par. 149). Replace pins hav
ing any defects.
(2) Inspect piston pin plugs. Look for large wear pattern on
ends of plugs. This is a sign of undue wear which does not
allow the piston pin to be centrally positioned. Nicks or
scratches on ends of plugs, or cracks in any part of the plug,
126

are cause for rejection. Reject plugs with excessive end

wear.
(3) Inspect piston ring wear surfaces. Reject any rings that
are ncuffed, scored, chipped, scratched, or have abrasions
elsewhere on the ring. Check the rings in the piston ring
grooves for side clearance (fig. 54). This clearance should
be checked around the complete diameter of the grooves for
all rings. Measurements must be within limits specified in
repair and rebuild standards (par. 149). Excessive ring
clearance can be caused by ring wear or ring land wear. If
ring clearance is less than normal, this probably means that
the ring land between the grooves is starting to break or bind.
Check the piston ring gap with the aid of the piston ring
gage and compreasor 41-G-534-50 (fig. 55). Check to the
limits specified in repair and rebuild standards (par. 149).
Reject any rings not within wear limits.
(4) Carefully examine entire piston for cracks and flaws. Small
cracks are seen under a strong light as irregular dark or
black streaks. Replace any cracked, warped, or distorted
pistons. Check ring grooves for wear. The grooves must
be within limits specified in repair and rebuild standards
(par. 149). Check the diameter of the piston skirts for wear.
Check the piston-to-cylinder dimensions to the limits specified
in repair and rebuild standards (par. 149).
(5) Inspect piston pin bores for wear, cracks, or abrasions. Re
place pistons which have bores worn beyond limits specified
in repair and rebuild standards (par. 149).
(6) All new piston rings should be checked in the grooves of the
piston to be sure there .is no sticking and that there is the
proper ring side clearance.
c. Repair
(1) Rejection of pistons for scores and scratches is a matter of
judgment. Use a fine mill file to remove metal raised from
minor scores and scratches.
(2) Piston rings cannot be repaired. Unserviceable rings must
be replaced.
(3) Pistons are marked, at original engine assembly, on the bot
tom of the piston pin boss, accessory case end. Replacement
pistons must be similarly marked.
68. Assembly of Pistons, Pins, and Rings

a. Using new rings as required, install piston rings in their original

positions with remover and replacer 41-R-237&-570 (fig. 53). Care
must be used when installing the rings so the ring lands will not be
scratched and the rings will not be distorted.
127

188833

Fiyvre 54.

Measuring piston ring side clearant-e.

Figure 55. Measuring piston ring gap clearance.

128

JBNG, COMPRESSION -

HUG, HST0K
N -776752*

., PISTON
PIN-7767525

ICtT, CONNKT1NO
ROD-7767521

Connecting rod and pistonexploded Hetc.

PIN, PISTON
7767527

PLUG, PISTON PIN7767528

Flf/nre 56'.

RING, Oil CONTROL 7403136

NUT, SI
7767522

b. Assemble piston pins and piston pin plugs in the pistons. Check
to be certain pin turns freely in the piston bore.
Section VIII. REBUILD OF CRANKCASE
69. Cleaning, Inspection, and Repair of Crankcase
a. deeming.
(1) Wash the two crankcase halves thoroughly with dry-cleaning
solvent or volatile mineral spirits.
(2) Remove the plugs from ends of the two main oil passages on
flywheel end, from the sides of the case opposite the main
bearing webs, and from the oil pan contact surface. Remove
the crankcase breather line hose elbow ((K), fig. 58) from
side of the case. Flow clean dry-cleaning solvent or volatile
mineral spirits through oil passages. Use a probe, if neces
sary, to dislodge sludge deposits. All passages must be clean
and free of chips and sludge.
b. Inspection.
( 1) Carefully check crankcase castings for cracks and flaws with
the aid of a strong light or the latest process available. Check
especially at base of studs and at sharp radius of flanges and
areas surrounding main bearing supports. Small cracks
probably will lead to major engine trouble later on. The
cross bolt openings (holes), of the crankcase are fitted with
permanently installed steel bushings to provide for accurate
crankcase alinement. The bushings should not be removed.
Loose bushings are cause for crankcase replacement.
Note. The crankcase halves are supplied as an assembly. If one
half is defective, replace both halves.

(2) Inspect conditions of mating flanges and mounting pads.

Examine the cylinder mounting pads and locating bores for
any damage caused by careless removal of crankshaft and
connecting rods. Check fan drive housing to the limits speci
fied in repair and rebuild standards (par. 150). Look for
discolorations on the crankcase mounting flanges, which may
indicate an oil leak.
(3) Check studs. All damaged or loose studs must be marked
for replacement. Check the special crankcase alinement
dowel-type bolt holes in the crankcase for oversize, elonga
tion, and obvious signs of misalinement.
(4) Check threaded openings in oil passages. Mark damaged
threads for repair as leakage may develop on assembly of
plugs.

130

(5) Install and bore check main bearings.

(a) Be sure that bearings are clean and that oil holes are open.
Use a wooden pin or sliver to clean out any sludge accumu
lation from oil grooves. A hard or sharp-edged tool can
easily damage soft bearing metal.
(b) The inspection of bearing surfaces cannot be specified
exactly. It is, therefore, largely a matter of judgment and
experience. The following general practices will assist in
determining whether a bearing is serviceable or should be
replaced.
1. If bearing surface shows signs of separating from the
underlying metal, replace the bearing.
2. Scratches on the bearings are not cause for rejection un
less the surface area destroyed is over 5 percent of the
tearing face. Replace bearings showing raised metal at
edges of the scratches.
3. Some loss of bearing metal from the grid pockets is not
unusual and is not cause for rejection unless the area
affected is over 25 percent of the total area.
4. Small particles of foreign matter imbedded in the surface,
are not cause for rejection and no attempt should be
made to remove them. However, if a concentration of
imbedded particles affects 5 percent of the surface, re
place the bearing.
5. The seriousness of the above defects is, of necessity, a
matter of good judgment. If there is a reasonable doubt
as to the ability of any bearing to continue in satisfac
tory service, it should be replaced.
the bearing thickness to the limits specified in
Check
(c)
repair and rebuild standards (par. 150). Bearing thick
ness is measured at the middle of bearing.
N<>tc. Never shim a worn bearing. A shim fitted hearing is not
round because one diameter is constant and the other is varied by
the shims.

(d) Examine the thrust faces of No. 3 main or thrust bearing.

Look for any above-mentioned defects. Check thickness
to limits specified in repair and rebuild standards (par.
150).
(e) Do not mar or destroy identification markings. Main
bearings must be installed in their original position. The
marking is etched on the steel back.
Note. Never use a scriber or sharp tool to mark bearings. Use a
grease pencil.

131

(/) Pinch check and here check main bearings as follows:

/. Spread a thin coat of Prussian blue evenly over the steel
backs of the bearings. Assemble them in their original
positions and locations in the crankcase halves.
#. Assemble the two crankcase halves and install the crank
case cross bolts and nuts. Ue straps 41-S~5906~30<>
(fig. 23) on the cylinder pad bolts and large washers on
the other cross bolts. Using a torque wrench, tighten
all nuts to 750 pound-inches by progressively tightening
nuts to 300, t>0<), and 751) pound-inches.
3. Cheek the bore of each main bearing to see whether it is
within limits specified in repair and rebuild standards
(par. 151). If bore check does not come within limits,
install a new bearing and repeat the check.
4. Check the clearance between the inner thrust hearing
flange and the crankcuse web. If clearance is less than
0.002 inch or more than 0.<M)8 inch, replace the bearing,
selecting a bearing to obtain this clearance.
5. Disassemble the crankcase and check the bearing back con
tact as shown by the blue transfer. Bearings must make
75 percent contact. If not, install a new bearing and
repeat the check.
c. Repair,
(1) Beplace defective studs (par. 57).
(2) Beplace defective Rosan inserts (par. 57).
(3) Clean up torn or damaged threads in threaded openings.
Use an old pipe tap so threads are not cut oversize. If threads
will not clean up, retap the hole to the next larger size plug.
(4) Remove minor nicks and scratches with an oil stone.
Scratches across a mating flange, which may lead to oil leak
age cannot be readily repaired. Replace any casting with
this defect.
70. Assembly of Crankcase Assembly
(fig. 58)

Install the crankease breather line hose elbow (K) in sides of case.
Install all pipe plugs in oil passages opposite main bearings, in flange
of oil pan contact surface, and in the ends of the main oil passages on
flywheel end. Refer to paragraph 103 for assembly of crankcase
halves.

132

CYLINDER, ASSY7403605

PISTON, W/RINGS,
-7

Figure 51.

CRANKSHAFT, W/FLYWHEfl
ASSY - 7403433

CRANKSHAFT THRUST
7376703

, MAIN,

ROD. CONNECTING,
ASSY-

CRANKCASE, HAUF,
LEFT (2-4-4)
SIM-7403361

Crankcase major componentsexploded view.

CRANKCASE HALF,
RIGHT (1-3-5)
SIDE-7

58. Craaikca&e fastening

DDSPACER, FAN ROTOR HOUSING

, FLYWHEEL END
CO-525230.

SWASHER, PLAIN502245.
TPLUG, PIPE7538997.
UPLUG, PIPE7538990.
VPLUG, FAN TOWER7348653.
WGASKET, ANNULAK142756.
XWASHER, PLAIN, FAN TOWER PLUG73
46692.
YNUT, SLTD7703684.
ZPIN, COTTER121223.
AANUT, PLAIN225854.
BBWASHER, LOCK120382.
CCSTUDCO-520627.

RNUT, PLAIN225853.

HBOI/T, CROSS, CRANKCASB7372684.

JPLUG, PIPE7767336.
KELBOW, HOSE, CRANKCASE BREATHER
LINE208803F.
LrCRANKCASE, HALF, RIGHT (1-3-5) SIDE
7403360.
MWASHER, PLAIN-7767318.
NNUT, PLAIN225854.
PNUT, JAM107823.
QNUT, JAM107822.

GSPACER, CROSS BOLT-7372680.

ATUBE, BALANCE, INTAKE MANIFOLD-73

48816.
BGASKETS, "O" RING-501232.
CFLANGE, BALANCE TUBE7348815.
DBOLT, DLD-HEX-HD7403158.
EPIN, COTTER121224.
FNUT, SLTD, CROSS BOLT7338679.

DOWEL-TYPE,

iwp Continued.

7410053.
ADSTUD-7403070.

ACBOLT.

CRAXKCASE

ALINEMENT

LLNUT. JAM-107381.
MMNUT, PLAIN225855.
NNWASBKK, PlAIN7725882.
PPBEARING, FAN DRIVE HORIZONTAL
SHAFT BEVEL
GEAR7351189.
00CHANKCASE, HALF, LEFT (2-4-6) SIDE
7403361.
RBWASHER, PLAIN,"502204.
SSBOLT,
DOWEL-TYPE, CRANKCASK ALINEME
NT
7410047.
TTPIN, DOWEL, FAN DRIVE VERTICA
L SHAFT BEAR
ING 7338668.
UUBEARING, FAN DRIVE VERTICAL SHA
FT7351157.
VVBOLT, HEX-HD7346715.
WWWASHER, PLAIN7375420.
XXBOLT. LOCKING, FAN DRIVE HOR
IZONTAL SHAFT
BEARING7375421.
YYBOLT, HEX-HD7346723.
ZZBOLT, HEX-HD7346606.
ABBOLT, HEX-HD73765)36.

KKPLUG, PIPE77(57337,

FFPLATE, RETAINING, OIL SKAL774461KI.

GOWASHER, PLAIN502266.
HHBOLT, DLD-HD583758.
JJGASKET. "O" RING TRANSMISSION FLA
NGE ADAPT
ER-7723892.

EKNUT. SLTD22.>h<>9.

Figure 59.

Crankshaft and flywheel

Section IX. REBUILD OF CRANKSHAFT AND CONNECTING

ROD ASSEMBLY
71. Disassembly of Crankshaft Assembly
a. Remove the spring around the crankshaft oil seal with spring as
sembly (fig. 59 ) and remove and discard the seal.
b. Remove the cotter pins and slotted nuts from the connecting rod
bolts (fig. 56). Record the breaking torque of the nut. If it is below
750 pound-inches, the nut should be removed and mica-base anti-seize
compound applied to the bolt thread. Replace the nut and tighten
to 750 pound-inches. If the nut does not tighten to this torque, the
bolt is stretching and should In? replaced. Loosen and remove the
connecting rod caps. Remove the rods and bearings from the crank
shaft. If neceasary, the caps can be loosened by tapping gently with
a soft hammer. Do not strike near the parting lines. Use care in
handling the connecting rod bearings as they are easily damaged.
Look for connecting rod and bearing location identification numbers.
Re-mark any connecting rods or bearings if the numbers are not
legible.
c. Remove the four drilled-head bolts holding the counterweight
stop plate ((B), fig. 64) to the crankshaft damper hub. Center the
crankshaft damper counterweight holes with the mating holes in the
hub, and remove the four solid damper counterweight pins ((C), fig.
(>4) from two counterweights. Slide the two counterweights off the
hub.
d. Remove the cotter pins from the four damper counterweight fe
male pins ((K),fig. 64) which hold the two remaining counterweights.
Use wrenches 41-W-870-50 (fig. 60) to unscrew the four pins. Re
move the four damper counterweight male pins ((H), fig. 64), pin
bushing ((J), fig. 64), and the female pins. Remove the two counter
weights.
e. Remove the transmission shaft pilot hall bearing (fig. 59) from
the bore of the flywheel flange.
/. Remove internal snap ring (fig. 59) holding the flywheel end
crankshaft oil plug in position. Remove the plug and discard the
"O" ring gasket. A 14-28XF-3 tapped opening is provided for pull
ing this plug. The crankshaft oil slinger (fig. 59), pressed in No. 1
bearing bore, is held in place by the crankshaft oil tube and should
not be removed.

72. Cleaning, Inspection, and Repair of Crankshaft Assembly

a. Cleaning. Clean all parts thoroughly with dry-cleaning solvent
or volatile mineral spirits. Flush out the oil passages from the jour
nals to the crankpins.
137

RA CO 155936
Figure 60. Rent wing vibration damper counterweight pi'**.

Inspection.
(1) Crankshaft.
(a) The crankshaft and vibration damper hub assembly are
furnished as one unit and stocked as such. The hub is
not replaceable.
(b) Continued operation of the engine is dependent upon the
concentricity of the crankshaft main bearing journals
and connecting rod journals. Examine the journals care
fully for any nicks, burs, grooves, galling, or hammered
and out-of-round condition.
(c) Check main bearing and connecting rod journal diameters
and the crankshaft run-out to the limits specified in repair
and rebuild standards (par. 151). To check run-out, sup
port the crankshaft in ''V'1 blocks by the end journals and
check with a dial indicator.
Note. Regrinding of crankshafts is not permitted. However,
very fine marking In the thrust area of the crank journals may bt>
polished over if new bearings are to be installed. Shafts requiring
regrinding must be replaced.

(d) Look for any indication of the connecting rods touch

ing or rubbing the crankshaft during operation. Scratches
138

RA PO 155937

Figure 61. Pinch check of connecting rod bearing.

(<?)

(/)
(g)

(h)

of any kind are particularly dangerous to satisfactory

crankshaft life and may be the cause of a future failure.
If niagnafiux equipment is available, inspect the crank
shaft by this method. If magnaflux is not available, care
fully inspect the crankshaft with a magnifying glass for
cracks, particularly in the areas around the crankshaft oil
tube holes and fillets adjacent to the cheeks. If cracks
are discovered, replace the crankshaft.
Examine the crankshaft carefully for any signs of scuf
fing or overheating. Such signs are an indication of a
defective bearing. Check the bearing again.
Inspect the crankshaft vibration damper hub carefully.
Examine pin bores for evidence of cracks, signs of scor
ing, or out-of-round condition. Defects cannot be cor
rected and the crankshaft must be replaced.
Remove the safety wire and check damper hub drilledhead bolts ((G), fig. 64) to 1,000 pound-inches torque.
JVote any evidence of hub movement on splined shaft .and
dowel pins. Should evidence indicate hub is not prop
erly secured, replace the crankshaft. Install the lock
ing wire after retorquing the hub bolts.
Note. The bolts should not be removed.
139

() Cheek the condition of the main accessory drive shaft

spline. Look for worn or damaged splines.
(j) Examine the dowel pins in the flywheel end flange. Pins
must be tight, not out-of-round, and show no signs of de
fects. Replace questionable dowel pins (par. 88).
(2) Counterweight*.
(a) Carefully examine damper counterweight pin bores
(fig. 64) for evidence of cracks, signs of scoring, or out-ofround.
.Vote. If a riamawi part in found, all damper counterweight
muHt he replaced. Tlie weights of these parts are matched ac
curately at assembly, and the critical balance might be destroyed
by the substitution of an unmatched part.

(b) Examine the pin bushings, damper solid pins, and pin
flanges for cracks, roughness, wear, and out-of-round. Re
place damaged parts. Each of these individual parts is
precision made, and interchangeability does not destroy the
critical balance of the assembled unit. Check to the limits
specified in repair and rebuild standards (par. 151).
(3) Connecting rods and bearings.
(a) Inspect the connecting rods very carefully as close limits
are specified in repair and rebuild standards (par. 151).
Check the rods for twist and bend using any of the standard
tools designed for that purpose. Do not attempt to
straighten a bent rod. Replace it with a new rod.
(b) Check the connecting rod bolts very carefully. Replace
any bolts that do not fit snugly when assembled in position
in the connecting rod. Examine the threads and look for
any evidence for gulling on the pilot diameter near the cen
ter of the bolt. Look for stretching, cracks, or scratches
on any portion of the bolt. Light scratches on the bolts
may serve as a starting point for a fatigue crack. The bolts
are highly stressed during engine operation. Replace all
bolts about which there is the slightest doubt.
(r) Clean carbon deposit from piston pin bores with crocus
cloth, wet with dry-cleaning solvent or volatile mineral
spirits. Examine bores for scoring or cracks and check pin
. fits in bearings to see that they are free. Check to the
limits specified in repair and rebuild standards (par. 149).
(d) Check the wear and surface condition of the connecting
rod bearings. The bearings should be replaced if the bear
ing metal shows signs of breaking loose or pitting in spots.
Check bearing thickness to the limits specified in repair
and rebuild standards (par. 151). Inspect oil holes and
grooves in bearings to be sure they are clean. Look for
140

identification markings and renew markings with a grease

pencil, if necessary. Never use a scriber or sharp tool to
mark bearings.
Repmr.
(1) Crankshaft.
(a) Polish out any fine scratches on main and connecting rod
journals, using crocus cloth and dry-cleaning solvent or
volatile mineral spirits.
(b) Scratches or scuffing on the crank cheeks must be removed
or the shaft must be replaced. Scratches of any kind are
dangerous and may lead to a future failure.
(f) Dowel pins are replaceable. Oversize pins are available
for replacement (par. 88). Loosen the three small hexsocket set screws (fig. 59) in the outside edge of the crank
shaft flange and extract the dowel pins.
(2) Connecting rod* and bearing*.
(ti) Piston pin bearings are replaceable. Press the bearing
from the connecting rod. To install a new bearing, heat
the bearing end of the connecting rod to 350 F. Shrink
the bearing with dry ice; then press it into place. Bore and
ream the. bearing to the limits specified in repair and re
build standards (par. 151).

Figure 62.
241130 O53 10

Chcckin(/ connecting rod side clearance.

141

63. Vibration damper counterweights installed.

(b) Whenever new bearings are installed, they must be pinch

checked in the mating connecting rod and bearing cap
(fig. til). Place the rod in a vise with soft jaws. Install
the two bearing halves in the rod and cap. Assemble the
bolts to secure the rod and cap firmly but do not tighten.
Insert a ().(M)15-inch feeler gage in the joint on one side
between the rod and cap. Tighten the bolt on the opposite
side to 550 pound-inches torque. Next, tighten the bolt on
the feeler gage side with a torque wrench until the cap
begins to pinch the feeler gage. The torque required to
reach this condition should be between 250 and 450 poundinches. If the torque required is not within this limit,
another hearing: should be installed and the test repeated.
When new bearings are installed, make certain they are
marked with identifying location numbers corresponding
to rod numbers.

73. Assembly of Crankshaft Assembly

a. Assemble the connecting rods and their bearings to the crank
shaft. Make certain that rods and bearings are in their proper lo
cation according to identifying numbers. (Rod numbers are on the
142

RA W> 155940

ABOLT, DLD-HD, PLATE583741.

UPLATE, STOP, COUXTEKWEIGHT73466H.
C- PIN, COUNTERWEIGHT774451)6.
D( 'OL'NTEB WE IGHT, DAMPER7521267.
EHUB, CRANKSHAFT DAMPKR7530701.
FKING, SNAP-7410378.
GBOLT, DLD-HD, HUB7767530.
HPIN, COUNTEHWEIGHT, MALE7372696.
JBUSHING. PIN7346493.
KPIN, COUNTERWEIGHT, FEMALE-7372697.
L FIX. COTTER121224.

I-'i(tarc (14.

CrttnkulKift vibration damperexploded view.

bottom, or oil pan side, when the rods tire positioned in the cylin
ders.) Bearings and journals should be lubricated with engine oil at
assembly. Connecting rod bolts should be inserted from the rod side,
and the wing bolt heads should be properly seated in the recesses
provided. Tighten the nuts evenly and torque to 800 pound-inches.
The torque range on these holts is 750-850 pound-inches. This range
is provided to permit alinement of the slotted nut and bolt cotter pin
hole. When the rods are assembled, make certain that the side clear
ance of the connecting rods (fig. 02) and bearings on the crankshaft
is to the limits specified in repair and rebuild standards (par. 151).
Replace parts not within these limits with parts which are within

143

these limits. Examine for cotter pin a linement and tighten nuts
further until cotter pins can be inserted. Insert cotter pins.
6. Assemble two of the four counterweights to the crankshaft
damper hub ((E), fig. 64) using the damper counterweight male pins
((H), fig. 64), pin bushings ((J), fig. 64), and the damper counter
weight female pins ((K), fig. 64) in the positions shown in figures
tlO and 64. Note that the counterweights must be located between
counterweights stop plate bolt holes in order to install the counter
weight stop plate when the counterweights are in place. Tighten the
pins, using wrenches 4 l-W-870-50 (fig. 60). Line up the slots in
the female pin nuts with cotter pin holes in male pin and install the
cotter pins. Assemble the other two counterweights to the hub, using
the solid damper counterweight pins ((C), fig. 64). Assemble the
counterweight stop plate ((B), fig. 64) to the hub and secure with
four drilled-head plate bolts (fig. 63) and safety wire.
c. Install n new "()'" ring gasket on the flywheel end crankshaft oil
plug (fig. 59). Install the plug in the flywheel end of the crankshaft.
Insert internal snap ring (h'g. 59) in the recess provided.
d. Place a new crankshaft oil seal with spring assembly (fig. 59)
on crankshaft at the flywheel end flange. The closed or flat side of the
seal is towards the flywheel flange. Install the spring by connecting
the two ends and inserting it in the oil seal groove.
c. Install a new or serviceable transmission shaft pilot ball bearing
(fig. 51)) in the bore of the flywheel end flange.
Section X. REBUILD OF OIL PUMPS
74. Scavenger and Pressure Oil Pump (Dual Unit)
a. Disassembly (fig. 65).
(1) Remove locking wire, slotted nuts, and plain washers.
Remove the drive gear support assembly (AA). Remove the
drive bevel gear (BB) and its snap ring (Y). Refer to para
graph 51 for removal of drive shaft (Z).
(2) Remove the driven bevel gear (BB) from the scavenger pump
housing (P).
(3) Remove locking wire, slotted nuts, plain washers, and drilledhead bolts holding the scavenger and pressure pump housings,
(P) and (F) together. Remove the scavenger pump housing,
tapping with a soft hammer, if necessary.
(4) Lift out the scavenger pump driven impeller (N) from the
housing.
(5) Tap the scavenger pump drive impeller (M) with a soft
hammer, and remove it from the pressure pump drive im
peller with shaft (H). Remove the Woodruff keys (EE)
from the drive impeller shaft.
144

Compress the "O" ring gasket (K) on the separator plate as

sembly (L) by applying hand pressure. This operation re
cedes the ring on one side and extends it above the retain
ing flange on the other side. It can then be pried off. Bemove
and discard gasket.
(7) Tap the separator plate assembly (L) gently with soft ham
mer.
Caution: Avoid striking the outer flange extremities as the
"O" ring gasket groove is easily fractured.
Remove the plate assembly from the pressure pump housing (F).
(8) Remove the pressure pump drive impeller with shaft (H).
(9) Remove the driven impeller shaft (J) from the pressure
pump housing (F) and slip off the pressure pump driven
impeller (G).
(10) Remove locking wire, slotted nut, and plain washer from
the stud in the bottom of the pressure pump housing and
slip off the pressure pump screen assembly (C).
ill) Remove locking wire and slotted nut in the bottom of the
pressure pump housing (F) and remove the driven im
peller shaft locking plate (E).
6. Cleaning and Inspection.
(\) Cleaning. Clean all parts with dry-cleaning solvent or
volatile mineral spirits.
('2) Inspection.
(a) Examine the pump mounting surfaces and all mating
faces for nicks and scratches. Remove any raised metal
with a fine mill file. No gaskets are used on these faces,
so they must be free from imperfections which would im
pair a tight oil seal.
(b) Inspect the gears and shafts by magnaflux. If this method
is not available, use a magnifying glass to check for
cracks. Cracked parts are defective ((e) below).
(c) Examine the gears for abrasions on the tooth faces and
for burs on the tooth corners.
(d) Examine the shafts for scoring or galling.
(e) Pump parts are not interchangeable. Any pump with
defective parts must be replaced with a new pump as
sembly. Good judgment must be used in determining
what parts are defective in cases of minor imperfections.
(/) Check all parts to the limits specified in repair and re
build standards (par. 152).

145

RAPD 155941A

figure 65.

Scavenger and pressure oil pump and linese&plorlf'd

Figure 65.

AASUPPORT, DRIVE GEAR, ASSY7376028.

BBGEAR, BEVEL. DRIVE AND DRIVEN (2)7346532,
CCSTUD7403070.
DDSTUD7403075.
KEKEY, WOODRUFF124545.
PFSTUD7350204.
GGSTUD7403512.

Scavenger ana" pressure oil pump and linesexploded viewContinued.

JSHAFT, DRIVEN, IMPELLER7403083.

KGASKET, "0" RING7372649.
LPLATE, SEPARATOR, ASSY74033551
MIMPELLER, DRIVE, SCAVENGER PUMP7403086.
NIMPELLER, DRIVEN, SCAVENGER PUMP7403087.
PHOUSING, SCAVENGER PUMP7403379.
QBOLT, DLD-HD583757.

ZSHAFT, DRIVE7346505.

YRING, SNAP7348754.

7403348.

HIMPELLER, DRIVE, PRESSURE PUMP, W/SHAFT

x-plotlfd

RNUT, SLTD7703684.
SWASHER, PLAIN502204
TSTUD7403068.
UBOLT, DLD-HD7346710.
VLINE, OUTLET, SCAVENGER PUMP7348752.
WLINE, SUCTION, SCAVENGER PUMP7348673.
XGASKET, SUCTION LINE7346510.

Scavenger and pressure oil pump and

ANUT, SLTD225869.
BWASHER, PLAIN502245.
CSCREEN, PRESSURE PUMP, ASSY734659T.
DNUT, SLTD225838.
EPLATE, LOCKING7744628.
FHOUSING, PRESSURE PUMP7403349.
GIMPELLER, DRIVEN, PRESSURE PUMP7408085.

Figure 65.

c. Assembly (fig. 65)

(1) Install the pressure pump driven impeller (G) on the driven
impeller shaft (J) from the milled-locking face end. Insert
the shaft in the bearing of the pressure pump housing (F),
and secure it with driven impeller shaft locking plate (E),
slotted nut, and looking wire. Lubricate all gears, shafts, and
bearings with engine oil.
(2) Install the pressure pump screen assembly (C) on the drilled
stud in the bottom of the pressure pump housing (F).
Secure with plain washer, slotted nut, and locking wire.
(3) Install the pressure pump drive impeller with shaft (H) in
the pressure pump housing.
(4) Install "O" ring gasket (K) on the separator plate assembly
(it) and install the separator plate assembly over the shafts,
matching the dowel pins with the proper dowel holes in the
pressure pump housing.
(5) Insert the Woodruff keys (EE) in the pressure pump drive
impeller with shaft (H) and slip on the scavenger pump
drive impeller (M). Install the scavenger pump driven
impeller (N) on the driven impeller shaft (J).
(6) Assemble the scavenger pump housing (P) to the separator
plate assembly (L) and pressure pump housing (F), and
secure with drilled bolts, plain washers, slotted nuts, and
locking wire.
(7) Install the driven bevel gear (BB) in the bearing in the
scavenger pumrphousing (P).
(8) Assemble the drive bevel gear (BB) in the drive gear sup
port assembly (AA). Install snap ring (Y) in the drive
bevel gear.
(9) Install the drive gear support assembly (AA) and drive bevel
gear with snap ring (BB and Y) on the scavenger pump
housing, meshing both drive and driven bevel gears (BB)
as the support assembly is being located on its dowel pins.
Secure with plain washers, slotted nuts, and locking wire.
See paragraph 107 for installation of drive shaft (Z). Check
backlash between bevel gears to limits specified in repair and
rebuild standards (par. 152).
75. Rebuild of Accessory Case Scavenger Oil Pump
a. Disassembly (fig, 66).
(1) Kemove the bevel gear (A) from the scavenger oil pump
housing cover (D).

148

(2) Remove locking wire, slotted nuts, and plain washers from
the housing studs and remove cover. Gently tap the cover
with a soft hammer to remove it from the dowels.
(8) Remove the drive impeller (K) and driven impeller (E)
from the scavenger oil pump housing assembly (F).
(4) Remove wire, slotted nut, and plain washer from the bottom
of the pump housing. Slip oft' the pressure pump screen
assembly (H).
b. Cleaning and Inspection.
(1) Cleaning. Clean all parts with dry-cleaning solvent or
volatile mineral spirits.
(2) Inspection.
(a) Examine the pump mounting faces and all mating sur
faces for nicks and scratches. Remove excess metal with
a fine mill file. No gaskets are used on these faces, so they
must be free from imperfections which would impair a
tight oil seal,
(b) Inspect the impellers and gear by magnaflux. If this
method is not available, use a magnifying glass to inspect
for cracks. Cracked parts are defective ((d) below).
(<?) Examine the impellers and gear for abrasions on the tooth
faces and for burs on the tooth corners. Examine the
shafts for scoring or galling.
(d) Pump parts are not interchangeable. Any pump with
defective parts must be replaced with a new pump assem
bly. Good judgment must be used in cases of minor or
questionable imperfections.
(e) Check all parts to the limits specified in repair and rebuild
standards (par. 158).
c. Assembly (fig. 66).
(1) Lubricate all gears and bearings with engine oil.
'(2) Install the drive impeller (K) and the driven impeller (E)
in the pump housing assembly (F).
(3) Install the scavenger oil pump housing cover (D) over the
drive and driven impeller and on the housing, locating it
on the housing dowels and studs. Secure with slotted nuts,
plain washers, and locking wire.
(4) Install pressure pump screen assembly (H) over its stud in
the bottom of the housing. Secure with plain Washer and
slotted nut. -Lock-wire the nut to the drilled hole in the
flange edge at bottom of the housing.
(5) Install bevel gear (A) in the housing cover, meshing the
splines with those of the impeller shaft.

149

Ul

Fit/Hff 6V;.
AcrcHMoi'y

PLAIN-502245
HOU${NG~7403373
DRIVEN7403342
1^-HOUSlNG, PUMP, ASSY7403344
$-STUD~~7403512
SCREEN, PRESSURE PUMP, ASSY7346597
JSTUD-74030^
IMPELLER, DRIVE7403341

oil

Section XI. REBUILD OF COOLING FAN AND FAN CLUTCH

ASSEMBLY
76. Disassembly of Cooling Fan and Fan Clutch Assembly
(fig. T)

The fun rotor cover (C) and the cooling fan and fan clutch assembly
were removed from the engine during disassembly of the engine into
subassemblies (par. 38). Note the position of the clutch-to-rotor
adapter (E) with respect to the thin edge of the rotor blades to as
sure proper position at assembly.
a. Remove cotter pins (Y), slotted nuts (Z), plain washers (CC),
and drilled-for-cotter-pin bolts (DD) holding the clutch-to-rotor
adapter (E) to the cooling fan rotor (F). Separate the rotor from the
adapter and clutch assembly.
b. Remove cotter pins (Y), slotted nuts (Z), and drilled-for-cotterpin bolts (D) holding the cooling fan clutch assembly to the clutchto-rotor adapter (E). Separate the clutch-to-rotor adapter from the
fan clutch assembly.
c. Remove cotter pins (Y), slotted nuts (X), and drilled hex-head
bolts (J) holding the fan clutch outer housing (upper) (L) to the
fan clutch inner housing (lower) (W). Separate disks, plates,
spacers, and inner housing (lower) from the-fan clutch outer housing
(upper) *(L).
d. Remove external snap ring (G) from the upper end of the clutch
drive hub (M) and remove the hub, with the inner ball bearing (N),
from the fan clutcli outer housing (upper) (L).
e. Remove internal outer housing snap rings (H) from the outer
housing and remove outer ball bearing (K).
/. Remove remaining external outer snap ring (P) from the lower
end of the hub and press off the inner ball bearing (N).

77. Cleaning, Inspection, and Repair of Cooling Fan Clutch

a. Cleaning,
(1) General. Clean all castings and machined parts with drycleaning solvent or volatile mineral spirits.
(2) Bearings. These bearings are the sealed type and must not
be washed in dry-cleaning solvent or volatile mineral spirits.
They are packed with lubricant sufficient for the life of the
bearing. Washing may penetrate the seal and remove lubri
cant. Wipe bearings clean, using a cloth moistened with
solvent.
&. Inspection and Repair.
(1) The fan rotor should be inspected for cracks, nicks, and
scratches. Use a fine mill file to remove raised portions of
151

metal caused by nicks and scratches. Any cracked or bent

blades are cause for rejection of the rotor.
Note.

Do nut straighten bent blade*.

(2) Inspect clutch-to-rotor adapter for distortion. See that the

mounting flange is flat and free from raised metal or dents
and scratches. The centering pilot of the adapter must be
without nicks or abrasions that would interfere with a neat
fit in the rotor.
(3) Inspect clutch disks, pressure plates, spacers, and clutch
housings for imperfections and signs of failure. There are
no deh'nte Units established for these parts and good judgment
must decide if parts are to be replaced.
(4) Inspect sealed ball hearings. Spin bearings with fingers
and check for audible evidence of roughness and wear. Check
bearings for wear of inner and outer races by supporting the
inner race in a vertical position and torsionally checking
for end play by oscillating the outer race. End play is evi
dence of wear. Note if seals of the bearings are damaged
allowing lubricant to escapeor dirt toenter. Replace all worn
or rough bearings.
Xote. It bearings are to be kept for an indefinite period before
installation, they must lx> protected by coating with nut-preventive
compound. Lubricating oil is not adequate.

(5) Parts should be checked to the limits specified in repair and

rebuild standards (par. 154).
78. Assembly of Cooling Fan and Fan Clutch Assembly
(fig. H7)
a. Insert outer ball bearing (K) in the fan clutch outer housing
(upper) (L), and secure with snap rings on each side of the bearing.

b. Push the large end of the clutch drive hub (M) through the
inner ball bearing (N) and install external outer snap ring (P).
c. Install the opposite end of the clutch drive hub in the outer
ball bearing (K) in the fan clutch outer housing (upper) (L).
d. Install one clutch drive disk (Q) over the clutch drive hub,
meshing its serrations with those of the drive hub.
e. Lay one clutch pressure plate (R) on the clutch drive disk
(Q). Install one clutch driven disk (S) over the dowels on the fan
clutch outer housing (upper) (L), with its serrations alined to mesh
with those of the clutch pressure plate (R). Install the thicker
clutch spacer (T) over the dowels on the fan clutch outer housing
(upper) (L).
/. Install the remaining clutch drive disk (Q), clutch pressure
plate (R), clutch driven disk (S), and the thinner clutch housing
152

Ui
CO

A I

Figure (17.

Bt-PIN, DOWEL, CLUTCH - 7403729

CCWASHER, PLAIN - 7744766
DO-BOLT, DLD-F/C-PIN - 7403743

AA-SPRING, CLUTCH - 7403739

Q-DISK, DRIVE, CLUTCH - 7539466

t-PtATE, PRESSURE, CLUTCH - 7539470
S-OISK, DRIVEN, CLUTCH - 7403741
T-SPACCR, CLUTCH - 7403738
U-SPACER, CLUTCH HOUSING - 7403740
V-BALL, CLUTCH - 587940
W-HOUSING, FAN CLUTCH, INNER (LOWER) - 7376948
X-NUT, SLTD-122925
Y-PIN, COTTER - 112726
Z-NUT, SLTD- 122942

Cooling fan and fan clutch (ism'inblyfj?/>/orfrrf view.

M-HUB, DRIVE, CLUTCH - 7403735

N-BgARING, BALL, INNER 7403732
P-RING, SNAP, EXTERNAL, OUTER - 7376O45

L-HOUSING, CLUTCH, OUTER (UPPER) - 7403736

JBOLT, DLD-HEX-HD - 7403727

K-BEARING, BALL, OUTER - 7403731

H-RING, SNAP, INTERNAL, OUTER HOUSING - 7414962

G--RING, SNAP, EXTERNAL-583002

1-ADAPTER, ClUTCH-TO-ROTOR - 7403734

F-ROTOR, FAN-8357826

A-SCREW, RD-HD - AIR-AN-520-416-36

t-WASHER, LOCK - 120380
C-COVER, FAN ROTOR - 8329030
D-BOLT, DID-F/C-PIN - 7403744

RA t>0 188BS2

AA

spacer (U) as in e above. Make certain the serrations of the parts

are property alined and the dowels are inserted in proper holes.
y. Install 15 clutch balls (V) and 3 clutch springs (AA) in their
recesses in the fan clutch inner housing (lower) (W). The springs
are positioned with the large end up.
h. Install the assembled disks, pressure plates, spacers, dutch
drive hub, and fan clutch outer housing (upper) (L) over the dutch
drive springs, keeping the serrations of all parts alined with thdowel pins over the holes in the fan clutch inner housing (lower)
(H*). (lently compress the assembly and secure with four drilled
hex-head bolts (J), slotted nut (X),and cotter pin (Y).
/. Install the eluteb-to-rotor adapter ( K) on the top side of the cool
ing fan rotor (F) with the pilot of the adapter fitted in the small diam
eter of the rotor.
\'ote. The top si<U> of the rotor has the sharp edges on the rotor blades.
Secure with drilled-for-cotter-pin bolt (DO), plain washer (C(').
slotted nut (Z), and cotter pin ( Y).

j. Install the clutch-to-rotor adapter and rotor assembly on the

upper housing of the cooling fan clutch assembly, positioning over the
locating dowels, and secure with drilled-for-cotter-pin bolt (D),
slotted nut (Z), and cotter pin (Y).
k. Install the remain ing external snap ring (G) over the upper end
of the dutch drive hub (M).
/. Install the cooling fan and fan clutch assembly to the engine and
install the fan rotor cover (0) (par. 124)

Section XII. REBUILD OF THROTTLE LINKAGE

79. Disassembly of Throttle Linkage
a. General. Ordinarily, complete disassembly of the throttle con
trols is not necessary at overhaul. However, a thorough visual in
spection should be made of the entire assembly while disassembling
from the engine (par. 43). If any defects are found, the linkage may
be disassembled as outlined below.
6. Removal of Throttle Linkaye. Removal of throttle from the
engine linkage necessitates breaking the complete throttle linkage as
sembly into two separate subassemblies. For overhaul purposes, these
will be handled as two separate units, to be referred to as throttle
linkagecross shaft and vehicle control levers assembly (fig. (59) and
throttle linkagegovernor linkage (fig. (>8).
c. Dixaxsembly of Croxx /Shaft and Vehicle Control Lever* Axxcm(1) Remove control lever spring (GG).
(2) Remove the outer external snap ring (A) from the left end
of the cross shaft (L) and remove the vehicle control outer
154

lever assembly (D). Remove the outer ball bearing (B),

snap riii# (C), and the remaining inner ball bearing (B)
from the lever. Remove inner external snap ring (A) from
the cross shaft (L).
(3) Remove cotter pin, slotted nut, and drilled-hex-head bolt
from the vehicle-to-carburetor inner lever assembly (E) and
remove the lever from the cross shaft. Remove Woodruff
key (M) from the left end of the cross shaft.
(4) Remove the external snap ring (A) at the ball bearing (B)
in the left ("2-4-f)) side camshaft gear housing cover assembly
(K) and slide the camshaft gear housing cover from the
cross shaft. Remove internal snap rings (C) from the gear
housing cover and press out ball bearing (B). Remove the
remaining snap ring (A) from the cross shaft. Remove the
vehicle control lever stop (J) by removing jam nut, plain
nut, and washer holding it on studs.
(5) Remove the cross shaft-to-carburetor control rod turnbuckle
assembly from the carburetor control cross shaft lever (T)
by removing cotter pin (R), Plotted nut (U), and plain
washers (P) and withdrawing drilled-hex-head bolt (N).
Disassemble the control rod turnbuckle assembly by removing
the right- and left-hand thread ball bearings (AA) and (Q)
and the right- and left-hand thread hex jam nuts (BB) and
(DD) from the cross shaft-to-carburetor-control-rod turnbuckle <CC).
(6) Remove the control-shaft-to-cross-shaft link assembly (X)
from the carburetor control cross shaft outer lever (HH) by
removing cotter pin (R), slotted nut (U), plain washers (P),
and drilled-hex-head bolt (\V).
(7) Remove cotter pin (R), slotted nut (S), and drilled-hex-head
bolt (Z) from the carburetor control cross shaft outer lever
(HH). Use a soft hammer, if necessary, to tap the lever from
the cross shaft. Remove Woodruff key (M) from the shaft.
(8) Remove the cross shaft support bracket (V) from the cross
shaft (L). Remove internal snap rings (C) and ball bearing
(B) from the support bracket. The bearing may be re
moved by tapping gently with a soft hammer.
(9) Remove the remaining cross shaft lever (T) from the cross
shaft (L) by removing cotter pin (R), slotted nut (S), and
drilled-hex-head bolt (Z). If necessary, tap the lever gently
with a soft hammer.
d. Dixaxsemhly of Governor Linkage (fig. 68).
(1) Remove the right- and left-hand thread control shaft-togovernor rod assembly from the control shaft-to-cross shaft
and governor lever (A) by removing cotter pin (H), slotted
155

Figure 68.

T-KXT, 010^/C-MN - 7410037

W-NUT, JAM - 107*22
V-NUT, FUUN-223W3
W-WASHCR, PiAW-i02245

O-BEARING, &AU, ROD ENO< LM-THD

-WASHC*, PLAIN -300044
S-NUT, SLTD- 7403213

F-NUT, JAM, NIX, IH-THD-7767WO

M-NUT, MM. Him, H-MO - 219706

N-ROO, CONTROL SHAFT-TO^XJVW
OUH-THO - 74033W
712O16

Throttle linkagegovernor linkageexploded vieur.

J-NUT, SLTD-225869
K-KXT, DLD-f/C-N - 7346697
t-WAWNG. Mil. ROD END, RH-THD - 712015

If-PIR COTTER-121223

-KEf, WOODRUFF - 103905

D~BAfilNG, SAIL-700063
I-MACKET, SUPPORT, CONTROL SHAFT -7414428
P-SHAFT, CONTROL, GOVERNOR - CO-326025

A-IEVER, CONTROL SHAFT-TO-CROSS SHAFT AM)

GOVERNOR - 7376046
-RNG, SNAP-583037
C-WNG, SNAP- 583015

(2)

(3)

(4)

(5)

nut (S), and plain washer (R), and withdrawing drilledfor-cottcr pin bolt (K). Disansemble the rod assembly by
removing the right- and left-hand thread rod-end ball bear
ings (L and Q) and right- and left-hand thread hex jam
nuts (M and P) from the right- and left-hand thread control
shaft-to-governor rod (N).
Remove the control shaft-to-cross shaft link assembly ((X),
fig. 69) from the control shaft-to-cross shaft and governor
lever (A) by removing cotter pin ((R), fig. 69), slotted nut
((U), rig. 69), and plain washers ((P), fig. 69), and with
drawing drilled-hex-head bolt ((W), fig. 69). Press ball
bearings ((Y), fig. 69) from the link.
Remove the control shaft-to-cross shaft and governor levers
(A) from the governor control shaft (F) by removing the
cotter pin (H), slotted nuts (J), and drilled-for-cotter-pin
bolts (T). Use a soft hammer, if necessary, to tap the levers
from the shaft. Remove Woodruff keys (G) from the control
shaft.
Remove external snap rings (B) from the governor control
shaft (F). Remove the control shaft from the governor
control shaft support bracket (E) by tapping the end of
the shaft with a soft hammer.
Remove internal snap rings (C) and ball bearings (D) from
the control shaft support bracket.

80. Cleaning, Inspection, and Repair of Throttle Linkage

a. Cleaning.
(1) Using a cloth dampened with dry-cleaning solvent or vola
tile mineral spirits, wipe dirt and foreign matter from the
external surface of all sealed bearings.
Note. Never put a sealed bearing in cleaning solvent, as the cleaning
solvent may penetrate the seal and destroy thf lubricating material
within the bearing.

(2) Clean all remaining parts in dry-cleaning solvent or volatile

mineral spirits.
&. Inspection and Repair.
( 1) Magnaflux all steel parts if this method is available. If not,
examine with a strong light for cracks and deep abrasions.
Any cracks are cause for rejection of a part.
(2) Hold bearings by center race and spin the outer race to de
tect any undue roughness or sticking or bearings. Rough
ness or sticking of bearings is cause for rejection of the part.
Replace defective bearings.
(3) Use a fine mill file to remove raised metal at dents or
scratches.
241130 O5311

Figure 69.

Throttle linkagecross shaft assemblyej-plodcd rtetr.

w*Wfc

Ui
O

INNER ASSY

Figure 69.

SNUT, SLTD22586S).

HHLEVER, CROSS SHAFT, OUTER.

GSPRING-LEVER73702r>l>.

FK_STUD74030(57.

EESTUD 74030(57.

DDNUT, JAM, HEX. LH-THD776795S.

CCTURNBUCKLE, CROSS-SHAFT-TO-CARBURETOR-CONTROL-RODCO-518936.

AABEARING, BALL ROD-KND, KH-THD712013.

BBNUT, JAM, HEX, RH-THD7767952.

'/,HOLT, DLP-HKX-HD74KMW7.

YBEARING, BALL74103%.

VBRACKET, SUPPORT, CROSS SHAFT7414535.

WBOLT, DLD-HEX-HD74O3164).
XLINK, CONTROL-SHAFT-TO-CROSS-SHAFT. ASSYCO520377.

TLEVER, CROSS SHAFT7376040.

UNUT, SLTD7403213.

Throttle linkagecross shaft assemblyexploded viewContinued.

7414536.
FNUT, JAM107822.
GNUT, PLAIN225853.
HWASHER, PLAIN502245.
JSTOP, LEVER7414517.
KCOVER, CAMSHAFT GEAR HOUSING, LEFT (2-4-6) SIDE,
ASSY7414513.
IxSHAFT, CROSS7414539.
MKEY, \VOODRUPF103905.
NBOLT, DLD-HEX-HD7346697.
PWASHElt, PLAIN -502244.
QBEARING, BALL, ROD-END, LH-THD712014.
HPIN, COTTER121223.

ELEVERVEHICLE-TO-CARBURETOR,

CRING, SNAP583015.
DLEVER, VEHICLE CONTROL, OUTER, ASSY7414537.

BBEARING, BALL700063.

ARING, SNAP583037.

(4) Cheek swivel joints in rod-end ball bearings. They must ro

tate freely. Replace any defective rod-end bearings.
(5) Bent rods and shafts may be straightened. Replace all parts
which can not be reconditioned.
(6) Check all parts to the limits specified in repair and rebuild
standards (par. 155).
81. Assembly of Throttle Linkage
a. Assembly of (1roxs Shaft and Vehicle Control Levers Awembly
(fig. 69).

(1) Install one snap ring (A) on the left end of the cross
shaft (L).
(2) Install ball bearing (B) in the left (24-6) side camshaft
gear housing cover assembly (K). Make certain the outer
race of the bearing does not rotate within the cover. Install
the internal snap rings (C) in the grooves on each side of the
ball bearing.
(3) Install the vehicle control lever stop (J) on the housing
cover and secure with jam nuts (F),plain nuts (G),and plain
washers (H). Install the camshaft gear housing and bear
ing assembly on the cross shaft (L) against the retaining
snap ring. Secure the position of the assembly on the cross
shaft by installing a second retaining snap ring (A) on the
cross shaft on the opposite side of the ball bearing.
(4) Insert Woodruff key (M) in the cross shaft and install
vehicle-to-carburetor inner lever assembly (E) on the shaft.
Secure in position with drilled-hex-head bolt (Z), slotted
nut (S),and cotter pin (R). The lever must be installed with
the larger part of the lever hub facing the left (2-4-6) side
camshaft gear housing cover assembly (K).
(5) Install internal snap ring (C) in vehicle control outer lever
assembly (D). Install ball bearings (B) in each side of the
outer lever assembly making certain the bearings are bottomed
against the internal snap ring (C) in the lever.
(6) Install a third retaining snap ring (A) in the second groove
on the cross shaft.
(7) Install the vehicle control outer lever assembly (B) and
bearing on the cross shaft. Make certain the lever is in
stalled in the correct position to engage the vehicle control
lever stop (J), when actuated by the governor. Secure the
position of the vehicle control outer lever assembly on the
cross shaft by installing the remaining retaining snap ring
(A).
(8) When assembled, the stop of the vehicle control outer lever
assembly (D) should engage the vehicle control lever stop

160

(J) on the left (2-4-6) side camshaft gear housing cover

assembly (K), and the stop of the vehicle-to-carburetor inner
lever assembly (E) should engage the top of the vehicle con
trol outer lever stop.
(9) Install the control lever spring (GG) on the pins of the
vehicle control outer lever assembly (D) and the vehicle-toearburetor inner lever assembly (E).
(10) Install the carburetor control cross shaft lever (T) on the
cross shaft and secure it with Woodruff key (M), drilled-hexhead bolt (Z), slotted nut (S), and cotter pin (R).
(11) Install ball bearing (B) in the cross shaft support bracket
(V) and insert the internal snap rings (C) in the grooves
on each side of the support bracket.
(12) Install the cross shaft support bracket and bearing assem
bly on the cross shaft (L), Install the carburetor control
cross shaft outer lever (HH) using Woodruff key (M),
drilled-hex-head bolt (Z), slotted nut (S), and cotter pin
(R) to secure it to the cross shaft.
(13) Assemble the cross shaft-to-carburetor control turnbuckle
assembly by installing right- and left-hand thread hex jam
nuts (BB) and (DD) on the right- and left-hand thread rodend ball bearings (AA) and (Q) and installing the rodend bearings in the cross shaft-to-carburetor-control-rod
turnbuckle (CC). Install the assembly on the cross shaft
lever (T) and secure with drilled-hex-head bolt (N"), plain
washer (P), slotted nut (U), and cotter pin (R).
>. Assembly of Governor Linkage (fig. 68).
(1) Install ball bearings (D) in the governor control shaft sup
port bracket (E) making certain they are bottomed against
the shoulder. Install snap rings (C) in the bracket to secure
the bearings. Check the bearings to see that they do not
rotate within the bracket.
(2) Insert the governor control shaft (F) in the support bracket
bearings. Make certain the shaft rotates freely before pro
ceeding further.
(3) Install external snap rings (B) on the shaft and insert
Woodruff keys (G) in the shaft.
(4) Install the control shaft-to-cross shaft and governor levers
(A) on the control shaft and secure them with drilled-forcotter-pin bolts (T), slotted nuts (J), and cotter pins (H).
The levers must be installed with the larger part of the lever
hubs facing the control shaft support bracket.
(5) Assemble the control shaft-to-governor rod assembly by
installing right- and left-hand thread hex jam nuts (M) and
(P) and right- and left-hand thread rod-end ball bearings
161

(L) and (Q) on the right- and left-hand thread control

shaft-to-governor rod (N). Install tKe assembly on the
control shaft-to-cross shaft and governor lever (A), and
secure with drilled-for-cotter-pin bolt (K), plain washer (R),
slotted nut (S), and cotter pin (H).

(6) Install ball bearings ((Y), h'g. 69) in the control shaft-tocross shaft link assembly ( (X), tt#. (it)). Install the link as
sembly on the control shaft-to-cross shaft and governor lever
(A) and secure with drilled-hex-head bolt ((W), tig. (>!>),
plain washers ( ( P), Hg. 05)), slotted nut ( (U), fig. 69), and
cotter pin ((R), Hg. (SO).

Section XIII. REBUILD OF MISCELLANEOUS PARTS

82. Oil Pressure Control Valve
70)

a.

(1) Remove locking wire from the valve cap. Unscrew the cap
from. the valve housing. Care should be exercised to prevent
the valve spring from jx>pping the cap out as threads are
disengaged. Discard the gasket. Pull the valve spring and
its spring seat from the housing.
(2) Unscrew the valve seat from the opposite end of the housing
and remove the control valve.
b. Cleaning. Clean all parts in dry-cleaning solvent or volatile
mineral spirits. Probe oil passages.
c. Inspection. Inspect the components for thread damage, flaws,
and abrasions. Check to the limits specified in repair and rebuild
standards (par. 15(5). Make certain that the spring seat operates
freely in the valve housing and that all oil passages in the housing
are free of dirt and sludge. Compress the spring and note any
weakness.
d. Repair. This valve is serviced as a complete unit and any de
fective part will necessitate replacement of the entire unit.
(1) Insert the control valve in the valve housing and install the
valve seat. Tighten securely by holding the housing in a
vise fitted with soft jaws.
(2) Place the spring seat in large end of the housing, insert the
valve spring, and install the valve cap and a new gasket.
Press the cap into place until the threads start to engage.
Secure the cap to the housing with locking wire. Adjust
ment of this valve usually is made at engine test by adding
plain washers in the housing cap over the valve spring. It
is set for 70-80 psi using engine oil SAE 50 at 180 F. If
162

SCAT, SPRING7403231
SPRING, VAlVf
7521773

Figure 70. Oil pressure control valveexploded view.

HOUSING, VALVE7403228

the desired pressure range cannot be reached, it is probably

because the spring is defective. However, loose main bear
ings or connecting rod hearings may be the cause of oil low
pressure. If so, they should be replaced. If there is a
question as to the reliability of the oil gage, install a master
gage in the line and check new readings.
83. Oil Filter By-Pass Valve

(% 71)

a. DiNOMxembly. Remove locking wire and unscrew the valve cap

from the valve housing. Discard the gasket. Compress the by-pass
valve on the valve spring1 until the snap ring is exposed on the valve
stem. Remove snap ring, valve housing;, by-pass valve, and valve
spring.
b. Cleaning. Clean all parts in dry-cleaning solvent or volatile
mineral spirits.
c. Inspection. Inspect the components for thread damage, flaws,
and abrasions. Check to the limits specified in repair and rebuild
standards (par. 157). Make certain that the valve stem is free in the
valve housing and that the valve spring is not weak.
d. Repair. This valve is serviced as a complete unit and any defec
tive part will necessitate replacement of the entire unit.
e. Assembly. Place the valve spring on the valve housing. Insert
the by-pass valve and compress valve and spring. Install the snap
ring on the valve stem at the valve cap end. Install the cap and a
new cap gasket. Secure the cap to the housing with locking wire.
The oil filter by-pass valve requires no adjustment.
84. Oil Cooler Pressure By-Pass Valve
(fig. 72)

a. Disassembly. Remove locking wire and unscrew the valve cap

from the valve housing. Discard the cap gasket. Compress the by
pass valve on the valve spring until the end of the valve stem is ex
posed and the snap ring can be removed. Remove snap ring, valve
housing, spring, and by-pass valve.
b. Clea/ning. Clean all parts in dry-cleaning solvent or volatile
mineral spirits.
c. Inspection. Inspect the components for thread damage, flaws,
and abrasions. Check to the limits specified in repair and rebuild
standards (par. 158). Make certain that the valve stem is free in
the valve housing and that the valve spring is not weak.
d. Repair. This valve is serviced as a complete unit and any de
fective part will necessitate replacement of the entire unit.
e. Assembly. Clamp the valve housing in a vise fitted with soft
164

VAtVI, SY-PASS -

Figure 11.

Oil filter by-pass valveexploded view.

SPRING, VAtVE
7539161

HOUSING, VAiYf7403226

RING, SNAP7410159

It

GASKET,
ANNULAR

JtA PO 155948

jaws. Place the valve spring on the valve housing. Insert the by
pass valve in the housing and compress valve and spring. Install the
snap ring on the end of the valve stem at the valve cap. Install the
valve cap and a new cap gasket. Secure the cap to housing with
locking wire. The oil cooler pressure by-pass valve requires no
adjustment.
85. Oil Cooler By-Pass Valve (Thermostatic)
(fig. 79)
This valve is factory adjusted to control oil flow at 185 F. It opens
to by-pass oil at a differential of UO psi. The valve cannot l>e disassem
bled and cleaned in the field. If there is doubt as to the reliability of
the unit, install a master temperature indicating unit in the oil
line and check the unit. It is also possible to check the valve opera
tion by putting the unit in a hot water bath and slowly bringing the
water temperature up to the desiral point. The valve must not be
placed in contact with the container. Raise it up on a brick or wire
form. If there is no valve travel, the unit is defective and must be
replaced.

86. Crankcase Oil Pan and Accessory Case Oil Sump

(fig. 78)

a. Disassembly. Remove the locking wire from the oil pan baffle
studs. Remove slotted nuts (E) and lift out the oil pan baffles (D).
Discard the baffle-to-oil pan gasket (C). The oil pan drain plug (J)
and the sump magnetic drain plug (R) for the accessory case sump
were removed at engine disassembly.
b. Cleaning. Wash the sump, oil pan, and baffle thoroughly with
dry-cleaning solvent or volatile mineral spirits,
c. Inspection.
(1) Examine the oil pan and sump for cracks with the aid of
a strong light or other available method. Any cracks are
cause for rejection. Small cracks will probably le; -f1 to larger
ones during subsequent operation of the engine.
(2) Examine the flange surfaces for any damage caused by care
less handling. Look for discoloration of the finished sur
faces as evidence of oil leakage.
(3) Inspect the threads of the drain plugs and drain plug open
ings for torn or damaged threads which may allow oil leakage.
(4) Inspect the baffles for warpage and cracks. Replace defective
baffles.

(5) Inspect all studs. Mark for replacement, all loose or bent
studs, or studs with damaged threads.
(6) Inspect Rosan inserts. Look for pulled inserts and damaged
threads.

166

'X

'8o
a
o

8-

**

5s

I
k

f*A

167

d. Repair.
(1) Replace loose or defective studs (par. 57).
(2) Use a fine mill file or an oil stone to remove any raised metal
at dents or scratches.
(i) Replace defective Rosn inserts (par. 57).
f. Assembly. Install oil pun baffle (D) on the oil pan, using a new
baffle-to-oil pun gasket (C). Secure with slotted nuts (E) and lock
ing wire. Install the oil pan uud the accessory case oil sump magnetic
drain plugs (.1) and (R), using new pan drain plug annular gasket
(H) and new sump drain plug annular gasket (Q). Install acces
sory case oil sump assembly (P) (pur. 115).
87. Flywheel Group
(fig- 24)

a. Removal. Refer to paragraph 53 for removal and disassembly

of the flywheel.
b. Cleaning. Clean all parts with dry-cleaning solvent or volatile
mineral spirits.
c. Inspection.
( 1) Inspect the torsion dumper friction disks (F), damper pres
sure plate (E), and damper spacer plate (J) for imperfec
tions or signs of failure. There are no definite limits estab
lished for these parts and good judgment must decide if parts
are to he replaced. Examine the torsion damper ring (D).
Replace the ring if cracks are evident or if a permanent set
or distortion is noticed. Examine the damper hub (B) for
worn or damaged splines. Replace the hub if such defects
are noted. Examine the flywheel cover plate (C), damper
spring driven plate (G), and damper hub plate (H) for wear
or damage which may lead to-a future failure.
(2) Inspect drive springs (M) for cracks and breaks. When
these springs are assembled with their seats, they should fit
snugly in the flywheel recesses. Any looseness is an indica
tion of a defective spring. Replace loose springs and test
other springs to the limits specified in repair and rebuild
standards (par. 159).
(3) Check the fit of the crankshaft-to-flywheel dowel pins in the
holes of the flywheel hub to the limits specified in repair and
rebuild standards (par. 159). Replace them if any looseness
is evident or if the inspection of the crackshaft indicates the
need for oversize dowel pins. Examine the flywheel for any
wear or damage which might lead to a failure.

168

A,GASKET, SUMP-TO-ACCESSORY-CASE7346528
GASKET, OIL-PAN-TO-CRANKCASE7346525
C-^GASKET, BAFFLE-TO-OIL-PAN7346536
^-AFFLE, OIL PAN 73466 U
NUT, SLTD225838
f-|AN, OJt, W/STUDS, ASSY7375417
-PLUG, PJPE7338672
li-GASKET, ANNULAR, PAN DRAIN PLUG 142756
*~PLUG, DRAIN. PAN7375428
PLAIN225854
MWASHER, P1AIN502204
HGASKfT, SUMP-TO-PAN7346557
fr-IUMP, OIL, ACCESSORY CASE, ASSY7375875
^GASKET, ANNULAR, SUMP DRAIN PLUG 105456
fc-i-PLUG, QftlUH MAGNETIC, SUMP-7375426
*-*NUT, JAM107822

Figure 73.

Oil pan and sumpexploded view.

169

88. Flywheel Repair

a. Over-size Dowel Pins.
(1) Dowel pins are secured in the crankshaft flange by .small
hex-socket set screws (fig. 59) in the outer surface of crank
shaft flange. Loosen these set screws and extract the dowel
pins.
(2) Three sizes of dowel pins (0.005, 0.010, and 0.015 in) an>
stocked for replacement. Fixture set 41-F-2SK)7-18f> (fig. 7)
is provided for dowel pin replacement.
b. Doirel Pin Replacement.
(1) Pilot the reaming fixture in the flywheel and bolt it in place,
With the special double-end reamer, ream the flywheel hoh>>
for the dowel pin selected.
(2) With same fixture and reamer, repeat the reaming operation
on the crankshaft flange.
(3) Drive new dowel pins in the crankshaft flange until the
grooves in the pins line up exactly with the set screw holes.
Tighten the set screws.

89. Valve Rockers

(fig. 74)
a. Cleaning. Clean assembled parts by washing in dry-cleaning
solvent or volatile mineral spirits.
b. Inspection.
(1) See that the adjusting screws turn freely. Inspect the as
sembly for cracks. Inspect the valve rocker bearings. If
they are loose or damaged, replace the entire valve rocker
assembly. See thai: the valve rocker roller turns freely
and is free of scuff or score marks. Replace the assembly
for any of these reasons. See that the oil tube passage is
clear in each valve rocker.
(2) Check assemblies to limits specified in repair and rebuild
standards (par. 1(50). Only clearance dimensions can be
checked. The valve rocker roller and roller hub clearance
can be checked by mounting u dial indicator against the
roller with the entire assembly positioned securely. Move
the roller to the extremes of its travel. Total indicator read
ing is the clearance.
c. Repair.
(1) Polish minor scratches and scores from the valve rocker
shafts ((S), fig. 52) with crocus cloth. Replace shafts with
loose oil tubes or heavy scoring.
(2) If the adjusting screw assembly (fig. 74) does not turn
freely, clean up any damaged threads. Replace the screw
170

NUT, ADJUSTING
SCRfW

ROCKER,
VALVE ~
7410259

SCREW, ADJUSTING, ASSY7767321

BEARING, VALVE
ROCKER - 7767323

BEARING, VALVE
ROCKER - 7767323

HUB,
ROLLER 7403181

INCHES

21

PIN, AXLE,
VALVE ROCKER
7403184

ROLLER, VALVE
ROCKER-7403183

PIN, LOCKING
7338673
RA PO 155951

Figure 7Jf Vah'c rocker exploded vicic.

if threads cannot be cleaned up. Defects in the valve rocker

assembly are not repairable. Replace any defective
assemblies.
90. Ignition Harness
a. Clean the ignition harness with a cloth dampened with a mild
soap and water. Pay particular attention to the spark cable insula
tors and contacts.
Caution: Never use solvent on electrical parts, as it decomposes
rubber.
b. Inspect all harness cables and connections for looseness, burned
or damaged condition, and frayed insulation or shielding. Repair
any defects or replace the defective part.
c. Check all cables for electri'cal continuity. With a high tension
ignition tester, test leads for electrical leakage. Replace any defec
tive detachable leads.
91. Intake Manifold
(% 97)
a. Disassembly. Eai^ manifold consists of three sections which
are attached to the cylinders, a connector which is attached to the
171

hotspot intake manifold housing:, and manifold balance tube fittings

which are connected by the balance tube extending through the
crankcase. All manifold sections are joined together with short hose
connections and secured with clamps. Loosen the hose clamps and
separate the sections. Remove pipe plug;s, elbow, and tee only if
necessary. These parts need not be removed for cleaning purposes.
b. Cleaning. Wash metal parts with dry-cleaning solvent or vola
tile mineral spirits. See that carbon deposits are removed from inner
surfaces. Clean hose connections with water. Discard hard or un
serviceable hoses.
c. Inspection.
(1) Inspect the intake manifold sections for cracks and flaws.
Keplace unserviceable parts. Check for nicks and burns on
the machined surface which mates with cylinder mounting
pad. Check to see if faces are flat, not warped, and that there
are no signs of leakage at the gaskets. Examine the intake
manifold balance tube flanges (K) for cracks and defects.
(2) Inspect Rosan inserts in castings and replace any which
are defective (par, 57).
(3) Hose clamps should be examined and damaged clamps re
placed.
(-t) Inspect pipe plugs, flared tube elbow, tee, and threaded open
ings for damage or any signs of leakage.
d. Assembly.
(1) Install pipe plugs in manifold sections for No. 1 and 2
cylinders. Install flared tube tee (Q) in manifold section
for No. 5 cylinder and 90-degree tube elbow (G) in manifold
section for No. 6 cylinder.
(2) Assemble cylinder No. 1 manifold section assembly (W),
cylinder No. 3 and 4 manifold sections (E), cylinder No. 5
manifold section assembly (U), cylinder No. 2 manifold
section (D), and cylinder No. 6 manifold section (F). Use
new manifold section hose (C) and new or serviceable hose
clamps. Tighten clamp only enough to keep sections from
turning in hoses.
92. Cylinder Head Oil Drain Manifold
(fig. 08)

a. Disassembly. Each cylinder head oil drain manifold consists of

three sections and two oil drain line assemblies. All manifold sec
tions except the end ones at No. 5 and No. 6 cylinders are identical
and are interchangeable on the engine. Each oil drain line assembly
is different and must be returned to its original position. All oil
drain manifold section bolts (Q) which h'old the sections to the
cylinder heads are alike. All oil drain manifold section hoses (A) and
172

hose clamps (N) are alike. Loosen the hose clamps and separate
sections.
b. Cleaniny. Wash all metal parts with dry-cleaning solvent or
volatile mineral spirits. See that all carbon, sludge, and foreign
material is removed from inner surfaces. The hollow bolts contain
drain holes which must be thoroughly cleaned. Use probes, if neces
sary, to remove dirt from bolt holey. Clean hoses with water. Keplaee hard or unserviceable hoses.
c. Inspection. Inspect lines and sections for cracks and flaws.
Replace unserviceable parts. Inspect the machined surfaces for nicks
;iiul burs. Look for signs of leakage at the gaskets. Remove minor
nicks and burs with an oil stone. Dress nicked or warped surfaces
on a surface plate or replace the manifold section. Examine hose
clamps and replace damaged or unserviceable clamps.
93. Exhaust Manifold Assemblies, Hotspot Intake Manifold
Housing, and Hotspot Tubes
(fig. 104)

a. General. The exhaust manifolds are supplied as a unit for each

side or bank of cylinders. A welded bellows between the section allows
for thermal expansion and movement of individual cylinders.
b. Cleaning. Wash parts in dry-cleaning solvent or volatile min
eral spirits.
c. Inspection and Repair. Inspect the mating flanges for flaws,
nicks, and burs. Look for signs of warpage and leakage at the flanges.
Inspect for cracks at flanges, bellows, and at areas around welded
joints. Weld minor cracks. Remove minor nicks and burs. Replace
manifolds which cannot be repaired.
94. Engine Shroud, Fan Rotor Housing, and Cooling Fan
Outlet Vane Housing

(fig. 17)

a. General. The shroud is fabricated as a unit except for small

fit-in pieces. The fan rotor housing is fastened to the shroud and
need not be disassembled unless defective parts are found.
b. Cleaning. Clean all parts with dry-cleaning solvent or volatile
mineral spirits.
c. Inspection and Repair.
(1) Inspect the shroud, fan rotor housing, and cooling fan out
let vane housing for cracks, warped or bent pieces, and for
damaged or improperly fitting pieces. Straighten, repair,
or replace any warped or damaged pieces. The rubber seal
of the shroud is important for proper engine cooling and
must be in good condition.
241130 O5312

173

Check all housing studs and replace any that are missing or
damaged. Inspect the speed grip retaining nuts which are
used for securing the covers at the flywheel and accessory
ends of the shroiul. To remove the nuts, compress the spring
clip and push the nuts from the shroud holes. Install the
nuts in the same manner.
(3) Check the separators of the cooling fan outlet vane housing
to be sure air How is not restricted.

95. Cooling Fan Drive

(fig. 75)
a.

(1) The fan drive vertical shaft hearing housing, oil seal hous
ing, and fan drive vertical shaft were removed during dis
assembly of the engine into su I assemblies (par. 54).
(2) The f>ermanent!y inclosed fan drive vertical shaft oil seal has
a tight press fit in its housing. Removal from the housing
will ruin the seal. If there is any evidence of leakage, re
place the seal.
('5) Remove the fan drive vertical shaft and its ball bearing
from the fan drive vertical shaft bearing housing. Press
the bearing from the shaft and remove the oil slinger.
A. Cleaning. ("lean all parts in dry-cleaning solvent or volatile
mineral spirits, ("se probes, if necessary, to clean out holes in tinbearing housing.
r. Inspection and Repair.
(1) Inspect the drive shafts by magnaflux or any other suitable
method. Any cracks are cause for rejection of a part. Minor
scratches or burs can l>e removed with an oil stone.
(2) Carefully check the condition of the ball bearing. Spin
the bearing outer race to detect any undue roughness or stick
ing. Roughness or sticking is cause for replacement.
(3) Examine the vertical shaft and fan drive horizontal shaft
bevel gear bearings. Note condition of thrust faces at con
tact surface with the bevel gears. Discolored surfaces are
an indication of insufficient lubrication. Examine passages
in the crankcase flange.
(4) The brass housings should lie checked for warpage and dis
tortion. Tlie mating faces must be free of nicks and burs.
Minor defects can be removed with a fine mill file.
(5) Check all parts to the limits specified in repair and rebuild
standards (par. 161).
d. Assembly.
(I) Install a new or serviceable fan drive vertical shaft ball bear
ing in vertical shaft bearing housing. Insert the fan drive
174

en

NUT, SITD225J69

GEAR, BEVEL, FAN

DRIVE HORIZONTAL
SHAFT-7414518

Coolintj fan drivec.rplodcd view.

HOSE-

M &

SHAFT, FAN DWVE

GASKfT, ANNUU*734*727

HOSE, HORIZONTAL
SHAFT-7403383
NIPPIE, HOSE7346497

GASKET, ANNULAR7346727

BEARING? VERTICAL
SHAFT-7351157

Figure 15.

GEAR, BEVIT, FAN DRIVE

VERTICAL SHAFT7414519

SLINGER, OIL7346506

RING, SNAP7414963

SHAFT, FAN DRIVE,

VERTICALi99

RING - 546884

GASKET, "O"

BEARING, FAN DRIVE

HORIZONTAL SHAFT
BEVEL GEAR 7351189

HOUSING, VERTICAL
SHAFT BEARING-

SEAL, Oil,
VERTICAL SHAFT7376044

6EARING, BAlt,
VERTICAL SHAFT
7539700

HOUSING, SEAL737

PIN, COTTER -

vertical shaft with the oil slinger in the bearing and check
the freedom of rotation.

(-2) If the fan drive vertical shaft oil seal shows evidence of leak
ge, press a new oil seal in the seal housing with the inner
spring loaded retainer to the erankcase gitle of the housing.
Make sure the outer case is* seated properly in the recess pro
vided in the top of the housing.
96. Vent and Fu*l Lints
(%s. 101 Mild 1W>)

lns|>ect all lines for leaks, cracks, and general deterioration. Look
for fraved spots or ureas which have been damaged by being in con
tact with other parts. Examine all line connectors and fittings for
damaged threads. Defective or damaged lines must be replaced to
eliminate any possibility of leakage. Line connectors and fittings
which are damaged should also be replaced.
97. Vacuum Heat Control Valve Assembly
(fig. 7)
//. Dixaxxeutbit/.

(1) Remove safety wire and eijjht drillecl-fillister-head screws

(BB) and plain washers ((.'(') holding the heat control unit
housing assembly (R) to the housing cover. Vacuum heat
control spring (P) will come out as the control unit hous
ing is removed.
(2) Remove iXMegree flared tube elbow (S), heat control ther
mostat nut (U), and plain check nut (T) from the heat con
trol thermostat assembly (Q).
(*l) Bend up the tabs on tab washer (DD) and remove the re
maining plain check nut (T) from the heat control valve
.shaft rod assembly (FF). Remove the heat control spring
upper and lower seats (X) and the heat control diaphragm
(EE).
(4) Remove three self-locking nuts (A) holding rod housing
cover (B) to the heat control rod housing (D). Remove
the cover and discard rod housing cover gasket (C).
0>) Remove cotter pin (G) and drilled-flat-head pin (F) hold
ing heat control valve shaft rod assembly (FF) to the heat
control valve assembly (J). Remove the rod from the
heat control rod housing (D). Separate the heat control
valve assembly (J) from the rod housing. Discard rod
housing-to-valve gasket (E).

(6) Remove the self-locking nuts (A) and plain washers (KK)
holding the heat control rod housing (D) to heat control unit
176

housing cover assembly (HH), Separate control rod hous

ing, rod housing inmilator (JJ), and the control unit housing
cover.
(7) Remove eight tap lock inserts (GO) only if defective and
replacement in indicated.
b. Cleaning.
(1) Clean all parts in dry-cleaning solvent or volatile mineral
spirits.
(2) Remove carbon deposits from the heat control valve assembly
with wire brush and scraper.
c. /ruipectian and Repair.
(1) Inspect components for damaged threads, flaws, and
abrasions.
(2) Use a fine mill file to remove any raised metal on contact
surfaces.
(3) Inspect the condition of the heat control lever shaft and
bearings in the heat control valve assembly for wear. Ex
cessive wear of these parts will necessitate replacement of
the heat control valve assembly.
(4) Check the vacuum heat control spring and the heat control
thermostat assembly to the limits specified below:
Approximate frw length of spring.-____________ 4. 38 in.
Maximum solid height of spring-_______________ 1.26 in.
Length under 22-25 pounds load__-_____________ 2. O6 in.
Dwitred rate__________.____.__________ 10.15 Ib-in.
Minimum piston travel (thermostat) between 28 ami 147 F_ 0.140 in.

d. Assembly.
(1) Make certain there is full travel and free movement of the
butterfly valve in the heat control valve assembly (J).
(2) Install rod housing-to-valve gasket (E) and heat control rod
housing (D) on the heat control valve assembly studs.
(3) Install rod housing insulator (JJ) on the studs of the heat
control unit housing cover assembly (HH) and install the
cover on the bottom flange of heat control rod housing (D).
Secure with plain washers (KK) and self-locking nuts (A).
(4) Install heat control valve shaft rod assembly (FF) so that
it engages the lever in the heat control valve assembly (J).
Secure with drilled-flat-head pin (F) and cotter pin (G).
(5) Install rod housing cover gasket (C) and rod housing cover
(B) and secure with self-locking nuts (A).
(6) Install heat control diaphragm (EE), with heat control
spring upper and lower seats (N) on each side of the dia
phragm, over the heat control valve shaft rod assembly (FF).
Secure with tab washer (DD) and plain check nut (T).
177

Ft-

II

U
RA PD 188848

Flaiirc 76.

178

Vacuum- heat control assemblyexploded rieir.

ANUT. SELF-LOCKING7039110.
HfOVER, HOD Hi (USING7414550.
CQASKET. HOD HOUSING COVER7414551.
l>HOUSING, HKAT CONTROL HOD7414335.
EGASKET, HOD HOUSiNO-TO-VALVE7414553.
FPIN, DLD-FL-HD--7414563.
GPIN, COTTERAIR-AN-381-3-12.
HBOLT, ULD-HDAIH-AN4K3H-7A.
JVALVE, HEAT CONTHOL, ASSY7416629.
KGASKET. HKAT CONTROL VALVE 741453:*.
LSTU DC( M01959.
AlSTUD7403501.
NSEAT, SFR1NCJ, UPPER AND LOWER737584<>.
I'SPRING, VACUUM HEAT CONTR(>L7375850.
t^-THERM( STAT, HEAT CONTROL, ASSY-7414547.
R-HOUSING, HEAT CONTROL UNIT, ASSY7414549.
SELBOW, FLARED TUBE, 90-DEG7767517.
TNUT, PLAIN, CHECK7414571.
UNUT, THERMOSTAT7414545.
VSTUD7403512.
\VLINE, FLEXIBLE, HEAT-COXTROL-TO-INTAKE-MAXIFOLD7744710.
XPIN, COTTEK121223.
YNOT, SLTD122942.
XWASHER, PLAIN502245.
AABRACKET, SUPPORT. HEAT CONTROL8329025.
MBSCREW, DLD-FIL-HD544396

ccWASHIER, PLAIN192588.

1)DWASHER. TAB7410167.
KBDIAPHRAGM, HEAT CONTROL7376254.
FFROD, HEAT CONTROL VALVE SHAFT, ASSY741454(5.
CGINSERT, TAP LOCK7414566.
HHCOVER, HEAT CONTROL UNIT HOUSING, ASSY7414548.
JJINSULATOR, HOD HOUSING7414544.
KKWASHER, PLAIN502245.
Figure 76. Vacuum heat control assemblyexploded viewContinued.

179

(7) Install 90-degree flared tube elbow (S) and heat control
thermostat assembly (Q) in heat control unit housing as
sembly (B).
(8) Install vacuum heat control spring (P) in heat control unit
housing. Install vacuum heat control unit housing to the
heat control unit housing cover assembly (HH), securing
with eight drilled-fillister-head screws (BB) and plain wash
ers (CC). Make certain that the pin on top of the ther
mostat properly engages the heat control valve shaft rod
assembly <FF).
(9) Adjust the thermostat assembly so that the butterfly valve in
the heat control valve assembly is within one-quarter of an
inch of the wall at 65 to 75 F.
(10) Install plain check nut (T) and thermostat nut (U) on the
threaded end of the thermostat. Secure thermostat nut with
safety wire.
98. Oil, Fuel, and Primer Filters
a. Oil Filter (fig. 77).
(1) Disassembly. Remove the oil filter head (E) from the filterelement center tube (A). Remove the drilled-hex-head bolt
(J) and its gasket. Discard the gasket. Remove element
nut (C). Remove the filter element tube disks (B) and disk
spacers (N).
(2) Cleaning. Clean the disks in dry-cleaning solvent or volatile
mineral spirits. Use compressed air to assist in cleaning de
posits from disks. New disks are furnished to replace any
disks which are defective.
(3) Assembly. Assemble the disks and spacers in order on the
tube, secure with element nut (C) and install the filter head
and gasket. Secure with annular gasket (H), drilled-hexhead bolt (J), and safety wire.
b. Fuel Filter (fig. 106).
(1) Disassembly. Drain the filter body by opening the drain
cock in the bottom of the housing. Separate the upper and
lower halves of housing by loosening the %-inch nut on the
top of the housing.
(2) Cleaning. Clean all parts in dry-cleaning solvent or vola
tile mineral spirits.
(3) Assembly. Install the filter core in the lower half of the
housing. Install these components to the upper half of the
housing, using new gaskets.

180

HGASKET, ANNULARJ 05451

'/BOLT, DLD-HEX-HD7744603
KNUT, JAM107822
LNUT, PLAIN225853
MWASHER, PLAIN502245
NSPACER, DISK7374145

Figure 77. Oil filterexploded view.

ELEMCNT, CgNTERAM-B 15209

,.
TUiE.7348755
ELEMENTAM-O3S214.164
t1,' FILTER HEAD7744815
Ott FILTERAM-03S573->40
, TORSfCWs), HANDLg~AAA-03S575-79
%HANDLE, HEADAM-AN15052-107

%''.. -'-,.- --it';.:" 'vJ,S/f- - v^-'jS'HJBlllSiJIHsiMPIPW

RAPD 155954

c. Priutw Filter (fig. 99).

(1) /*ixa*#mb1y. Disassemble the primer filter assembly by
loosening the nut of the filter bail assembly ((R) (ft) ) and
separating the filter head ((R) (1)) and the filter bowl ((R)
(4)). Remove gasket element and bowl.
(*2) Cleaning. Clean all parts in dry-cleaning solvent or vola
tile mineral spirits.
(3) Assembly. Install filter element ( (R) (3)) in the filter head.
Install the filter bowl and bail to the head, using a new
gasket.
99. Hotspot Intake Manifold Housing Assembly
(fig. 78)
a.

(1) Remove the 90-degree flared tube elbow (Q), air-metering

valve assembly (P), and 90-degree pipe elbow (N) from the
hotspot intake manifold housing.
(2) Leave all inspection plugs and pipe plugs installed in the
hotspot intake manifold housing unless there is an indica
tion they should be removed for additional inspection and
cleaning. "
b. Cleaning.
(1) Clean all external and internal surfaces of all parts with
dry-cleaning solvent or volatile mineral spirits.
(2) I Tse air pressure to remove loose carbon deposits from in
ternal surfaces of hotspot intake manifold housing.
c. Inspection and Repair.
(1) Inspect the components for thread damage, flaws, and abra
sions. Check studs for damaged threads or looseness.
Look for casting def ects< Flange faces must be free of nicks
and burs. Inspect air-metering valve for signs of sticking
or damaged plunger.
(2) Use a fine mill /lie to remove any raised metal at dents or
scratches on contact surfaces.
d. Axxembly. Install air-metering valve assembly (P), 90-degree
flared tube elbow (Q), and 90-degree pipe elbow (N).
100. Oil Coolers and Lines
(fig. 79)

a. Disassembly.
(1) Remove transmission cooler inlet and outlet line assemblies
(N) and (P). Remove engine oil cooler inlet and outlet
line assemblies (W) and (U) and their connectors. Remove
transmission elbow (Q). Discard gaskets.
182

(2) Remove oil cooler titennostatic by-puss valve assembly (A)

from the by-pass valve housing (C). Remove the housing
from the oil cooler by removing safety wire and drilled-hexhead bolts (E) and (F).
(3) If the coolers were not removed at engine disassembly, re
move them from the engine shroud by removing drilled-hexheud bolt (L), plain washer (K), and jam nuts, plain nuts,
and washers securing the cooler studs to the shroud.
(4) Discard all gaskets.
6. Cleaning.
(I) Clean all parts in dry-cleaning solvent or volatile mineral
spirits.
("2 ) Clean the lines, elbows, and coolers internally by flushing with
dry-cleaning solvent or volatile mineral spirift.
(3) Use stiff brush (bristle) and pressure air hose to remove dirt
and foreign matter from external surfaces of oil cooler
radiators.
(4) Refer to paragraph 85 for checking and testing oil cooler
by-pass valve (thermostatic).
c. Inspection and Repair.
(1) Use a fine mill file to remove any raised metal at dents or
scratches on gasket contact surfaces.
(2) Inspect woven shielding of oil lines and discard if there is
any evidence of breaks or abrasions.
(3) With the aid of a strong light, or better method, if available,
check for cracks in the oil cooler by-pass valve, valve housing,
and all connectors. Any cracks are cause for rejection.
.(4) Seal openings of oil coolers and apply internal air pressure
(not to exceed 60 psi). Put in clear water and examine for
leaks. Replace leaky coolers.
JTofe. Leaky oil coolers cannot be soldered as hot oil under pres
sure will dissolve solder and force it out,

(5) Refer to paragraph 57 for replacement of studs and Rosan

inserts.
d. Assembly.
(1) Assemble oil cooler by-pass valve housing (C) to oil cooler.
Use new housing gasket. Use plain washers (D) and drilledhex-head bolts (E) and (F). Secure with safety wire,
(2) Assemble all connectors to the transmission oil cooler assem
bly (J). Use new connector gaskets (EE). Use plain
washers and drilled-hex-head bolts and secure with safety
wire. Assemble transmission elbow (Q) to transmission.
(3) Assemble all connectors to the engine oil cooler. Use a new
connector gasket (EE), plain washers, and drilled-hex-head.
bolts. Secure with safety wire.
183

RA PO 188849

Figure 78.

184

Carburetor, hotspot intake manifold housing, and accessory case

coverexploded view.

ACARBURETOU, ASSY7403299.
BNUT, JAM-107882.
CNUT, PLAIN225854.
DWASHER, PLAIN502204.
E-COVER, ACCESSORY CASE, ASSYCO-525394.
FGASKET, "O" RING7374220.
GSTUD74035O3.
HNUT, JAM107822.
JNUT, PLAIN225853.
KWASHER, PLAIN--502245.
LSTUDCO-52O660.

MPLUG, PIPE7338670.
NELBOW, PIPE, 90-DEGCO-520675.
PVALVE, AIR-METERING, ASSY7767922.
QELBOW, FLARED TUBE, 90-DEG7346726.
RPLUG, PIPE7538990.
SHOUSING, HOTSPOT INTAKE MANIFOLD, ASSY7376925
1PLUG, HEX-HD7414583.
2GASKET, AXXULAR142752.
TGASKET, CARBURETOR-TO-HOUSING7376030.
USPACER, MOUNTING, CARBURETOR7375858.
VNUT, PLAIN BRASSCO-520663.
Figure 78.

Carburetor, hotspot intake manifold housing, and accessory case

coverexploded vieicContinued.

185

A-VALVE, BY-PASS, THERMOSTATIC, ASSY _ 7344573

ft-GASKET, ANNULAR, BY PASS VAIVE - 7403580
C-HOUSING, BY-PASS VAIVE - 7375877
&-WASHER, PLAIN - 5022*5
I-BCM.T, DLD-HEX-HD-7376120
F-BOLT, DLD-HEX-HD - 7346710
0-GASKET, 8Y-PASS VALVE HOUSING - 7375878
H-STUD
J-COOLER, Oil, ASSY ~ 7376040
K-WASHER, PLAIN - 502204
l-BOLT, OtO-HEX-HD - 7410038
M-CONNECTOR, ENGINE AND 'TRANSMISSION COOLER INIET AND OUTLET
AND CONTROL HOUSING INIET AND OUTLET - 7376009
N-UNE, INLET, TRANSMISSION COOLER, ASSY - 7376839
P-LINE, OUTLET, TRANSMISSION COOLER ASSY - 8328916
Q-ELBOW, TRANSMISSION - 74)4559
R-CLIP, TRANSMISSION AND ENGINE OIL COOLER OUTLET LINES - 7376082
5-BOLT, HEX-HO - 7414584
T-STUD
U-LINE, OUTLET,. ENGINE OIL COOLER, ASSY-8328917
V-CONNECTOR, INLET, ENGINE COOLER - 7376013
W-LINE, INLET, ENGINE OIL COOLER, ASSY - 7375861
X-NUT, BALL SLEEVE, COMPRESSION TUBE FITTING - 7372660
Y-SLEEVE, BALL, COMPRESSION TUBE FITTING - 193457
Z-NUT, PLAIN-225854
AA-NUT, JAM-107823
Bft-BOLT, DLD-HEX-MO - 7376759
CC-BOLT, DLD-HEX-HD - CO-520661
DO-CONNECTOR, OUTLET, TRANSMISSION AND ENGINE COOLER - 8328920
It-GASKET, CONNECTOR - 7346579
RA PD 188829

Figure 79.

186

Oil coolers and linesexploded' rieic.

(4) Assemble oil cooler thermostatic by-pass valve assembly (A)

in oil cooler by-pass valve housing (C). Use new by-pass
valve annular gasket (B) and secure with safety wire.
(5) Assemble the oil coolers to the engine shroud assembly, using
plain washers, plain nuts, and jam nuts on the studs securing
the upper and the lower right two corners of the coolers. Use
plain washers and drilled-hex-head bolt (L) and secure with
safety wire at the bottom left corner of each cooler.
(6) Assemble transmission cooler outlet line assembly (P) to
transmission elbow (Q) and secure to shroud assembly with
its clip.
(T) Assemble engrine oil cooler outlet line assembly (U) to its
connector and secure to the shroud assembly with its clip.

RA m 18880$!

Figure 80.

Cwnkcaae studdinffleft (2-4-6) side.

187

RA PD 155960

Figure 81. Crankcase studdingright (1-3-5) side.

188

T8S8JS

Figure 82. Accessory case studdingleft-front vieic.

241130 O5313

189

a
R> PO 18881 A

Figure 83. Accessory case studding left-rear Hew.

190

101. Stud Data

Note that studs are threaded NC (national coarse) on one end and
XF (national fine) on the other. The NC end is threaded into the
casting. Part numbers (table II) for oversize studs have a letter
suffix to indicate the size. Oversize studs are marked on the coarse
thread end as shown in figure H4.

STUD

CT*KinAn
aiANUAito

CO FAIT NO
SUFFIX

NONE

0.003
OVERSIZE

0.007
OVERSIZE

MABK

0.012
OVERSIZE

RA TO 155964

fiffttrr Kj.

(trcmizf tud identification.

Table 11. Stud Identification

Kit) NO

17

17

KEF LTR

LENGTH
iFROM BOSS

!
i
i

TO END
OF STl'I)
(INCH)

0. 44

0. 66

0. 78

37

1. 00

39

0. 97

39

1. 46

NO i:EQI>

MFO NO

CO-401881
CO-401881-H
CO-401881-S
CO-401881-J
12 CO-401885
CO-401885-H
CO-401885-S
CO-401885-J
CO-401836
CO-401836-H
CO-401836-S
CO-401836-J
CO-401861
CO-401861-H
CO-401861-S
CO-401861-J
CO-401861
CO-401861-H
CO-401861-S
CO-401861-J
CO-401931
CO-401931-H
CO-401931-S
CO-401931-J

ORD NO.

7403066
7065766

7065767
7065768
7403067

7767804
7767805
7767920
7403503
7410395
7348596
7348597
7403097
7744572
7744573
7744574

7403097
7744572
7744573
7744574
7403075
7767348
7767361
7767362

191

Table 11. Stud IdentificationContinued

FIQ NO.

40

192

REF LTR

LENGTH
FROM BOSS
NO. REQD
TO END
OF STUD
(INCH)

0.82

40

2.02

40

1. 06

40

0. 88

40

0. 77

40

KK

1. 00

41

1. 30

41

2. 53

41

0. 88

41

3. 09

41

CC

0. 97

42'

0. 97

MFC NO.

CO-401836
CO-40 1836-H
CO-401836-S
CO-401836-J
CO-401883
CO-401883-H
CO-40 1883-S
CO-401883-J
CO-401813
CO-401813-H
CO-401813-S
CO-401.81 3-J
CO-401824
CO-401 824-H
CO-401824-S
CO-401824-J
CO-401823
CO-401823-H
CO-401823-S
CO-401823-J
CO-401813
CO-401813-H
CO-401813-S
CO-401813-J
CO-401822
CO-401822-H
CO-401822-S
CO-401 822- J
CO-401831
CO-401831-H
CO-401831-S
CO-401831-J
CO-401809
CO-401809-H
CO-401809-S
CO-401809-J
CO-401873
CO-401873-H
CO-401873-S
CO-401873-J
CO-401824
CO-401824-H
CO-401824-S
CO-401824-J
CO-401945
CO-401945-H
CO-401945-S
CO-401945-J

ORD N(

7403f

7410;

7348!
7348!
7403C
7744f
7744*
7744(
7403C
7744?
7744J
77445
74035
73486
73486
73486
7403C
77448
77447
77447
7403C
77448
77445
77445
74035
73486
73486
73486
74035
73699
73699
73699
74035
73486
73486
73486
74031
77447
77446
77446
74035
73486
73486
73486
74035
73488
73488
73488

Table II. Stud Identification Continued

FIO NO.

REF LTR

LENGTH
FROM BOSS
NO. REQD
TO END
OF STUD
(INCH)

45

NN

0.88

45

PP

0.81

46

CC

0.75

46

QQ

0.85

46

RR

0.91

52

0.97

18

52

LL

0.71

52

MM

0.94

24

CO
Oo

pp
v>^>

1.34

MFQ NO.

CO-401824
CO-401824-H
CO-401824-S
CO-401 824- J
CO-401824
CO-401824-H
CO-401824-S
CO-4018-24-J
CO-401808
CO-40 1808-H
CO-401808-S
CO-401 808- J
CO-401824
CO-401824-H
CO-401824-S
CO-401 824- J
CO-401824
CO-401824-H
CO-401824-S
CO-401824-J
CO-401813
CO-401813-H
CO-401813-S
CO-401813-J
CO-401867
CO-40 1867-H
CO-40 1867-S
CO-401 867- J
CO-401861
CO-401 86 1-H
CO-401861-S
CO-401 86 1-J
CO-520627
CO-520627-H

ORD NO.

7403501
7348668
7348669
7348670
7403501
7348668
7348669
7348670
7403212
7338646
7348651
7348656
7403501
7348668
7348669
7348670
7403501
7348668
7348669
7348670
7403071
7744803
7744555
7744556
7403515
7348779
7348780
7348781
7403097
7744572
7744573
7744574

S
4 O
PO ^9ftfi97
\^\J~\j&\j\j&
t *)T
^9ftfi97
PO O*UO*
\j\J

58

AD

0.97

65

0.68

65

CC

0.95

CO-401812
CO-401812-H
CO-401 812-S
CO-401812-J
CO-401823
CO-401823-H
CO-40 1823-S
CO-401 823- J
CO-401812
CO-401812-H
CO-401812-S
CO-401812-J

7403070
7744801
7744630
7744629
7403068
7744855
7744732
7744731
7403070
7744801
7744630
7744629

193

Table II. Stud IdentificationContinued

FIO NO.

LENOTH
KKOM BOSS
\O. REQI>
TO END
OK 8TL'I>
(INCH)

65

DD

1. 52

65

FF

0. 44

65

GG

0. 57

66

0. 56

66

0. 82

73

73

7Q
i\)

0. 46

1. 37

32

22

80

T
H
A

0. 62
0. 56
0.84

3
2
2

80

1. 34

80

0. 88

80

0.94

72

TO
* 7

194

KEF LTR

MFQ NO,

OKD NO.

CO-401931
CO-401 93 1-H
CO-401931-S
CO-401 93 1-J
CO-401869
CO-401 869- H
CO-40 1869-S
CO-401 869-J
CO-401882
CO-401 882- H
CO-40 1882-S
CO-40 1882-J
CO-401882
CO-401 882- H
CO-40 1882-S
CO-40 1882-J
CO-401823
CO-40 1823-H
CO-40 1823-S
CO-401 823- J
CO-401869
CO-401 869- H
CO-40 1869-S
CO-40 1 869-J
CO-401871
CO-401871-H
CO-401 87 1-S
CO-40 1871-J

7744662

CO-401937
CO-401 937- H
CO-40 1937-S
CO-401 937- J
CO-401819
CO-40 1819-H
CO-401 8 19-S
CO-401 8 19-J
CO-401811
CO-40 181 1-H
CO-40 181 1-S
CO-40 18 11- J
CO-401879
CO-40 1879-H
CO-40 1879-S
CO-40 1879-J

7403508
7348797
7348798
7348799
7403098
7744813
7744564
7744563
7403069
7767333
7767334
7767335
7403141
7767342
7767343
7767344

7403075
7767348
7767361
7767362
7350204
7348785

734878ti
7348787
7403512
7348782
7348783
7348784
7403512
7348782
7348783
7348784
7403068
774485,5
7744732
7744731
7350204

7348785
7348780
7348787

74030JW
7744661
7744663

Table II. Stud IdentificationContinued

F1CJ SO.

REV LTR

LENGTH
FROM BOSS
NO. REQD
TO END
OF STUD
(INCH)
4

80

5.31

80

1.46

80

1.09

16

81

A
A

1.38

17

81

0.48

81 1

1.00

82

1.06

82

0.97

82

0.97

82

0.70

82

0.84

0.89

82

'

MFG NO.

CO-401942
CO-401942-H
CO-40 1942-S
CO-401 942-J
CO-401889
CO-401889-H
CO-401889-S
CO-401 889-J
CO-401819
CO-401819-H
CO-401 810-S
CO-401819-J
CO-401830
CO-401830-H
CO-401830-S
CO-401 830- J
CO-401882
CO-401 882-H
CO-401 882-S
CO-401 882- J
CO-401941
CO-40194 1-H
CO-401 94 1-S
CO-401941-J
CO-401861
CO-401861-H
CO-401861-S
CO-401861-J
.CO-401861
CO-401861-H
CO-401861-S
CO-401861-J
CO-401861
CO-401861-H
CO-401861-S
CO-401861-J
CO-401823
CO-401823-H
CO-401823-S
CO-401823-J
CO-401867
CO-401867-H
CO-401867-S
CO-401867-J
CO-401811
CO-40181 1-H
CO-40181 1-S
CO-40181 1-J

ORD NO.

7403518
7348806
7348807
7348808
7403509
7348788
7348789
7348790
7403098
7744813
7744564
7744563
7403504
7348671
7348672
7348673
7403512
7348782
7348783
7348784
7403517
7348803
7348804
7348805
7403097
7744572
7744573
7744574
7403097
7744572
7744573
7744574
7403097
7744572
7744573
7744574
7403068
7744855
7744732
7744731
7403515
7348779
7348780
7348781
7403069
7767333
7767334
7767335
195

Table II. Stud IdentificationContinued

FIO NO.

196

REF LTR

LENGTH
FROM BOSS
NO. REQD
TO END
OF STUD
(INCH)

82

0. 88

82

0. 70

82

0. 83

82

1. 28

82

0. 57

82

1. 06

83

1. 95

83

1. 56

83

3. 37

83

0. 88

83

1. 34

83

0. 88

MFO NO.

CO-401824
CO-401824-H
CQ-401824-S
CQ-401824-J
CO-401823
1
CO-401823-H
CO-40 1823-S
CO-401823-J
6 CO-401823
CO-401823-H
CO-401823-S
CO-401823-J
17 CO-401882
CO-401882-H
CO-401882-S
CO-401882-J
2 CO-401822
CO-401822-H
CO-401822-S
CO-401822-J
6 CO-401861
CO-401 86 1-H
CO-401861-S
CO-401861-J
6 CO-401939
CO-401939-H
CO-401939-S
CO-401939-J
6 CO-401889
CO-40 1889-H
CO-401889-S
CO-401889-J
1 CO-401926
CO-401926-H
CO-401926-S
CO-401926-J
3 CO-401824
CO-401824-H
CO-401824-S
CO-401824-J
1 CO-401819
CO-401819-H
CO-401819-S
, CO-401819-J
2 CO-401945
CO-401945-H
CO-401945-S
CO-401945-J
6

ORD NO.

7403501
7348668
7348669
7348670
7403068
7744855
7744732
7744731
7403068
7744855
7744732
7744731
7403512
7348782
7348783
7348784
7403500
7348665
7348666
7348667
7403097
7744572
7744573
7744574
7403516
7348800
7348801
7348802
7403509
7348788
7348789
7348790
7403510
7348791
7348792
7348793
7403501
7348668
7348669
7348670
7403098
7744813
7744564
7744563
7403519
7348812
7348813
7348814

Table II. Stud IdentificationContinued

FIG NO.

REF LTR

LENGTH
FROM BOSS
NO. REQD
TO END
OF STUD
(INCH)

83

2.22

83

1.57

83

1.60

83

0.83

83

0. 88

12

69

EE

0.72

69

FF

0.72

CO-402357
CO-402357-H
CO-402357-S
CO-402357-J
CO-401931
CO-401931-H
CO-401931-S
CO-401931-J
CO-401837
CO-401837-H
CO-401837-S
CO-401837-J
CO-401811
CO-40181 1-H
CO-40181 1-S
CO-40181 1-J
CO-401824
CO-401824-H
CO-401824-S
CO-401824-J
CO-401885
CO-401885-H
CO-401885-S
CO-401885-J
CO-401885
CO-401885-H
CO-401885-S
CO-401885-J

ORD NO.

74O3651
7403652
7403653
7403654
7403075
7767348
7767361
7767362
7403072
7767378
7767446
7767447
7403069
7767333
7767334
7767335
7403501
7348668
7348669
7348670
7403067
7767804
7767805
7767920
7403067
7767804
7767805
7767920

PA ^90^4.^

0 7c

104
AVI**

MFO NO.

PO ^90^4. *\ TT

pA_t;9nf\4. tv-G!

CO-520545-J
104
j.\f*

111"*

I.

/;/;
DO

. uu

104

76

to
0 . 70

. &&

PA ^90^4- ^

CO-520545-H
CO-520545-S
CO-520545-J
CO-520550
CO-520550-H
CO-520550-S
CO-520550-J
CO-520546

CO-520546-H
CO 520546-S
CO 520546-J
CO 401959
CO-401959-H
CO-401959-S
rrudniQfjft-.T
197

Table II. Sffwrf Idf*ti1trti&*Continued

no NO.

76

LENGTH
FROM BOSS
NO. RCQD
TO END
OF 8TUl>
(l.VCH)

REF LTR

a 57 !

76

78

a 89 |
ii

78

0. 8 i j

4. 25 ,,

MFO .NO.

I CO-401824
! CO-401824-H
! CO-401824- S
CO-40 1 824- J
i ! CO-401882
CO-40 1 882- H
CO-40 1882-8
CO-40 1 882- J
2 CO-401836
CO-401 836- H
CO-40 1836-S
CO-40 1836- J
4 CO-520660
CO-520660-H
CO-520660-8
CO-520660-J

OKJ>

740350!

7348668
7348669
7348670
7403512
7348782
7348783
73487S4
7403503
7410395
7348596
7348597

Section XIV. ASSEMBLY OF ENGINE FROM SUBASSEMBLIES

102. Torque Tightness
During engine assembly, numerous references are made to torque
specifications. Torque wrenches with indicating scales are provided
for tightening nuts to specified limits. Readings on these scales are
worthless unless the wrenches are used properly. It should be under
stood that it is not the force required to turn the nut that is important,
but the resultant pull on the stud itself. Therefore, resistance of the
nut to turning must be reduced to a minimum. Threads must be
undamaged and clean and, they must be lubricated with mica-base
antiseize compound to reduce unavoidable friction.
Xotc. When usintr a torque wrench, the final reading must be taken while
the nut is turning.

If the torque reading is close to that specified when the wrench is

at the end of its swing, back off the nut slightly and change the wrench
position; then pull to the desired reading while the nut is turning.
To start a partially tightened nut will require a much higher torque
than that required to keep it turning. Do not exceed the torque speci
fied. Refer to torque specifications (par. 163). The ratio of poundstorque to pounds-pull on the stud is not an even ratio and excess torque
may easily overstress the stud.

198

103. Assembly of CrankcoM, Cronkshcrft, and Main Bearings

a. Install Crankshaft A*embly. Lay the crankcase halves on a
suitable table or bench with the bearing halves up. Install the main
bearing shells in their respective bores and coat them with engine oil.
The crankshaft thrust main bearing (fig. 57) in No. 3 location must
have a minimum clearance of 0.002 inch between the bearing web and
(he under face of the thrust flange. Lift the crankshaft assembly,
consisting of the crankshaft, connecting rods, vibration damper, and
crankshaft oil seal, with crankshaft lifting sling 41-S-3829-720 (fig.
>8), and lower it gently into the left (2-4-6) side crankca.se half, guid
ing the connecting rods through the cylinder mounting holes. Lift
the right (1-3-5) side crankcase half with crankcase lifting eye
41-E-615-350 (fig. 27) high enough to clear the ends of the connecting
r<xls, and lower it gently over the crankshaft, guiding the connecting
rods through the cylinder mounting holes. The right (1-3-5) side
stud hole must line up with the stud in the flywheel end diaphragm
of the left (2-4-6) side. Install connecting rod protectors -il-P-2839:.35 (fig. 23).
b. Install CrankcaJte Cro** Bolts and Flange Bolts (fig. 58). In
stall the two special-dowel-type crankcase alinement bolts (AC) with
plain washers (NX) in the flywheel end flange and the one dowel-type
(rankcase alinement bolt (SS) with plain washer (RR) in accessory
end flange, by tapping gently with a soft hammer from right (13-5)
side. Add washers, plain nuts, and jam nuts. Install the 12 crankcase cross bolts (H). Use the large cross bolt spacers (G) and cross
bolt slotted nuts (F) for locations other than through the cylinder
pads. Use protectors or straps 41-S-5906-300 (fig. 23) under the
eight slotted nuts on the cylinder mounting pads to prevent imprint
ing of the machine-finished surfaces. Install the crankcase top flange
hex-head bolts (AB), washers, and nuts. Tighten all nuts. Do not
torque at this time. Tighten flywheel and diaphragm slotted nut (EE)
and safety wire.
c. Check Crankshaft End-Play (fig. 85). Install a dial indicator to
the flywheel flange. Insert a pinch bar or large screwdriver between
the crankshaft counterweight and the main bearing web. Pry the
crankshaft through its limits of end-play. End-play should be 0.008
to 0.012 inch for new parts and 0.008 to 0.017 inch for reconditioned
parts. If end-play is not within these limits, disassemble the crankcase and install a new thrust main bearing.
d. Crankshaft Oil Seal (fig. 58). The crankshaft oil seal with
spring assembly (fig. 59) should be inserted in the recess in the crankcase, with the parting line of the seal staggered so it will not be on
the split line of the crankcase (the flat face is away from the crankcase). Install the lower and upper oil seal retaining plate (FF) to
199

TRANSMISSION
ADAPTER FtANGE

*A PO 155965

Figure 85. Checking crankthaft end-play.

the crankcase with drilled-head bolts (HH), plain washer (GG),

and safety wire.
e. Fan Drive Bearing Installation (fig. 58). Install the fan drive
horizontal shaft bevel gear bearing (PP) in the crankcase opening:
so the lock pin hole will be in position to receive fan drive horizontal
shaft bearing locking bolt (XX). Install the locking bolt and safety
wire. Install the bronze fan drive vertical shaft bearing (UU) in the
crankcase opening with the dowel pin hole in line with the pin hole in
the crankcase. Insert the bronze fan drive vertical shaft bearing
dowel pin (TT).
/. Flywheel (fig. 59). Install the flywheel with dowel pin assembly
on the crankshaft hub dowels. One dowel is 3 degrees off center line
on the crankshaft flywheel hub to assure proper installation in refer
ence to timing marks on flywheel. Install the flywheel bolt locks and
flywheel to crankshaft drilled-head bolts. Torque to 1,000 poundinches. Bend up the tabs of the bolt locks.
g. Torsion Damper (fig. 24). Install drive springs (M) and drive
spring seats (N) in the flywheel recesses. Install damper spacer plate
200

(J), damper friction disk (F), damper hub plate (H), damper spring
driven plate (G), and damper hub (B), using dowel pins to line up
damper hub, hub plate, and spring driven plate and dowels in flywheel
to line up spacer plate. Secure with drilled-hex-head bolts (A)
uud torque to 400 to 500 pound-inches. Install the other damper
friction disk (F), damper pressure plate (E), torsion damper ring
(I)), flywheel cover plate (C), and its holding bolts. Insert trans
mission drive quill for alining hub. Torque flywheel cover plate bolts
to 300 pound-inches.
h. Kit Assembly (Engine Stand}. Place crankcase assembly on
engine stand 41-S-4942-20 (fig. 8). Secure with all nuts for safety.
104. Installation of Fan Drive Housing, Fan Drive Shafts
and Bevel Gears
(fig. 75)
a. Install the internal snap ring in place in the groove in the splines
of the fan drive horizontal shaft bevel gear. Through the opening of
the fan drive housing in the crankcase, insert the fan drive horizontal
shaft bevel gear into its bearing.
6. In the side opening of the fan drive housing on the crankcase,
facing the flywheel end, assemble the fan tower plug ((V), fig. 58)
with a new copper annular gasket ((W), fig. 58) on the inside. Secure
with the fan tower plug slotted nut, plain washer, and cotter pin ((Y),
(X), and (Z), fig. 58) on the outside.
c. Through the same opening, place the fan drive vertical shaft
bevel gear against its thrust face. Mesh it with the mating horizontal
shaft bevel gear. Install a new "O"' ring gasket, in the recess of the
vertical shaft bearing housing. Install the housing over the studs.
Install the fan drive vertical shaft, its oil slinger, and vertical shaft
ball bearing on the shaft. Install the fan drive vertical shaft in its
bearing in the crankcase, meshing the splines of the shaft in spline of
the fan drive vertical shaft bevel gear. Install the ball bearing in the
housing. Tap gently with a soft hammer.
d. Install the fan drive vertical shaft oil seal housing and inclosed
seal (par. 95) and secure with plain washers, slotted nuts, and safety
wire.
e. Install the fan drive horizontal shaft hose nipple with a new
copper gasket in the opening, facing the accessory end. Screw it
tightly into the end of the fan drive horizontal shaft bevel gear bear
ing. Install the horizontal shaft hose and clamps. Insert fan drive
horizontal shaft into the horizontal shaft bevel gear.
105. Installation of Pistons, Cylinders, and Air Deflectors
a. Install Pitton* in Cylinders. Lubricate cylinder bores and pis
ton rings with engine oil at assembly. Insert the piston assembly in
201

large end of piston ring gage and compressor 41-G-534-50 (fig. 86).
Guide the assembly into its cylinder until the rings have entered the
cylinder bore. Be sure that the piston is assembled in the correct
cylinder and is positioned according to marking on the bottom of the
piston pin boss. Cylinders are marked on the rocker box contact
flange, intake side. Slip off the gage and compressor and leave the
piston pin partially inserted in the piston pin boss. Assemble all
pistons to their cylinders in this manner. Install neve cylinder base
k*O" ring gaskets ( (A), fig. 5-2).
b. Install Cylinder* on Crankcaxe (fig. 87). Remove nuts from
cylinder pad cross bolts and lift off straps 41-8-590(5-300 (fig. 23).
Install engine turning wrench 41-W-906-130 ((J), fig. H). Turn
engine to bring the connecting rod of No. 5 or 6 cylinder as far out of
the crankcase as possible. Place the piston and cylinder assembly
over the connecting rod, aline the piston bores, and insert the piston
pin. Remove connecting: rod protectors 41-P-2839-535 (fig. 23)
and slide cylinders into place'. Check the position identification
marking.
\otc.

Marking on the boss goes to the accessory case end.

Insert the cylinder over its hold-down studs on the crankcase and in
stall the cylinder hold-down hex nuts ((E), fig. 52) and torque to 400
pound-inches at assembly. While crankshaft is in same position, in
stall the opposite cylinder. Install other cylinders in the same man
ner. Install the 1'2 slotted crankcase cross bolts ((H), fig. 58) and
nuts. Torque all crankcase cross bolt nuts by progressively tighten
ing to 300, 600, and 750 pound-inches, starting with bolts in the center
cylinder and working toward each end. The top flange crankcase
bolts and the dowel bolts are torquecl to 175 pound-inches after the
cross bolts have been properly torqued. After all cylinders are in
stalled, retighten all cross bolt nuts to 750 pound-inches. Install
jam nuts on the cylinder hold-down nuts. While installing cylinders
to the crankcase, it sometimes becomes necessary to keep the crankcase cross bolt nuts tight to prevent binding of the crankshaft in its
bearings. Replace and tighten nuts, using straps 41-S-5906-300
(fig. 23) just enough to free the crankshaft. Line up cotter pin holes
and install pins.
c. Install Cylinder and Cylinder Head Air Deflectors and Intercylinder Baffles (fig. 18).
(1) Install the four intercylmder baffles ((G), fig. 52), using
hex-head bolts and lock washers ((H) and (J), fig. 52).
(2) Install the six cylinder head air deflectors ((KK), fig. 52)
over their studs and slide into place over the cylinder head
fins.
(.3) Lay the eight cylinder air deflectors in position on the cyl
inders and secure them with the drilled-hex-head bolts ((J)>
202

GAGi AND COMPRESSOR

4T-G-S34-50

jftA KMJSM4;
Figure 86.

Installing piston and rinys in cylinder.

203

GASKET, "O"
RING- 170148

CONNECTING 403006

Figure 87.

Installing ci/linder.

fig. 88), lockwashers (N), end air deflector springs (K), air
deflector hooks (L), air deflector clamps (M), and plain
nuts (P). Connect the deflectors with air deflector spacers
((E), fig. 88), using drilled-hex-head bolts ((D), fig. 88),
slotted nuts ((C),h'g. 88), and cotter pins ((B), fig. 88).
106. Installation of Scavenger and Pressure Oil Pump
(fig. 65)
a. Install the scavenger and pressure oil pump (dual unit) (fig. 11)
to the crankcase mounting studs and secure with four plain washers
(S), slotted nuts (R), and safety Avire.
l>. Install scavenger pump suction line (AV) with a new suction line
gasket (X). Secure to the crankcase with two slotted nuts (A) and
safety Avire.
107. Installation of Accessory Case to Crankcase
a. Insert the accessory drive shaft ((Z), h'g. 35) in the crankshaft
vibration damper hub. Install three "O" ring gaskets on the accessory-case-to-crankcase oil transfer tubes. Install the accessory to
crankcase gasket ((T), fig. 31). Install the fan drive horizontal
shaft hose nipple (fig. 75) in the accessory case with a new gasket.
204

ADEFLECTOR, AIR, CYLINDERS NO. 1 AND 67375871.

BFIX, COTTER-121223.
CNTJT, SLTD225838.
DBOLT, DLD-HEX-HD583752.
ESPACEK, AIR DEFLECTOR7744730.
FDEFLECTOR, AIR, INTERMEDIATE CYLINDERS7345414.
GDEFLECTOR, AIR, CYLINDERS NO. 2 AND 57375873.
HWASHER, LOCK120380.
JBOLT, DLD-HEX-HD7376018.
KSPRING, AIR DEFLECTOR, END7744734,
L-HOOK, AIR DEFLECTOR-7744720.
MCLAMP, AIR DEFLECTOR7744861.
XWASHER, LOCK120217.
PNUT, PLAIN225850.

Figure 88.

Cylinder air deflectorsexploded vieir.

Connect hose on nipple with clamp. Install the pressure oil pump
drive shaft ((Z), fig. 65). Mesh the splines of the shaft in the splines
f the pressure pump drive bevel gear.
&- Install the accessory case to the crankcase, sliding the case on
the studs and entering the accessory drive shaft ((Z), fig. 35), pres
sure oil pump drive shaft ((Z), fig. 65), and the fan drive horizontal
shaft (fig. 75) in their respective positions in the accessory case. It
"lay be necessary to turn the engine with engine turning wrench
41-W-906-130 ((J), fig. 6) to mate the splines of gears in accessory
241130 O53-

-14

205

case. Secure the accessory case to the crankcase, using 1*2 plain
washers, plain nuts, jam nuts, (> plain washers, slotted nuts, and
safety wire.
108. Installation of Camshaft* and Valvt Rockers

(fig. 45)

a. Install the left camshaft drive shtft housing nuts (GG) over the
drive shaft housing (HH). Install nev "O" ring gaskets (V) on
the housing and insert the housing in the camshaft drive housing as
sembly (Z). Tighten the drive shaft housing nut fingertight.
b. Remove the left (24-6) side valve rocker shaft brackets ((I"),
rig. ;>:>) from the cylinders. Install the camshaft and camshaft gear
housing assembly (fig. '21 ), entering the camshaft drive shaft housing
(HH) in the camshaft drive shaft sti|>|>ort (,1,1). Position the inter
cylinder connectors (U) in the cylinder head counterbores. Replace
the valve rocker shaft brackets in their original positions. Torque
valve rocker shaft bracket bolts (fig. 91) progressively to 17o pourulinches and secure with safety wire.
\ote. The long drive shaft housing (HH) goes on the left (2-^J-O) Hide and
the short drive shaft housing I ( VV). fig. -Mil on the right < l-3-.">) side.

intake valve rocker clear

c. Set valves. Set Xo. 4 and 0 cylinder
v
a noes (fig. 90) to 0.007 inch and secure the adjusting screw jam nuts.
Set No. '2 cylinder intake valve clearance to O.ltX) inch (par. 100).
Set all exhaust valve clearances with gage 41-0-415-375 (fig. 89) to
0.014 inch between the cam lobe and the valve rocker roller and secure
with the adjusting screw nuts. It is necessary to set the exhaust valve
clearance in this manner us the end of the valve is in its spring retainer
recess and a feeler gage cannot be used at the valve.
d. Install the camshaft gear housing to the Xo. -2 cylinder with
hex-head bolts ( P) and tab washers (Q).
e. Tighten the camshaft drive shaft housing nuts, using crowfoot
wrench 41-W-871-80 ((E), rig. 5). Secure with safety wire.
Note. f>o not install camshaft drive shaft (M) until valve and magneto
timing is done (par. 100).

f. Install the camshaft and camshaft gear housing assembly for the
right (1-3-5) side (fig. 20) as in b above. Set No. 1 intake valve
clearance to 0.100 inch and No. 3 and 5 cylinder intake valves to
0.007 inch clearance. Exhaust valves will be set at 0.014 inch at roller
and camshaft as in c above.
Note. Do not install camshaft drive shaft ((Q), fig. 46) and tachometer
shaft ( (Z), fig. 46) until engine is timed (par. 109).

206

ROLLER, VALVE
ROCKER74Q3T83
IROCKER, EXHAUST VALVE
(ASSY7410281

E41-6-415-375

ROCKER, INTAKE VALVE,

ASSY7410281

RAPD 15596

Fiuure 89.

Figure 90.

Settiny cfhaunt valre rocker clearance.

Adjusting intake valve rocker clearance for engine timing.

207

BRACKET, ROCKER
SHAFT-7403353
\CAP, CAMSHAFT BEARING
/ 7403352

RA PD 180569
Figure 91. Torquing valve rocker shaft bracket bolts.

109. Valve and Magneto Timing

a. Set Right (1-^6) SiU Valve Timing.

(1) Set No. 1 cylinder intake valve clearance to 0.100 inch, using
gage 41-G-415-375 (fig. 90). Rotate the crankshaft clock
wise, as viewed from the accessory end, with engine turning
wrench 41-W-906-130 ( (J), fig. 6), until timing mark "OPP
ENG 1 & 2 INT 100 CL'' (opposed cylinders engine,
cylinders No. 1 and 2 intake valve clearance 0.100 inch) is
alined with the timing pointer.
Note. The flywheel also contains timing marks for "V" engines.
Be certain to use timing marks designated "OPP ENGINE," (fig. 93).

Turn right (1-35) side camshaft counterclockwise (fig. 92)

as viewed from the accessory end until No. 1 intake valve has
just closed. The closing point is precisely determined by
rotating the intake valve rocker roller by hand as the cam
shaft is being turned. The valve is closed at the instant the
roller becomes free. Insert the camshaft drive shaft, using
remover and replacer 41-R-2378-575 (fig. 19). If the shaft
will not enter the splines, withdraw it and turn slightly and
attempt to insert in mating splii\es. It may be necessary to
turn the shaft a number of times until mating splines are
found.
208

Caution: Do not drive it in.

The camshaft drive shaft is machined with a 21 -tooth spline
on the inner end and a 25-tooth spline on the outer end. This
differential number of teeth in the splines gives the drive
shaft a vernier effect It is therefore possible to index the
shaft so it will engage the mating splines of its gears, with
out changing the relationship of the camshaft to the crank
shaft, thereby providing an accurate setting,
("heck the timing as follows:
(a) Rotate the crankshaft one-eighth turn counterclockwise,
as viewed from the accessory end, to remove gear back
lash.

(b) Slowly rotate the crankshaft clockwise, turning thft No. 1

intake valve rocker roller at the same time. Stop turning
at the instant the roller becomes free.
(r?) Observe position of the timing mark and pointer. If they
are alined, engine is timed correctly. If they are misalined by more than one-quarter of an inch, withdraw the
camshaft drive shaft and repeat the timing, procedure.

Note. If correct timing cannot be done as outlined above, it may

be necessary to install the camshaft drive shaft when the timing
mark is one-eighth of an inch to one-quarter of an inch out of line
with the timing pointer.

(3) Install the camshaft oil transfer outer plug ((R), h'g. 4b),
using remover and replacer 41-R-2378-5751 (rig. 19). Se
cure the plug with an internal snap ring ((S), fig. 46).
Install gear housing cover ((U), fig. 46), using a new
gasket. Secure with plain washers ((V), fig. 46), drilledhead bolts ((W), fig. 46), and safety wire. Install the
tachometer drive shaft ((Z), fig. 46) and tachometer trans
mitter drive adapter ((BB), fig. 46) with new oil seal ((DD),
fig. 46). Secure with plain washers, plain nuts, and jam
nuts ((V), (LL), and (KK), fig. 46). Install tachometer
gasket ((EE), fig. 46) and tachometer drive cover ((FF),
fig. 46). Secure with plain washers, plain nuts, and jam
nuts.
b. Set Magneto Timing.
(I) After timing the right (1-3-5) side valves, rotate the crank
shaft clockwise, as viewed from the accessory end, until the
timing mark "OPP ENG IGN" is alined with the pointer.
Note. If magneto timing is performed independently of valve timing,
line up the flywheel timing mark and pointer with the No. 1 cylinder
on its compression stroke.
Install new magneto gaskets ((E), fig. 40). Remove the
magneto cover and aline the timing marks, using timing
209

LEFT
(2-4-6)
SIDE
CAMSHAFT
ROTATION

CRANKSHAFT
ROTATION

RIGHT
(1-3-5)
SIDE
CAMSHAFT
ROTATION

VIEWED FROM ACCESSORY END

RA PD 180570
Figure 92. Crankshaft and camshaft rotation diagram.

mark "L*? (fig. 94) on the magneto housing. Install the

magnetos with mounting studs centered in the adjusting
slots.
Xote. Use the timing line marked "L" on the magneto housing.
timing line marked "R" is for rotation in the opposite direction.

The

Secure the magnetos with plain washers, plain nuts, and

jam nuts ((C),(B), and (A), fig. 40).
(2) Synchronize the magnetos, using timing light 41-L-1439
() Secure the timing light ground cable clip to one magneto
housing.
(b) Clip the two remaining leads to the breaker post of each
magneto.
(c) Rotate the crankshaft counterclockwise, as viewed from *"
accessory end, one-eighth of a turn; then slowly rotate
clockwise until timing lights come on.
(d) Both lights should come on at the time the flywheel timing
mark alines with the pointer. If they do not, loosen the
magneto fastening nuts and adjust magnetos until both
lights come on. Tighten fastening nuts. When mag
netos are synchronized and timed, observe whether mag
neto timing marks are alined. If they are not, it means
that the breaker point adjustment is incorrect. Adjust
210

breaker points (TM 9-1825E). Install and time the

magnetos.
(e) Install the magneto adapters and secure with lock washers
and drilled-fillister-head screws ((F) and (E), fig. 101).
c. Set Left (2-4-6) Side Valve Timing. After timing magnetos,
rotate the crankshaft clockwise, as viewed from accessory end, until
the flywheel timing mark "OPP ENG 1 & 2INT 100 CL" alines with
timing pointer. Set and check left side valve timing in the same man
ner as right side (a above). Install the oil-transfer outer plug and
snap ring ( (L) and (K), fig. 45). The left (2-4-6) side camshaft gear
housing cover assembly ((H), fig. 45) is installed with the throttle
linkage (par. 119).
d. Reset No. 1 and 2 Cylinder Intake Valves. Reset No. 1 and 2
cylinder intake valves to 0.007 inch. Remove engine turning wrench
41-W-906-130 ((J), fipr. 6).

TIMING HOLE
IN TRANSMISSION
TIMING NOTCH
ON TRANSMISSION
ADAPTER PILOT
TIMING
MARKS

CENJERIINE OF
CYLINDERS LEFT (2-4-6) SIDE

CYLINDERS RIGHT (1-3-5) SIDE

FLYWHEEL
AS VIEWED FROM FLYWHEEL
END OF ENGINE

TIMING
MARKS

RA PD 180571

Figure 93, Valve and Ignition timing diagram.

211

Fiyurc 94. Magneto timing mark*.

110. Installation of Valve Rocker Covers

Install all valve rocker covers. Position ignition harness clip as
semblies ((W), fig. 101) over bolt holes on flywheel side of No. 1 and 2
and the accessory side of No. 5 and 6 rocker covers. Install plain
washers, lock washers, and hex-head bolts ((Y), (X), and (W), fig.
52). Install valve rocker box covering plates ((T), fig. 45 and (L),
fig. 46) on No. 5 and 6 cylinders with new gaskets. Secure with tab
washer and bolts. Fasten No. 1 and 2 valve rocker covers to their
camshaft housings with tab washers and bolts.
111. Installation of Fuel Pomp, Governor Assembly, and
Governor Control Shaft Bracket Assembly
(fig. 68)
a. Install governor assembly with new governor gasket ((F), fig.
41). Secure with plain washer, plain nut, and jam nut ((G), (H),
and (J), fig. 41).
6. Install the governor control shaft support bracket (E). Secure
with plain washers, plain nuts, and jam nuts (W), (V), and (U).
c. The control shaft-to-governor rod assembly was installed on the
control shaft-to-cross shaft and governor lever (A) during assembly
of the throttle linkage (par. 81). Install the other end of the rod as212

sembly on the governor rocker arm ((Z), fig. 109) securing with
drilled-for-cotter-pin bolt, plain washer, slotted nut, and cotter pin
(K),(R),(S),and(H).
d. Install fuel pump assembly ((Y), fig. 41) with a new fuel pump
gasket ((X), fig. 41). Secure with plain washers, plain nuts, and jam
nuts ((M), (N),and (P), fig. 41).
112. Installation of Hotspot Intake Manifold, Carburetor, and
Breather Tubes

(hg. 78)
a. Install hotsjKrt intake manifold housing assembly (S) to the
accessory case assembly cover (E) and secure with four plain wash
ers (D), four plain brass nuts (V), and two plain washers, plain nuts,
and jam nuts (K), (J), and (H).
b. Install left (2-4-6) side accessory case breather tube (fig. 95).
Tighten the tube nuts.
c. Install carburetor assembly (A) on the hotspot intake manifold
housing studs using new carburetor-to-housing gaskets (T). and car
buretor mounting spacer (U). Secure with plain washers, plain nuts,
and jam nuts (D), (C), and (B).
113. Installation of Accessory Case Scavenger Oil Pump

(fig. 66)

Install the scavenger oil pump assembly to the mounting; flange of

accessory case. Position the scavenger oil pump bevel gear (A) and
secure pump with five plain washers and slotted nuts (C), and (B) and
safety wire. Install crankcase scavenger oil pump outlet line ((V),
fig. 65) and accessory case scavenger oil pump outlet line ((V), fig. 31)
and secure with one drilled-head bolt and safety wire as shown in
figure 11.
114. Installation of Crankcase Oil Pan

Insert the intake manifold balance tube ((A), fig. 58) in the crankcase. Install balance tube flanges ((C), fig. 58) with new "0" ring
gaskets ((B) fig. 58) and secure with drilled-hex-head bolts ((D),
fig. 58) and safety wire. Install the crankcase oil pan assembly (fig.
96) with a new oil pan-to-crankcase gasket ((B), fig. 73). Secure
with 38 plain washers, plain nuts, and jam nuts ((M), (K), and (L),
fig. 73).
115. Installation of Accessory Case Oil Sump

Install the oil pressure regulator spill line and its snap ring ((X)
and (W), fig. 31) in position. Install the accessory case oil sump
213

'ADAPTER, WEATHER ~" ':.

TUE, ACCESSORY CASE-

GASKET,
TUBf ADAPTER
7410066

ELBOW: FLARED

TUBE, 45 DEG7410042

TUBE. BR
RIGHT (1-3-5)
SIDE, ASSY
7410449

TUNE, BREATHER,
LEFT (2-4-6) SIDE,
ASSY-7414502

Figure 95. Accessory case Ireather tubes, breather tube adapter, and
lifting eyeexploded view.

2U

END)

(Accesses?
RA TO 155958

Figure 96.

Crankcaae oil pan ansenibly.

assembly ((P), fig. 73) with new sump-to-accessory case and sump to
pan gaskets ((A), and (N), fig. 73). Secure the sump to the side
of the oil pan with four drilled-hex-head bolts, plain washers, lock
washers ((V), (M), and (-W), fig. 73). Install the 16 plain washers,
plain nuts, and jam nuts ((U), (T), and (S), fig. 73) which hold the
sump to the accessory case.
116. Installation of Intake Manifolds and Connectors
(% 97)

a. With engine turned upside down install the right (1-3-5) side
and left (2-4-6) side manifold assemblies (par, 91) on cylinders, us
ing new gaskets. Secure sections to cylinders with plain washers (R),
plain nuts (S),' and jam nuts (T).
b. Install left (2-4-6) side and right (1-3-5) side intake manifold
connectors (A), and (X), using new intake manifold connector-tohotspot intake manifold housing gaskets (Y). Install manifold sec
tion hoses (C), and new or serviceable hose clamps (B). Secure con
nector flange to the hotspot intake manifold housing flange with plain
nuts (S) and jam nuts (T).
c. Install the intake manifold balance tube connector tubes (H)
with connector tube hoses (J), hose clamps (N), and new connector
tube-to-manifold section gaskets (P), inserting the intake manifold
balance tube (M) in the hoses as the connector tube assemblies are posi215

A-CONNECTOR, INTAKE MANIFOLD, LEFT (2-4-6) SIDE-7414532

B-CLAMP, HOSE - 502948
C-HOSE, MANIFOLD SECTIONS - 7375237
&-MANIFOLD SECTION, CYLINDER NO 2-7346554
i-MANIFOLD SECTION, CYLINDER NO 3 AND NO 4-7767246
P-MANIFOLD SECTION, CYLINDER NO 6-7348832
O-ELBOW, TUBE, 90 DEC-7767517
H-TUBE, CONNECTOR, INTAKE MANIFOLD BALANCE TUBE - 7348830
J-HOSE, CONNECTOR TUBE-7403382
K-FLANGE, BALANCE TUBE ~ 7348815
t-GASKET, "O" RING-501232
M-TUBE, BALANCE, INTAKE MANIFOLD - 7348816
N-CLAMP, HOSE-502919
P-GASKET, CONNECTOR TUBE-TO-MANIFOLD SECTION - 7346510
Q-TEE, FLARED TUBE - 7065764
R~ WASHER, PLAIN-502245
S-NUT, PLAIN - 225853
T-NUT, JAM- 107822
U-MANIFOLD SECTION, CYLINDER NO 5, ASSY - 7348831
V-PLUG, PIPE - 7538990
W-MANIFOLD SECTION, CYLINDER NO 1, ASSY-7346553
X-CONNECTOR, INTAKE MANIFOLD, RIGHT (1-3-5) SIDE - 7414531
Y-GASKET, INTAKE MANIFOLD CONNECTOR-TO-HOTSPOT INTAKE
MANIFOLD HOUSING - 7744566
Z-PLUG, PIPE - 7767336
AA-GASKET, MANIFOLD SECTIONS - 7744566
BB-WASHER, LOCK-120214
CC BOLT, HEX-HD - 583749
RA PD 18882
DO-BOLT, DLD-HEX-HD - 7403158

Figure 97.
91A

Intake manifold, balance tube and connectorsexploded view.

tioned. Secure the connector tubes to the manifold sections with lock
washers (BB), hex-head bolts (CC), and safety wire.
d. Position all hoses on attaching parts. Center them so clamps get
a positive grip on the manifold sections U avoid leakage. Tighten all
clamps.
117. Installation of Cylinder Head Oil Drain Manifold
(fig. 08)
a. Attach oil drain cylinder manifold sections No. 1,2, 3, 4, 5, and 6
(C), (B), and (R) to their cylinder head mounting pads, using new
manifold section-to-cylinder head gasket (M) and annular gasket (P)
(n the manifold, sect ion bolts (Q). Vse new manifold section hose
(A) and new or serviceable hose clamps (X). Tighten the bolts and
secure them with safety wire.
b. Install the cylinder head oil drain manifold-to-oil pan adapter
( U) to the crankcase oil pan, using a new gasket. Secure with drilledhex-head bolts (W), and (X), plain washers (V), and safety wire.
<?. Install engine end cylinders Xo. 1,2, o, and 6 oil drain line assem
blies (E), (H), (AA), and (8) and sump end cylinders No. 1 and 2
oil drain line assemblies (F) and ((i) in their respective positions,
using; new hoses, new or serviceable clamps, and new gaskets. Secure
them with hex-head bolts (Z) and lock washers (Y).
d. Position the hoses and clamps, making certain the clamps get a
positive grip on the hoses of the manifold sections to avoid leakage.
Tighten the clamps.
e. Install left and right camshaft gear housing oil drain hoses (J)
and (D), with clamps on the connections of the No. 1 and 2 cylinder
oil drain line assemblies (E) and (H), to the camshaft gear housings.
Tighten the clamps.
118. Installation of Primer Lines and Pilfer
(fig. 99)
a. Install primer fuel filter mounting bracket (S) to left camshaft
gear housing. Secure with plain washer (N), plain nut (P), and
jam nut (Q). Screw the filter assembly to the bracket. Install primer
filter bracket tube connectors (M) in the bracket.
6. In each cylinder primer line nozzle, install the intercylinder
primer line tube tees (F), and secure them with the compression tube
fitting safety ball sleeves (D) and sleeve nuts.
c. Install intercylinder primer line (B) and primer-filter-to-cylinder-No. 1 line (L) on the right (1-3-5) side cylinders. Secure primeriilter-to-cylinder-No. 1 line (L) to the accessory case cover with primer
line clips (J), primer line clip bracket (G), fillister-head screws (H),
and self-locking nut (K). Install intercylinder primer line (B) and
217

IO

OB

Fit/lire 98.

Cminder head oij <1r<iin manifold<>rplo<lcd

K>

Fiffure 98. Cylinder head oil drain manifoldexploded viewContin

ued.

ZBOLT,' HEX-HD583749
AALINE, OIL DRAIN, CYLINDER NO. 5 ASSY-7375425

17ADAPTER, MANIFOLD-TO-OIL PAN7375423

VWASHER, PLAIN502245
WBOLT, DLD-HEX-HD7348770
XBOLT, DLD-HEX-HD7346710
YWASHER, LOCK120214

PGASKET, ANNULAR100452
QBOLT, MANIFOLD SECTION7707928
KMANIFOLD SECTION, CYLINDER NO. ft7375430
SLINE, OIL DRAIN, CYLINDER NO. 6, ASSY7375424
TGASKET, OIL DRAIN LINES AND ADAPTER7346510

ifGASKET, MANIFOLD SECTION-TO-CYLINDKR HEAD7767938

NCLAMP, HOSE502919

KELBOW, HOSE, 45 DBG, MALE PIPE END734(1711

J^-CLAMP, HOSE502912

JHOSE, OIL DRAIN, LEFT CAMSHAFT GEAR HOUSING7403466

ELINE, OIL DRAIN, CYLINDER NO. 1, ASSY7403471

FLINE, OIL DRAIN, CYLINDER NO. 1, ASSY (SUMP END)
7408470
GLINE, OIL DRAIN, CYLINDER NO. 2, ASSY (SUMPEND
)7408472
HLINE, OIL DRAIN, CYLINDER NO. 2, ASSY7408473

DHOSE, OIL DRAIN, RIGHT CAMSHAFT GEAR HOUSING-740888

BMANIFOLD SECTIONS, CYLINDER NO. "734<>r83

CMANIFOLD SECTION, CYLINDER NO. 1, 2, 3 AND 4734
6582

AHOSE, MANIFOLD SECTION74Q338l>

APLUG, PRIMER LINE TEE7744647

LINE, PRIMER, INTERCYLINDER7372618
CNOZZLE, PRIMER LINE, ASSY7410158
BSLEEVE, BALL, SAFETY, COMPRESSION TUBE FITTING1899U
INUT, BALL SLEEVE COMPRESSION TUBE FITTING189894
F__TEE, TUBE, INTERCYLINDER PRIMER LINE7744648
CBRACKET, PRIMER LINE CLIPCO-526759
HSCREW, FIL-HD132105
jCLIP, PRIMER LINE572898
KNUT, SELF-LOCKING503209
LLINE, PRIMER-FILTER-TO-CYLINDER-NO 17414582
MCONNECTOR, TUBE, PRIMER FILTER BRACKET501105
NWASHER, PLAIN502245
*_NUT, PLAIN225853
QNUT, JAM107822
RFILTER, PRIMER, ASSY-7346703
COMPOSED OF
1HEAD, FILTER
2GASKET, BOWL

3ELEMENT
4^-BOWL, FILTER, ASSY
5SAIL, FILTER, ASSY
SBRACKET, FILTER MOUNTING7375416
TLINE, PRIMER-FILTER-TO-CYLINDER-NO 27376935

RA PD 188828

Figure 99. Primer filter and linesexploded view.

220

Fiyure 100.

Installing spark plug.

primer-filter-to-cylinder-Xo. 2 line (T) on the left (2-4-6) side cylin

ders. Install primer line tee plug (A) in intercylinder primer line
tube tees (F) on cylinders Xo. 4 and 5. Xo. 6 cylinder does not have
a primer nozzle. The opening in the cylinder contains a pipe plug.
119. Installation of Throttle Linkage
a. Cross Shaft and Vehicle Control Levers Assembly (fig. 69).
Position the camshaft gear housing cover assembly ((H), fig. 45)
over studs on left (2-4-6) side camshaft gear housing assembly ((X),
fig. 45). Position cross shaft support bracket (V) over studs on acces
sory case cover. Secure the housing cover and support bracket with
plain washers (H), plain nuts (G), and jam nuts (F).
b. Install the cross shaft-to-carburetor control rod turnbuckle as
sembly at the carburetor, using drfilled-hex-head bolt (X), plain
washers (P), slotted nut (U), and cotter pin (K). Refer to paragraph
129 for adjustments.
c. The control shaft-to-cross-shaft link assembly (X) was installed
on the control shaft-to-cross-shaft and governor lever ((A) ( fig. 68)
during assembly of the throttle linkage (par. 81). Install the other
end of the link assembly on the outer cross shaft lever (HH), secur
ing with drilled-hex-head bolt (W), plain washers (P), slotted nut
(U), and cotter pin (R).
d. Install the right (1-3-5) side accessory case breather tube (fig.
95) at the accessory case breather tube adapter (fig. 95).
241130 O5315

221

puo

CM

<*>

Figure 101.

P- LINE, FLEXIBLE, IGNITlON-HARNKSS-TO-lNTAKE-M.vN1 FOLD7410040

QGASKET, ANNULAR, SPARK PLUG
RPLUG, SPARK, 14MM7525550
SLEAD, DETACHABLE, SPARK PLUG7324011
TNIPPLE, TUBE7324013
UBOLT, HEX-HD735015)9
VWASHER, LOCK120214
WCLIP, IGNITION HARNESS, ASSY705871
XHARNESS. IGNITION. ASSY7414507
YSPACER7403682
ZLINK, IGNITION HARNESS CLIP7403578
AABOLT, HEX-HD128122

Ignition harness and vent Jincsexploded viewContinued.

NELBOW, FLAUED TUBE, 45-DEQ7767516

L CLIP, IGNITION HARNESS7403577

MNUT, SELF-LOCKING503209

KSCREW, RJ)-HD7403667

JBRACKET7403760

HNUT, JAM107822

ANUT. PLAIN225853
BWASHER, LOCK120214
CCLIP, CLOSED, CUSHIONED, MAGNETO CABLE7338649
DBOLT, HEX-HD7414560
ESCREW, DLD-FIL-HD7338612
FWASHER, LOCK131183
GGASKET, IGNITION-HARNESS-TO-MAGNETO7338655

120. Installation of Starter and Generator

(fig. 43)
a. Install the generator and starter drive assemblies (par. 59).
b. Assemble the generator assembly to the generator drive assem
bly with a new generator and starter gasket (E). Secure with plain
washers (D), hexhead nuts (C), and jam nuts (B). Note the posi
tion of the generator terminal in figure 3.
c. Install starter mounting adapter (L) on the starter drive assem
bly (K) using a new generator and starter gasket (E) and special
self-locking adapter nuts (M). Position the starter on the starter
drive assembly and turn pinion to secure starter. Note position of
starter pinion (fig. 14).

121. Installation of Spark Plug, Booster Coil, and Ignition

Harness
a. Install Spark Plugs. Insert spark plugs in their holes with in
serting wrench 41-W-329750 (fig. 100), using a new spark plug gas
ket. With a deep-socket wrench, tighten to 200-225 pound-inches
torque.
b. Install Ignition Harnex* Assembly (fig. 101). Install the igni
tion harness assembly. Secure to cylinder heads No. 1, 2, 5, and 6
with hex-head bolts ( (W), fig. 52). The ignition harness clip assem
blies (W) were installed previously (par. 110). Fasten the ignition
harness clip (L) to the bottom of the accessory case in two places.
Secure with spacers ( Y) ignition harness clip link (Z), and hex-head
bolts (AA). Fasten the clip to the link with round-head screws (K)
and self-locking nuts (M). Install ignition harness clip (L) to
bracket (J) on the left (2-4-6) side camshaft drive shaft support
(( JJ), fig. 45), securing with roundhead screws (K) and self-locking
nuts (M). Place ignition harness adapters on magnetos, using new
ignition harness-to-magneto gaskets (G). Secure with lock washers
(F) and drilled-fillister-head screws (E), Fasten magneto cable
closed cushioned clips (C) to the booster coil and filter assembly
bracket (fig. 102), securing with hex-head bolts, lock washers, and
plain nuts (D), (B), and (A). Install spark plug cable with ter
minals to spark plugs, using cnnvfoot M*rench 41-W-871-62.
c. Install Booster Coil With Filter Assembly and Ground Cables
(fig. 102). Install the booster coil with filter assembly on the booster
coil and filter assembly bracket. Secure with lock washers and round
head screws. Install the left magneto ground short cable from the
outer connector of the booster coil to outer magneto. Install the right
magneto ground long cable from the inner connector of booster coil
to inner magneto.
224

CABIE, GROUND,
MAGNETO, LEFT,
SHORT-7353260

CABLE, GROUND,
MAGNETO, RIGHT,
LONG-7414527

ELBOW, FLARED TUBE, 90 OEG

7767517

MAGNETO, ASSY7401411

TEE, FLARED TUBE7065764

COIL, BOOSTER,
W/FSITERASSY7725157

urn, FLEXIBLE,

LINE, FLEXIBLE, MAGNETQTO-MAGNETO, ASSY7744709

CARBURETOR-TOMAGNETO,
,ASSY~ 7414565

SCREW, RD-HD
132903
WASHER, LOCK -120217
,CKIT, BOOSTER COIL
AND FILTER, ASSY-7410456
WASHER, PtAJN-502245
NUT, PLAIN -~ 225853
107122

Figure 102.

RA Ft) 188854

Magnetos, booster coil, and vent linesexploded view.

225

BOOSTER
SWITCH

FILTERS

INNER MAGNETO

ACCESSORY END

MAGNETO
COIL

FLYWHEEL END
OUTER MAGNETO

24-VOLT FEED

Ignition wiring diagram.

DIRECTION OF
ROTATION

Figure 103.

TO NEUTRAL POSITION SWITCH

BREAKER
POINTS

RA CD 180577

ACCESSORY END
FlYWHKt END

d. Inittall Magneto and Gable Vent Linen. Install the carburetorto-magneto flexible line assembly (ag. 102). Install the longer mag
neto-to-magneto flexible line assembly (fig. 102). Install the ignitionharness-to-intake-manifold flexible line ((P) fig. 101) to No. 5 and 6
cylinder manifold sections ((U) and (F), fig. 97).
122. Installation of Exhaust Manifold Assemblies, Hotspot
Tubes, and Vacuum Heat Control Valve
a. Install six new manifold gaskets on the cylinders and position
the exhaust manifold assemblies on the right and left side cylinder
mounting studs. Secure with plain washers and self-locking nut.
b. Install inlet and outlet hotspot tube assemblies ((L), and (A),
fig. 104) on the exhaust manifolds and hotspot intake manifold hous
ing with new gaskets. Secure at exhaust manifold flange with drilledhex-head bolts and brass slotted nuts ((J), and (G), fig. 104). Se
cure at hotspot intake manifold housing flange with brass plain nuts
((N), fig. 104).
<?. Position vacuum heat control valve assembly ((J), fig. 76) on
outlet flange of right (1-3-5) side exhaust manifold with heat control
valve gasket ( (K), fig. 76) and secure with three hex-head bolts and
safety wire.
d. Connect heat control-to-intake manifold flexible line ( (W), fig.
76) to 90-degree flared tube elbow ( (S) , fig. 76) in the heat control unit
housing assembly ((R), fig. 76) and flared tube tee ( (Q), fig. 97) in
cylinder No. 5 intake manifold section.
123. Installation of Engine Shroud and Oil Cooler Assembly
a. Position the engine shroud and oil cooler assembly on the acces
sory and flywheel end fan rotor housing spacers ((M), fig 35 and
(DD) , fig. 58) . Install the four fan rotor housing supports ( P) . Se
cure the shroud, fan rotor housing, and supports with plain washers
and drilled-hex-head bolts (E) and (F). Install plain washers and
self-locking nuts (E) and (D) on the fan rotor housing spacers.
. Install oil cooler seal lower hose (S) and oil cooler seal hose
lower bracket (L) on the cylinder head studs. Secure with plain
washers (H), slotted nuts (J), and cotter pins (K).
c. Install the left (2-4-6) side and right (1-3-5) side hotspot tube
slot cover assemblies (G) and (CC), the right (1-3-5) side flywheel
end shroud assembly (Z), the left (2-4-6) side and right (1-3-5)
side main shroud flywheel end cover assemblies (U) and (Y), and the
heat control rod housing cover assembly (BB) on the engine shroud.
Install the right and left main shroud exhaust hole covers (AA) and
(V) . Secure the covers with hex-head bolts with integral lock washer
(X) and speed grip retainer nuts (W).
227

K
K9
09

Figure 104.

Exhaust manifold assemblies, hotspot intake manifold housing, and hotspot tubes-exploded

RA PD 188844

MGASKET, HOTSPOT INLET TUBE7410458

NNUT, PLAIN, BRASSCO-520662
PHOUSING, HOTSPOT INTAKE MANIFOLD, ASSY7376925
QSTUDCO-520545

RSTUDCO-520550

SSTUDCO-520546

GNUT, SLTD, BRASSCO-501658

HGASKET, HOTSPOT TUBE7410457

Figure 104. Exhaust manifold assemblies, hotspot intake manifold housing, and- hotspot fwbe*exploded viewContinued.

JBOLT, DLD-HEX-HDCO-520664

LTUBE, HOTSPOT, INLET, ASSY7347781

BMANIFOLD, EXHAUST, LEFT (2-4-6) SIDE, ASSY7347783

KSTUDOO-520545

CMANIFOLD, EXHAUST, RIGHT (1-3-5) SIDE, ASSY7376943

DNUT, SELF-LOCKING7403648
EWASHER, PLAIN7744570
FGASKET, MANIFOLD-TO-CYLINDER7744568

ATUBE, HOTSPOT, OUTLET, ASSY7347782

Figure 105. Oil filler pipe and crankcase breather line assemblyexploded view.

230

AELBOW, H08K, 90 DEG>~500S61

I?CLAMP, HO8J<>502912
CHOSE, OIL FILLER PIPE-TO-TRANSMI8SIONCO40190S
DLINE, TRANSMISSION BREATHER7414556
EGAGE, BAYONET TYPE, OIL LEVEL7410452
FHOSE, BREATHER LINE CONNECTION7403387
GXUT, PLAIN225851
HWASHER, LOCK7<K2sT6Kl
JCLIP, CLOSED. CUSHIONED, LINE7338649
KBOLT, HEX-HD501813
I^-LINE, FLAME-ARRESTOR-TO-FILLER-PIPE7414580
MELBOW, FIBRED TUBE, 90 DEG7707517
NSCREW, DLD-HDAIR-AN-503-416-8
I'ARRESTOR, FLAME, ASSY7414540
QNUT, SLTD122942
KBRACKET, SUPPORT, FLAME ARRESTOR7410450
SLINE, CARBURETOR-TO-FLAME-ARRESTOR7410451
TCLAMP, HOSE502915
LTGASKET, OIL FILLER PIPE7767802
VBOLT, DLD-HDCO-401368
WLINE, CRANKCASE-TO-OIL-FILLER-PIPE7410453
XBRACKET, OIL FILLER PIPECO-525273
YNUT, SELF-LOCKING7039110
fcBOLT, HEX-HD W/INT-LOCK WASHER7416584
AASEAL, OIL FILLER PIPE CAP8328610
BBPIPE, OIL FILLER, W/CAP, ASSYCO-525331
Figure 105.

Oil filler pipe and crankcase breather line assemblyexploded

viewContinued.

231

to

Figure 106.

Fuel systemcfplodcd vicir.

RD-HO -132903

RAPO 188846

AA-LINE, FLEXIBLE, FUEL FIlTER-TO-FUa. PUMP,

ASSY-7768134
-CLIP, CLOSED, CUSHIONED, UNE - 7403577
CC-FILTER, FUEL, ASSY - 7026004
DLD-HEX-HD - 7346718

ASSY-7744711

1-LINE, FLEXIBLE, FU& PUMP-TO-BtEATHER

W-PUMP, FUEL, ASSY-7410094

X-SCREW, RD-HD - 7403767
Y-CUP, LOOP-TWe - 572914

R-CUP, CUSHIONED, LOOP-TYPE - 7338649

SGASKET, FUEL PUMP - 7006868
T-ELBOW, FLARED TUBE, 45 DEG - 7410042
U-ELSOW, FLARED TUBE, 90 DEG-7346726
V-EUOW, FLARED TUBE, 90 DEG-7767517

O--CARBURETOR, ASSY - 7403299

0

I P-SCREW,

L-NUT, SELF-LOCKING ~ 503209

IK-CUP, LOOP-TYPE-7403271
NN-BRACKE
T, CLIP - CO-525469

K-UNE, FLEXIBLE, FUEL PUMP-TO-CARBURETOi,

ASSY-7376926

H-glBOW, FLARED TUBE, 45 DEG - 7767556

J-ELBOW, FLARED TUBE, 45 DEG - 7744714

1-NUT, JAM - 107823

C-NUT, PLAIN-225854
D-WASHER, PUIN - 502204
1-ELBOW, PIPE 90 DEC-7521299
F-PLUG, PIPE -7538990
<*~ELBOW, HOSE-7376136

A~8RAOC|T, FUEL FILTER-7414501

</. Install oil control housing inlet and outlet connectors using
new connector gaskets ((EE), fig. 79). Secure with their plain
washers, plain nuts, and jam nuts. Connect engine oil cooler inlet
and outlet line assemblies ((W) and (U), fig. 79), using wrench
41-W-1593-600 ((C), fig. 5).
e. Install transmission cooler inlet connectors, securing with hexhead bolts and plain washers and using new connector gaskets ((EE),
fig. 79). Connect the transmission cooler inlet line assembly ((N),
fig. 79).
/. Secure vacuum hfcat control support bracket ((AA), fig. 76) to
the shroud using hex-head bolt with integral lock washer (X).
124. Installation of Cooling Fan Rotor, Fan Clutch Assembly,
and Fan Outlet Vane Housing
Place fan rotor and clutch assembly on fan drive vertical shaft
(fig. 75), meshing splines on the shaft with splines in the clutch
drive hub ((M), fig. 67). Secure with slotted nut and cotter pin
(fig. 75). Clearance between the fan rotor blade tips and the fan
rotor housing must be 0.070-inch minimum. Install the fan rotor
cover ((C), fig. 67). Secure with lock washers and screws. Install
cooling fan outlet vane housing assembly ((B), fig. 17) and secure
with 14 self-locking nuts ((A), fig. 17).
125. Installation of Crankcase Oil Filler Pipes and Breather
Lines
(fig. 105)
Install crankcase oil filler pipe with cap assembly (BB) with a
new oil filler pipe gasket (U). Secure to the oil pan with drilled
head bolts (V) and safety wire. Secure the oil filler pipe bracket
(X) to the shroud with hex-head bolt with integral lock washer (Z).
Install the crankcase-to-oil-filler-pipe line (W) with new hoses and
new or serviceable hose clamps. Assemble the flame arrestor assembly
(P) and flame arrestor support bracket (R) with the flame-arrestorto-filler-pipe line (L) and carburetor-to-flame-arrestor line (S), using
new breather line connection hoses (F) and hose clamps (T). Lo
cate flame arrestor bracket on accessory case studs and secure with
slotted nuts and safety wire. Fasten the flame-arrestor-to-filler-pipe
line to the shroud with closed cushioned line clips (J), hex-head bolts
(K), lock washers (H), and plain nuts (G). Install hose and clamps
from carburetor-to-flame-arrestor-line-hose elbow ((G), fig. 106) on
the carburetor.

233

126. Installation of Fuel Filter and Linot and Oil Rltor Assembly
(fig. 106)
a. Install fuel filter bracket (A) to the accessory case. Secure with
plain washers (D), plain nuts (C), and jam nuts (B). Install fuel
filter assembly (CC) to the bracket. Secure with plain washer,
drilled-hex-head bolt (DD), and safety wire. Install fuel filter-tofuel pump flexible line assembly (AA), Secure this line to ignition
harness using loop-type clips (M), closed cushioned line clips (BB),
roundhead screws (X), and self-locking nut (L).
b. Install fuel pump-to-carburetor flexible line assembly (K) and
secure to the accessory case cover mounting stud with loop-type
clip (M).
<?. Install fuel pump-to-breather line flexible line assembly (Z).
Secure with loop-type cushioned clips (B), loop-type clips (Y), round
head screws (X), and self-locking nut (L).
d. Install the oil filter assembly ((A), fig. 31) in its housing in the
accessory case, using a new gasket. Secure with plain washers, plain
nuts, and jam nuts. Install the oil filter magnetic drain plug ((C),
fig. 81) with a new drain plug gasket ((I>), fig. 31) in the accessory
case below the oil filter.
Section XV. TiSTS AND ADJUSTMENTS
127. Oil Pressure
Oil pressure can be raised (par. 82), but not lowered, with the
type of control valve used. If the oil pressure at operating temper
ature is too high at 2,000 rpm, install a new oil pressure control valve.
If pressure is too low, adjust it to 70-80 psi, using engine oil SAE 50
at 180 F., by adding up to three plain washers in the cap,
128. Throttle Linkage
a. General. The adjustment of the throttle control linkage is ac
complished to a great extent in the manufacture of the engine. The
adjustments necessary for the effective operation of the governor and
carburetor are outlined below and in the paragraph on governor
adjustment in the pertinent operator's manual.
J. Adjustments.
(1) Adjust for full travel of the carburetor throttle plates in the
following manner: disconnect the right-hand thread rodend ball bearing ((AA), fig. 69) from the control shaft-tocross shaft and governor lever ((A), fig. 68). Lengthen or
shorten the rod as necessary to accomplish full travel from
the full open stop on the carburetor to the full idle stop
on the carburetor.
234

Note. The vehicle control lever D), flg. 68) and the carburetor
throttle control lever should be against their stops simultaneously at
full open position.

(2) Adjust for full travel of the governor in the following man
ner: Make certain the governor is extended to the full limit
of its travel. Advance the carburetor throttle plates to the
full open position. Next install and adjust the length of
the right- and left-hand thread control shaft-to-governor
rod ((N), fig. 68) until the governor rocker arm ((Z),
fig. 109) clears the rocker arm stop pin ((H), fig. 109) by
0.010 inch. . Secure all jam nuts on the throttle control rod
and on the control shaft-to-governor rod.
129. Accessories
Tests and adjustments on accessories are outlined in the pertinent
operator's manual and pertinent technical manuals.
Section XVI. RUN-IN TEST
130. Preparation for Run-in
Install the engine on a dynamometer or transmission. Preoil the
engine by forcing oil, under pressure, into the oil system. This insures
adequate lubrication to the engine parts until the engine pump supply
reaches them. If no preoiling equipment is available, fill all external
oil lines and oil coolers with the proper grade oil. See that an ade
quate supply of oil is in the oil pan. Adjust throttle linkage as out
lined in paragraph 128.
131. Hydrostatic Lock
a. General. Hydrostatic lock is the result of engine cylinders be
coming flooded with oil or fuel when the engine is not running. Care
should be taken when starting the engine in case a hydrostatic lock
condition is present, since such a condition may damage internal parts.
b. Starting Engine. With the ignition switch in the "OFF*' posi
tion rotate the crankshaft a few revolutions with the starter to deter
mine if the engine turns over freely, with no possibility of hydrostatic
lock. The slip clutch in the starter is so designed that no damage to
engine parts can occur .under this condition. However, damage can
result if the ignition switch is on and the spark plugs fire, thus turning
the engine over. If the engine does not turn over with the starter,
investigate for hydrostatic lock.
c. Detection and Correction. Hydrostatic lock can be detected by
removing one spark plug from each cylinder and noting any evidence
of liquid. If liquid is present in the cylinders, it can be removed by
235

rotating the crankshaft with engine turning wrench 41-W-90H-130

((J), fig. 8) with the ignition switch in the "OFF" position. Turn
the engine over several times to make certain all liquid has been
removed.

132. Engine Run-in

. Run-In Schedule*. A rebuilt engine should be started and runin in accordance with one of the following: schedules. If any piston
rings or cylinders on the engine have been changed or the cylinders
honed, use the long run-in schedule in table III. If the piston rings
and cylinder bores are unchanged, use the short run-in schedule in
table IV.
ToW ///. Long run-in tcktdult
PERIOD

I...................

2...----. 3..-----..-. . . ..
4...................
5-..---------...-...
6.... ...............
7...................
8...- ......... -----9 . .
10....---.--.-.--....
11...................
12...................
13-.------.-.--..---.
14.-...--....-....-..

MINUTES

30
30
30
30
30
30
30
30
30
30
15
15
15
15

RPM

BHP
(OBS+FAN)

0
15.9
27.2
44
66
95
128
172
227
284

,000

,000
,200
,4OO
,600
ow
, MM

2,000
2,200
2,400
2,600
2,800
2, 4OO
2,000
1,600

Max
Max
MAX
Max

AB8 MAN
PRESSURE
IN BO

18. C

17. C
16. 5
15.2
15.0
16.0
17.5
20.0
22.0
23 5

Table IV. Short run-in schedule

PERIOD

I.-..---.. ...........

2_... ................
3-... .----..._.-.....
4-...,. ......... ..
5....-- ....... .
6.. ...._... ..........
1. ............... ...
8-----. .............

236

MINUTES

15
15

15
15
15
15
15
15

RPM

1,000

1,200

1,600
2.0OO
2,200
2.4OO
2,600
2,800

BHP
(OB8+FAN)

0
27.2
66
128
172
227
284
Max

AB8 MAN
PRESSURE
IN HO

18.0
16.5
15.0
17.5
20.0
22.0
23.5

b. Oil Consumption Cheek. Oil consumption may be measured in

the following manner:
(1) Repair all oil leaks.
(2) Run the engine and shut it down when the oil is at operating
temperature.
(3) Allow 10 minutes for foam on the oil to settle. Measure
the oil level.
(4) Kun the engine for 1% hours at 2,800 rpm and maximum
horsepower.
(5) Shut down and allow 10 minutes for foam on the oil to settle.
(6) Measure the amount of oil required to raise the oil to its
original level.
(7) Maximum allowable oil consumption is 1% gallons in li/2
hours. If it exceeds that, find the cause. Refer to trouble
shooting (par. 14).
133. Governor Adjustment
(fig. 108)
Upon completion of engine run-in, adjust governor in the follow
ing manner:
a. With thp throttle in the wide open position, and the engine
operating at full load, remove dust cap (FF) and turn the speed
adjusting screw (DD) until the engine operates at 2,800 rpm. (Clock
wise rotation of this screw increases the engine speed.) Replace the
dust cap and install safety wire.
b. With the metering screw (J) backed out one turn from the
completely closed position, the throttle in the wide open position,
and the engine operating at no load, adjust the metering screw until
the engine speed is 2,950 rpm (fig. 107). (Clockwise rotation of this
screw decreases the engine speed.) Install the metering screw plug
(G) and a new plug washer (H).

241180 O6316

237

M
8

SPEED ADJUSTINi
SCREW

ATMOSPHERIC PRESSURE

TO CARBURETOR

SECTION THRU NO
LOAD ADJUSTING
VALVE

ATMOSPHERIC PRESSURE

SPEED ADJUSTING

Figure 107. Governor operating! positionscross

sectional view.

FIGURE 2
2800 RPM FULL LOAD

MEDIUM HIGH PRESSURE

SPEED ADJUSTING SCREW

ATMOSPHERIC PRESSURE

TO CARBURETOR

TO FOOT PEDAL

2950 RPM NO LOAD

FIGURE 3

RA PO 196951

ATMOSPHERIC PRESSURE

TO FOOT PEDAL

CHAPTER 5
HYDRAULIC GOVERNOR
134. Description and Data
a. De*rripti(yn. The mechanical-hydraulic type governor is
mounted on the right (1-3-5) side camshaft drive housing and is gear
driven from the camshaft driven idler bevel gear ((A), fig. 41). Its
function is to maintain engine speed below predetermined limits, re
gardless of engine load. The governor has three basic systems. The
first system is a fly-ball-and-race-type mechanism, consisting of four
balls riding between a flat disk and a conical cover. Axial movement
of the cover, caused by the centrifugal force of the rotating balls, actu
ates the second or pilot valve system. The pilot valve moves back and
forth over oil passage orifices, as governed by the fly-ball system,
thereby controlling the flow of oil to the third or oil pressure system.
Oil pressure, supplied from the main oil gallery of the engine, pro
duces the amplified energy required to actuate the hydraulic piston,
which in turn controls the governor-to-carburetor control linkage.
Maximum engine speed at no load is controlled by adjustment of the
metering screw which controls the oil pressure in the hydraulic system.
Refer to paragraph 133.

b. Data.

Make_________________________________-_____ Novi
Type_________________________________________ centrifugal
Uotation (mechanical) ___________________ counterclockwise
Novi part number ____________________- MI-538551)

135. Disassembly of Hydraulic Governor

a. Remove Governor. Refer to paragraph 36.
b. Remove Cylinder Head Rocker Arm and Pixton Awembly (fig.
108). Remove the four cylinder head cap screws (B) and lock wash
ers holding cylinder head with rocker arm and piston assembly (D)
to body with plugs and sleeve assembly (L). Remove the assembly
and remove piston spring (F). Discard the cylinder head gasket (E).
c. Disassemble the Governor Body with Plugs and ffleeve Awembly
(%. 108).
239

(1) Remove parts (Q), (R), (8), (T), (U), and (V) as an assembly from body with plugs and sleeve assembly (L). Re
move snap rings and separate assembly. The drive shaft with
lower race assembly (V) is not disassembled.
('2) Remove stop screw (\V) and stop screw washer (X) from
the body and withdraw oil distributing valve (P) with its
spring and retaining washer.
(#) Remove the ad just ing screw dust cap (FF) from the governorbody; unscrew the adjusting screw safety nut (KE) holding
the speed adjusting screw (Dl>). Remove the nut and screw
and lift off the dust cap washer (AA). Remove the two
cover h'llister-head screws (CC) and lock washers (BH)
which hold adjusting screw cover (2) to the body. Remove
cover and discard the gasket.
(4) Remove the plug which covers metering screw (J) from the
body. Remove plug washer (H). Turn the metering screw
out and remove the spring.
(L Dimwemble the f'ylinder Head Awembly (fig. 109).
(1) Drive out the grooved pin (X) holding the piston rod clevis
(Y) to the piston rod (G). Pull the clevis from the rod.
Remove the piston rod dust seal diaphragm (E), the piston
rod compression spring (F), and flat washer (W). Remove
the expansion plug from piston rod clevis (Y) and remove
rocker arm shaft (C) and its bearing. Remove governor
rocker arm (Z) and its lubricating fitting.
(2) Pull the piston rod with piston attached from the cylinderhead (J). Remove the piston rod packing lower gland
retaining ring (P), piston rod packing lower gland (N).
piston rod rubber packing (M), piston rod packing upper
gland (L), and piston rod packing compression spring (K).
Discard packing. Remove cylinder head bearing (V). Do
not attempt to remove rocker arm stop pin (H).
(3) Drive out the grooved pin (S) holding the piston with guide
pin assembly (B) to the piston rod. Pull the piston from
the rod. Do not remove the piston guide pin (Q) unless
obvious damage makes replacement necessary.
136. Cleaning, Inspection, and Repair of Hydraulic Governor

a. Cleaning.
(1) Clean the piston rod dust seal diaphragm with a cloth
dampened with soapy water.
(2) Wash all other parts in dry-cleaning solvent or volatile
mineral spirits. Clean all ports and openings with probes,
if necessary, and blow out with air to make sure all dirt has
been removed.
24O

Figure 108,

t-RiNG, SNAP, THRUST BCAWNG - 7745000

S-^ARING, BAIL, THRUST-7767272
T-RACl, SAU, mER-7744fW
U-BALL, ACTUATING -104924
V-SHAFT, DRIVE, W/lOWJt RACi, ASSfVf-SCRfW. STOP - NI-52651
X-WASHER, STOP SCREW - N-52dS3
Y-GASXET, COVER - 7744172
Z-COVER, ADJUSTING SCREW -7767218
AA-WASHER, DUST CAP - 7008794
M-WASHER, LOCK -131184
CC-SCREW, fIL-HD, COVER - 7410331
DO-SCREW, SPEED ADJUSTING 7008795
tf-NUT, SAFETY - 7008796
W-CAP, DUST - 7008443

Governor assemblyexploded vieiv.

LUB*, HYDRAUUC TYPE - 4I-F-448-200

:-4CREW, CAP, CVUNOER HEAD - 426942
C-WASHiR, LOCK, CYLINDER HEAD SCREW -120214
B-HEAD, CYUNDER, W/ROCKER ARM AND PISTON, ASSY - 7521293
I-GASKET, CYUNDER HEAD -7008455
P-SPRING, PISTON - 7767254
O-PtUG, METERING SCREW - 7744998
H-WASHfR, PLUG-7744173
J-SCRfW, METERING 7416392
K-SPRJNG, METiRING SCREW - 7376084
1-8ODY, W/PIUGS AND SLIEVE, ASSY-NI-52511D
M-WASHER, RETAINING, VALVE SPRING - 7744996
NSPRING, COMPRESSION, VALVE - 7744190
JP-VALVE, Oil DISTRIBUTtNG - 7521292
4AP, BALL RACE-7744180

a
t

<s
o

i
o

a
a,
it

to

^
J

S
fl
?

a,
3,
S.

b. Inspection.
(1) Check the castings for cracks and see that the mating sur
faces are smooth and free of flaws.
(2) Check the piston rod for scoring and wear.
(3) Check the cylinder walls for scores and abrasions.
(4) Check the movement of the piston in the cylinder and oil
distributing valve in the bore.
(5) Check springs for signs of failure.
(6) Check the piston rod dust seal diaphragm for cracks, de
terioration, and obvious damage which would make it un
serviceable.
*
*5
?
|
*
|
8
S
"
|
|

|
o
I
?
a
I
&

I
*

(7) Check the thrust ball bearing ((S), fig. 108) for wear and
defects.
(8) Check parts to limits specified in repair and rebuild standards
(par. 162).
c. Repair,
(1) Replace all worn or defective parts.
(2) If piston rod is scored, smooth the rod with crocus cloth.
(3) Clean up all scratches or abrasions on cylinder walls and
piston with crocus cloth.
(4) Remove all burs from oil passage openings. The edges
of these openings should be smooth. Clean them carefully
with a scraper, if necessary, and blow out with air.

137. Assembly of the Hydraulic Governor

a. Awemble the Cylinder Head Assembly (fig. 109).
(1) Install the hydraulic-type lubricating fitting (A) in the
governor rocker arm. Install the rocker arm shaft bearing
(B) in the piston rod clevis (Y) and install the rocker arm
and shaft in the clevis. Install rocker arm clevis expansion
plug(D).
(2) Place a new or serviceable piston with guide pin assembly
(R) on the piston rod and secure with grooved pin.
(3) Install the cylinder head bearing (V) in the head. Using
new packing, assemble piston rod packing compression spring
(K), piston rod packing upper gland (L), the rubber piston
rod packing (M), piston rod packing lower gland (N), and
piston rod packing lower gland retaining ring (P) in the
cylinder head.
(4) Assemble piston rod with attached piston in the cylinder
head. Install piston rod compression spring (F) and a new
or serviceable piston rod dust seal diaphragm (E) on the
piston rod. Place piston rod clevis (Y) on the rod and se
cure with grooved pin (X).
243

Note. Ait O.-HMm-h fm travel (fig. ill)) of the platon rod and
must b* iuaitttin*Hj. I*M*> Hut wanhtrn I\V> tin required between
pigton rod foapri**ilon Mprfug <F) and cylinder head U) to obtain
correct fre travel.

See that the ends of the diaphragm are seated in the grooves
in the cylinder head and clevis.
6. Assemble the Hydraulic Governor Axxembly (fig, 108).
(1) Place the piston spring (F) in the governor body and inHtali
the cylinder head with rocker arm and piston assembly (1))
with a new gasket in jxKsition as shown in figure 108. Secure
with cylinder head screw lock washers (('), cylinder head
cap screws (B) and safety wire.
(2) Install the ball upj>er race (T) on the drive shaft with lower
race assembly (V), placing the four actuating balls (U) in
their recesses, and install ball race snap ring (Q). Install
the thrust ball hearing (S), thrust bearing snap ring (B),
and oil distributing valve (P) on the upper race. Install
spring in valve and place valve spring retaining washer (M)
on the end of the valve compression spring (X). Install the
complete assembly in the body and secure with stop screw
(W), a new stop screw washer (X), and safety wire.
(3) Install speed adjusting screw (DD) in its cover. Place a
new dust cap washer (AA) over the screw. Install the ad
justing screw safety nut (EE) but do not tighten it. Plate
a new cover gasket (Y) on housing and install cover assembly.
Be sure the dog [wint on end of speed adjusting screw (DD)
seats in valve spring retaining washer (M). Secure the

FLAT WASHER, N I-54052

RA PD 196953

Figure 110. Governor piston rod travel.

cover with two cover fillister-head screws (CC) and lock

washers (BB). Install safety wire. Install dust cap (FF).
Note. Diint cap Is lock-wired after adjustment* are made on engine.

(4) Insert the metering screw spring (K) and the metering screw
(J). Do not try to adjust setting at this time. Install
metering screw plug (G) with a new plug washer (H).

245

CHAPTER 6
REPAIR AND REBUILD STANDARDS
138. General
The repair and rebuild standards included herein give the mini
mum, maximum, and key clearances of new or rebuilt parts. They
also #ive 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.
An asterisk (*) in the 4k\Vear limits" column indicates that the part
or parts should be replaced when worn beyond the limits given in
the "Sizes and fits of new parts" column. In the "Sizes and fits of
new parts'' column, the letter UL" indicates a loose fit (clearance)
and the letter "T" indicates a tight fit (interference).
139. Accessory Case and Subassemblies Mating Bores and
Pilots
(par. 57)
a. Starter Drive Assembly.
Fig No.

111

6.
Ill

c.
Ill

246

Kef Llr

Point of measurement

ID of pilot bore in accessory

case.-------......--.----P
Pilot OD of drive assembly.. _
M-P
Fit of drive assembly incase..
Generator Drive Adapter.
J
ID of pilot bore in accessory
case--.-------.-.---.----G
Pilot OD of adapter.-------G-J
Fit of adapter in case. -.....Magneto Drive Housing.
E
ID of pilot bore in accessory
case.-..-..-._.--..-.--._
D
Pilot OD of housing. -------D-E
Fit of housing in case.-----._

Sizet and fill of ntw parti

Wear limitt

5.6875 to 5.6895
5.6865 to 5.6885
0.0010T to 0.0030L

5.6910
5.6850
0.0045L

4.8125 to 4.8165
4.8060 to 4.8100
0.0025L to 0.0105L
4,2500 to 4.2510
4.2485 to 4.2495
0.0005L to 0.0025L

Point of

d. Magneto Driven Bevel Gear Adapter.

ID of pilot bore in accessory
C
III
case.....----..,._..,....
Pilot OD of adapter.........
P
118
Fit of adapter in case.......
OP
Housing, Right (l-S-6) tide.
Drive
e. Camshaft
ID of pilot bore in accessory
X
III
case.....................
OD of housing.........
Pilot
Q
N-Q
Fit of housing in case........
/. Canukajt Drive Houting, Left (2-4-3) side
ID of pilot bore in accessory
F
111
cane--..------.-.....---..
Pilot OD of housing.........
H
Fit of housing tin case.......
F-H
9 Oil Filler Element.
ID of bore in accessory case...
B
111
To be OD of filter-element....
A
Fit of element tube in case....
A-B
Pump Outlet Line.
Oil
Scavenger
h.
of hole in accessory case...
ID
K
Ill
OD of line..................
L
Fit of line in case. ----------K-L

Site* and ftt of new part*

Wear llmtti

2.8750 to 2.876O
2.8735 to 2.8745
0.0005L to 0.0025L
2.1250 to 2.1260
2.1237 to 2.1247
0.0003L to O.OO23L

2.1272
2.1225
0.0035L

2.1250 to 2.1260
2.1237 to 2.1247
0.0003L to 0.0023L

2.1272
2.1225
0.0035L

1.5000 to 1.5020
1.4950 to 1.4990
0.0010L to O.OO70L
0.8745 to 0.8755
0.8700 to 0.8740
0.0005L to O.OO55L

RA PD 180584A

Figure til.

Repair and rebuild standard points of measurement for accessory case

and subassemblies mating bores and pilots.

247

14O. Accessory Case Drive Gearing

(par, 57)
a. Fan Drive Gear Bearings.
Fiff ATo.

112

E
A
A-E

112

Print

Rtf Ur

V
E-V

OD of bearings, -_._...--- ...

ID of fan drive gear outer bear
ing liner,.--- .,.....-.-_-_
Fit of bearings in outer bearing
liner ..-----_-,...----_--.
I D of liner in accessory caae_ . .
Fit of bearing in accessory case
liner _..---._--.-.--..----

Stttt and ftti of new parti

Wtar limitt

2.8341 to 2.8346

2.8333

2.8345 to 2.8353

2.8361

0.0012L to 0.0001T
2.8345 to 2.8353

0.0020L
2.8361

0.0012L to 0.0001T

0.0020L

1.3779 to 1.3784
1.3775 to 1.3780
O.OO01L to0.0009T

1.3775
1.3784
0.0005L

6. Fan Drive Gear.

112

c.
112

d.
112
e.
113

/.
112

g.
113
112

113
113

h.
113
112

248

Large OD of shaft on fan drive

gear- ,..--.._.._....-,-__..
C
I D of fan drive gear bearings , .
C-D
Fit of shaft in bearings. ..-.,.
Fan Drive Gear Outer Bearing Liner.
B
Pilot OD of liner. ...........
F
ID of pilot bore in accessory
case, -,----_-_,..,-._--__.
B-F
Fit of liner in case. ..,..--_-.
Fan Drive Gear Oil Seal Housing.
U
Small OD of housing..---- -..
G
ID of bore in accessory case_ . .
G-U
Fit of housing in case. .._._..
Accessory Drive Gear Roller Bearing (Large).
U
OD of large drive gear roller
bearing- .--_.......-____.
W
Large ID of liner in accessory
case-...---- -------------U- W
Fit of bearing in case. ..___..
Accessory Drive Gear Roller Bearing (Small).
S
OD of bearing.......... .....
T
Small ID of liner in accessory
case.. .,--.._--__...__-__.
S-T
Fit of bearing in liner. ..._..
Accessory Drive Gear.
X
Small O D of shaft on gear. . . .
R
ID of small drive gear roller
bearing.-.- __ .__..--._____
R-X
Fit of gear in bearing, .......
C
I D of drive gear bearing spacer .
C-X
Fit of gear in spacer. -.__-_..
Y
Large OD of shaft on gear. _ . .
T
ID of large drive gear roller
bearing...-. _ ......-__'__..
T-Y
Fit of gear in bearing. - _.___.
Starter Driven Bevel Gear.
M
Small ID of gear......----..
K
OD of starter driven bevel
gear bearing surface on power
take-off drive shaft. ...___..
K-M
Fitof gear onshaft---.---- __,

3.3735 to 3.3745
3.3750 to 3.3760
0.0005 L to 0.0025 L
2.4395 to 2.4410
2.4375 to 2.4385
O.OOIOT to 0.0035T
3.9364 to 3.9370

3.9355

3.9365 to 3.9375
0.0011L to 0.0005T

3.9384
0.00201

3.5427 to 3.5433

3.5423

3.5428 to 3.5438
0.0011L to 0.0005T

3.5442
0.0015L

1.9678 to 1.9684

1.9675

1.9680 to 1.9685
O.OO07L to 0.0004T
1.9690 to 1.9750
0.0006L to 0.0072L
2.1660* to 2.1666

l.6So
0.001 OL

2.1649 to 2.1654
0.0006T to 0.0017T
1.5310 to 1.5320

1.5326

1.5300 to 1.5306
0.0004L to 0.0020L

1.5294
0.0025L

fig No.

Kef Ltr

113

Q
R
Q-R

113

P
N

114

N-P
M-N

i. Magneto
G
113
H
G-H
113

114

j.
113

113
fc.
113
I.
113

114

Point of measurement

^ilotODongear---------..-.
ID of power take-off drive gear.
Fit of starter gear in power
take-off gear.--....,..._..
Large ID of gear.............
OD of starter driven bevel
gear ball bearing. _.._..__..
Fit of bearing in gear.....-_..
Desired backlash (at mean
dimension) with starter drive
bevel gear.------...-,---Total backlash--.,_--.......
Drive Bevel Gear.
OD of shaft on gear....--.--ID of accessory drive idler gear.
Fit of magneto gear in idler

IDof gear...--.-,-..--,..,.
OD of magneto drive bevel
gear bearing..__.__.__._..
Fit of bearing in gear __..___.
E-F
Desired backlash (at mean di
U-V
mension) with magneto
driven bevel gear. __..___..
Total backlash....--....-...
Idler Gear Shaft.
Drive
Accessory
shaft-..- -............
ODof
J
ID of magneto drive bevel gear
D
bearing,._.....--.-.....
Fit of shaft in bearing. _._,___
D-J
ID of shaft bearing in accessory
A
case- ---.--.--.---------..
A-J
Fit of shaft in bearing-.......
Camshaft Drive Idler Gears.
OD of gear....-- ----------S
ID of liner in accessory case-..
B
B-S
Fit of gear in liner..,...
Camshaft Drive Idler Bevel Gears.
OD of bevel gear_._.-.__._-L
ID of camshaft drive idler
K
gear--..-.-------,-----.,
Fit of bevel gear in idler gear-.
K-L
Desired backlash (at mean di
G-H
mension) with camshaft driv
en idler bevel
Total backlash..
E
F

Sizet and fits of new parts

W'tar limitr

4.6235 to 4.6245
4.6245 to 4.6250
0.0005L to 0.0025L
2.6774 to 2.6784
2.6767 to 2.6772
0.0002L to 0.0017L
0.0080 to 0.0120
0.0048 to 0.0152

0.0191

1.6240 to 1.6250
1.6250 to 1.6260

1.6230
1.6270

O.OOOOL to 0.0020L
1.1562 to 1.1572

0.0030

1.1580 to 1.1590
0.0008T to 0.0028T
0.0080 to 0.0120
0.0060 to 0.0140

0.0179

0.9988 to 0.9993

0.9968

1.0020 to 1.0030
0.0027L to 0.0042L

1.0043
0.0045L

0.9995 to 1.0005
0.0002Lto 0.0017L
1.6220 to 1.6230
1.6250 to 1.6260

1.6200
1.6280

0.0020L to 0.0040L

0.0060L

1.3115 to 1.3120

1.3095

1.3125 to 1.3135
0.0005L to 0.002O

1.3155
0.0040L

0.0080 to 0.0120
0.0058 to 0.0142

0.0181

249

K>

figure 112.

Repair and rebuild standard points of measurement for accessory

case drive gearing (front) and diaphragm assembly.

RA PO 196954

RA PD 196955

Figure US.

Repair and rebuild standard points of measurement for accessory case

drive gearing (rear).

251

Figure 114-

Repair and rebuild tandard points of measurement for accessory case year backlash.

RA n 1WS6

141. Starter Drive Assembly

(par. 58)
a. Starter Drive Adapter,
fig No. Kef Ur

115

A
D

Point of measurement

8izet and fitt of new -parti

Small ID of adapter......... 3.500 to 3.502

Small OD of starter drive bear
ing liner.---.,-.-.,-...... 3.497 to 0.3499
A-D
Fit of liner in adapter........ 0.001 L to 0.005L
116
C
Pilot ID of adapter.......... 4.125 to 4.127
D
Pilot OD of starter mounting
adapter................... 4.120 to 4.122
C-D
Fit of starter in adapter....... 0.003L to 0.007L
6. Starter Drive Bearing Liner.
Small ID of liner............ 3.1235 to 3.1265
C
115
OD of oil seal.... ........... 3.1280 to 3.1320
B
B-C
Fit of seal in liner........... 0.0015T to 0.0085T
OD of starter jaw ball bearing. 3.1491 to 3.1496
G
115
Mating ID of liner.......... 3.1496 to 3.1503
E
E-G
Fit of ball bearing in liner. . . . O.OOOOL to 0.0012L
OD of outer starter jaw bear
J
115
ing spacer. ..---__-..__... 3.1380 to 3.1440
E-J
Fit of spacer in liner. ........ 0.0056L to0.0123L
OD of starter jaw roller bear
L
115
ing. --------------------- 3.1491 to 3.1496
E~L
Fit of roller bearing in liner. . . O.OOOOL to 0.0012L
c. Starter Jaw.
1.5748 to 1.5753
115
F
OD of starter
H
ID of starter jaw ball bearing. 1.5743 to 1.5748
F-K
Fit of ball bearing on jaw.... O.OOOOT to 0.001 OT
115
K
ID of inner starter jaw bearing
spacer....-.---.-.--_---.. 1.5910 to 1.5970
F-K
Fit of spacer on jaw,-_-_-.-- 0.0157L to 0.0222L
115
M
ID of starter j aw roller bearing. 1.5743 to 1.5748
F-M
Fit of roller bearing on jaw... O.OOOOT to 0.0010T
d. Starter Drive Betel Gear.
115
N
ID of gear.--..------------- 1.5755 to 1.5765
F
OD of starter jaw...___..-__- 1.5748 to 1.5753
F-N
Fit of gear on jaw...-_-_-..- 0.0002L to 0.0017L
114
M-N
Desired backlash (at mean di
mension) with starter driven
bevel gear-_,.-_-----._---- 0.0080 to 0.0120
Total backlash--.--__-._.--. 0.0048 to 0.0152
114
N-P
Desired backlash (at mean di
mension) with scavenger aid
pump bevel gear.-_....._-- 0.0080 to 0.0120
Total backlash-------------- 0.0060 to 0.0140

241130 O5317

Wear limUi

3.1483
3.1511
0.0020L

3.1483
0.0020L
1.5738
1.5758
0.0010L

1.5758
0.0010L
1.5775
1.5738
0.0027L

0.0191

0.0179

253

Figure 115.

Repair and rebuild standard point* of mtasuremrnt for Xarltr drift atmmbiy.

Ut

10
v\

1A

t for starter and generator mounting pilots.

Figure 116.' Repair and rebuild standard points of measuremen

INCHtS

142. Generator Drive Adapttr Assembly

(par. 58)
a. Generator Drive Adapter,
fig. No.

Ktf Ltr

117

B
A
A-B
P
Q
P-Q
B
A

}>oint e/mtatunmtHi

ID of oil seal bore in adapter..

OD of oil seal--------------Fit of seal in adapter. ..,..,.
117
ID of dowel hole in adapter-..
OD of dowel pin-.-----,,-.-.
Fit of pin in adapter- --....-,
116
Pilot ID of adapter-...,.-.-.
Pilot OD of flange on genera
tor assembly.-..-.-- .....
A-B
Fit of generator in adapter..,.
b. Generator Driven Bevel Gear.
117
D
OD of gear..---.----.-.---.
C
ID of generator drive adapter.
C-D
Fit of gear in adapter........
114
Q-R
Desired backlash (at mean di
mension) with generator drive
bevel gear................
Total backlash--.-....-...-.
c. Generator Drive Hevel Gear.
117
J
ID of gear----.-......-.--..
K
OD of bevel gear bearing...-.
J-K
Fit of bearing in gear. --.-...
114
Q-R
Desired backlash (at mean
dimension) with generator
driven bevel gear..........
Total backlash.--.-.-----...
d. Generator Drive Bevel Gear Bearing.
117
L
ID of bearing (after assembly).
H
OD of bearing surface on gen
erator drive bevel gear shaft.
H-L
Fit of gear in bearing........
117
F
ID of dowel hole through bear
ing-.---.-----....-.----..
E
OD of dowel pin--,-.-.-.-...
E-F
Fit of pin in bearing...._....
e. Generator Drive Bevel Gear Bracket.
117
M
ID of bracket bore.....-. ....
G
OD of generator drive bevel
gear shaft. -.......-.--...
G-M
Fit of shaft in bracket bore...
117
X
ID o dowel hole in bracket.-Q
OD of dowel pin-.-..------N-Q
Fit of pin in bracket.........

25*

Situ and fitt of tuw port*

H'tur linn,

J.999 to 2.O01
2.002 to 2.O06
0.001T to 0.007T
0.2500 to 0.2510
0.2501 to 0.2503
0.0009L to O.0003T
4.125 to 4.127
4.120 to 4.122
0.003 L to 0.007L
1.8720 to 1.8730
1.8750 to 1.8760
0.0020L to O.0040L

1.8700
1.8780
0.00601

0.0080 to O.O120
0.0042 to O.0158

0.0197

1.1875 to 1.1890
1.1900 to 1.1910
0.0010T to O.0035T
0.0080 to O.012
0.0042 to O.0158

0.0197

0.9995 to 1.0005

1.0025

O.9980 to 0.9985
O.0010L to 0.0025L

0. 9960
0. 0045L

O.llSOto 0.1230
O.I 235 to 0.1265
0.0005T to 0.0085T
0.6870 to 0.6880
0.6865 to 0.6870
O.OOOOL to O.O015L
0.2480 to 0.2490
0.2501 to 0.2503
0.001 IT to 0.0023T

Ul

Figure 117.

Repair and rebuild standard points of measurement for generator adapter assembly.

1U K)

143. Magneto Drive Housing Assembly

(par. 58)
a. Magneto Drive Housing Adapter.
Fit No.

Rtf Ltr

Point of mttuuremtiit

ID of adapter....--....----_B
OD of oil seal--------..---.A
A-B
Fit of seal in adapter.....
ID of dowel hole in adapter...
C
118
OD of dowel pin...,.........
J
C-J
Fit of pin in adapter ...--. .
6. Magneto Driven Idler Bevel Gear.
OD of gear. .----...-...-...
V
118
ID of driven idler bevel gear
D
adapter,..................
D-V
Fit of gear in adapter.........
S-T
Desired backlash (at mean
114
dimension) with magneto
drive idler bevel gear.......
Total backlash..............
c. Magneto Drive Housing.
ID of bore in housing.........
G
118
OD of magneto driven idler
E
bevel gear adapter.........
E-G
Fit of adapter in housing.....
ID of bore in housing.........
H
118
OD of magneto gear.........
F
F-H
Fit of magneto gear in housing.
ID of bore in housing........
T
118
U
OD of magneto drive idler
bevel gear................
T-U
Fit of drive idler gear in
housing.._..._...........
K
118
ID of dowel hole in housing....
OD of dowel pin.............
J
J-K
Fit of pin in housing.........
d. Magneto Driven Bevel Gear With Integral
Shaft.
OD of spark advance governor
Q
118
coupling bearing seat on
shaft....__--.--..........
ID of bearing in spark advance
governor coupling.........
Fit of coupling on shaft118
OD of spark advance governor
R
bearing seat on shaft-.-_--.
M
ID of bearing in spark advance
governor assembly.........
M-R
Fit of governor on shaft.
118
OD of adapter bearing seat on
S
shaft.....__--__..._..._..
N
ID of magneto driven bevel
gear adapter..__.._..___..
N-S
Fit of shaft in .adapter. -.__..
118

258

Sittt intrf fill of ntw part*

Vl'Mr limit,

2.1240 to 2.1260
2.1270 to 2.1310
0.0010T to O.O070T
0.2500 to 0.2510
0.2501 to 0.2503
0.0009L to O.O003T
1.6225 to 1.6230

1.6205

1.6250 to 1.6260
0.0020L to 0.0033L

1.6280
0.0045 I

0.0080 to 0.0120
0.0065 to 0.0135

0.0159

2.1875 to 2.1885
2.1860 to 2.1870
0.0005L to O.OO25L
1.3750 to 1.3770
1.3720 to 1.3730
0.0020L to O.OO50L
1.7500 to 1.7510

1.3787
1.3703
0.0067L
1.7530

'1.7480 to 1.7485

1.7460

0.0015L to O.OO30L
0.2490 to 0.2500
0.2501 to 0.2503
0.0001T to O.O013T

0.0050L

0.8715 to 0.8725

0.8695

0.8745 to 0.8755
0.0020L to O.O040L

0.8775
0.0060L

0.8715 ' to 0.8725

0.8695

0.8735 to 0.8740
0.0010L to 0.0025L

0.8760
0.0045L

1.4975 to 1.4985

1.4955

1.5000 to 1.5010
0.0015L to O.OO35L

1.5030
0.0055L

fig flit. Ktf Llr

114

U-V

Point o/MMtir<ie<it

fee and ftt / *tv part*

Desired backlash (at mean di

mension) with magneto drive
bevel gear................ 0.0080 to 0.0120
Total backlash.............. 0.0060 to 0.0140

Wear limit*

0.0179

259

Figure 118.

Repair and rebuild standard points of measurement for magneto drive housing assembly.

144. Governor Drive, Fuel Pump, and Camshaft Drive Housing

(par. 58)

o. Camshaft Drive Housing, Right (1-3-5) Side.

pig No. Ref Ltr

119
119

b.
119

119

114

c.
119

d.
119

119

119

114

Point oj mauurement

A * Pilot ID of housing..........
Pilot OD of governor body.. _
W
Fit of body in housing.......
A-W
Pilot ID of housing-----,.-__
N
Pilot OD of fuel pump drive
H
adapter._._-.___-_._.____
Fit of adapter in housing.
H-N
Camshaft Driven Idler Bevel Gear.
OD of gear _,._-___.___._.__
T
ID of bearing in camshaft drive
P
housing. -,-_-_-.--.._-.,_
P-T
Fit of gear in housing........
ID of oil transfer inner plug
S
hole in gear..-_-.._.-..._.
OD of camshaft drive oil trans
R
fer inner plug ..._-...-,.R-S
Fit of plug in gear,.,-____.._
G-H
Desired backlash (at mean
dimension) with camshaft
drive idler bevel gear.
Total backlash......---..-_Camshaft Drive Shaft.
ID of inner end of shaft-----C
Spherical OD of camshaft drive
Q
oil transfer inner plug.
Fit of plug in shaft. _-.-.---C~Q
Governor Bevel Gear.
ID of governor drive shaft hole
D
in gear.-----------------OD of drive shaft on governor
V
lower race. _--.-- r --------D-V
Fit of shaft in gear,_,....._Distance across flats in square
E
hole in gear..-.,---------Distance across flats of square
U
end of drive shaft on gover-'
nor lower race_ - ___--_'_E-U
Fit of square shaft in gear.
OD of gear._----..--------F
ID of bearing in camshaft drive
B
housing. __._--.----_----B-F
Fit of gear in housing -------J-K
Desired backlash (at mean di
mension) with fuel pump
bevel gear.-_-_-_-.-------
T otal backlash --------------

.Size* and fit* of new partt

Wear limits

3.000 to 3.001
2.997 to 2.999
0.001L to 0.004L
3.125 to 3.126
3.123 to 3.124
0.001 L to 0.003L
1.3095 to 1.3105

1.3075

1.3125 to 1.3135
0.0020L to 0.0040L

1.3155
0.0050L

0.6245 to 0.6255

(*)

0.6260 to 0.6270
0.0005T to 0.0025T

(*)
(*)

0.0080 to 0.0120
0'0058 to 0.0142

0.0181

0.4995 to 0.5005

0.5020

0.4970 to 0.4980
0.0015L to 0.0035L

0.4955
0.0050L

0.6250 to 0.6260

0.6280

0.6240 to 0.6245

0.6220

0.0005L to 0.0020L

0.0040L

0.312 to 0.314

0.319

0.304 to 0.306
0.006L to 0.010L
0.9970 to 0.9980

0.299
0.015L
0.9950

0.9995 to 1.0005
0.0015L to 0.0035L

1.0025
0.0055L

0.0080 to 0.012
0.0059 to 0.0141

0.0180

26?

e. Fuel Pump and Governor Drive Bevel Gear.

Fig tta. Kef Ltr

119

114

/.
119

119

114

114

262

Paint of mttuurrmritt

AtoM md ftt ol MW p*rt

M
P

ODof gear..----.,-------..
ID of bearing in camshaft drive
housing,.-----..--------M-P
Fit of gear in housing- ..__,..
K-L
Desired backlash (at mean
dimension) with fuel pump
bevel gear. _.-.-.-------..
Total backlash.--....----...
Fuel Pvmp Bever Gear.
L
Large OD of gear__-..__-..
K
ID of large bearing in fuel
pump drive adapter. ____..K-L
Fit of large OD of gear in
adapter. ..--.--..--._--.G
Small OD of gear....,.--_-..
J
ID of small bearing in fuel
pump drive adapter..__-..G-J
Fit of small OD of gear in
adapter. .-_..-...--.-_-..
K-L
Desired backlash (at ntiear
dimension) with governor
and fuel pump drive bevel
gear.....---------------. Total backlash.--.-..--- ....
J-K
Desired backlash (at mean
dimension) with governor
bevel gear- _.--....--__.-.
Total backlash..-....-.-_--.

Wear limn,

1.3095 to 1.3105

1.3075

1.3125 to 1.3135
0.0020L to 0.0040L

1.3155
0.0060L

0.0080 to 0.0120
0.0059 to 0.0141

0.0180

1.9335 to 1.9345

1.9320

1.9360 to 1.9370

1.938.5

0.0015L to 0.0035L
0.9980 to 0.9990

0.0050L
0.9965

1.0000 to 1.0010

1.002,5

'

0.004.5L

"01 toO.OOSOL

0.0080 tc J.J12
0.0059 to 0.0141

0.0180

0.0080 to 0.0120
0.0059 to 0.0141

0.0180

Figure 119. Repair and rebuild standard points oj measurement for governor drive, fuel pump, and camshaft drive housing.

RA

145. Power Tdce-Off Drive Assembly

(par. 58)
o. Power Take-0/ Drive Shaft.
Fig No.

Rtf Ur

112
113

J
V
J-V
L
N

Point of mtaturtr*t*t

OD of small end of shaft. .....

ID of bearing in accessory case.
Fitof shaft in case..---....-.
1 12
OD of large end of shaft,....,
ID of bearing in power take-off
drive adapter.. ...... _....
L-N
Fit of shaft in adapter. ->....
6. Power Take-OS J^i* Adapter.
112
%I
Pilot OD of adapter-----..-H
ID of pilot bore in accessory
112

H-M
Q
P
P-Q

Fit of adapter in case. .__._.

ID of bearing bore in adapter.
OD of bearing....-.-----...
Fit of bearing in adapter - ...

1 .4970 to 1 .4980
1 .5000 to 1.5010
0.0020L to 0.0040L
1.7470 to 1.7480

H'eor limit*
1.4950
1.5030
0.0060L
1.7450

1.7500 to 1.7510
0.0020L to 0.0040L

1.7530
0.0060L

Situ and flti of new parti

4.6230 to 4.6240
4.6250 to 4.6270
0.0010L to 0.0040L
2.0000 to 2.0010
2.0015 to 2.0025
0.0005T to 0.0025T

146. Camshaft and Drive, Right (1-3-5) Side

(par. 61)
a. Camsha/ts,
fig No. Rtf Ltr
Point of mtarurement
120
Y
OD of camshaft journals _.._._
Maximum out-of-round of jour
nals full indicator reading,..
Maximum run-out of center
journal when supported on
end journals full indicator
reading.- _____.._.,.__-_-.
122
K
ID of camshaft bearings......
120
K-Y
Fit of bearings on journals....
120
X
OD of large journal on end of
camshaft _..--..-._---.-.Z
ID of bearing in camshaft gear
housing. _----...-_----*-.
X-Z
Fit of camshaft in housing....
6. Camshaft Driven Idler Bevel Gear.
120
B
ID of gear. _..........-.--..
EE
OD of camshaft drive oil trans
fer inner plug...._.-_.-.-.
B-EE
Fit of plug in gear. .____,--.120
A
OD of gear........----,--.C
ID of bore in camshaft drive
housing. ___,__._____,---.
A-C
Fit of gear in housing ___,...114
G-H
Desired backlash (at mean di
mension)
with camshaft
drive idler bevel gear__.....
Total backlash..-.--._------

264

Sfztt and fit* of new part*

1.3090 to 1.3100

WeaTlimtti
1.3070

0.0010

0.0020

0.0020
1.3120 to 1.3130
0.0020L to 0.0040L

0.0150
1.3150
0.0060L

2.4965 to 2.4975

2.4945

2.5000 to 2.5010
0.0025L to 0.0045L

2.5030
0.0065L

0.6245 to 0.6255

(*)

0.6260 to 0.6270
0.0005T to 0.0025T
1.3095 to 1.3105

(*)
(*)
1.3075

1.3125 to 1.3135
0.0020L to 0.0040L

1.3155
0.0060L

0.0080 to 0.0120
0.0058 to 0.0142

0.0181

c. Camshaft Drive Bevel Gear.

fig .Vo.

120

120

114

d.
120

120

114

e.
120

/.
120

Q120

120

120

Ref Llr

Point of meaturement

OD of gear.._-._.,.._.____.
ID of camshaft drive shaft
support -.-.----._._-___.._
Fit of gear in support...-,--_
D-CC
ID of gear..-.---__._.___--_
BB
OD of camshaft drive oil trans
H
fer outer plug---,_.___..__
Fit of plug in gear.....__.___
H-BB
Desired backlash (at mean
A-B
dimension) with camshaft
bevel gear._.______,-__.__
Total backlash,-_...-__-___-_
Camshaft Bevel Gear.
OD of pilot on gear,__.-_.,__
V
ID of mating bore in cam
W
shaft. ..... --_-_,___.--___
Fit of gear pilot in camshaft- - V-W
ID of gear..................
U
Small OD of camshaft oil re
J
taining cover. ---,_-_,-_--.
Fit of cover in gear,-.., _____
J-U
Desired backlash (at mean
A-B
dimension) with camshaft
drive bevel gear.._________
Total backlash- _._.__.____._
Camshaft Drive Shaft.
ID of both ends of shaft_...
F
Spherical OD of camshaft
G
drive oil transfer inner and
outer plugs.,-__..._---..Fit of plug in shaft-_-..----F-G
Camshaft Gear Housing.
ID of bore in housing. .____..
AA
OD of camshaft drive shaft
DD
support- ._..----_-----_-Fit of support in housing ----A A-DD
Tachometer Drive.
Distance across flats of square
L
end of tachometer drive
shaft-_.,___--_--_--..----Distance across flats of hole in
K
camshaft oil retaining cover.
Fit of shaft in cover. ... - ----K-L
OD of tachometer drive shaft.
M
ID of tachometer drive adapter
T
bearing. ,____._-__-_-_-_-Fit of shaft in bearing-.__..-.
M-T
Pilot OD of tachometer drive
N
adapter. _____--_------_ID of adapter bore in camshaft
E
gear housing.------------Fit of adapter in housing.....
E-N
D
CC

Sizet and fttt of new parts

Wear limits

1.4030 to 1.4040

1.4010

1.4065 to 1.4075
0.0025L to 0.0045L
1.0750 to 1.0760

1.4095
0.0065L
1.0770

1.0740 to 1.0745
0.0005L to 0.00201-

1.0730
0.0030L

0.0060 to 0.012
0.0055 to 0.0165

0.0204

1.3115 to 1.3125
1.3120 to 1.3130
0.0015L to 0.0005T
1.0000 to 1.0010
0.9980 to 0.9990
0.0010L to 0.0030L
0.0060 to 0.0120
0.0055 to 0.0165

0.0204

0.4995 to 0.5005

0.5020

0.4970 to 0.4980
0.0015L to 0.0035L

0.4955
0.0050L

2.4380 to 2.4390
2.4367 to 2.4377
0.0300L to 0.0023L

0.507 to 0.509
0.510 to 0.512
0.001L to 0.005L
0.7470 to 0.7480

0.7450

0.7495 to 0.7505
0.0015L to 0.0035L

0.7525
0.0055L

4.3090 to 4.3110

4.3070

4.3125 to 4.3135
0.0015L to 0.0045L

4.3155
0.0065L

265

Fiff >V

120

Kff tlr

P
Q

120

P Q
R
S
R-S

266

Point of m<eamtntt

11) of oil seal bore in tachometer

drive adapter...
()1) of tachometer drive adapt
er oil Meal
Fit of *eal in adapter .....
II) of bearing lH>re in tach
ometer drive adapter. .
01.) of adapter Ix-ariiiK-... . .
Fit of twarinK in adapter...

Stirs and /tit of nru port*

Wear li

1.499 to 1.500

(*)

1.501 to 1.505
O.OO1T to 0.006T

()
(*)

0.8750 to 0.8755
0.8770 to 0.8780
O.OO15T to 0.0030T

(*)
(*)
(*)

Figure 120.

Repair and rebuild standard points of measurement for camshaft and drnv, right (1-S-S) si<ie.

RA PD 196960

147. Camshaft and Drive, Left (2-4-6) Side

(par. 61)
a. Camshafts.
Point of mtaturenunt
OD of camshaft journals.
Maximum out of round of
journals. Full indicator
reading.__--___._---.._.-Maximum run out of center
journal when supported on
end journals. Full indicator
reading. ..................
122
K
ID of camshaft bearings.
K-S
Fit of bearings on journals
ID of rocker box cover plate
121
G
(cylinder No. 6) ----------G-S
121
Fit of camshaft in plate.
121
T
OD of large journal on end of
camshaft. . ...............
121
ID of bearing in camshaft gear
housing... ......-.--_...F-T
Fit of camshaft in housing
6. Camshaft Driven Idler Bevel Gear.
ID of gear. .................
121
M
K
OD of camshaft drive oil trans
fer inner plug.-----------K-M
Fit of plug in gear. __-_.____.
L
OD of gear. _____-..--._-...
121
ID of bore in camshaft drive
J
housing .__.-__.-----_---J-L
Fit in gear in housing. -._..-.
G-H
114
Desired backlash (at mean di
mension)
with camshaft
drive idler bevel gear. ____.
Total backlash.......--__--.
c. Camshaft Drive Bevel Gear.
OD of gear. ______.__-,---..
121
P
H
ID of camshaft drive shaft
support. -_----------_---H-P
Fit of gear in support. -_...-ID of gear. __.-...-----_---.
121
Q
C
OD of camshaft drive oil trans
fer outer plug. ............
C-Q
Fit of plug in gear. ----__--..
A-B
Desired blacklash (at mean
114
dimension) with camshaft
bevel gear, .______-_-__.__
Total backlash-..---.-- ----d. Camshaft Bevel Gear.
121
B
OD of pilot on gear. --------U
ID of mating bore in camshaftB-U
Fit of gear pilot in camshaft..
Fig ATo.
121

268

Ref Ltr
S

Size* and fiti of new part

1.3090 to 1.3100

Wear limit)
1.3070

0.0010

0.0020

0.0020
1.3120 to 1.3130
O.O020L to 0.0040L

0.1050
1.3150
0.0060L

1.3120 to 1.3130
0.0020L to 0.0040L

1.3150
0.0060L

2.4965 to 2.4975

2.4945

2.5000 to 2.5010
0.0025L to 0.0045L

2.5030
0.0065L

0.6245 to 0.6255

(*)

0.6260 to 0.6270
0.0005T to 0.0025T
1.3095 to 1.3105

(*)
(*)
1.3075

1.3125 to 1.3135
0.0020L to 0.0040L

1.3155
0.0060L

0.0080 to 0.0120
0.0058 to 0.0142

0.0181

1.4030 to 1.4040

1.4010

1.4065 to 1.4075
0.0025L to 0.0045L
1.0750 to 1.0760

1.4095
0.0065L
1.0770

1.0740 to 1.0745
0.005L to 0.0020L

1.0730
0.0030L

0.0060 to 0.012
0.0055 to 0.0165

0.0204

1.3115 to 1.3125
1.3120 to 1.3130
0.0015L to 0.0005T

fig Ho. Re) Ltr

121

114

V
A
A-V
A-B

e. Camshaft
121
E
D
D-E
/. Camshaft
121
R
N
N-R

Point of measurement

IDof gear......-_.-...._-..
Small OD of camshaft oil re
taining covers.-...........
Fit of cover in gear. -...---..
Desired backlash (at mean dimeneion) with camshaft
drive bevel bear. ..........
Total backlash.--...--..---.Drive Shaft.
ID of both ends of shaft.--..Spherical OD of camshaft drive
inner and outer oil transfer
plugs.-...-----..-------Fit of plug in shaft..........
Gear Housing.
ID of bore in housing-------OD camshaft drive shaft support-----.-----.------Fit of support in housing.....

241130 O53

8ize and fit* of new parts

Wear limitt

1.0000 to 1.0010
0.9980 to 0.9990
O.OOIOL to 0.0030L
0.0060 to 0.0120
0.0055 to 0.0165

0.0204

0.4995 to 0.5005

0.5020

0.4970 to 0.4980
0.0015L to 0.0035L

0.4955
0.0050L

2.4380 to 2.4390
2.4367 to 2.4377
0.003L to 0.0023L

269

Figure 121.

Repair and rebuild standard points of measurement for camshaft and drive, left (-4-6) side.

148. Cylinder*
(par. 64)
a. Cylinder Barrel.
Fig No,

122
124

6.
122

c.
122

122

d.
122
122
e.
122

122

RefLtr

Point of meatuTtment

OD of cylinder barrel...-.-,.
AA
ID of cylinder pad bore in
A
crankcase-..-.-._--.-_---_
Fit of cylinder barrel in crankA-AA
case--. ._.,..._.._.___..-.
Bore.
Cylinder
Bore diameter 1 inch from bot
BB
tom of skirt (bottom of ring
travel)-..................
Bore diameter opposite center
of barrel fins.--.........-.
Bore diameter at top of cylinber barrel.-.__._..........
Maximum out of round of cyl
inder bore..-.-.-_-._...-.
Valves.
OD of intake valve stem. -.-.
A
ID of intake valve guide.-...
H
Fit of stem in guide.---__-.-.
A-H
Angle of intake valve seat with
stem--..---.-------_ ----OD of exhaust valve stem..-_
EE
ID of exhaust valve guide..- _
U
Fit of stem in guide.--------U-EE
Angle of exhaust valve seat
with stem.._--.. _---..
Valve Guides.
OD of intake valve guide......
G
ID of guide bore in cylinder head.
X
Fit of guide in cylinder head...
G-X
OD of exhaust valve guide-..-.
V
ID of guide bore in cylinder head.
Y
Fit of guide in cylinder head...
V-Y
Intake Valve (Seat) Inserts.
Small OD of insert.----.,---C
Small ID of bore in cylinder
head..-------------------Fit of insert in bore...-.-Large OD of insert----------B
Large ID of bore in cylinder
head .______..--. - Fit of insert in bore. ...._...
Width of valve seat....------Angle of seat....-------------

Mzet and fu of new parts

Wear Hmit

6.112 to 6.116
6.125 to 6.130
0.009L to 0.018L

5,7460 to 5.7490

5.7590

5,7425 to 5.7455

5.7550

5.7380 to 5.7410

5.7537

0.0010

0.0030

0.4975 to 0.4980
0.4995 to 0.5005
0.0015L to 0.0030L

0.5020
0.0050L

45 deg 15 min
0.5575 to 0.5580
0.5615 to 0.5625
0.0035L to 0.0050L

0.5660
0.0080L

45 deg 15 min
0.6890 to 0.6895
0.6870 to 0.6880
0.0010T to 0.0025T
0.7525 to 0.7530
0.7495 to 0.7505
0.0020T to 0.0035T
2.6928 to 2.6942
2.6840 to 2.6860
0.0068T to 0.0102T
3.1220 to 3.1260
3.1300 to 3.1320
0.0040L to 0.0100L
0.16
0.06 to 0.09
44 deg 45 min to 45
deg 0 min.

Angle of relief (for narrowing

width of seat)-..---------- 30 deg and 60 deg

271

/ Kxkautt Vaivt (Seat)

Fiff .Vo.

122

Htf Llr

/Vl of me<twtme*l

CC

Small OD of insert
Small ID of bore in cylinder
head
.. . .
Fit of insert in bore
Urge OH of inaert. ....
Large If) of bore in cylinder
head
....... _ . .
Fit of insert in bore
Fit of vsive .scat
Angle of neat

DD

.u** and fit of

2.2558 to 2.2572
2 2470 to 2 2490
0 0008T to 0 OI02T
2.6840 to 2 6880
2 6920 to 2.6940
0.0041, to O.OIOOL
0.06 to 0.011
44 tleg 45 ruin to 45
deg 0 ruin

O.ltt

Angle of relief (for narrowing

width of seat)
30 deg and 60 deg
g. Valve Springs.
122
R
Outer valve spring (large):
Scale reading
. . . . .
124 4 Ib 10% at
1 56 in
Scale readin . ...
85.0 Ib i 5% at 2 12
in
Maximum solid height . . . .
1.47 in
122
S
Intermediate valve spring (me
dium)
Scale reading ........ 74.9 Ib f 10% l
1.56 in
Scale reading ...... . . .. 51.2 Ib 5% at 2.12
in

122

Maximum solid height

Inner valve spring (small).
Scale reading
. . . .
Scale reading

1.34 in
.

. ......

Maximum solid height . . . .

h. Valve Spring Keats.
122
J
ID of valve spring seat (both
halves) ....
.
, .
VV
Large OD of valve guides (on
short end).. . ... . - .
J-W
Fit of seat on guides..
.
t. Valve Rocker Shaft.
122
M
OD of shaft........ .
\
ID of valve rocker bearing.
M-X
Fit of shaft in bearing .......
122
L
ID of holes in valve rocker
shaft bracket and camshaft
bearing cap. ..............
L-M
Fit of shaft in bracket and cap.

272

40.0 Ib 10% at
1.38 in
25.8 Ib 5% at 1.93
in
1.28 in
0.7870 to 0.7930
0.7780 to 0.7840
0.0030L to 0.01501.
0.7480 to 0.7485
0.7495 to 0.7505
0.0010L to 0.0025L
0.7485 to 0.7495
O.OOOOL to 0.0015L

0.7455
0.7530
0.0050L

j. Camthaft Bearing Cap and Rocker Shaft Bracket.

Kef Ur

Paint of me<aurr*trt

122

122
121

F
F-Q
K
S

ID of dowel holes in bearing

cap and rocker shaft
bracket ...................
ODof dowel pinH _,-.----_
Fit of pint) in cap and bracketID of camshaft bearing.......
OD of camshaft journal, left
(2-4-6) side ............
OD of camshaft journal, right
(1-3-5) Hide ....... - ... .
Fit of bearing on journal (both
side*)....
........

ftp A'o

120

AA
K-S
K-AA

Site* o*4 fti of ntw part*

Wear l+nit*

0.2500 to 0.2510
0.2501 to 0.2503
0.0009L to 0.0003T
1.3120 to 1.3130

1.3150

1.3090 to 1.3100

1.3070

1.3090 to 1.3100

1.3070

0.0020L to 0.0040L

0.0060L

Jt. Cylinder Head Dowtl fins.

122

F
K-F

ID of dowel hole* in cylinder

0.2470 to 0.2480
head . . . . . .............
0.2501 to 0.2503
OD of dowel pins.......
Fit of piiiH in cylinder head. _.. 0.002IT to 0.0033T

273

K>

Figure 122.

Repair and rebuild standard points of measurement for cylinders.

149. Pistons
(par. 67)
a. Pitton Diameter .
ftt -V- Ktf UT
of mearurement
123
H
Piston diameter at top of skirt
at 90 deg to piston pin......
J
Piston diameter at bottom of
skirt at 90 deg to piston pin.
6. Pitton Ringt.
123
A
Outside width of compression
ring (Xo. 1 (top) ring),.,,.
X
Inside width of No. 1 ringgroove

A-X

123

B
W
B-W

123

C
F
OF

123

D
G
D-G

Size* and fitt of new parti

Wear liniu

5.7285 to 5.7305

5.72551

5.7320 to 5.7330

5.7290

0.0925 to 0.0935

in piston ................. 0.0980 to 0.0990

Fit (side clearance) of Xo. 1
ring in groove,__,.-.___._ 0.0045L to 0.0065L
Gap clearance of Xo. 1 ring
when fitted in 5.750 inch
ring gage.-.-.-_. ......... 0.0500 to 0.0600
Outside width of compression
ring (Xo. 2 ring) .......... 0.0925 to 0,0935
Inside width of Xo. 2 ring groove
in piston_,....,_._-_____.. 0.0980 to 0.0990
Fit (side clearance) of Xo. 2
ring in groove.,...-_-__.-. 0.0045L to 0.0065L
Gap clearance of Xo. 2 ring
when fitted in 5.750 inch
ring gage.,.-.--------.--. 0.0500 to 0.0600
Outside width of oil control
ring (Xo. 3 ring).......... 0.1860 to 0.1865
Inside width of No. 3 ring
groove in piston.... ....... 0.1890 to 0.1900
Fit (side clearance) of Xo. 3
ring in groove..----------- 0.0025L to 0.0040L
Gap clearance of Xo. 3 ring
when fitted in 5.750 inch
ring gage---_------.-.,--- 0.0350 to 0.0450
Outside width of oil control
ring (No. 4 (bottom) ring).. 0.1860 to 0.1865
Inside width of No. 4 ring
groove in piston.... ..,_,-. 0.1880 to 0.1890
Fit (side clearance) of Xo. 4
ring in groove... .......... 0.0015L to 0.0030L
Gap clearance-of Xo. 4 ring
when fitted in 5.750 inch
ring gage---_.---.-.--.--- 0.0350 to 0.0450

c. Piston Pin.
123
U
OD of piston pin.....-...--V
ID of piston pin hole in piston.
U-V
Fit of pin in piston ...-.....123
R
ID of piston pin bearing._.-,R-U
Fit of pin in bearing..------123
T
ID of piston pin.---.-------E
OD of piston pin plug-------E-T
Fit of plug in pin. ..........

1.3750 to 1.3752
1.3755 to 1.3757
0.0003L to 0.0007L
1.3762 to 1.3764
0.0010L to 0.0014L
0.9678 to 0.9688
0.9668 to 0.9678
O.OOOOL to 0.0020L

0.1025
O.OlOOL
0.0650

0.1015
0.0090L
0.0650

0.1910
0.0050L
0.0600
0.1850
0.1910
0.0040L
0-060
1-3745
1.3762
0.0012L
1.3770
0.0020L

275

296961 Od V

td .I0f t'>M.>.

150. Crankcase
(par. 69)
a. Cylinder Pad Bore.
fig No.

124

Ke/ttr

Point of meaturement

fiHetandfUiofnewpart,

ID of cylinder pad bore in

crankase....-._._.-..___ 6.125 to 6.130
122
AA
OD of cylinder barrel..--..., 6.112to6.116
122
A^AA Fit of cylinder barrel in bore .. 0.009L to 0.018L
6. Main Bearings.
124
F
ID of bearing bore in crankcase...................... 3.8140 to 3.8145
124
C
Main bearing thickness....... 0.1562 to 0.1567
124
K
Outside width of thrust main
bearing web in crankcase..- 1.745 to 1.747
I)
Inside width of thrust main
bearing face_.___.,_...___ 1.749 to 1.751
E-D
Fit of bearing over crankcase
web...................... 0.002L to 0.006L
125
M
OD of main bearing journals on
crankshaft-------.------.. 3.4970 to 3.4980
124
B
ID of main bearings at proper
tightness._-__..._._..._,_ 3.5015 to 3.5040
B-M
Fit (oil clearance) of bearings
on journals- -.._--.--.._,. 0.0035L to 0.0070L
c. Fan Drive Shaft Bearing and Bearing Housing Bores.
126
B
ID of bearing housing bore in
crankcase_.._.-.__-...._ 4.7500 to 4.7510
138
Q
OD of bearing housing....... 4.7480 to 4.7490
B~Q
Fit of housing in crankcase... 0.0010L to 0.0030L
126
G
ID of fan drive vertical shaft
bearing bore in crankcase-.. 1.2500 to 1.2510
F
OD of fan drive vertical shaft
bearing-...-.---------.-.- 1.2488 to 1.2493
F-G
Fit of bearing in crankcase.,-- 0.0007L to 0.0022L
126
H
ID of vertical shaft bearing
dowel pin hole in crankcase- 0.1835 to 0.1845
E
OD of vertical shaft bearing
dowel pin.....------------ 0.1850 to 0.1870
E-H
Fit of pin in crankcase....... 0.0005T to 0.0035T
126
D
ID of fan drive bevel gear bear
ing bore in crankcase------- 1.6880 to 1.6890
C
OD of fan drive bevel gear
bearing,-.--..-------.--.- 1.6875 to 1.6880
C-D
Fit of bearing in crankcase..-- O.OOOOL to 0.0015L

Wearlimiti

0.1542
(*}
(*)
(*)
3.4957
3.5053
0. 0085

277

Figure 124-

Repair and rebuild standard points of measurement for rranfcrase anrf crankshaft.

Figure 125.

Repair and rebuild standard points of measurement for crankshaft and flywheel.

RA PO

'iHtirf

12t

Kepair anil rehutlii standard points of mrasurrntent for rrankrnse fastening parts.

--?S;5..,T^. - *'^'^^Pjr.-'

' ^:\^j^'|jjfc'*j|J|gji.
':;""- 'vv..'.j,;:r>>V'' . : ':*'f ^'"";.-^^:""'-'': -:'>^" ^>;:' -" ;::: ' '-';.-.;'? ;";":: y-^-i-U'""' "''"' 1=

^V:': .^-V^:10|45^^^

151. Crankshaft and Connecting Rod Assembly

(par. 27)
a. Crankshaft.
Fig No. Ref Ltr

125

125

A
A-B
K
F

125

F-K
D

125

E
D-E
L
J

125
124

J-L
M
B
B- M

125

125
123

C
X
C-N

125

Point of measurement

Crankshaft to be in dynamic
balance within 0.25 oz-in at
2,800 rpm.
ID of oil slinger bore in crankhaft.,.__.__._-..........
OD of crankshaft oil slinger -..
Fit of Hlingcr in crankshaft _...
ID of transmission drive shaft
pilot bearing bore in crank
shaft .. _. - ..-..._-.__-_..._
OD of transmission drive shaft
pilot ball bearing..........
Fit of bearing in bore........
1D of flywheel dowel pin hole in
crankshaft -.----__.-_-.-._
OD of flywheel dowel pin.-.-.
Fi t of pin in crankshaft......
OD of flywheel end of crank
shaft-....---------------ID of crankshaft pilot bore in
flywheel.._____._____._-._
Fit of flywheel on crankshaft-.
OD of main bearing journals,.
FD of main bearings at proper
tightness. .......--.-..-..
Fit (oil clearance) of bearings
on journals.__-_._----_..Taper in length of one main
bearing journal (must be
uniform) ._-_---.---.----Maximum out of round of main
bearing of journals,. ------Maximum run-out of Nos. 2 and
3 main journals when sup
ported at Nos. 1 and 4
journals full indicator read
ing- _..--.---.._--------OD of connecting rod journal- ID of connecting rod bearing at
proper torque tightness on
bolts (par 163)......-.--Fit (oil clearance) of journal in
bearing.. ..-._..--.------Inside width of connecting rod
journal. - -----------------

Size* and fitt of new partt

Wear UmU

1.569 to 1.571
1.571 to 1.572
O.OOOOT to 0.003T
2.8338 to 2.8346

2.8350

2.8340 to 2.8346
0.0006L to 0.0008T

2.8336
0.0010L

0.6245 to 0.6255
0.6255 to0.6257
O.OOOOT to 0.0012T

(*)
(*)
(*)

6.9985 to 6.9995
7.0000 to 7.0010
0.0005L to 0.0025L
3.4970 to 3.4980

3.4957

3.5015 to 3.5040

3.5053

0.0035L to 0.0070L

0.0085

0.0005

0.0010

0.001

0.005
3.2480 to 3.2490

0.006
3.2460

3.2525 to 3.2540

3.2560

0.0035L to 0.0060L

0.0080L

1.577 to 1.581

1.584

281

fif \o.

123

Kit ttr

P
C-P

125

Putml of *MHrwa|

Outside width of crankshaft

end of connecting rod Fit (aide clearance) of rod on
crankshaft. __._,...__....,
Maximum out of round of con
necting rod journal-...-.-.
Taper in length of one journal
(must be uniform). .......

b. Main Bearings.

124

125
124
125
124
c.
123

123
123

123
123

125
123
125

282

M** n<J fit of flf peril

Wt*r lt+tl,

1.567 to 1,569

1.564

0.008L to 0.014L

0.017L

O.OO10

0.0020

0.0005

0.0010

Outside width of thrust bear

ing ..,,,.....,.. 1.9890 to 1.9910
X
Inside width of thruat bearing
journal- 1.9990 to 2.0010
C-X
Cranknhaft end play.
O.OO80 to 0.0120
B
ID of main bearing,* at proper
tightness ...-..-..-,.
3.5015 to 3.5040
M
OD of main bearing journals.. 3.4970 to 3.4980
B-M
Fit (oil clearance) of bearings
on journals,.............. O.OO35L to 0.0070L
C
Main bearing thickness (std). 0.1562 to 0.1567
Connecting Rods.
K
ID of piston pin bearing bore
in connecting rod........ .. 1.5340 to 1.5350
S
OD of piston pin bearing. . . .. 1.5370 to 1.5375
K-S
Fit of bearing in rod....... .. 0.0020T to 0.0035T
R
ID of piston pin bearing.... .. 1.3762 to 1.3764
Lr
OD of piston pin.......
1.3750 to 1.3752
K-l"
Fit of pin in bearing......... O.OOIOL to 0.0014L
L
ID of bolt hole in connecting
rod and cap .............. 0.5620 to 0.5630
Q
OD of connecting rod bolt. ... 0.5613 to 0.5618
L-Q
Fit of bolt in rod and cap. - . .. O.OO02L to 0.0017L
P
ID of bore of large (crank
shaft) end of connecting rod. 3.5315 to 3.5320
X
ID of connecting rod bearing
when installed with proper
torque on bolts (par. 163)
3.2525 to 3.2540
Rod bearing thickness at ends. 0.1389 to 0.1392
Rod bearing thickness at cen
ter....................... 0.1394 to 0.1397
C
OD of crankshaft journal. . _ .. 3.2480 to 3.2490
C-X
Fit (oil clearance) of bearing
journal-.................. O.OO35L to 0.0060L
P
Outside width of connecting
rod at crankshaft end....... 1.567 to 1.569
C
Inside width of connecting rod
journal.----..-.....-...-. 1.577 to 1.581
C-P
Fit (side clearance) of rod on
crankshaft................ O.OO8L to 0.014L
Allowable twist of connecting
rod._......_............. O.OO05 per inch of
bearing length

1.9840
2.0060
0.0170
3.5053
3.4957
0.0085
0.1542

1.3770
1.3745
0.0020L

3.2560
0.1379
0.1384
3.2460
0.0080L
1.564
1.584
0.017L

d. Crantthqfl Vibration Damper.

rt0H. KtfLt,

Potet / mttmremet

&** *t fill of *tu> part,

H'f

1.8160
ID of damper hub holes.,.-,,. 1.8125 to 1.8140
1.3630
OP of counterweight pin,..,.. 1.3647 to 1.3657
493L
0.4468Lto0.4
.....
hub-.......
in
Fit of pin
1.8160
IDof counterweight holes..... 1.8125 to 1.8140
127
Fit of pin in counterweight.... 0. 4468L to 0,4493L
OD of counterweight pin bush
127
1.6980
1.6994 to 1.7O04
ing
counter
in
Fit of bushing
D~L
weight................... O.H2lLto0.1146L
Fit of bushing in damper hub,. 0.1121L toO. 1146L
F-L
127
ID of counterweight stop
A
127
plate....... ............. 3.6875 to 3.6000
OD of damper hub flange,.,. _ 3.6855 to 3.6870
G
Fit of stop plate on hub..----- 0.0005L to 0.0045L
A-G
0.7690
Inside width of counterweight- 0.7570 to 0.7630
K
127
0.7430
0.7510
to
0.7490
hub........
damper
of
Width
H
0.0200L
Fit of counterweight over hub. 0.0060L to 0.0140L
H-K
Outside width of counterE
J27
weight.................... 1.6530 to 1.6630
Inside width of counterweight
B
pin...-...-....,......-..- 1.6750 to 1.6800
Fit end play of pin in counter
B-E
weight.-. .-_---.--_-,.--.- 0.0120L to 0.0270L
OD of male counterweight pin, 0.8730 to 0.8740
J
127
IDof counterweight bushing.. 0.8745 to 0.8755
X
Fit of male pin in bushing.... 0.0005L to 0.0025L
X-J
OD of female counterweight
P
127
pin..,..,.-..---..---...-. 0.8730 to 0-8740
Fit of female pin in bushing.. O.OOOoL to 0.0025L
P-X
e. Flywheel and Torsion Damper.
Note. See paragraph 159 for internal flywheel and torsion damper standards.
(*)
OD of flywheel dowel pin..... 0.6255 to 0.6257
E
125
ID of dowel pin hole in crank
D
(*)
shaft.,...-. .............. 0.6245 to 0.6255
Fit of pin in crankshaft...... O.OOOOT to 0.0012T (*)
D-E
(*)
ID of dowel pin hole in fly wheel 0.6245 to 0.6255
G
125
(*)
0.0012T
to
O.OOOOT
.....
flywheel-...
in
Fit of pin
E-G
ID of crankshaft pilot bore in
J
125
flywheel.........--------- 7.0000 to 7.0010
of flywheel end of crank
OD
L
shaft,. .,-.--.----,---.-- 6.9985 to 6.9995
Fit of flywheel on crankshaft- 0.0005L to 0.0025L
J-L
127

F
C
C~F
D
C-D
L

283

RA PO 180599
Figure 127. Repair and rebuild standard points of measurement for crankshaft
vibration damper.

152. Scavenger and Pressure Oil Pump (Dual Unit)

(par. 74)
a. Oil Pump Housings and Separator Plate.
Situ and fttt of netc parti
Point of meaturemtnt
Fig No. Ref Ltr
Thickness of separator plate. ... 0.620 to 0.630
H
128

ID of dowel holes in separator

plate............. ..... ..OD of separator plate dowel pins.
BB
AA-BB Fit of pins in plate.-...-..--.-ID of dowel holes in both pump
W
housings.,...,..__...-.....\V-BB Fit of pins in housings. ........
AA

128

ll'tar limits

0.2490 to 0.2500
0.2501 to 0.2503
0.000 IT to 0.001ST
0.2500 to 0.2510
0.0009L to 0.0003T

6. Impeller End Play.

128

284

Depth of impeller bores in pump

housings:
Scavenger (upper) pump
housing-.------------ 1.628 to 1.630
Pressure (lower) pump
housing.-.-----.----- 1.503 to 1.505

1.633
1.508

fig Ifa. K*1 Ur

C

K-C

e. Impellert
D
128

128

A-D
FF
GG

128

FF-GG
C
B
B-C

128

128

K
K

DD
Y

128

128

Y-DD
F

F-J
EK
Z

128

Z-EE
G

L
G-L

Point o/ mtajnirrment

Length of impellers:
Scavenger pump impel
lers.,-.., ..........
Pressure pump impellers.
End play between impellers and
housing with pump bolted
tight (both pumps)........
and Shafts.
OD of pressure pump end of
driven impeller shaft.......
ID of small bore in pressure
pump housing..__._.._.,__
Fit of shaft in housing. ......
OD of faring surface on pres
sure pump end of pressure
pump drive impeller.......
ID of large bore in pressure
pump housing..._,.__.__..
Fit of impeller in housing.,.,
Major diameter of all im
pellers -_-_..,,_ ........ ...
ID of all impeller bores in both
housings,...,.............
Fit (radial clearance) of im
pellers in housing..........
ID of driven impellers........
OD of impeller bearing sur
faces on driven impeller
shaft..------,------.--.-Fit of impellers on shaft......
OD of bearing surface on shaft
of pressure pump drive im
peller --.-.--.-.-_-------.
ID of scavenger pump drive
impeller..._...._-.----.-.
Fit of impeller on shaft.......
OD of large bearing on oil pump
driven impeller shaft...___.
ID of bore in oil pump sepa
rator plate.._-._---..-----Fit of shaft in plate. ,.,_.----.
OD of large bearing on shaft of
pressure oil pump drive im
peller --_.,------.-------ID of bore in oil pump sepa
rator plate..-_-_,_----.--Fit of shaft in plate. --------OD of bearing surface on scav
enger pump end of driven
impeller shaft._..-_-.---.ID of bearing in scavenger
pump housing-...---.-..-.
Fit of shaft in housing..

241130 O5319

fktet ana fit* o/ new part*

Wear limit t

1.625 to 1.626
1.500 to 1.501

1.622
1,497

0.002 to 0.005

0.008

0.8106 to 0.8110

0.8100

0.8120 to 0.8130
0.0010L to 0.0024L

0.8146
0.0030L

0.9350 to 0.9356

0.9330

0.9370 to 0.9380
0.0014L to 0.0030L

0.9400
O.OOoOL.

2.3306 to 2.3310

2.3290

2.3350 to 2.3360

2.3370

0.0020L to 0.0027L
0.8197 to 0.8202

0.0035 L
0.8216

0.8171 to 0.8175
0.0022L to 0.0031 L

0.8157
0.00451.

0.8192 to 0.8196
0.8197 to 0.8202
0.0001 L to 0.0010L
0.9981 to 0.9985

0.9975

0.9995 to 1.0005
0.0010L to 0.0024L

1.0021
0.0030L

0.9978 to 0.9982

0,9955

0.9995 to 1.0005
0.0013L to 0.0027L

1.0028
0.0050L

0.8106 to 0.8110

0.8100

0.8120 to 0.8130
0.0010L to 0.0024L

0.8146
0.0030L
285

fig

128

*JM <*Mf HI / *** iMrt*

CC

OD of bearing aurfaee on scav

enger pump end of drive
impeller.--.,-.,-.,..,-... 0.8103 to 0.8107
ID of bearing in scavenger
pump housing-............ OKI20 to 0.8130

X-CC
Fit of impeller in housingd. /*ressure Pump Driven Bevel Gear.
OD of gear ...
R
128
ID of bearing in scavenger
8
pump housing. .
R-S
Fit of gear in houning .......
C-D
l>sired backlash (at mean di
114
mension) with pressure pump
.......
drive bevel gear
Total backlash. ..............
t. F*re*sure Pump Drive Revel Gear.
OD of gear
X
128
ID of hearing iu drive bevel
P
support..................
X-P
Fit of gear in support.......
C-D
Desired backlash (at mean di
1 14
mension) with pressure pump
driven bevel gear..........
Total backlash. ...... .......
/. Scavenger Oil Pump Housing.
ID of dowel hole in scavenger
I'
128
pump housing.............
OD of drive bevel gear support
T
dowel pin. ...............
T-t"
Fit of pin in housing. ......
JD of dowel hole in drive bevel
128
Q
gear support .............
Q-T
Fit of pin in support.........
V
ID of outlet line hole in scav
128
enger purnp housing...- . . .
OD of connecting end of scav
M
enger pump outlet line.
M- V
Fit of line in housing.........

286

Writ limit,

0.8080

0.0013L to 0.0037L

O.HI53
0.00501.

1.2480 to 1.2485

1.246.1

1.2500 to 1.2510
0.0015L to 0.00301.

1.2525
0.00451.

0.0080 to 0.0120
0.0065 to 0.0135

0.0174

1.2480 to 1.2485

1.2465

I.250O to 1.2510
0.0015L to 0.0030L

1.2525
0.00451,

0.0080 to 0.0120
0.0065 to 0.0135

0.0174

0.2490 to 0.2500
0.2501 to 0.2503
O.OOOJT to 0.0013T
0.2500 to 0.2510
0.0009L to 0.0003T
0.8745 to 0.8755
0.870O to 0.8740
0.0005L to 0.0055L

OB

Figure 128. Repair and rebuild standard points of measurement for scavenger and pressure oil pump (dual unit}.

RA PD 180600

153. Accessory Case Scavenger Oil Pump

(par. 75)
a. Impeller End Play.
fig Aro
129

Rif Ltr
M

G
M-G
6. Impellers
129
L

129

129

c.
129

129

114

d.
129

129

288

t'oint of mecuurtmtnt

and flit of new parti

Depth of impeller bore in

housing.,.__._. ......... 1.6280 to 1.6300
Length of impellers,...........
1.6250 to 1.6260
Knd play between impellers and
housing with pump bolted
tight.
.......... 0.0020L to 0.0050L

01) of external spline on drive

impeller ....... ..-.-.-...
B
ID of internal spline in bevel
gear . . . . ..........
B-L
Fit of gear on impeller spline...
OD of shafts of both impellers
F
(both ends). ...........
.
ID
of
impeller shaft bores in
D
cover and housing. ........
D-F
Fit of shaft of impellers in cover
and housing____..--.-...._
G
Major OD of both impellers- ..
H
ID of both impeller bores in
housing. ..__....--._-...,G-H
Fit (radial clearance) of impel
lers in housing. ...........
Scavenger Pump Drive Bevel Gear.
OD of bevel gear......... ...
A
C
ID of gear bore in cover......
A-C
Fit of gear in cover..........
B
ID of internal spline in bevel
gear. .... ...............
OD of external spline on drive
impeller ...-......---- ...
B-L
Fit of gear on impeller spline
N-P
Desired backlash (at mean di
mension) with starter drive
bevel gear. ___._..,_..__-.
Total backlash..............
Scavenger Pump Housing.
ID of dowel holes in housing..
K
J
OD of dowel pins... --------J-K
Fit of pins in housing...-.._.
E
ID of dowel holes in cover. _ ,.
E-J
Fit of pins in cover.....---..

It 'tar It mill

1.6330
1. 6230
0. 0080L

0.7885 to 0.7910
0.8300 to 0.8400
0.0390L to 0.0515L
0.8100 to 0.8106

0.8080

0.8120 to 0.8130

0.8150

0.0014L to 0.0030L
2.3306 to 2.3310

0.0050L
2.3290

2.3350 to 2.3360

2.3376

0.0020L to 0.00271,

0.00351,

1.1220 to 1.1230
1.1250 to 1.1260
0.0020L to 0.0040L

1.1205
1.1275
0.0055L

0.8300 to 0.8400
0.7885 to 0.7910
0.0390L to 0.0515L
O.OO80 to 0.0120
0.0060 to 0.0140
0.2480 to 0.2490
0.2501 to 0.2503
0.001 IT to0.0023T
0.2500 to 0.2510
0.0009L to 0.0003T

0.0179

M
09

Figure 129.

Repair and rebuild standard points of measurement for accessory case scavenger oil pump.

7JTJT

RAPD 180601A

154. Cooling Fan and Fan Clutch Assembly

(par. 77)
o. Outer (I'pptr) Clutch Housing,
fit \'o

130
130

Ktf Ltr

Q
8
Q/-S
C
D
C-D

Point of mtturime*t

6. Jnntr (Lower) Clutch Housing.

K
ID of housing ._....-.-...-130

130

c.
130
138
130
130
d.
130
e.
130

/.
130

G
ODof inner hub ball bearing G- K
Fit of bearing in housing
L
ID of dowel hole in housing. _ .
D
OD of dowel pin ............
D-L
Fit of pin in housing.........
Clutch Drive Hub.
E
Small ID of hub ............
E
OD of hub end of fan drive ver
tical shaft .--_.-..-....--_
E-E
Fit of hub on shaft...........
F
OD of large end of hub.......
X
ID of inner hub ball bearing. _ .
F-X
Fit of hub in inner bearing,. ..
P
ODof small end of hub.... . .
R
ID of outer hub ball bearing- .
P-R
Fit of hub in outer bearing. - .
Clutch Driven Disk.
H
ID of dowel hole in driven disk.
D
OD of dowel pin _........--_.
D-H
Fit of pin in disk............
Clutch-to~Rotor Adapter.
A
ID of dowel hole in adapter. - D
OD of dowel pin .-.......-..A-D
Fit of pin in adapter......._.
T
Pilot OD of adapter.-.--..-B
Pilot ID of rotor--.-..-.---B-T
Fit of adapter in rotor. ..,-__
fan Clutch Hall.
J
Spherical diameter of ball-

g. Fan Clutch Springs.

130

290

*4 fit* / **> parti

Wtar Hmtti

2 833(1 to 2.8346
ID of outer housing.......
OD of outer hub ball bearing.. 2. 8341 to 2.83-Hi
O.OOOSLtoO.OOlOT
Fit of bearing in housingID of dowel hole in outer hom
ing ............... ...... 0.2795 to 0.2805
OD of dowel pin ............... 0.2810 to 0.2815
Fit of pin in housing.......... O.OO05T to 0.0020T
2.6774 to 2.6782
2.6767 to 2.6772
OOO02I, to 0.0015L
0.2835 to 0.2845
0.2810 to 0.2815
0.0020L to 0.0035L
0.9845 to 0.9865

0.9885

0.9835 to 0.9840
0.0005L to 0.0030L
1.5745 to 1.5750
1.5743 to 1.5748
O.OOO3L to 0.0007T
1.3770 to 1.3775
1.3775 to 1.3780
O.OOOOL to 0.0010L

0.9815
0.00501

0.2835 to 0.2845
0.2810 to 0.2815
0.0020L to 0.0035L
0.2835 to 0.2845
0.2810 to 0.2815
0.0020L to 0.0035L
9.436 to 9.438
9.438 to 9.440
O.OOOL to 0.004L
0.6245 to 0.6255

Maximum free length of spring- 1.29

Solid height of spring. ....... 0.550
Scale reading at 0.630 inch
length............-...-.- - 36 to 40 Ib

(*)

Figure ISO.

Repair and rebuild standard points of measurement for cooling fan and fan clutch assembly.

RA PO 196966

155. Throttle Linkage

(par. 80)

o. Cross Shaft
Fif No. Rtf Ltr
131
E
A
A-E
131
D

131

B
B-D
C

B-C
G
F
G-F
b. Governor
132
D
A
A-D
132
C
B
B-C

292

Assembly.
Point of meaturtmtnt
OD of cross shaft..-..--.--..
ID of ball bearing-..--..,.-.
Fit of bearing on shaft.......
ID of cross shaft bearing bore
in bracket and cover..... . ,
OD of ball bearing.-.---...Fit of bearing in bracket. _ . _ .
ID of bore in vehicle control
lever-..-.... .............
Fit of bearing in lever.-.....
ID of bore in control link-.. -.
OD of bearing.,.............
Fit of bearing in control link..
Linkage.
OD of governor control shaft _ .
ID of ballbearing-..---.---Fit of bearing on shaft.......
ID of control shaft support
bracket.---.-----..---.--OD of ball bearing.--......-.
Fit of bearing in bracket... _.

Siut and fiti of new parti

0.6240 to 0.6245
0.6247 to 0.6250
0.0002L to 0.0010L

1.3738 to 1.3748
1.3745 to 1.3750
0.0003L to 0.0012T
1.3748 to 1.3756
0.0002T to 0.001 II,
0.7758 to 0.7764
0.7769 to 0.7774
0.0005T to 0.0014T
0.6240 to 0.6245
0.6247 to 0.6250
0.0002L to 0.0010L
1.3748 to 1.3756
1.3745 to 1.3750
0.0011L to 0.0002T

Wear ttmiti

M
-O

Figure 131.

Repair and rebuild standard points of measurement for throttle linkage-cross shaft assembly.

RA D 196967

Figure 132.

Itepair and rebuild standard pointt oj meaturtment for throttle lt nkagf^offrMr Unkvgt.

156. OH Pruur* Control Valve

(par. 82)
a. \'alve Blem.
133

6.
133

r.
133

fMn/ of meaturement
OD of valve Ktem ............

Niza and fitt of new parti

0.2420 to 0.2460

ID of valve Ktem hole in hous

ing. ..................... 0.2490 to 0.2505
A-B
Fit of nteni in housing . . . . .
0.0030L to 0.00851.
Valve Spring Seal.
I)
OD of valve upring Heat ...... 1.2470 to 1.2475
("
ID of valve Kpring seat bore in
housing --------- .... 1.2500 to 1.2510
CM)
Fit of neat in housing. . .-.,.. 0.0025L to O.OO40L
Valve Spring.
K
Maximum free length ........ 2.91
Maximum solid height. ...... 2.00
Scale reading at 2.25 inch
length...... ----------- 107 5 Ib

Wear limit!
0.2385

0.2540
0.0120L
1.2450
1.2530
0.0060L

295

INCHES

Figure 138.

RA PD 180606

Repair and rebuild standard points of measurement for oil pressure control valve.

157. Oil Filter By-Pats Valve

(par. 83)
o. Valve Stem.
Fif ffo. Rtf Mr

134

A
B

Point of measurement

Siut and fitt of new part*

OD of valve stem...--..-,.. 0.2420 to 0.2460

ID of valve stem hole in hous
ing- ..................... 0.2490 to 0.2505
A-B
Fit of stem in housing--.-.... 0.0030L to 0.0085L
6. Valve Spring.
134
C
Approximate free length...... 2.16
Maximum solid height....... 1.06
scale reading at 1.38 inch
.-----...-..--..-- 27.7 2.5 Ib

Wear limit!

0.2385
0.2540
0.0120L

297

Figure 134-

Repair and rebuild standard points of measurement for oil filter by-pass valve.

158. Oil Cooler Pressure By-Pass Valve

(par. 84)
a. Valve Stem.

fig No
135

Re/ iJr
A

Point of measurement
OD of valve stern.... .........

ID of valve stem hole in hous

ing
......... .......
A-B
Fit of stem in housing........
/>. Valve Spring.
135
C'
Maximum free length, ........

Size* and fit* of new parti

0.3070 to 0.3090

Wear limitt
0.3015

0.3115 to 0.3135
0.0025L to 0.0065L

0.3190
0.0120L

2.10

Maximum solid height,_ .......

1.36

Scale read ing at 1.75 inch length.

96.59.51b

299

Figure 1S5.

Repair and rebuild standard points of measurement for oU cooler pressure by-pass valve.

IA PO 180608

159. Flywheel Group

(par. 87)
a. Flywheel.
Point o/ mtasvrrment

Fig ft a. Re) Ltr

136

ID of cover plate dowel pin hole

Suet and fit* of new part*

in flywheel.................
OD of cover plate dowel pin...
Fit of pin in flywheel..........

0.4365 to 0.4375
0.4376 to 0.4378
O.OOOlT to 0.0013T

in flywheel..-------........
OD of friction disk dowel pin..
F
Fit of pin in flywheel..,.......
F-G
6. Flywheel Cover Plate.
ID of dowel hole in cover plate.
M
136
of cover plate dowel pin..
OD
E
Fit of pin in plate...-------E-M
OD of coverplate.- _........
B
136
ID of cover plate flange on fly
H
wheel-------------------Fit of cover plate in flywheel-.
B-H
c. Damper Hub and Spring Driven Plate.
ID of dowel hole in damper hub
L
136
and spring driven plate...-.
OD of hub dowel pin.....-.-N
Fit of pin in hub and plate....
Lr-N
Small OD of damper hub...-.
C
136
ID of damper spring driven
D
plate..------------------Fit of plate on hub--,-..-.-C-D
d. Flywheel Torsion Damper Drive Spring.
Free length of drive spring..-.
K
136
Maximum solid height ------Scale reading at 1.75 inch
length_.----------------

0.4995 to 0.5005
0.5009 to 0.5011
0.0004T to 0.0016T

136

136

E
E-J

B
B-H
G

Wear limit*

ID of cover plate flange on fly

wheel. _.-.-..-..__._.__._. 18.125 to 18.127
OD of flywheel cover plate..... 18.122 to 18.124
Fit of cover plate in flywheel.-. 0.001L to 0.005L
ID of friction disk dowel pin hole

241130 O5320

0.4380 to 0.4390
0.4376 to 0.4378
0.0002L to 0.0014L
18.122 to 18.124
18.125 to 18.127
O.OOlL to 0.005L
0.4990 to 0.5000
0.5001 to 0.5003
O.OOOlT to 0.0013T
2.124 to 2.125
2.125 to 2.126
O.OOOL to 0.002L
1.782 to 1.797
1.375
38 to 56 Ib

301

Figure 1S6.

Repair and rebuild standard points of measurement for flywheel and torsion damper.

160. Va!v Rocfctrs

(par. 89)
o. Valre Rocker Roller.

Point of auvntrement
ID at roller . .............
F
K
O0 of roller hub-.....
K-F
Fit ol hub in roller, ..... .
(i
Outrt/de width of roller,....
frufidc width of valve rocker
J
G-J
Fit of roller in rocker^ .
l'a/p Roektr Hearing.
OD of bearing.-..
A
ID of vlve rocker..-.-.....
B
Fit of bearing in rocker.
A~B
I'alvt Kocker Roller Axle Pin.
OD of roller axle pin., _...._,
C
ID of roller axle pin hole in
II
valve rocker.....-.--,,.-,
Fit of pin in rocker..........
C-H
ID of roller hub-............
D
Fit of pin in hub (roller hub
C-D
also locked to pin) .........

Fit No.

137
137

137

e.
137

137

RtJUt

Figure 1S7

ftttu and fit* of neie pant

0.5625 to 0.5630
0.5580 to 0.5585
0-0040L to 0.00501,
0.3060 to 0,3080
0.3115 to 0,3135
0.0035L to 0.0075L

tt'tarlimUt
0.5650

0,5560
0.0070L
0.3035
0.3160

0.0100L

0.8780 to 0.8790
0.8745 to 0.8755
0.0025T to 0.0045T
0.3120 to 0.3130
0.3120 to 0.3130
O.OOlOL to 0.0010T
0.3115 to 0.31 25
0.0005L to 0.0015T

Repair and rebuild standard points of measurement for valve rocker

assembly.
303

161. Cooling Fon Drive

(par. 95)

a. Fan Drive B*9l Gear.

138
114

J
H
H-J
E-F

OD of drive gear.. ... - ......

ID of drive gear bearing-... .Fit of gear in bearing ........
Desired backlash (at mean di
mension) with fan driven
bevel gear .......---- . . . Total backlash..........

6. F an Driven Bevel Gear.

138

138

114

It
M

L.M
G
N
GN
E~F

Wtr limUi

1.3725 to 1.3730
1.3750 to 1.3760
0.0020L to 0.0035L

1.3705
1.3780
0.0055 L

0.0100 to 0.0140
0.0084 to 0.0158

0.0197

ID of driven gear lower pilot. - 0.0360 to 0.9370

OuO of lower gear bearing on
drive vertical shaft........ O.9350 to 0.9355
Fit of gear on shaft ......... 0.0005L to 0.0020L
ID of drive gear upper pilot.. 1.2500 to 1.2510
OD of gear upper bearing on
drive vertical shaft........ 1.2490 to 1.2495
Fit of gear on shaft. _-....... 0.0005L to 0.0020L
Desired backlash (at mean di
mension) with fan drive bevel
gear.....-....,.,........ 0.0100 to 0.0140
Total backlash,.....-.-..--. 0.0084 to 0.0158

c. Fan Drive Vertical shaft.

138
M
OD of lower end of vertical
shaft..-..---.....--.-....
K
ID of vertical shaft bearing in
crankcase...,....-.-....-.
KM
Fit of shaft in bearing-------138
L
ID of fan driven bevel gear
lower pilot. ...............
LM
Fit of gear on shaft- ._..-....
138
X
OD of gear upper bearing on
vertical shaft _.,.___---.-G
ID of driven gear upper pilot, .
G N
Fit of gear on shaft. ._.-....138
F
OD of large bearing surface on
vertical shaft..............
P
ID of inner oil slinger........
F- P
Fit of slinger on shaft........
138
R
ID of vertical shaft ball bear
ing. ...--.......-- ------F-R
Fit of bearing on shaft.,.--..
138
S
ID of vertical shaft oil seal-..
F-S
Fit of seal on shaft -..-.-....
138
E
OD of small (upper) end of
vertical shaft ------- -...-,.
130
E
ID of fan drive hub.-------E-E
Fit of hub on shaft..-_-.-...

304

Slut tniftttof %tw parti

0.9390
0.9330
0.0040L
1.2530
1.2470
0.0040L

0.0197

0.9350 to 0.9355

0.9330

0.9370 to 0.9380
0.0015L to 0.0030L

0.9400
0.0050L

0.9360 to 0.9370
0.0005L to 0.0020L

0.9390
0.0040L

1.2490 to 1.2495
1.2500 to 1.2510
0.0005L to 0.0020L

1.2470
1.2530
0.0040L

1.3779 to 1.3784
1.3780 to 1.3790
0.001 IL to 0.0004T
1.3775 to 1.3780
0.0001 L to 0.0009T
1.3800 to 1.3820
0.0016L to 0.004IL
0.9835 to 0.9840
0.9845 to 0.9865
0.0005L to 0.0030L

0.9815
0.9885
0.0050L

d. Vertical Drive Shaft Bearing Homing.

fit No. Kef Llr

138

138
126
e.
138

/.
126
g.
126
126

Point o) meumremtnt

ID of bearing housing. ,.....

OD of vertical shaft ball bear
ing...................._
Fit of bearing in housing-... _
C-D
OD of pilot on bearing hous
Q
ing......................
ID of bearing housing bore in
B
crankcase-.--.-----------Fit of housing in crankcase--B-Q
fan Drive Oil Seal Housing.
ID of oil seal bore in housing-A
OD of vertical drive shaft oil
B
seal.--,---.,------------Fit of seal in housing..-,--..
A~B
Fan Drive Gear Bearing.
OD of drive gear bearing,..._
C
ID of bore in crankcase. ----D
Fit of bearing in crankcase....
C-D
Vertical Drive Shaft Bearing.
OD of bearing....--.-.-----F
ID of bore in crankcase.-----G
Fit of bearing in crankcaseF-G
OD of bearing dowel pin ----E
ID of bearing dowel pin hole in
H
crankcase_...-..-.-----Fit of pin in crankcase...._
E-H
D
C

Sizet and flit of new partt

WearUmitt

2.8345 to 2.8353
2.8340 to 2.8346
0.0013L to 0.0001 T
4.7480 to 4.7490
4.7500 to 4.7510
0.0010L to 0.0030L
2.623 to 2.625

(*)

2.627 to 2.632
0.002T to 0.009T

(*)
(*)

1.6875 to 1.6880
1.6880 to 1.6890
O.OOOOL to 0.0015L
1.2488 to 1.2493
1.2500 to 1.2510
0.0007L to 0.0022L
0.1850 to 0.1870
0.1835 to 0.1845
0.0005T to 0.0035T

305

/55.

Repair and rebuild standard point* of meaturemfnt for tooling fan drive,

APD

162. Hydroulk Governor

(par. 138)
a- Governor Body.
fit N ft*/ Lit

Point of mtatvrtntnt

ID of hydraulic valve sleeve in

governor body............
OD of hydraulic valve.......
K
Fit of valve in body.........
E-J
ID of piston bore in governor
C
139
body... --.-.-_..._,.....
OD of piston...............,
A
Fit of piston in body.........
A-C
6. Actuating Bait Race.
OD of shaft on lower race....
O
139
ID of shaft bore in upper race.
H
Fit of lower to upper race....
G-H
r. Actuating Ball.
OD of actuating ball..........
F
139
139

d. Spring*.
O
139
139

140
140

F
H

Oil metering valve spring..

Piston compression spring.
Piston rod spring--------Piston packing spring.... .

e. Pitton Rod.
Small OD of piston rod. ......
M
140
1D of bore in clevis,......-_.
X
Fit of clevis on piston rod.,..
M-X
/. Piston Rod Bushing.
ID of bushing......--.-.---.
L
140
Large OD of piston rod......
G
Fit of rod in bushing....... -.
G-L
OD of bushing.....--.----.
K
140
ID of bushing hole in piston
J
head...--.......----.-.-Fit of bushing in head._....- J-K
g. Rocker Arm Bushing.
ID of bushing......--..-C
140
OD of rocker arm shaft _...-.
B
Fit of shaft in bushing.-----B-C
OD of bushing.------------D
140
ID of bushing bore in clevis.-.
E
Fit of bushing in clevis. -----D-E
h. Rocker Arm.
ID of rocker arm..---------A
HO
OD of rocker arm shaft.----B
Fit of shaft in arm..--------A-B

n* fU of new port*

Wear limit*

0.8125 to 0.8135
0.8112 to 0.8117
0.0008L to 0.0023L

0.8145
0.8092
0.0050L

1.9995 to 2.0005
1.9980 to 1.9990
0.0005L to 0.0025L

2.0025
1.9970
0.0050L

0.433 to 0.435
0.4365 to 0.4390
0.0015L to 0.0060L

0.431
0.4410
0.0080L

0.6255 to 0.6245

0.6195

28 Ibat 1.300 in5%

12Ibat 2.640in5%
40 Ibat 0.670 in5%
3.6 Ibat 0.610 in 5%
0.4340 to 0.4350
0.4325 to 0.4335
0.0005T to 0.0025T
0.5010 to 0.5020
0.4995 to 0.5005
0.0005L to 0.0025L
0.6270 to 0.6280

0.506
0.4945
0.0080L

0.6255 to 0.6265
0.0005T to 0.0025T
0.4390 to 0.4400
0.4350 to 0.4355
0.0035L to 0.0050L
0.565 to 0.566
0.563 to 0.564
0.001T to 0.003T

0.4420
0.4345
0.0080L

0.4340 to 0.4350
0.4350 to 0.4355
O.OOOOT to 0.0015T

307

09

Figure 139.

Repair and rebuild standard points o/ measurement for hydraulic

governor assembly.

RA PO 196970

Figure 1^0.

Repair and rebuild standard points of measurement for hydraulic governor piston head assembly.

en 6

163. Engine Torque Wrench Specification

(par. 102)
a. Standard Torques For Studs and Holts.
TVftw

Siu (ditnuttr)

._............-.-..._.._.__-.......__....._._..._
% (0.25OO)-Me (0.3125). ... ..................................................
H (0.3750)-.... .................................................
% (0.4375).....................................................
H (0.5000)- ... .................................................
K (0.5625)......................................................

75-100
150-175
275-325
400-450
550-600
800-850

b. Torques for Engine Studs and Bolts.

Fit No

101
122
122
123
126
122
126
126
126
126
126
125
127
127
136
136
126

310

Kef Ltr

R
D
P
Q
A)
Z|
L
J
K
M

X
H
Q
M
P
A
P

Location

............... - ........
Sparkplugs.-.
Cylinder barrel nuts, _-- ...... ...................
Valve rocker support bolts,....--_.... ....... .
_.....-......
Connecting rod bolt..... ......
.. . . ...... . _
Crankoase cross bolt nut... _..

Torqm (Ib-in)

200-225
400
170-180
750-850
725-775

. ... 175
Crankcase to crankcase bolts (?{)...
Crankcase to crankcase bolts (fan tower, short)... ... 175
Crankcase to crankcase bolts (fan tower, long) (%)... 300
Crankcase alinement dowel-type bolt, (flywheel end) 400-425
We).
150-175
Crankcase stud nut (inside flywheel housing).... - Flywheel mounting bolts.-.-.-.-.---,----..--.-... 1,000
Damper hub stop plate bolts..--------- ........... 275-325
Damper hub mounting bolts _.......--._..--...._. 1,000
300
Flywheel cover plate bolts.- -------------------400-450
Torsion damper hub bolt.-. --------------------Transmission mounting studs.-.---.---_---------- 450

APPENDIX
REFERENCES
1. Publication Indexes
The following publication indexes and lists of current issue should
be consulted frequently for latest changes or revisions of references
given in this appendix and for new publications relating to materiel
covered in this manual:
Index of Administrative Publications_________ SR 310-20-5
Index of Army Motion Pictures and Film Strips and Kine
scope Recordings_____________________ SB 110-1-1
Index of Blank Forms and Army Personnel Classification
Tests_.______________________ SR 310-20-6
Index of Tables of Organization and Equipment, Reduc
tion Tables, Tables of Allowances, Tables of Organiza
tion, and Tables of Equipment_____________ SR 310-20-7
Index of Technical Manuals, Technical Regulations, Tech
nical Bulletins, Supply Bulletins, Lubrication Orders,
and Modification Work Orders.___________ SR 310-20-4
Index of Training Publications..__________. SR 310-20-3
Introduction and Index (supply catalogs)_____ ORD 1
Military Training Aids____________ FM 21-8
Ordnance Major Items and Major Combinations and Per
tinent Publications--.. SB 9-1

2. Supply Catalogs
The following catalogs of the Department of the Army Supply
Catalog pertain to this materiel:
a. Destruction to Prevent Erwmy Use.
Land Mines and Components; Demolition Explosives and
Related Items; and Ammunition for Simulated Artil
lery Boobv Trap, Hand Grenade, and Land Mine
Fire ORD 3 SNLR-7

6. Repair and Rebuild.

Antifriction Bearings and Related Items. ORD 5 SNL H-12
Cleaners, Preservatives, Lubricants, Recoil Fluids, Special
Oils, and Related Maintenance Materials ORD 3 SNL K-l
311

Electrical Fittings.-.-.-- ORD 5 SNL H-4

Items of Soldering, Metallizing, Brazing, and Welding
Materials: Gases and Related Items.____ ORD 3 SNL K-2
Lubricating, Equipment, Accessories, and Related Dis
pensers, ORD (*) SNL K-3
Lubricating Fittings, Oil Filters, and Oil Filter Ele
ments..._. .- ORD 5 SNLH-16
Major Items ami Major Combinations of Group G-_ ORD 3 SNLG-1
Miscellaneous Hardware ORD 5 SNL H-2
Oil Seals-_ ORD 5 SNL H-13
Pipe and Hase Fittings. -_ ORD 5 SNL H-6
Shop Set, Engine and Power Train Rebuild Company
(Armament), Depot Maintenance- - ORD ( SNL J-9, Sec. 8
Shop Set, Engine Rebuild Company (Automotive), Depot
Maintenance-. .-ORD 6 SNL J-9, Sec 3
Shop Set, Machine, Field Maintenance..... ORD 6 SNL J-H, Sec 16
Standard Hardware. ORD 5 SNL H-l
Tool Set, General Mechanic's__. ORD 6 SNL J-10, Sec 4
e. Vehicle.
Full-Track Armored Infantry Vehicle T18E1_ ORD 8 SNL G-260
3. Forms
The following forms pertain to this material:

WD AGO Form 9-1, Material Inspection Tag

DA Form 9-3, Processing Record for Storage of Vehicles and Boxed
Engines, (tag)
WD AGO Form 9-4, Vehicular Storage and Servicing Record (card)
WD AGO Form 9-71, Locator and Inventory Control Card
WD AGO Form 9-72, Ordnance Stock Record Card
DA Form 9-76, Request for Work Order
DA Form 9-77, Job Order Register
WD AGO Form 9-78, Job Order
DA Form 9-79, Parts Requisition
WD AGO Form 9-80, Job Order File
WD AGO Form 9-81, Exchange Part or Unit Identification Tag
DA Form 446, Issue Slip
DA Form 447, Property Turn-In Slip
DA Form 460, Preventive Maintenance Roster
DA Form 461-5, Limited Technical Inspection
DA Form 468, Unsatisfactory Equipment Report
DA Form 478, MWO and Major Unit Assembly Replacement Record
and Organizational Equipment File
() See ORD 1, Introduction and Index, for published catalog* of the ordnance section
of the Department of the Army Supply Catalog.

DA Form 811, Work Request and Job Order

DA Form 811-1, Work Request and Hand Receipt
WD AGO Form 86;',, Work Order
WD AGO Form 8(56, Consolidation of Parts
WD AGO Form 867, Status of Modification Work Order
DP Form (i, Report of Damaged or Improper Shipment
DP Form 317, Preventive Maintenance Service Due (Sticker)
4. Other Publications
The following explanatory publications contain information perti
nent to this materiel and associated equipment:
a. Camouflage.
Camouflage, Basic Principles_________________ FM 5-20
Camouflage of Vehicles___._______________ FM 5-20B
b. Decontaw in at ion.
Decontamination-______________________ TM 3-220
Defense Against Chemical Attack_____________ FM 21-40
r. Destruction to Prevent Enemy Use.
Explosives and Demolitions_____________________ FM 5-25
Ordnance Service in the Field-________________ FM 9-5
d. (reneraJ.
Cooling Systems: Vehicles and Powered Ground Equipment_____-_________-___________ TM 9-2858
Inspection of Ordnance Materiel in the Hands of Troops- TM 9-1100
Instruction Guide: Operation and Maintenance of Ord
nance Materiel in Extreme Cold (0 to -65 F.)~-_ TM 9-2855
Military Vehicles.,.__________________.________ TM 9-2800
Motor Vehicles (Ordnance Corps Responsibility)_ AR 700-105
Mountain Operations______________~ FM 70-10
Operations in the Arctic_____ FM 31-71
Precautions in Handling Gasoline AR 850-20
Preparation of Ordnance Materiel for Deep-Water Ford
ing___________________.______- TM 9-2853
Principles of Automotive Vehicles TM 9-2700
Report of Accident Experience_ SR 385-10-40
Spark Plugs--------------------------------------- TB ORD 818
Storage BatteriesLead-Acid Type TM 9-2857
Supplies and Equipment: Unsatisfactory Shipment
Report SK 700-45-5
e. Repair and Rebuild.
Abrasive, Cleaning, Preserving, Sealing, Adhesive, and
Related Materials Issued for Ordnance Materiel TM 9-850
Hand, Measuring, and Power Tools TM 10-590
313

Instruction Guide: Care and Maintenance of Ball and

Roller Bearings..__-- TM 37-265
Lubrication,._-_ TM 0-2885
Maintenance and Care of Hand Tools..____ _ TM 9-867
Maintenance Supplies and Equipment: Maintenance Responsibilities and Shop Operation.._______ AR 750-5

Modification of Ordnance Materiel.- _._ ______ SB 9-38

Ordnance Maintenance and General Supply in the Field.. FM 9-10

Ordnance Maintenance: Carburetors._________ TM 9-1826A, B,C, D
Ordnance Maintenance: Electrical Equipment. ___ TM 9-1825A,
B, C, D, E
Ordnance Maintenance: Fuel Puinps____________ _ TM 9-1828A
Ordnance Maintenance: Vehicular Maintenance Equip
ment, Grinding, Boring, Valve Reseating1 Machines, and
Lathes.______ __ TM 9-1834A
Painting Instructions for Field Use__.________ TM 9-2851
Parts Reclamation from Tactical and Administrative Vehicles-___ --___-_-___-______. SR 750-130-10
Preventive Maintenance of Electric Motors and Gen
erators._______-__ __ __ .____...__ TM 55-105
/. Operation.
Full-Track Armored Infantry Vehicle T18E1__...__ TM 9-755B
g. Shipment and Standby or Lwiff-Term /Storage.
Army Shipping Document_________________ TM 38-705
Instruction Guide: Ordnance Packaging and Shipping
(Posts, Camps, and Stations)______.________ TM 9-2854
Marking and Packing of Supplies and Equipment:
Marking of Oversea Supply______________ SR 746-30-5
Military StandardMarking of Shipments___... MIL-STD-129*
Ordnance Storage and Shipment ChartGroup G_ TB 9-OSSC-G
Preparation of Supplies and Equipment for Shipment:
Processing of Unboxed and Uncrated Equipment for
Oversea Shipment_____________________ AR 747-30
Preservation, Packaging, and Packing of Military Sup
plies and Equipment_____________________ TM 38-230
Processing of Motor Vehicles and Related Unboxed Ma
teriel for Shipment and Storage______________ SB 9-4
Protection of Ordnance General Supplies in Open Stor
age__...._____________.__ TB ORD 379

Shipment of Supplies and Equipment: Report of Damaged

or Improper Shipment.:_______________ SR 74545-5
Standards for Oversea Shipment and Domestic Issue of
Ordnance Materiel Other than Ammunition and Army
Aircraft_________._________________ TB ORD 385
Copies may be obtained from Aberdeen Proving Ground, Maryland.

314

_____________INDEX____________
Accessories:

Paragraphs

33
Drive ratio.. _______________________________________
Installation (See Individual item)
33
Number included on engine...----_.__-_______..._____
36
Removal.. _________________________________________
Accessory case:
59
Assembly from subassemblies..__.___.________________
57
Cleaning, inspection, and repair. _.____-___-___-.__-___
24
Description., _______________________________________
56
Disassembly. _______________________________________
107
Installation.,_______________________________________
58
Rebuild of subassemblies. ____________________________
51
________
_____________________
Removal._____________
Accessory drive. (See Accessory case.)
Accessory drive ratios. (See Accessories)
Adapter, breather tube, accessory case:
26
Description...................______-_-_.-__--__--._
59
Installation.,..__.........-.-_.....--.----..----.-._
58
Rebuild....,.-__...........--....._-.-_-_._--..--..
56
Removal.--,---------------------.----------------Adapter, drive, fuel pump. (See Housing, camshaft drive.)
Adapter, drive, generator. (See Drive, generator.)
Adapter, drive, magneto. (See Housing, magneto drive.)
Adapter, drive, starter. (See Drive, starter.)
Adjustment. (See Tests and adjustments.)
Air deflectors. (See Deflectors, air, cylinder.)
2
Allocation, field and depot maintenance.-.------------.---Arrester, flame. (See Line, flame arrestor-to-filler pipe.)
Assembly of engine from subassemblies-.------------------- 102-126
Bafflles, air, cylinder. (See Deflectors, air, cylinder.)
Balance tube, intake manifold:
Installation,.--------------------------------------Removal.-------------------------------------(See also Induction system.)
Bearing, camshaft. (See Cylinders.)
Bearings, connecting rod:
. ' ,.
------------------------------Assembly.--,.------Cleaning, inspection, and repair-..--.--.------------

T^.
------------------------------Description-,-------Removal _.---------------------------------------"Bearings, main:
Cleaning, inspection, and repair..-..----------------Description....----------------------------------""Installation-.---------------------------------"""
Removal _---------------------------"------""""""
Bearing, piston pin. (See Crankshaft.)

Page

47
47
48
103
78
41
72
204
82
63

43
103
82
72

6
198

114
42

2l3
58

73
"
M
_,.

14-s

Aa
^

9
^_
,-g
..

J3()
^
19g
70

BooMtcr coil. (See Coil, boo*tei.)

Bracket, support, governor control shaft:
Installation ..........................................
Removal................ .... ......................
Breathing system, description of....-...-.,.,...._. ........

Fmr*t*
Ill
43

212
59

26

43

62

109

Camshaft hearing cap. (J$* Cap, can w haft hearing.)

Camshaft gear housing. (See Cain*haft and gear housing* )
Camshafts And drivers. (AW {'am*hafw and gear hou**irm,)
Camshaft* and gear housings*:

Assembly........................ ..................

Cleaning, inspection, and repair. . ....................

Description.........................................
DtHa**embly........ ............ ..................
Installation .........................................
Removal........................

Cap, camshaft bearing:

Description........
.
........_..
lastallation.........................................
Removal..,-.
.--.-.-.......-.
Cap, connecting rod. (.SV C'rankha/t.)
Carburetor:
Description.........................................
InstaJlation.. .......................................
Ileino va)...........................................
Cleaning and draining. (See Prefiaration of canine for rebuild.)
Clutch, cooling fan. (See Cooling fan and fait clutch.)
Coil, booster:
Description.. .......................................
Installation . .......................................
Removal....-...-.------....---.--..-...-....-....Common tools and equipment. (See Parts, special tool.i and
equipment.)
Compression pressure, trouble shooting of.................
Connecting rod. (See Rod, connecting.)
Connectors, intercylinder. (See Camshaft* and gear housings.)
Coolers, oil:
Description.. ,....-....-...................,...._...
Rebuild............................................
Removal....--..-..--........-......-........---...
Cooling fan and fan clutch:
Assembly.,......-...................._..,......-...
Cleaning, inspection and repair-.---..------,--..-----Description.--.-.-..-........-.--..-.--...-...-.-...

Disassembly.__..__..._._._.,_.__.._.__.__..._..__..
Installation.----....-......-..--..,-..-,.....-,-..-Removal....----..--...-....-----.-.--.......,--.-.
Troubleshooting.-.-...........-......--.......----.
Cooling system, description of. __._____...____,_......___..
Cover, accessory cae. (See Accessory case.)
Covers, shroud. (See Shroud covers.)
Covers, valve rocker:
Description.........................................
Installation----.--.----.--.....--..-.---..-..------.
Removal..--...------.--.-....-.-...----.--.-.-----

316

61
23
60
108

108
41
108
206

47

60

22
65
63

40
125
114

4,28
112
36

7,45
213
48

29
121
06

45
224
48

14

25

4,15
100
38

7,33
182
48

78
77

152
151

27

44

76
124
38
14
27

151
233
55
25
44

22
110
45

40
212
JBO

Crankeaae.

Meaning, in*jx>ction, and repair. -,-..---._...._._.._.,

69
j-

70

132

............'.'.'_''"_'.'
Imtallation
Crankshaft
Afwernbly
Cleaning, inf>eetion, and repair ---....-._.__..___...__
Description
Di*aM*ernbly
-.--.---.-....-.-...............
Kndplay.
-...-.--.-....-..... ..._......
IiiMtailation
.-.....................
...--.-.--.Removal
vibration, crankDamper,
Cranknhaft vibration damper. (See
fthaft.j
Cylinders:
-.-.-.--.----.-....-...-._.
.
Axticmbly . . . . .
--.....-..,..........repair.
Cleaning, inspection, and
Descript ion . _ . .-....,.....,.. . ................._.-.
.....................................
DisassemblyInstallation .........................................
..-..---.-............._..--Removal .....
Cylinder air deflectors. (See Deflectors, air, cylinder.)

103

199

70
72
J9
yj
103
103
55

.^n
137
Qg
qy
199
199
70

65
64
22
63
105
52

125
114
40
114
201
64

105
44
15-33

201
59
33

59
56
3755

103
72
53

104
95
54

201
174
68

59
58
56

103
82
72

59
58
S6

103
?2
72

'

A**mhiy_..

.........................

Damper, torsion. (See Flywheel.)

Damper, vibration, crankshaft. (See Crankshaft.)
Deflectors, air, cylinder:
Installation. .... .-.................--...-.-..,-.--.
Removal ,..................................-...._..
Description and data. .-.-.....-._-........-....---__-....
Diaphragm, accessory case:
Installation. --.....--.---,----.--..----_--.--..----Removal. .---.....-..--.---.--.---.--------..-----Disaasembly of stripped engine into subassemblies . . ...__..._
Drive, cooling fan:
Installation.-... ----------------------------------Rebuild--.-.--.-.---.---.-------------------------Removal-.-.-.-.----.-..--.-----.-------------------Drive, generator:
Installation.---..----,--.--------------------------Rebuild..-..-.-.----- _ ..- -
Removal... ---------------------------------------Drive, governor and fuel pump. (See Housing camshaft drive.)
Drive, main accessory. (See Accessory case.)
Drive, starter:
Installation---.-.----------------------------------Rebuild...------------------------------ -----Removal...---------------------------------------Engine:
Description and data..---.--------------------------Nomenclature-------------------------------------- "-
Troubleshooting.
Engine assembly from subassembhes.-.. ----------------241130053 21

130

" **
317

Engine nomenclature. (See Engine.)

Engine shroud. (See Shroud, engine.)
Exhaust manifold. (See Manifold, exhaust.)
Eye, lifting, accessory case. (See Adapter, breather tube
accessory case.)
Fan, cooling. (See Cooling fan and fan clutch.)
Fan drive. (See Drive, cooling fan.)
Filter, fuel:
Description_..-.-....-..__........._......_.....,.__.._
Installation.. .....................,..._._...,..._...
Rebuild.............. ............................
Removal-.-.--...---.-.--. ...................... ...
Filter, oil:
Installation. .....-....._.-....._....,._.......____.
Rebuild...-._.....-..-..............,-....,_..___..
Removal........ .-..-.-....-._-_.-...--.....-___-..
Filter, primer:
Description.._-......--.....-..-.,._..-..,._...__._.
Installation.................... ...-.--._,....___...
Rebuild.. ... ...................................
Removal....--....-.--..-._.._.......-....._....-_..
Flame arrestor. (See Line, flame-arrestor-to-filler pipe.)
Flywheel:
Cleaning and inspection--.._...._...___.._,....____._
Description.--.-.......-....-............,.-.-..--..
Installation..- _.......-._.._...___...___......__..,_.
Removal.....---------.,.-..-.....-..-...--.-..-_..
Repair.-._.._.-..--._-_.-....___.............____..
Forms, records, and reports....-_._..__.__..___......_._-.
Fuel filter. (See Filter, fuel.)
Fuel pump. (See Pump, fuel.)
Fuel pump drive adapter. (See Housing, camshaft drive.)
Fuel system:
Description.....-...-.-.--...-........._....-.,____.
Trouble shooting-......--_.-..-__.__.___.._.._.____.

Par*trp**
28
126
98
36

45
234
180
48

126
98
36

234
180
48

28
118
98
36

45
217
180
48

87
19
103
53
88
3

168
38
199
66
170
6

28
14

45
25

25
14
Gear failures, trouble shooting of.._..___.___.__.._._.-___.
Generator:
46
31
Description.....-..-..--....._.-__.._-.._-_.-...-__-224
120
Installation..___-_._._..____...___..__.___..._.____.
48
36
Removal--..----------.---.-----..___-_--.--_-----Generating system:
25
14
Trouble shooting._-.__,.-_____.-___._.,__._.._,_-__...
(See also Generator.)
Governor and fuel pump drive. (See Housing, camshaft drive.)
Governor, hydraulic:
Adjustment. (See Run-in test.)
243
137
Assembly....__.-...-.--_......._--...-_. -.-----.
240
136
Cleaning, inspection, and repair.-.-...-..__.----..__-Description and data....._......_-_.-,..__....__.___. 16,134 36,239
239
135
Disassembly.------..-.----...-.--..-----.--....---212
Ill
Installation...._-..............--.--.....-.......__48
36
Removal.-----.-.--..------,.-.__...--......------_
Governor, spark advance:
45
29
Description...__.-.......-....-.__--...___...----__318

Governor, spark advanceContinued

Installation.,-......................................
Removal.,.........................................
Guides, valve. (See Cylinders.)
Harness, ignition:

Cleaning and inspection.-.___-....._-__...___,,,_____

Installation. --,-.----...._._.____._...___...,-___,___
Removal..... .._.._..._.__.____..___._._._____,_
Ventilation. ..-..__.____._.______.___.____,,__._____
(See also Ignition system.)
Housing, hearing, fan drive vertical shaft. (See Drive, cooling
fan.)
Housing, camshaft drive:
Installation _--._,.__--..-_.-...___._..,._-..,_.._.__
Rebuild...__......_.-..____.-_--____.._._...__.___.._
Removal --..--_---_..,.-_..-.__...__....-._-__.__._
Housing, camshaft drive shaft. (See Camshafts and gear
housings.)
Housing, camshaft gear. (See Camshafts and gear housings.)
Housing, cooling fan outlet vane:
Installation...-.----.-._.---_-,-_-,_______-____--___
Removal.--.-..--._...,,-....._.-._-...............
(See also Shroud, engine.)
Housing, fan rotor. (See Shroud, engine.)
Housing, hotspot intake manifold:
-....-.-....,-.,--,-...-------.--..--,,---.,---.-.-.-----,-.---------,---.---,---.--.-.-.,.-,---------------,---.----Housing, magneto drive:
Installation---..--,--.._,---.-------------.---,----Rebuild.------..---..---,--------------------------Removal-----..----,-.-,---------.---,------------Housing, oil control:
Installation.--,..-.-.------------------------------Rebuild-.-----.,-----------.----.---.-------------Removal ,----_-,,---,--,------,-------------------Housing, oil seal, fan drive vertical shaft. (See Drive, cooling
fan.)
Hydraulic governor. (See Governor, hydraulic.)
Hydrostatic lock.....---,---,-------------------------Troubleshooting.---,.------.--.-------------------Ignition harness. ' (See Harness, ignition.)
Ignition system:
Description---.------------------------ --------Troubleshooting..---------------------------------(See also Harness, ignition.)
Induction system:
Description.-.---------------------- ------------Trouble shooting. _-__------------------------------Inserts, heli-coil. (See Cylinders.)
--.--._
_---------------------------Inserts, Rosan-_
Inserts, valve, (seat) (See Cylinders.)
Intake manifold. (See Manifold, intake.)

Paraorapkt
59
56

p*gt
103
72

90
121
35
29

171
224
43
45

59
58
56

103
82
72

124
37

233
53

112
99
50

213
182
62

59
58
56

103
82
72

59
58
56

103
82
72

131
14

235
25

4>
14

' ~
Zd

25

o7

lo

319

Line, erakea*e~to-ojj filler pip*.

Installation. ......
Removal ........

...........

f*rpjiaj
135
39

233
55

123
37

233
53

115

213

(See alao Breathing system.)

Line, flame arrestor-to~oil filler pipe:

Installation...........
Removal .......
...............
..
(Set alao Breathing jtystem.)
Line, spill
Installation
.......

Removal
............
......
Line*, fuel:
Inspection and repair
Removal . . .
Lines, oil cooler. {.SW Cooler*, oil.)
Lines, primer:
Installation. .........
............. ......
Removal.
.......
. .
Lines, vent:
Inspection and repair ....................
.
(See also Breathing system.)
Linkage, throttle. (See Throttle linkage.)
Lubrication system :
Description . . . .....................................
Trouble .shooting.
. .............................

Magneto:
Description. .............. ............................
Installation........... ............ ............. .....
Removal ............. ......... ......................

51

63

96
36

176
-18

118
4

217
80

96

176

4, 15
14

7, 33
25

4, 29
109
36

7, 45
208
48

116
91
42

215
172
58

117
92
41

217
172
58

93
122
40

1 73
227
58

14

25

(See also Ignition system.)

Magneto drive adapter. (See Housing, magneto drive.)

Magneto drive housing. (See Hou.sing, magneto drive.)
Main accessory drive. (See Accessory case.)
Main bearings. (See Bearings, main.)
Manifold, intake:
Installation. ..........................................
Rebuild...... ........................................
Removal..... .......................................
Manifold, oil drain, cylinder head:
Installation. . ..."............................,....-....
Rebuild-..--.--...------.....--. -.-..--.-....---..-.
Removal.............................................
Manifold, exhaust:
Inspection and repair ..................................
Installation-.--.--.---..--.---...-.--..--------.---.-.
....-....--,---.......-.....---.--.-..-----Noise, trouble shooting of ....-.....-....-.---..---.-.----.Nomenclature. (See Engine.)
Oil
Oil
Oil
Oil

control housing. (See Housing, oil control.)

coolers. (See Coolers, oil.)
cooler by-pass valve. (See Valve, by-pass, oil cooler (thermostatic).)
drain manifold. (See Manifold, oil drain, cylinder head.)

320

Oil filter pipe, (Sef Pipe, 0U filler, crankcaae.)

Oil filter, (Set Filter, oil.)
Oil filter by-pa** valve. (See Valve, bypass, oil filter.)
Oil pan, (See Pri, oil.)
Oil pressure control valve. (See Valve, oil pressure control.)
Pan, Oil:

Parafr*J*

17
H4
86
49

-..-------....--_-,_.-........ __
Description . . _ .
(imtaliation _ . ...-..--.--..--._,_,........-.....__..___.._,
Rebuild ---.-.....-..-.,,_,.-_.,_...__..__._.__.___._.__
Removal. ........,_.,._,___.._,..__,...,_,_.______.__
Part*, gpecial tools, and equipment for field and depot (mainte
nance) ... ....-.......,,.-..............._.._._.._.____ 7-10
Pin, piston:
21
Description. --..,..--.....-.-._...__.._._-_.,..___.__.
Rebuild. (See Pistons.)
Pipe, oil filler, crankcase:
125
Installation ..,-.,..-....._-__.,_..._............___.__
39
_._____
._...._.._
.._....__
Removal ....--.-,-_-.......-_
Pwtona:
68
Asaembly... -.._........___...._...____....,.___...._
67
.....
..._.-...
..,-.--..
repair..
and
,
Cleaning, inspection
21
.....,.
.._.....
..._,...
Description ..-....-,-.....,.
66
........
Disassembly -...-..-...----........-....,..,..
105
Installation... . .....................................
52
.
.........
.........
.........
.........
....
Removal.
Piston pin. (See Pin, piston.)
Piston ring. (See Ring, piston.)
Plug, oil transfer. (Sft Shaft, drive, camshaft.)
Plug, piston pin. (See Pistons.)
PJug, spark. (Sft Spark plugs.)
Power take-off:
59
Installation....... ..................................
58
Rebuild............................................
56
----,-----------.,--------Removal.--. -.------Preparation of engine for rebuild:
35
Cleaning and draining....... ._.___.__,,..--_.--..---34
General--.--------..-..--..-------..--------.--- 36
--------------_._----__.--s.
accessorie
of
Removal
Primer filter. (See Filter, primer.)
Primer Unas. (See Lines, primer.)
Pump, fuel:
28
Description...,..-----.----------------------------i 11
Installation.--.-.-----,-------------------- ------ae
------------------------------Removal--------Pump, oil scavenger, accessory case:
4- 15
Description....-.-------------------------'--------113
Installation..-,--------------------------'--------75
Rebuild...--,--- ..
48
-------------------------'--l-.------Remova
Pump, oil, scavenger and pressure (dual unit) :
Description.. - -'- - - "i -,j --------------- ------------ ___..,_,-.--
Ti
Rebuild
Removal .._-_----------------------""-"""""""""

Pafe

33
213
116
52
11

40
233
55
127
126
40
125
201
62

103
82
72
48
48
48

45
2l2
48
7> a3
213
148
73
204
144

321

Radio interference filter. (S Coil,

Records. (St Forms, recurtl**, and reports.)
Removal of accessories. uSW ,VeeHoriw ami individual ititto.)
Repair and rebuilt! standard*:
Accessory eajte and tHibaMttembhe** matinjt borcw atxi pilot*.
Accessory ea*e drive gearing. .
Aee?Hs*ory eav*e Ht'avenger oil pump
Camshaft HIU! drive, left (2~4~6> s*ide. . .
Camshaft ami drive, right (1-3-5) side
Cooling fan and fan eitttch assembly.
Cooling fan drive
Crankease.
Crankshaft and conneftiitK rtxl aMMeiubly - .
Cylinders
Kngine torque wrench Hpeciftcatioiw,
.......
Flywheel jcmup.
...............
(Generator drive adapter a^embiv... ...........
Governor drive, fuel pump and camtha/t drive noti*iitg
Hydraulic governor
................ ......
Magneto drive hottsiug aj^mbly. .
...... .........
Oil cooler preMsure by-j>a*wi valve............. ....... ..
Oil filter by-pa-w valve. ..,..,_.......
Oil pressure control valve. -..........................
Pistoiw,............................................
Power take-ofT drive aswetnbly. .,...._..,.,.,.. .
Scavenger and prer^ure oil putup (dual unit)............
Starter drive assembly........................
Throttle linkage.. .
.. ............ .
Valve rocker*..
....... ..........
...
....
Report*. t.SVr Forms, recouls, and reports.)
Ring, piston:
Description................................. .......
Rebuild. (See Piston*.)
Rocker box covers. (See Covers, valve rocker.)
Rocker, valve:
Cleaning, inspection, and repair. .....................
Description, .,....._..._..._.____..__.__.,,____..__..
Installation.........................................
Removal... .....................................
Rod, connecting.
Description........................................
Rebuild. (See Crankshaft.)

Removal..----....-..--........-..-.--....-........
Rosan inserts. (See Inserts, Rosan.)
Rotor, cooling fait. (See Cooling fan and fan clutch.)
Run-in teat:
Engine run-in.........................-...-..--.-...
Governor adjustment-.-,..-....-...------...-----...
Preparation for run-in...,..,.........--........_-.._
Scope of manual.--....-.-.-.....-,...--.--...-....-.....
Screw, adjusting, valve rocker. (See Rocker, valve.)
Seal, oil, crankshaft. (See Crankshaft.)
Seizure of parts, trouble shooting of......-.-_--... ..__....

322

lWrp/u
139
140
J53
147
146
154
161
150
151
148
163
159
142
144
162
143
158
15?
156
149
145
152
141
155
160

248
288
268
354
390
304
27?
281
271
310
30J
256
2*1 J
307
258
299
297
295
275
264
284
253
292
303

21

40

89
22
108
47

170
40
206
60

20

39

55

70

132
133
130

236
237
235

14

25

Herding switch** and unit:

Dwciiptiou -.-.---...-....___.__..___._.
iiwtallation ...................... ....'_.. ~~~_"_"_\',".

Itemoviii .-..-..--........................,.._..
KhAft, drive, cam*li/i .
Iiuttallat ion .-....,.-..-...._.__...___..__._______,__
Removal -----..-........_...................,..,__
r, drive, tachometer:
.............. --.-..-_...._.,_.__.,
(iixtaltation .
..-..---.--_----..-...............
Removal .
horizontal:
f, fan drive,
....................................
Installation
Removal ........................ ..................
Hha/J, fan drive, vertical. (.SYr Drive, coolinn fan.)
Sluift, valve rocker. {.SY^ Kocker, valve.)
KhrmH coven*:
Installation ........................................
......................... ....
He i nova) ..,-.Shroud, engine:
( 'leaning and inspect ion ..............................
Installation -............................._.........
Uenioval ....................................... . . . .
Kpark pingx:
I>w>roiittecttiiK park plug leads. .......................
Installation .........................................
Uenioval. ...........................................
Special tools and equipment, (fife Parts, special tools, and
equipment.)
Springs, valve:
Description ..,..........,.._............,....,.....
Rebuild. (See Cylinders.)
Starter:
Description .......,..,............--....-.---------Installation...................--..--.-..--.---.----Removal ,-.----.----. -----------------------------(See also Starting system.)
Starting system :
Trouble shooting. ----------------------------------(See also Starter.)
Studs:
Data-..- ------------------- -----------Identification-....-------------------- ------------Replacement.-..-.--- ----------------------

30
59

103

53

72

jog
47

208
go

109
4?

208
60

104
51

201
63

123
37

227
53

94
123
37

] 73
227
53

36
121
63

48
224
114

22

40

30
120
36

46
224
48

^a

101
101
57

Sump, accessory case oil:

Installation.-.....----------------- ------... ... .......
Rebuild
...... - - - --
------------------------------,-._-.-----Removal
Support, camshaft drive shaft. (See Camshafts and gear
housings.)
Switch, sending, high temperature warning light. (See Send
ing switches and unit.)
Switch, sending, low pressure warning light. (Sec Sending
switches and unit.)
323

Tablet:
Lone ron-ln schedule ...........
Short run-in schedule ....
Special took and equipment for field and depo' mainte
nance .......
StudsTabulated data....

i*ffr9**
J33
133

ft*
339
330

10
101
6,33

II
101
9,47

26

43

15
59
84
36, 58

33
103
164
48, 82

15
85
100
100

33
166
182
182

15
59

33
103

Tests and adjustments:

Accewories.
129
235
Oil pressure . .
127
234
Throttle linkage
128
334
Throttle linkage:
Assembly
8|
160
Cleaning, inspection, and repair
80
157
Disassembly. .. . .
70
154
Installation
110
221
Removal
43
59
Timing....
109
208
Tools (See Parts, special tools and equipment.)
Torque:
Specifications
163
310
Tightness...
.........
......
102
108
Torsion damper. (St< Flywheel.)
Trouble shooting:
Detailed procedures.............. ...
.
14
25
General, engine.,
................... ...
13
25
General instructions and procedures.............._..
12
24
Purpose.......
. ... . .....................
II
24
Tube, balance, intake manifold. (Sre Balance tube, intake
manifold.)
Tube, breather, accessory case:
Installation.
......................
112, 119 213,221
Removal,.................... .............. ........
50
62
Unit, sending, oil high pressure gage.
and unit.)

(See Sending switches

Valves, air-metering, description of...............

Valve, by-pass, oil cooler:
Description..........................................
Installation.
...................................
Rebuild.,...........................................
Removal...........................................
Valve, by-pass, oil cooler (thermostatic):
Description.._-...,,..............,..-.,.._...._-_..
Inspection..........................................
Installation.........................................
Removal................ ....... ................
Valve, by-pass, oil filter:
Description.. --....-...-.....-..-....-..........._..
Installation...-......-......-..-.....--.-...-..---..

Rebuild............................................
Removal.....-..---....-......--..-............_...
Valve, control, oil pressure:
Description...-.-------.--...........................
Installation. ._........................_.........-..

324

83
36,58

164
48,82

15
59

33
103

Valve, control, oil prw#ure~~Continued

PVWJ*
f*tt
Rebuild,.....,,,
.
...,._........._ ..........
82
162
Removal
......................,_
36,58 48,82
Valve, exhauMt:
Clearance.....
.......... ................
108
206
Description ......
............
22
40
Rebuild. (See Cylinder*.)
Timing
..........
109
208
Troubleshooting
.............
14
25
Valve guide". (Set Cylinder*.)
Valve, intake:
Clearance....
....... 108,104)206,208
Description
22
40
Rebuild. (See Cylinder*.)
Timing..
...................
109
208
Trouble xhooting
.........
......
14
25
Valve rocker. (See Rocker, valve.)
Valve rocker cover. (See Cover, valve rocker.)
Valve (*eat) iimert*. (See Cylinders.)
Valve MpringK. (See Cylinders and Springs, valve.)
Valve, vacuum heat control, assembly:
Installation
.........................
122
227
Rebuild
.................
97
176
Removal
. .
...............
40
58
Vent linen. (See Lines, bent.)
Vibration damper, crankshaft. (See Crankshaft.)
Warning light*.

(See Sending switches.)

325
U. S. GOVERNMENT PRINTIN6 OFFICE: O1*53