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Full text of "Technical Manual TM 9-1804A Engine Willys L-134"

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TO 19-75AA-67 

DEPXITMENT OF THE AIIMr TECHNICAL MANUAL 



ORDNANCE MAINTENANCE 

ENGINE 

(WILLYS-OVERLAND 

MODEL MC) 

AND CLUTCH 

FOR 1/4 TON 

4x4 UTILITY TRUCK 

M38 



DEPARTMENT OF THE ARMY • JUNE 1951 



This CD produced by 

Military Media, Inc 

Copyright 1999 



CONTENTS 



CHAPTER 1. INTRODUCTION PanigrapA* Page, 

Section /. General____- 1-3 1-2 

/J. Description and data 4-5 3 

CHAPTER 8. PARTS, SPECIAL TOOLS, AND EQUIPMENT 

FOR RELD AND DEPOT MAINTENANCE e-8 8 

CHAPTER 3. TROUBLE SHOOTING 

Section 7. General 9-10 U 

//. Engine -- 11-12 12 

CHAPTER 4. ENGINE 

Section J. Description and data 13-18 15-16 

//. Power plant removal from vehicle 19-20 16-17 

///. Preparation of engine for rebuild. -. 21-30 30-40 

IV, Disassembly of stripped engine into subassemblies 31-41 43-52 

V. Rebuild of cylinder block, head, and oil pan 42-43 53 

V/. Rebuild of water pump 44-47 68-59 

VTL Rebuild of connecting rods and pistons 48-53 62-7 1 

VIIL Rebuild of camshaft. 64r-55 71-72 

IX. Rebuild of valve and valve springs 56-59 73 

X. Rebuild of valve tappets 60-63 74 

XI. Rebuild of oil pump and oil strainer _ 64^67 76-78 

XII. Rebuild of crankshaft 68-69 81 

XIII. RebuUd of flywheel 70-74 82-83 

XIV, Rebuild of intake and exhaust manifolds 75-78 83-84 

X V. Assembly of engine from subassemblies 79-93 85-96 

XVI. Installation of accessories 94^103 96-^8 

XVII. Run-in tests and adjustments 104^106 98 

XVni. Assembly of power plant 107-126 100 

CHAPTER 5. CLUTCH 

Section I. Description and data 127-128 104 

//. Disassembly of pressure plate 129-131 104 

///. Assembly of pressure plate 132-134 107 

CHAPTER 6. ENGINE VENTILATION FOR DEEP WATER 
FORDING OPERATION 

Section I. Description and data 135-141 109-110 

II. Inspection and repair of engine ventilation system 142-143 110-111 

///. Test of internal crankcase pressure - 144-147 111-112 

CHAPTER 7. SERVICEAilLITY STANDARDS 148-167 121 -128 

APPENDIX, REFERENCES 129 

INDEX - - 1^2 



Hi 



CHAPTER 1 
INTRODUCTION 



Section i. GENERAL 

1. Scope 

flf. This manual is published for the information and guidance of 
personnel responsible for depot maintenance of this materiel. It con- 
tains information on maintenance which is beyond the scope of the 
tools, equipment, or supplies normally available to using organizations. 
This manual does not contain information which is intended pri- 
marily for the using organization, since such information is available 
to ordnance maintenance personnel in the pertinent operator's techni- 
cal manuals or field manuals. 

b. This manual contains a description of and procedures for re- 
moval, disassembly, inspection, repair, rebuild, and assembly of the 
engine and clutch for the %-ton 4x4 utility truck M38, The appendix 
contains a list of current references, including supply catalogs, techni- 
cal manuals, and other available publications applicable to the 
materiel. 

e, TM 9-804 contains operating and lubricating instructions for the 
materiel and contains all maintenance operations allocated to using 
organizations in performing maintenance work within their scope. 

d, TM 9-1804B contains service information on the power train, 
body and frame. 

e, TM 9-1825A or TM 9-1825B contains service information on the 
Delco-Eemy or Auto-Lite electrical equipment. 

/. TM 9-1826A contains service information on the Carter carbu- 
retor. 

g, TM 9-1828 A contains service information on the AC fuel pump. 

A. This first edition manual is being published in advance of com- 
plete technical review of all concerned. Any errors or omissions 
will be brought to the attention of Chief of Ordnance, Washington 
26, D. C, ATTENTION : ORDFM-Pub. 

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 
are based upon availability of tools, parts, and trained personnel and 
will apply as reflected in the allocation of maintenance parts listed in 
the appropriate columns of the current ORD 8 supply catalog per- 
taining to the %-ton 4x4 utility truck M38. Instructions for depot 
maintenance are to be used by maintenance companies in the field 
only when the tactical situation makes the repair functions imperative. 
Provisions of parts listed in the depot stock guide column of ORD 8 
supply catalogs will be made to field maintenance units only when the 
emergency nature of the maintenance to be performed has been certi- 
fied by a responsible officer of the requisitioning organization. Those 
operations which can be performed as "emergency field maintenance" 
are specifically covered in this manual. 

3. Forms, Records, and Reports 

a. General. Forms, records, and reports are designed to serve 
necessary and useful purposes. Responsibilities for the proper execu- 
tion of these forms rests upon commanding officers of all units main- 
taining this equipment. It is emphasized, however, that forms, 
records, and reports are merely aids. They are not a substitute for 
thorough practical work, physical inspection, and active supervision. 

h. Authorized Forms. The forms generally applicable to units 
maintaining this equipment are listed in the appendix. No forms 
other than those approved for the Department of the Army will be 
used. For a current and complete listing of all forms, see 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. 

(?. Field Report or 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 reports 
are required whenever accidents involving injury to personnel or dam- 
age to materiel occur. 

d. Reiport of Unsatiseactory Equipment or Materials. Any 
suggestions for improvement in design and maintenance of equip- 
ment, safety and efficiency of operation, or pertaining to the applica- 
tion or effect of prescribed petroleum fuel, lubricants, and/or 
preserving materials, will be reported through technical channels, as 
prescribed in SR 700-^5-5, to the Chief of Ordnance, Washington 25, 
D. C, ATTN: ORDFM, using DA AGO Form 468, Unsatisfactory 
Equipment Report. Such suggestions are encouraged in order that 
other organizations may benefit. 



Note. Do not report all failures that occur. Report only repeated or recurrent 
failures or malfunctions which indicate unsatisfactory design or material. How- 
ever, reports will always be made in the event that exceptionally costly equipment 
is involved. See also SR 700-45-5 and the printed instructions on DA AGO 
Form 468. 

Section II. DESCRIPTION AND DATA 

4. Description 

a. The engine described in this manual is a Willys- Overland 
4-cylinder, L-head gasoline unit (fig. 1, 2, and 3) with a counter- 
balanced crankshaft. The camshaft is driven off the crankshaft 
through gears (figs. 37 and 39). The oil pump (fig. 64) is located 
externally on the left side of the engine and is driven by a gear cut 
integrally on the camshaft. The "front" or timing-gear end of the 
engine will be referred to as the front end. The "rear" or flywheel 
end of the engine will be referred to as the rear end. The terms 
"right" and "left," as used with reference to the engine, are as viewed 
from the rear end and looking toward the front end. Cylinders are 
numbered 1 through 4 starting at the front end. The distributor is 
driven directly from the oil pump drive gear. Keference is made to 
chapter 4, this manual, for complete information and to operator's 
manual, TM 9-804, for tabular data. 

h. The clutch (fig. 81) is a single plate 8i^-inch dry disk type. The 
pressure plate (fig. 82) is well protected against corrosion for under- 
water operation and three springs give a total plate pressure of from 
990 to 1080 psi to provide 147 Ib-ft torque. The driving plate is faced 
on both sides with center vibration neutralizer springs. Refer to 
chapter 5 for complete information and tabular data. 

€. The engine ventilation system for underwater operation (fig. 4) 
consists of the standard crankcase ventilating system with the addi- 
tional necessary external watertight tubes required to assure under- 
water operation or prevent damage due to condensation. Detailed 
information is contained in chapter 6 of this manual and all tabular 
data in TM 9-804. 

5. Data 

Make and type ^ Willys-Overland 4-cylinder, L-head, in- 
ternal combustion gasoline driven 

Model MC 

Over-all dimensions (including flywheel assembly) 

Length 26.53 in 

Width 21.16 in 

Height 27.34 in 

Dry weight complete with flywheel 365 lbs 

Maximum brake horsepower 60 at 4,000 rpm 

Maximum torque 105 Ib-ft at 2,000 rpm 

Number of cylinders ^ 4 




Figure 1. Left side view of power plant. 




fA m 357991 



Figure 2. Front view of engine. 




mmmmmm 



Figure 3. Right side view of power plant. 



A - WINDSHIELD WIPER TO AIR ClfeANEH VENT IINE 

» -aiEl TANK TO A(R CLEANBi VENT IM^ 

C -DASH EL0OW TO DASH TEE LINE 

D » DASH aSOW 

E ~ iUAKE MASTER CYLINOER TO DASH aBOW VENT INC 

F - CARBURETOR TO AIR NTAKE PIPE 

G - CRANKGASE VB^ VALVES 

H- VACUUM LINE TIE 




Figure 4- yentilation of units for deep water fording. 



RA fp 3579*6 



CHAPTER 2 

PARTS, SPECIAL TOOLS, AND EQUIPMENT FOR FIELD 
AND DEPOT MAINTENANCE 



6. 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 re- 
building the materiel. 

7. Parts 

a. Maintenance parts are listed in Department of the Army Supply 
Catalog ORD 8 SNL G-740 which is the authority for requisitioning 
replacements. Parts not listed in the ORD 8 catalog, but required by 
depot shops in rebuilding operations, may be requisitioned from the 
listing in the corresponding ORD 9 catalog and will be supplied if 
available. 

5. Standard and commonly used tools and equipment having gen- 
eral application to this materiel are authorized for issue by T/A and 
T/O&E, They are not specifically identified in this manual. 

8. Special Tools and Equipment 

The special tools and equipment tabulated in table I are listed in 
Department of the Army Supply Catalog ORD 6 SNL G-27, Section I. 
The tabulation contains only those special tools and equipment neces- 
sary to perform the operations described in this manual, is included 
for information only, and is not to be used as a basis for requisitions. 

Note, Special tool sets in OKD 6, SNL G-27, Sec. I, in addition to special tools, 
also contain standard and commonly used tools and equipment specifically appli- 
cable to this material. 




nmm^TOBMu 




! I^^SS^^^m ff^^l^:^^ 





Figure 5. Special tools. 



Table I. Special Tools and Equipment for Field and Depot Maintenance 





Identifying Number 


Keferences 






Fig. 


Par. 




GAGE, valve cap clearance 


41-G-500-90 

41-P~2956-4 

41-P-295&-15 

7083446 

41-R-2329-700 

41-R-2379-25 

7083262 
7083263 
7083261 


5,62 

5, 39, 40 
5,48 
5,49 
5, 50, 51 
46 


59 

39 

44 
44 
46 
43 


Measure clearance between end of exhaust 


PULLER, crankshaft and camshaft geai^ 


valve stem and rotator cap. 
Removing crankshaft and camshaft gears. 


PULLER, water pump, drive gear 


Removing water pump drive gear. 


PULLER, water pump impeller _ 


REFACER, water pump bushing 


Refacing water pump. 


REMOVER AND REPLACER, valve guide, in 
set 

Composed of: 

ADAPTER 


Removing and replacing valve guides. 


ADAPTER . 




DRIVER 









CHAPTER 3 
TROUBLE SHOOTING 



Section I. GENERAL 



9. Purpose 



Note. Information in this chapter is for use of ordnance maintenance per- 
sonnel in conjunction with and as a supplement 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 per- 
sonnel for corrective action. 

Operation of a deadline vehicle without a preliminary examination 
can cause further damage to a disabled component and possible injury 
to personnel. By careful inspection and trouble shooting, such dam- 
age and injury can be avoided and, in addition, the causes of faulty 
operation often can be determined without extensive disassembly. 

10. General Instructions and Procedures 

This chapter contains inspection and trouble-shooting procedures 
to be performed while a disabled component still is mounted in a 
vehicle and after it has been removed. 

a. The inspections made while the component is mounted in the 
vehicle are visual for the most part and are to be performed before 
attempting to operate the vehicle. The object of these inspections is 
to avoid possible damage or injury and also to determine the condition 
of and, when possible, what is wrong with the defective component. 

h. The trouble shooting performed while the component is mounted 
in the vehicle is that which is beyond the normal scope of organiza- 
tional maintenance. Check the trouble shooting section of TM 9-804 
or any other pertinent operator's manual, to be sure the trouble is not 
a defect normally corrected by the using organization, then proceed 
as outlined in this chapter. 

(?. Inspection after the component is removed from the vehicle is 
performed to verify the diagnosis made when the component was in 
the vehicle, to uncover further defects, or to determine faults if the 
component alone is received by the ordnance installation. This in- 
spection is particularly important in the last case because it often 

11 



is the only means of determining the trouble without completely 
disassembling the component. 

d. Trouble shooting a disabled component after it has been removed 
from the vehicle consists of subjecting it to tests on a dynomometer. 
This chapter discusses those symptoms which can be diagnosed by 
using the testing equipment and interprets the results in terms of 
probable causes. 

Section IL ENGINE 

11. General 

Most engine troubles are accessory troubles. The trouble-shooting 
portion of TM 9-804, or the specific manuals (par. \d^ 6, /, and g) 
covering the particular accessories used with this engine normally 
will cover the trouble shooting of all engine accessories. This section 
covers only those troubles which can develop within the engine itself. 

12. Procedure 

a. Seizure of Parts. When an engine cannot be turned over by 
hand or with a starter, seizure of parts is the cause. Remove the 
starter and with a small bar, attempt to turn the flywheel. If the 
flywheel can be turned the probable seizure is in the starter. If the 
flywheel will not turn clockwise, seizure can usually be isolated to a 
hydraulic lock. If flywheel will not turn in either direction, proceed 
as outlined in the following paragraphs. 

Caution: Exercise 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 
require a complete teardown and cleaning of the lubrication system. 

h. 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 is covered under the individual systems. 
Gear failure repairs frequently can be confined to replacement of the 
damaged parts. 

Caution: Exercise great care in deciding what repairs must be 
made. Disassembly and cleaning of part or all of the engine may be 
necessary due to contamination of the engine lubricating system or 
moving parts with chips. 

c. Noise. Unusual engine noises can be caused by worn, broken, or 
improperly adjusted parts and by lack of lubrication. Ability to iso- 
late trouble causing a noise is a matter of experience and even then is 
somewhat inaccurate. When noise occurs, shut down engine immedi- 
ately for investigation. Some of the more common noises and their 
causes are — 

12 



(1) Grinding noise. Turn the engine by hand. If it is some- 
what tight and the grinding persists, a bushing or bearing 
is probably failing. Refer to ^ above. 

(2) Sharp tapping noise. A defective valve or incorrect valve 
clearance will produce this sound. Start the engine and lis- 
ten through a suitable length of pipe or a screw driver pressed 
against the cylinder block. The tapping from the defective 
unit will be much sharper and louder than from the others. 

d. Air Intake Manifold and Valves. 

(1) Preliminary instructions. Most induction system difficulties 
are covered in the pertinent operator's manual. Difficulties 
that are not covered therein and the methods of locating them 
are listed under (2) below. 

(2) Procedure. Examine the camshaft for damage. Follow 
whichever of the following that applies : 

{a) Camshaft damaged. If the camshaft is damaged, do 
whichever of the following that applies : 

1. Camshaft hearing or journal damaged. Eepair or replace 

damaged parts. 

2. Camshaft broken. Replace with new camshaft. 

{h) Valve stuck. Remove valve cover. Turn the engine and 
observe if all valve stems move up and down properly. If 
any valves are stuck open, it will be readily noticeable. A 
stuck valve will sometimes damage the camshaft. Repair 
the valve difficulty and inspect the camshaft for conform- 
ance to serviceability standards (par. 156). 

e. Starting System. 

(1) Preliminary instructions. Most defects are covered in the 
pertinent operator's manual. A failure or seizure in the gear 
train are other difficulties that may occur. 

(2) Procedures. Turn the engine by hand. If it cannot be 
turned, refer to a above. If it turns, attempt to crank engine 
with the starter. If the engine does not turn over, remove 
starter for repairs as outlined in pertinent technical manual 
(par. 1). 

/. Engine Low in Power. Stop engine and proceed as in <?(1) 
above. If that is not the cause, trouble shoot as outlined in the perti- 
nent operator's manual. 

g. Engine Misfires and Runs Rough. Trouble shoot as outlined 
in pertinent operator's manual and in d above. 

h. Engine Fails to Start. Refer to pertinent operator's manual 
and to d and e above. 
i. Engine Lubrication System DEFEcrriVE. 

(1) Preliminary instructions. Make the checks outlined in the 
pertinent operator's manual. If the trouble is not isolated, 
proceed as in (2) below. 

953383—51 2 1 3 



(2) Procedures, 

{a) Low oil pressure. Obstructed oil passages or worn or 
burned out bushings and bearings could cause this con- 
dition. If the obstructing material in the oil passages is 
something that might be throughout the rest of the engine, 
rebuild the entire engine; otherwise, remove the obstruc- 
tion. If worn parts are the cause, rebuild engine. 
(b) Excessive oil consumption. Excessive oil consumption 
caused by worn or scored engine parts should be diagnosed 
carefully to determine whether a complete engine rebuild 
or only a cylinder, piston and piston ring overhaul is 
required. 
j. Generating System. If tests in the pertinent operator's manual 
do not isolate the trouble, remove and replace with new assembly. 
Consult the pertinent technical manual for detailed instructions 
(par. 1). 



14 



CHAPTER 4 
ENGINE 



Section I. DESCRIPTION AND DATA 

13. General 

The Willys-Overland Model MC engine is a conventional design 
four-cylinder L-head-type unit (figs, 1, 2, and 3). The crankshaft 
(fig. 43) is mounted on three replaceable shell-type bearings and is 
counterbalanced to reduce vibration. Extra long connecting rods with 
replaceable shell-type bearings and three- ring aluminum pistons are 
used. The camshaft rotates on four bearings, the rear three being 
reamed openings in the crankcase and the front a replaceable, babbitt- 
lined steel bushing. The camshaft is driven by helical cut timing 
gears (fig. 37). 

14. Engine Lubrication System 

Engine lubrication is accomplished by a force-feed continuous cir- 
culating system. An oil pump (figs. 64 and A, fig. 28) mounted ex- 
ternally on the left side of the engine and driven by a gear cut integ- 
rally with the camshaft provides the necessary oil pressure. Drilled 
passages in the crankcase provide oil flow to the cranksaft and cam- 
shaft bearings and passages in the crankshaft provide oil flow to the 
connecting-rod bearings and timing gears. The pistons and valve 
tappets are lubricated by oil spray from the connecting rods. 

15. Electrical System 

The engine electrical system is of the 24-volt type. All electrical 
units are sealed to allow operation underwater and where necessary 
shielded to provide satisfactory radio interference suppression. 

16. Crankcase Ventilation System 

The engine crankcase is sealed to allow operation underwater. It 
is ventilated through a line (fig. 4) connected to a vacuum-controlled 
valve mounted in the intake manifold. A sealed-intake hose provides 
air for underwater operation. Crankcase ventilation may be blocked 

T5 



off by closing control valves (fig. 85) to provide build up of pressure 
within the crankcase to prevent water from entering the engine when 
the vehicle is submerged. 

17. Power Plant 

The vehicle and the engine, transmission, and transfer, are designed 
to permit removal of the complete power plant with minimum labor 
(fig. 23). The power plant rear mounting in the chassis is at the 
transmission, which makes it impossible to place the engine, without 
transmission and transfer attached, on a stand for test. The entire 
power plant must be removed when it is necessary to remove the engine 
for rebuilding. 

18. Data 

Cylinder bore 3.125 in 

Piston stroke 4.375 in 

Piston displacement 134.2 cu in 

Compression ratio 6.48 to 1 

Valve-timing setting Intake closes 50° after top center 

with 0.020-in clearance 
Valve clearance Hot or cold engine) : 

Intake 0.016 in 

Exhaust 0.016 in 

Valve events : 

Intake opens 9° before top center 

(0.039-in piston travel) 

Intake closes 50° after top center 

(3.722-in piston travel) 

Exhaust opens 47* before top center 

(3.799-in piston travel) 

Exhaust closes 12° after top center 

(0.050-in piston travel) 

Ignition timing Set 5* before top center 

(automatic advance) 

Spark-plug gap 0.030 in 

Firing order 1-3^^2 

SAE horsepower 15.63 

Accessories (number of each) : 

Generator 1 

Starter 1 

Spark plugs 4 

Carburetor 1 

Fuel pump 1 

Generator output 25 amp 28.5 v 

Section II. POWER PLANT REMOVAL FROM VEHICLE 

19. General 

a. Both the vehicle and power plant are designed to permit removal 
of the power plant, which includes the engine, radiator, clutch and 

16 



housing, transmission, and transfer as a unit, with a minimum of time 
and labor. Should other than minor engine adjustments be required, 
remove the entire power plant assembly (par. 20) . 

h. All disconnect points are painted yellow as a guide for removing 
the assembly. 

20. Removal of Power Plant 

a. Disconnect Battery Cable. Unhook the two hood clamps, 
raise the hood and lay it against the windshield. Disconnect the bat- 
tery ground cable (fig. 6) . 





If 

L * 

1 






'--■■■-•■"--'■-■'■-"-''•■■••'^^ 


mtim 


G)%OUND CABLE^^^^^^^K^H 













Figure 6. Battery disconnect point. 

d. Disconnect Eadiator-Beace Eod (fig. 7) . Loosen retaining nut 
on radiator ; remove brace rod from slotted bracket, swing rod out of 
position from pivot end, and lay brace rod on cowl. 

c. Eemove Hinged Radiator Guard. Disconnect the three head 
light cable connectors at the left-front head light (fig. 8) . Loosen the 
top bolt, at each side of the radiator guard panel and loosen the two 
lower bolts, on each side (fig. 9). Lay the radiator guard assembly 
forward on the bumper and remove guard from hinge sockets. 

d. Disconnect Eadiator From Frame Cross Member. Working 
from underneath, remove the two nuts and lock washers which attach 
the radiator to the frame cross member (fig. 10) . 

e. Disconnect Oil-Pressure- Gage and Water-Temperature-Gage 
Sending Units. Disconnect the oil-pressure-gage sending unit cable 
(figs. 7 and 32) located on the left side of the engine. Disconnect the 
water temperature gage sending unit cable on the right side of the 
cylinder head (fig. 11) . 



17 




A ^ RADIATOR BRACE ROD OISCONHECT POINT 
B - CHOK£ CABLE 
C -~ THROTTLE CABLE 

D ™ VENTllATiNO VALVE CONTROL CABLE 
E - Oil PRESSURE GAGE SENDING UNIT DISCONNECT POINT 
f_„ WINDSHIELD VESPER HOSE DISCONNECT POINT 

O ^ VENTILATING VALVE CONTROL CABlg RA PD 357972 

DISCONNECT POINT 

Figure 7, Engine compartment disconnect points. 




Figure 8. Bead light disconnect points. 



18 




A ™ RADIATOR GUARD TOP BOLT 
ft _ RADIATOR GUARD tOWSt BOLT 
C ™ RADIATOR GUARD HINCe 

.::■*: ■..:...■ ^m~^S7W4 



Figure 9. Radiator guard disconnect points. 




Figure 10. Radiator disconnect points. 



19 




PD 357976 

Figure 11. Water-temperature-gage sending unit disconnect point. 



f. Disconnect Exhaust Pipe (fig. 12) . Eemove the two nuts that 
secure the exhaust pipe to the intake manifold. Pry the exhaust pipe 
from the intake manifold. 



^^^^^^BvAOHS^SMPt^l^ 






m^^m FUEL FSIMER LfNE DiSCONhKr^ IC 


Iffl 


m\ mm^^^^^^ .,::V.. ■— -- ■■■ ■■ 




o!^^57977^HHb9^^BI 




r 

r 

4 



Figure 12. Left side of engine disconnect points. 



20 



g, Discoifl^NECT Fuel and Vacuum Lines. Disconnect fuel tank 
line hose connector from fuel pump (fig. 30) and disconnect primer 
line at intake manifold (fig. 12). Disconnect windshield wiper hose 
from vacuum line at vacuum line tee (fig. 15) . 

A. Disconnect Choke and Throttle Control Cables (fig. 7) . Re- 
move the nut and bolt from the choke and throttle hold down bracket. 
Loosen the set screw on the carburetor choke lever and remove the 
choke control cable. Disconnect accelerator from ball connection at 
floorboard (fig. 17). 

L Disconnect Ventilating-Yalve Control Cable. Remove the 
bolt and nut on the ventilating valve control bracket. Loosen the set 
screw on the ventilating valve mounted on the manifold and remove 
the ventilating-valve control cable (fig. 7). Loosen the set screw on 
the ventilating valve directly to the rear of the oil filler tube and remove 
the ventilator valve control cable (fig. 13) . 

;/'. Remove Air Cleaner (fig. 13). Disconnect windshield-wiper 
and fuel-tahk-to-air-cleaner vent lines at air cleaner. Disconnect air- 
cleaner-to-dash-tee line at air cleaner. Loosen the hose clamps that 
secure the air-cleaner hoses at the air cleaner and remove the hoses. 




A -™ WNDSHiStD WIPER HOSE DiSCONNECT K)iNT 
B -AIR CIEANER INLST HOSE 
C~Am CLEANER BRACKET DISCONNECT POINT 
D -Alft CLEANER 

E-rua TANK TO AIR CLEANER VENT LINE 

F ~ AIR CLEANER OUTLET HOSE 

0™ SPARK PLUG CABLE 

H - VENTILATING CONTROL VALVE CABLE HOLD DOWN BRACKST . 

J - HOSE CLAMP ■ :wv„j^-..r^ r-^^---:-:^^^ 

K - VENTILATING CONTROL VALVE CABLE '■^^..W^^:m 

Figure 13. Disconnect points. 

21 



Kemove the four wing screws that secure the air cleaner to the mount- 
ing bracket located at the right side of the cowl and remove air cleaner. 

h. Disconnect Electrical Cables. Disconnect the starter, auxil- 
iary power receptacle, and generator regulator cables at the starter 
terminal (fig. 14). Disconnect the field, armature, and ground cable 
by disconnecting the plug from the connector at the generator (fig. 
16) . Disconnect primary cable at distributor (figs. 14 and 16) . 

I. Eemove Floor Plate and Shipt Levers. Place transmission 
gearshift lever in neutral (TM 9-804) . Remove the 24-cap screws and 
internal toothed lock washers from the floor pan (fig. 17) . Remove 
transfer gear shift lever knobs. Remove the floor pan. Loosen clamps 
securing rubber boot to the transmission gear shift housing (fig. 17). 
Slide boot up and unscrew gearshift lever (fig. 18) . Remove gearshift 
lever. Unscrew the fulcrum pin (D, fig. 20) and remove the transfer 
gearshift levers. Remove brake-pedal-shaft-clamp bolt and remove 
brake-pedal shaft (fig. 18). 




Figure H. Disconnect points, 

m. Disconnect Front and Rear Propeller Shafis (figs. 19, 20, 
and 21). Remove the four bolts, nuts, and lock washers securing the 
propeller shaft flanges to the transfer. Tie the end of the front shaft 
to the frame with a piece of wire. 

n. Disconnect Speedometer Cable (fig. 22). Disconnect the 
speedometer cable at the transfer. 

o. Remove Hand Brake, Clutch, and Engine Stay Cables (fig. 
21). Remove the clevis pin that secures the hand-brake cable to the 
hand-brake control lever at rear of transfer case. Remove the hand- 
brake-cable clamp at the engine support plate. Disconnect the clutch 



22 




A ™ THROTTLE CABLE DISCONNECT POINT 

B ~ CHOKE CABLE DISCONNECT POINT 

C - VACUUM DISCONNECT l»OiHT 

& - LEFT WINDSHiaO WIPER NOSE DISCONNECT POINT 

E ^VgNtriATiNG VALVE CONTROL CABLE DISCONNECT POINT 



RA PO 357996 



Figure 15. Disconnect points. 



cable at the clutch shaft. Loosen nut on each side of transfer case to 
allow engine-stay-cable ball socket to slide freely and remove engine 
stay cable. 

p. Attach Lifting Hook (fig. 23) . Install a lifting hook in the 
rear lifting eye on the cylinder head. Place a slight tension on the 
lifting chain or cable. 

q. Disconnect Engine Front Supports (fig. 24). Kemove the 
two nuts and bolts from each engine front support, allowing the 
mounting brackets to remain attached to the engine. When this opera- 
tion is performed the engine ground strap at the engine right-front 
support will be disconnected. 

r. Disconnect Transmission From Frame (figs. 19 and 20). Re- 
move nut and washer securing right side of transmission and transfer 
case to frame cross member. Remove nuts on right and left side secur- 
ing transmission and transfer case to frame cross member to permit 
power plant to slide to right for easy removal. 

s. Disconnect Clutch Linkage. Move the rear of the power 
plant to the right and disconnect the clutch linkage at the ball stud 
(fig. 21). 



23 







Figure 16. Disconnect points. 



mmm^M- 




A - ACCEIERATOR PEDAL OlSCONNea fOim 

S - TRANSMISSfON GEAR SHlfT LEVER 800T ClAMF 

C ~~ BOOT 

D - FLOOR PAN SCREW 

E _ TRANSFER OBM SHIFT lEVEf^ SOOT 

F - RETAINiNG RING 



mm 357980 



Figure It. Disconnect points. 



24 




A-TRANSMISStON GEAR SHI?T tEVER DISCONNECT POiNT 

B^CtUTCH UNKAGE DISCONNECT POINT 

C-SRAKE PEDAL SHAfT 

&-81tA!CE PEDAl SHAFT DRAFT PAD SPRING 

fi^BRAKE PtDAl SHAFT WASHER 

F-BRAKE PEDAl SHAFT PAD 

0-ERAKE PEDAL SHAFT DISCONHfiCT POINT 



RAPD 357981 



Figure 18. Disconnect points. 



25 



MH^HJ^wiW^^^^^^^^^^BpRO^t^t. SHAFT DISCONNECT {>0INTM 








Bp ; J TltANSMiS$tON &iSCONNfcC!_gOjHj|^ 



Figure 19. Disconnect points. 




A^mMT vm?m.^ sha?t mscotmEa point 

B-TftANSFSIi-TR^^SMISSlON DISCONN^T K^NT 
C-TRAH^SR VENT UHE 

0~TSANSre» GEAR SHIFT lEV^ DISCONNECT POINT 
E-BtAN^R-HeAHSMfSSlON DlSCONNEa POINT 

Figure 20. Disconnect points. 



fiA PD 3579^3 



26 




A - ENGINE STAY CABLg 

B-HAND &RAKE CABLE 

C ^ ENGINE STAY CABLE DISCONNECT POINT 

D" CLUTCH LJNKAOE BAIL STUD DISCONNECT POINT 

E ~ HAND 8KAKE CABLE DISCONNECT POINT 

F ™ REAR PROPELLER SHAI^T DISCONNECT POINT 



;lA:fi>-::-:|iliPj 



Figure 21. Disconnect points. 



17 




Figure 22, Speedometer caUe disconnect points. 

t. Remove Power Plant From Vehicue. 

^ote. Make sure all disconnects have been accomplishad. 

While rolling the vehicle to the rear, carefully lift power plant out 
of vehicle (fig. 23) . Block up power plant. 



28 



il::::;;ii:::|l||i:l|iliiliiiiii:^^ 




Figure 2S. Lifting power plant from vehicle. 




Figure 24. Disconnect points. 



953383—51 3 



29 



Section III. PREPARATION OF ENGINE FOR REBUILD 

21. Drain Coolant and Oil 

Drain the coolant from the radiator and the engine by opening the 
radiator drain cock (fig. 30) and the drain cock located on the right side 
of the engine. Kemove the oil pan drain plug and drain the engine oil. 

22. Removal of Radiator 

Loosen the two radiator outlet hose clamps and slide the hose back on 
the metal tubing and remove the hose. Loosen the radiator inlet hose 
clamps at the water pump and at the radiator and remove the hose. 
Lift radiator from support rods {G.g. 25) . 

23. Removal of Starter 

(fig. 26) 

Remove the cap screw and lock washer that secures the starter 
bracket to the cylinder block. Remove the two cap screws and lock 
washer that secure the starter to the clutch housing, and remove the 
starter. 



30 




A - ROD, SUPPORT, RADiATOI^ TO ENGINE/RIGHT - 7372804 

B - RAOJATOR, W/ SHROUD, ASSEMBLY - 7372B01 

C » NUT, fiADlATOR MOUNTING ~ 1 20370 

D - COCK, DRAIN, RADIATOR ™ 103647 

E ^ PUilEY, DRIVE, FAN AND GENHRATOR ^ 73725;§g 

F ™- COVEr?, TIMING G€AR ^ 7372576 

G ^ PUMP, FUEL AND VACUUM - 7375380 

H ~ PAN, Oil -7371 278 

J ™ PLUG, DRAIN, 7/8 IN » 340661 

K - PfPE, EXHAUST - 7375077 . 

l ™ CABIE, HAND BRAKE - 7375066 



M ~ CABie, STAY, ENGINE - 7372548 



KA PD 357945 



Figure 25, Underside view of power plant in vehicle. 



31 




Figure 26. Starter mounting screws. 

24. Removal of Transmission and Transfer 

(figs. 28 and 29) 

Remove the two nuts, bolts, and lock washers on top of clutch hous- 
ing. Eemove the remaining four bolts and nuts securing the clutch 
housing to the engine rear plate and remove clutch housing, transmis- 
sion, and transfer as a complete unit. 



32 




AfR CLEAHEt . 

Am CtEAHS. TO FUa TANK VENT UNE ^g 

C - A!R CLEAHER HOSE ClAMP 
-^ASS CLEANER OUUO HOSE 

K -^ VENTiLATOi? VAiVE CONTtOl CASIE BHACKST:!! 
f -VENTIIATOR VAiVE CONTROL CA&Li 

Am INTAKE PIPE 

WATER OUTIET eiBOW {THERMOSTAT HOUSING); 

RADIATOR BRACE ROD 

CARSURETOR 

•RAOIATOt TO WATER OUTLET ElBOW HOSE f 

■WATER PUMP 
N '- RADIATOR SHROUD 
P - Oa FILLER PIPE CAP 

n - BATTERY BOX 

S - GENERATOR 

T - VOiTAGE REGULATOR 

U - DISTRIBUTOR 



RA PD Z57997 



Figure 21. Front view of engine compartment. 







HAW 33^«4« X W 



Figure 28. Three-quarter left rear vietv of power plant. 



A— PUMP, OIL ASST~7375072 

B— UNIT, SENDING, ENGINE OIL PRES- 
SURE— 7728856 

C~MANIFOLD, INTAKE, W/STUDS— 
7372562 

T>~MANIFOLD, EXHAUST— 7375054 

E— LINE, VENTILATION, DISTRIBUTOR, 
13-INCHES LONG 

F— S HAFT, CROSS, ACCELERATOR, 
W/LEVER, AND B R A C K E T— 
7375069 

G— SPRING, RETURN ACCELERATOR— 
7375068 

H— ROD, CONTROL, THROTTLE— 
7375111 

J— PLUG, EXPANSION— 541402 

K— COVER, VALVE SPRING COMPART- 
MENT— 7371237 

L— HOUSING, CLUTCH— WO-801629 



M— LEVER, TRANSMISSION, GEAR- 
SHIFT— 7374974 
N— COVER, INSPECTION, CLUTCH— 

7371341 
P— HOUSING, GEARSHIFT LEVER— 

WO-801730 
Q— DRUM, HAND BRAKE— 7371010 
R— LEVER, OPERATING, HAND BRAKE— 

7697434 
S— STUD, BALL, CONTROL LEVER 

TUBE— A246557 
T— BRACKET, MOUNTING, R E A R— 

7372544 
U~CABLE, CONTROL TUBE LEVER— 

7372821 
V— NUT, HEX— 120369 
W — SUPPORT, ENGINE OIL PRESSURE 

GAGE SENDING UNIT— 7375148 
X— DRAIN PLUG— 340661 



Figure BS.—Continued 



35 




RA PD 357946 
Figure 29, Three-quarter right rear vieto of power plant. 



36 



A— COVEK, TRANSFER CASE, REAR— R— LINE, VENTILATING, DISTRIBUTOR 

WO-A1508 TO AIR INTAKE PIPE 

B— SCREW, CAP, yi6-14NC x 1^—122267 S— UNIT, SENDING, ENGINE WATER 
C— HOUSING, TRANSMISSION GEAR- TEMPERATURE GAGE— 7728851 

SHIFT LEVER— WO-801730 T— PLUG, EXPANSION— 541402 

D— LEVER, TRANSMISSION GEAR- U— DISTRIBUTOR, W/COIL~7375375 

SHIFT— 7374974 V— STARTER— 7762616 

E— L EVER, TRANSFER GEARSHIFT W— PAN, OIL— 7371278 

(FRONT LEVER DRIVE)— 7374966 X— SCREW, CAP, %-24NF x 1% 

F— COVER, INSPECTION, CLUTCH— Y— NUT, %6-14NC— 120369 

7371341 Z— HOUSING, CLUTCH— WO-801629 

G— UNIT, SENDING, ENGINE OIL PRES- AA— SCREW, CAP, %-24NF x 1% 

SURE GAGE— 7728856 AB— SHAFT, SHIFTER, TRANSFER 
H— SHAFT, CROSS, ACCELERATOR CLUTCH GEAR FORK— WO-A962 

W/LEVER, AND BRACKET— AC— YOKE, FRONT PROPELLER SHAFT 

7375069 TO TRANSFER, W/SHIELD— 

J— LINE, VENTILATION, DISTRIBUTOR 7371208 

TO VACUUM LINE TEE AD — CASE, TRANSMISSION— 7372877 

K—PLUG, SPARK— 7524258 AE—CASE, TRANSFER- 7375051 

L— CARBURETOR— 7372509 AF— DRUM, HAND BRAKE — 7371010 

M— LINE, VENTILATING, CARBURETOR AG— FLANGE, COMPANION, REAR PRO- 

TO AIR INTAKE PIPE PELLER SHAFT— 7371035 

N— HOSE, CARBURETOR TO AIR IN- AH— SCREW, LOCKWASHER, %-16NC x 

TAKE PIPE— 7375120 %— 443608 

P— EYE, LIFTING— 7375026 AJ— LEVER, TRANSFER GEARSHIFT 
Q— CABLE, SPARK PLUG— 7528173 AND (HIGH AND LOW RANGE)— 

7528174 7697470 

Figure 29. — Continued 



37 



25. Removal of Carburetor 

(fig. 27) 

Loosen hose clamp securing hose to carburetor, slide clamp back 
on hose and remove hose (fig. 27) . Remove carburetor air vent line 
from carburetor (fig. 32) and move line out of way. Remove the 
fuel line connecting the carburetor and fuel pump. Remove the ac- 
celerator return spring from the carburetor and accelerator lever (fig. 
31) . Disconnect throttle control rod at the adjusting block. Remove 
the two carburetor hold-down nuts, lock washers and accelerator 
spring clip, and remove carburetor. 

26. Removal of Fuel and Vacuum Pump 

(fig. 30) 

Disconnect fuel lines at fuel pump. Disconnect the two vacuum 
lines at base of pump. Remove the two screws and lock washers that 
hold the fuel pump to the cylinder block, and remove the fuel pump. 

27. Removal of Generator 

(fig. 33) 

Remove generator- adjusting-brace cap screw. Loosen the two gen- 
erator pivot bolts. Raise the generator to release the tension on the 
two fan belts, and remove the two belts. Remove the two pivot bolts 
that hold the generator to the support bracket, and remove the gen- 
erator. Remove the two cap screws that hold the support bracket to 
the cylinder block, and remove the bracket. 

28. Removal of Oil Filter 

(fig. 27) 

Disconnect oil filter inlet and outlet lines at the filter. Remove the 
cap screw that secures the oil-filler-pipe clip to the cylinder block. 
Remove two oil filter bracket screws and remove oil filter. Remove 
the three cylinder head nuts that hold the oil filter mounting bracket 
to the cylinder head and remove the bracket. 

29. Removal of Distributor 

(fig. 33) 

Disconnect the four spark plug cables at each plug. Slide the 
cables through the spark plug hold- down bracket. Disconnect the two 
vent lines at the distributor. Remove distributor mounting cap screw 
and remove distributor. 



38 




A - COCK, DRAIN, RADIATOR - 103647 

B - Um, PUMP TO FUEL TANK ^ 7375038 

C- PUMP, FUEL AND VACUUM - 7375380 

D-UNE, FUEL PUMP TO CARBURETOR - WO-S0 1380 

£ -LINE, VACUUM PUMP TO VACUUM UNE TEE - WO-800870 

F - SCREW, 5/16-18NC x 2 -7375385 



=M PD 35^00$ 



Figure 30. Removal of fuel pump. 



39 




A-cAmmmoti 

& - THRO.mE AND CHOKE CONTROL CA816 CONDUIT CtAMP 

C - THROniE CONTROL ^OD 

- THROHLE CONTROL ROD ADJUSTING BLOCK 

t - THROTTLE CONTROL 

F ~ CHOKE CONTROL 

™ ACCELERATOR CROSS SHAFT 
H ™ ACCEiERATOt FEOAl 

J ^ ACCELERATOR PEDAL HNGE 
K ™ ACCELERATOR FOOT REST 

1 ~ ACCELERATOR PEDAL. TO CROSS SHAFT LEVER CONNECTOR 

M - ACCELERATOR PEDAl TO CROSS SHAFT LEV£i? CONNECTOR BOOT 
N ™ ACCELERATOR RETURN SmiHG CLIP {THROTTlE CONTROL ROD ADJUSTING SLOCK? 
P -»• ACCELERATOR fiETURH SPRING 

Q - ACCELERATOR UBUm SPgINO CLJP |CARSUf?IETOI? MDUHTfHG STUD) 
R - MANIFOLD 

S ™ THROHLE VALVE LBVER STOP ADJUSTING SCREV/ 
T~THROTUE CABLE 'STOP 
U ^ THROTTLE LEVER 
V - CHOKg CONTROL CABli CLAMP SWIVEL SC8EW 



RA Pp 357W 



Figure 31. Accelerator and choke linkage. 



30. Removal of Fan 

(fig. 32) 

Eemove the four cap screws and lock washers that hold the fan to 
the fan and water pump pulley and remove the fan. 



40 




A " FAN AND OENERATOR DRJVE PUUEV GUARD T 

g ^ CRANKSHAFT NUT U 

c - GEAR covm V 

D - FAN W 

g ^ fAN AI^D WATER PUMP PULLEY X 

f ™ FAN 8EITS - Y 

O -~WAT£R PUMP Z 

H - SY.PASS TUSE AA 

4 ^ Oft urn AB 

K - OIL FILTEJ? AC 

I - Ofl FIILSR ?(Pe AD 

M - Oil FillEii PIPE CAP AMD GAO£ AE 

N - VENTILATiNG VAi.V£ AF 
P „ WATER OUTIET ElBOW {THERMOSTAT HOUSING) AG 

™ UFTiNG EYE AH 

n ~- CARBUfiETOR TO AIR INTAKE flPE HOSE AJ 

S- CARBURETOR CHOKE VAIVE BODY WC 



CARBURETOR VENT UNE 

CHOKE CABIE HOLD DOWN CUP 

CARBURETOR 

CARBURETOR FUEl LiNE 

THROTTLE iEVER 

ACCELERATOR RETURN SPRING 

VENTltATiNG VAtVE 

PRIMER PUMP UNE 

VACUUM PUMP UNE 

CRAHKCASE VBMT UNE 

VALVE SPRiNG COMPARTMENT COVSR 

COVER SCREW 

Oil PRESSURE GAGE SENDING UNIT ; 

0!L PUMP 

ENGINE REAR PiATE 

FUEL AND VACUUM PUMP 

FUEl iNlET LINE ELBOW 



Figure 32. Left-front view of engine. 



41 




A - PRESSUSg PtATE 
B ~~ FlYWHESl 
C - ENGINE RiAJ? PIATE 
D - OJL PRESSURE GAGE SENDiNG UNIT 
E *- ACCELERATOR CROSS SHAFT 
F_ EXPANSION PLUG 
O- WATER TEMPERATURE GAGE SENDING UNIT 

n ™ msTRiauTOR vmT im^ 

J -- DISTRIBUTOR COVER 
K~ SPARK PlUG CABLE 

t ^ DISTRI&UTOR VENT UNE 
M-AIRJNTAKE PIPE 

I^UlVlNmAtJNQ CO^TROl VALVE 

'tlt^;U^^)^:mmJEf ElBOV/ {THERMOSTAT MOUSINGI 



8 - Oil FllLER PfPE CAP AND GAGE 

S - Oil FILTER BRACKET 

T ™ Oil FILTER 

U - on FILLER PIPE CLIP 

V -FAN 

W ^ Otl FILLER Pm 
X^ WATER PUMP 

Y _ FAN &aTS 

t - DISTRIBUTC^ W/COIl 
AA ~ GB^ERATOR 
A6 ™ STARTER SWITCH 
AC ™ STARTER 

Ab ^ ENGINE GROUND STRAP 
AE-OIL PAN' 



Figure 33. Right-rear view of engine. 



42 



Section IV. DISASSEMBLY OF STRIPPED ENGINE INTO 
SUBASSEMBLIES 

31. Removal of Water Pump 

(fig. 27) 

Loosen the two clamps securing the by-pass tube (fig. 32) between 
the water pump and cylinder head, and remove the tube. Kemove 
the four cap screws and lock washers that hold the water pump to 
the cylinder block (fig. 27) and remove the water pump. 

32. Removal of Intake and Exhaust Manifold 

Eemove the crankcase vent line that connects the intake manifold 
and valve compartment cover (fig. 32). Kemove distributor to 
vacuum-line-tee vent line. Kemove the seven nuts, and lift the intake 
and exhaust manifold off the engine. 

33. Removal of Water-Outlet Elbow and Thermostat 

(fig. 32) 

Kemove the three nuts and lock washers that secure the water outlet 
elbow to the cylinder head and remove the elbow. Remove the thermo- 
stat retainer and thermostat. 

34. Removal of Clutch Disk 

(fig. 33) 

Lfoosen the six pressure-plate-cover cap screws in sequence, a little 
at a time, to prevent distortion of the pressure-plate cover. Remove 
the six cap screws, pressure plate cover, pressure plate, and clutch disk. 

35. Removal of Flywheel 

(fig. 33) 

Remove the two cap screws and four nuts and lock washers that 
hold the flywheel to the crankshaft. Tap the flywheel off the crank- 
shaft with a brass hammer. Lift the engine rear plate from the 
engine. 



43 



36. Removal of Cylinder Head 

(figs. 36 and 41) 

Remove the lock washers and nuts that secure the cylinder head to 
the cylinder block, and remove the cylinder head, lifting eyes, air 
intake pipe and oil filler pipe. 

37. Removal of Valves and Springs 

Remove the two cap screws and crankcase vent body from the valve 
compartment cover, and remove the cover. With a valve lifter 41-L- 
1410 inserted between the valve tappet and valve-spring retainer, 
compress the valve springs of the valves that are in closed position, 
and remove the valve-spring-retainer locks (fig. 34). Turn the 
crankshaft to lower the tappets and remove each retainer lock. Re- 
move the valves and place them in a valve carrying board so that they 
will be installed in the same positions, dompress the valve spring 
with the valve lifter on each valve tappet that is in the closed position 
and pull the spring off the valve guide. Turn the crankshaft until 
the tappets are in the lowest position and remove each valve spring. 







A -^ SPRING, VALVE ~- 7375035 
8 ™ RgTAINER, VALVE SPf^ING - 7371236 
C ~ UFTER, VALVE «- 4t.L"1410 
D ™ LOCK, VALVE SPRING RETAINER ™ 7371230 
E ™ TAPPET, VALVE - 7372585 

F ^ SCI?EW, ADJUSTING, VALVE CLEARANCE - 7371 25S 
G ™ CAMSHAFT - 7744320 

Figure 3Jf. Removing valve spring retained locks. 



8A PD 357951 



44 



'A- ^i;. 




A—DISTRIBUTOR, W/COIL, ASSY 

B— CYLINDER HEAD GASKET 

C— EXHAUST VALVE GUIDE 

D— INTAKE MANIFOLD 

E— V A L V E SPRING COMPARTMENT 

COVER 
F— HEAT CONTROL VALVE 
G— VENT BODY TO VALVE SPRING 

COVER GASKET 
H— EXHAUST MANIFOLD 
J— V A L V E SPRING COMPARTMENT 

VENT BODY 
K— DISTRIBUTOR SHAFT FRICTION 

SPRING 
L— DISTRIBUTOR AND OIL PUMP DRIVE 

GEAR 
M— OIL PUMP TO CYLINDER BLOCK 

GASKET 



m^m;;^^4^: 



N— OIL PUMP 

P— OIL PUMP BODY COVER 

Q— OIL PUMP PRESSURE RELIEF 

VALVE 
R— VALVE SPRING 
S— VALVE SPRING SHIM 
T — VALVE SPRING RETAINER 
U— OIL PUMP SHAFT 
V— OIL PAN 
W — DRAIN PLUG 
X— OIL STRAINER SUPPORT 
Y— BEARING DOWEL PIN 
Z— MAIN BEARING CAP SCREW 
AA— OIL STRAINER 
AB~OIL FILLER PIPE 
AC— OIL FILLER PIPE AND GAGE 
AD--SPARK PLUG CABLE 



Figure So. End sectional mew of engine. 



953383—51- 



45 




mft>:^^r^ 



A— FAN 

B— WATER PUMP 
C— BY-PASS TUBE 
D— PISTON 
B— PISTON PIN 
F— WATER OUTLET ELBOW 
G— VALVE 
H— SPARK PLUG 
J— CYLINDER HEAD 
K— EXHAUST MANIFOLD 
L— CYLINDER BLOCK 
M— VALVE SPRING 

N— VALVE CLEARANCE ADJUSTING 
SCREW 



P— ENGINE REAR PLATE 

Q— CAMSHAFT 

R— FLYWHEEL 

S— VALVE TAPPET 

T— CRANKSHAFT 

U— OIL STRAINER SUPPORT 

V— OIL STRAINER 

W— CONNECTING ROD 

X— CRANKSHAFT GEAR 

Y — FAN BELT 

Z— CRANKSHAFT NUT 

AA— FAN AND GENERATOR PULLEY 

AB— ENGINE FRONT PLATE 

AC— CAMSHAFT GEAR 



Figure 36. Side sectional view of engine. 



46 



C _ WASHER, PlAtN" 774 U06 
^ <^AR. CftANK$HArr » 774 14 1 5 
€ -. OtAK CAMSHAfT - 7741 4 J 9 
f ™ HATE, THRUST ^ 7744320 
G ~ SPACE!!;. THRUST PtATE ™ 774 J 407 
H ~- KEY, 3/16 X. 3/4 - 124549 
J ™ SEARING, BUSHING TVPE- 7744319 
K » VAlVg - 7036579 
L ^ SPRING, VALVE ^ 7371235 
M - RCTArNER, VAIVS SPRING » 7^7 n3^ 
N^tOCK, VAIVE SPRING RETAlNa^ 7371238 
P ^ SCREW, ADiUSBNG, VAlVg CIEARANCE -^ 7371 25S 
Q _ TAPPET, VAtVE - 7372585 
it -CAMSHAFT -77414 18 



|~. 



^ SmiHIID 




Figure S7. 



|?AP& 357917 



Camshaft, crankshaft and camshaft gears, and valves— exploded 

view. 



38. Removal of Oil Pan and Oil Strainer 

Turn the engine on its side. Remove the cap screws that secure the 
oil pan and fan pulley guard to the cylinder block (figs. 32 and 38). 
Remove oil pan and gasket. Remove the two cap screws from the oil 
strainer support and remove the oil strainer and gasket (fig. 38), 

39. Removal of Camshaft Gear and Camshaft 

Remove the crankshaft nut and crankshaft pulley. Remove the 
eight nuts, lock washers and bolts that secure the engine front plate 
to the cylinder block and remove the timing-gear cover. Remove 
Woodruff key, oil slinger, and thrust washer. Remove cap screw 
and lock washer that secures the camshaft gear and remove cam- 
shaft gear washer. Using puller 41-P-2956-4 remove camshaft and 
crankshaft gears (figs. 39 and 40). 

Note. When removing the camshaft gear, remove one camshaft thrust plate 
cap screw to allow proper seating of puller without disturbing timing marks on 
crankshaft and camshaft gears. 



47 



SUPPORT, OIL $tSA)NH-*7371244 

. SCREW, tccKv/ASHe,.: : ■■: 
sJh - isNC X 3/4 ^ \m6n 



■liyrP0m^.-.:WO-63O398 
■' ■.■^G^ICgT. Olf PAH- 




PAN, Olt-737 1278 

■^Si^fi; DRAIN, PI.UG-^737 1284 

■: SCREW, ^/!6™ 13NC x 5/8 __« 

■ . ^ 1 20220 ■■ '"jL 



** «i 



WASHER, iOCK 
- 120214 



PLUO, DRAIN ™ WO-63P97^ 
RAPD 357988 



Figure 38. Oil pan — exploded view. 

Remove timing gear oil fitting. Remove remaining cap screw and 
remove camshaft thrust plate, Woodruff key, and thrust plate spacer. 
Remove three l^-inch cap screws and lock washers securing oil pump 
to cylinder block and remove oil pump. Lay the cylinder block on 
its side. Pull all the valve tappets toward the top of cylinder block, 
and remove the valve tappets. Remove three cap screws and exter- 
nal toothed lock washers, and two nuts and lock washers securing 
engine front plate to cylinder block and remove the plate. 



48 



40. Removal of Pistons and Connecting Rods 

(% 42) 

Remove the two jam nuts, two connecting rod bolt nuts, and connect- 
ing rod bearing cap from each connecting rod. Remove all carbon 
from the top of the cylinder walls. Tap the connecting rod and piston 
out of the cylinder block with the handle end of a hammer. Install 
the connecting rod caps on the rods in the same position as originally 
installed to insure proper mating of parts upon assembly. 



A - GEA!?, CRANKSHAFT- 774 1 41 5 
8-RTTJNG, OIL- 7372557 




C-Omn, CAMSHAFT -774 141 a 
0-PyUER-'4NP.2W6-:4: . 

Figure 39. Removing camshaft gear using puller Itl-P-2956-^. 



49 




A-~FtniNG, Oil™ 7372557 

8~PUTE, THRUST™ 7744 3 20 

C- SPACER, THRUST PLATE ™ 774 1 407 

D~- CAMSHAFT -- 7741418 

I ~~ GEAR, CRANKSHAFT -774U\5 

F-~PUU£R-:4l-P-2956-4 

Q-wkiHCH, opm-mo 



RA PD 358001 



Figure J^O. Removing crankshaft gear using puller — J^l-P~2956-Ii. 



50 




A- NUT --76978^ 

B - KEY, WOOOaUf F ^ 1 24549 

C - PUttr, TWIN GROOVE, FAN AND GgNgRATOR DRIVE - 7372558 

- COVER, TfMING GiAR - 737257« 

E -- SEAL, on, CRANKSHAFT -^7375028 

f - SUNGER, Oil, FfiONT™737M6! 
G - GASKET, COVeR ™ 7371 \59 
H ~ PLATE, ENGfNE, FRONT - 7372578 

J - HEAD, CYLINDER - 7Z72S56 

K -^ GASKET, CYUNDER HEAD -774141 2 

1 ™ BIOCK. CYUNDER - WO - 800 1 00 
M - PUTE, ENGINE. REAR - 737502? 

N ~ SEAL, Oil, REAR BEARING - 73725A0 
? - BEARING, MAIN, REAR » {USE SET 7371 493J 
» SCREW, BEARING CAP - 7371 227 
8 ^ BEARING, MAIN, Ce^TER - (USE SET 7371493) 
S --BEARING, MAIN, FRONT ~ 73725*4 {U$E SET 7371493J 
T - BEARING, CAMSHAFT, &USHiNG TYPE - 7744319 
U - GASKET, ENGINE FRONT PLATE - 7741 427 
V ~ CUSHION, MOUNTING, FRONT - 7372550 

HAPti tUS^Om 



Figure J^l. Cylinder Hock, main bearings, and head — encploded view. 



51 



;|fi;t;f||:=|l|::|;|;|||||||:::i||||i 




SSiSl^S^i?;^ WK^:-:3y^8.:-:EN 'miomi:'::. : ■: ' 



siiii 



Figure 42. Connecting rod — exploded view. 



41. Removal of Crankshaft 

Remove the two cap screws irom each main bearing cap and remove 
the three main bearing caps {hg, 41). Lift the crankshaft from the 
cylinder block. 



52 



A - SUNGER, OIL, FRONT ™ 7371161 
B - SPACER, CRANKSHAFT - 77414U 
C - GEAR, CRANKSHAPT -77 4] 4} 5 
D - KEY, WOODRUFF ~~ 1 24552 
I ™ WASHER, THRUST ~ 7371 160 
p^ SHIM, FRONT -737 12 26 
G ~ SEARING, MAIN, FRONT, UPPER - CG8-20500 
H - PIN, DOwa, BEARING - 7371229 
J - BEARING, MAIN, CENTER, UPPER - CO8-20502 
K -SEARING, MAIN, SEAR, UPPER - CGB-20504 
i ™ BOif , FLYWHEEL - WO-d3 2 1 57 
M - CRANKSHAFT - 774447^ 
. N:--::PIN, dowel, F IYWHEEL ^ WO-632.1 56 
: ;>■ ^ SEAmNG,^ -MAIN, iSAR,, LOWER- ~ CGB.205<3-5 ' 
a »* SEARING, MAIN, CENTER, LOWER ^ CG6-20503 
t - iiARING, MAIN, f RONT, LOWER ™ CGB-20501 




RA PO 358005 



Figure ^S. Crankshaft — exploded view. 



Section V. REBUILD OF CYLINDER BLOCK, HEAD, AND OIL PAN 

42. Cleaning 

Strip off all old gaskets and sealing compounds from all machined 
surfaces. Remove plugs and clean all oil passages in the cylinder 
block with steam or compressed air. Scrape the carbon from the cylin- 
der block and head. Clean the cylinder block, head, and oil pan 
thoroughly with dry-cleaning solvent or volatile mineral spirits paint 
thinner. 

43. Inspection and Repair 

a. Oil Pan (fig. 38) . An oil pan with stripped threads in the drain 
plug opening, or an oil pan that is badly dented or deformed, must be 
replaced. 



53 



&. Cylinder Head (fig. 41). A cracked or warped cylinder head, 
or a cylinder head with stripped threads in the spark plug holes, must 
be replaced. 

<?. Cylinder Block (fig. 41) . A cracked or damaged cylinder block 
must be replaced. All loose expansion plugs (figs. 28 and 29) or dam- 
aged studs must be replaced {d below.) A scored, ridged, discolored, 
or excessively worn front camshaft bearing (fig. 37 and par. 154) 
must be replaced {e below). Measure the other three camshaft bear- 
ings with a micrometer caliper. If the bearings are larger than speci- 
fied (par. 154), the cylinder block must be replaced. Measure the 
cylinder bores with a micrometer caliper and dial gage. If any cylin- 
der bores are out-of -round, tapered, or worn beyond wear limits (par. 
149), the block must be rebored to next oversize or replaced. Pitted, 
burned, or nicked valve seats must be reseated. Check the clearance 
of the valve guides with new valves. If the clearance exceeds that 
specified (pars. 165 and 156), the valve guides must be replaced (/ be- 
low) . If the clearance exceeds 0.003 inch between valve tappet and 
valve tappet bore, ream bore to 0.004-inch oversize and install 0.004- 
inch oversize valve tappets when assembling engine. If valve tappet 
bore will not clean up at 0.004-inch oversize, the cylinder block must 
be replaced. 

d. Replace Studs (fig, 58). Kemove all damaged studs with a 
standard stud puller. To remove a broken stud, center punch the top 
of the stud and drill approximately two-thirds of the length of the 
broken stud with a small drill, then follow up with a larger drill. 
However, the drill selected must leave a wall thicker than the depth of 
the threads. Select an extractor (EZ-Out) of the proper size, insert 
it into the drilled hole, and screw out the remaining part of the broken 
stud. Install the studs with a standard stud driver. Drive all studs 
until no threads show at the bottom of the unthreaded part of the 
studs. 

e. Replace Camshaft Bearing. Drive a punch between the cam- 
shaft bearing and cylinder block (fig. 44) , and tap the camshaft bear- 
ing out of the cylinder block. To install the camshaft bearing, drive 
it in place with a fibre block, making sure the oil hole in the bearing is 
in line with the oil passage in the cylinder block. Stake the camshaft 
bearing in place with a punch (fig. 45) . Line ream the camshaft front 
bearing to conform to serviceability standards (par. 154). 



54 



liiiiiiiiiBiiiiiiiiiBilii 




c ™ BiocK, cyf^^iiilliiiii 




mmmmmmMmm 



Figure 44' Removing camshaft J)earing from cylinder Mock, 

/. Replace Valve Guides. Remove the guides using valve-guide 
remover and replacer 41-R-2379-25. When installing valve guides, 
drive all intake and exhaust valve guides into the block using valve- 
guide remover and replacer 4^1-R-2379-25 (fig. 46), leaving a dis- 
tance of 1 inch from the top of the guide to the top of the cylinder 
block for exhaust- valve guides, and a distance of 1%6 inches for the 
intake-valve guides. 



55 




Figure 45. Staking camshaft hearing in place. 



56 




Figure ^6. Installing valve guides using adapter 708S262 and driver t08S26L 



57 



Section VI. REBUILD OF WATER PUMP 
44. Disassembly 

Pull the water pump bearing retaining ring from the water pump 
(fig. 47). Eemove the water pump impeller using puller 7083446 
(fig. 49). Eemove the water-pump seal and washer. Press out the 
water pump bearing and shaft assembly and water pump pulley from 
the water pump body as a unit. Remove the water pump pulley 
(fig. 48) from the water pump bearing and shaft assembly using puller 
41-P-2958-55). 



A - PiJUXy, f AN AND WATER t»UMf^ - 7372558 

B - SHAFT, W- BEARING, ASSY - 737 J8U 

C "~ RfHG, RETAJNING - WO-*36298 

~ BODY, WATER PUMP - 7372S07 

£ ~ WASHiS ^ WO-800003 

f ^ SeAt~WO-80r048 

G-~tMPEUER-^737!383 

« -^ GASKET, WATER POMf* TO CYLINDER 6lOCK-»Wa637053 




iK^^ $5790|: 



Figure 47. Water pump — exploded view. 



45. Cleaning 

Clean all parts thoroughly in dry-cleaning solvent or volatile min- 
eral spirits paint thinner. 

46. Inspection and Repair 

a. Water Pump Bodt (fig. 47) . A cracked or damaged water pump 
body must be replaced. Ref ace seat using ref acer 41-Er-2329-700 (figs. 
50 and 51). 

h. Water Pump Impeller (fig, 47) . A water pump impeller that is 
cracked or that has a broken fin must be replaced. 

G. Water Pump Pullet (fig. 47). A distorted or damaged water 
pump pulley must be replaced. 



58 



WRENCH 



f:^?!^^fKSiS^.ft«f||ff^S; 



:J^m 



PULLEY - 7372550 




Figure 48. Removing fan and water pump pulley using puller /fl-P-29o8-15. 

d. Water-Pump Beaking and Shaft Assembly (fig. 47). Rotate 
the water pump bearing ; if the bearing binds or has a tendency to stick, 
it must be replaced. Bearings that have side or end play, must be re- 
placed. 

47. Assembly 

Press the front (short) end of the water-pump bearing and shaft 
assembly into the water pump pulley (fig. 47) . Press the pulley and 
bearing and shaft assembly into the front end of the water-pump body 
until the groove on the bearing is alined with the small slot in the 
body. Dip a new seal assembly and seal washer in hydraulic brake 
fluid and install them in the water-pump impeller. Press the shaft 
into the impeller until the end of the shaft is flush with the end of the 
impeller. Install the bearing retaining ring. 



59 



)ii§^i^l:j:^■f^^y}4ig^^^ 




Figure 49. Removing water pump impeller using puller 108SHQ. 



60 



0OOY, WATfiR ?UMP 




um:-^^9om- 



Figure 50. Water-pump refacing tool 4f-R-S3^0-70(?, 




Figure 51. Ref<icing waier-pump-dodp seal surface using refacer .^l^R-232. 



61 



953383—31 5 



Section VII. REBUILD OF CONNECTING RODS AND PISTONS 

48. Disassembly 

Eemove the piston rings (fig. 42) using a standard ring remover. 
Remove the piston pin lock bolt and push the piston pin out of the 
piston. 

49. Cleaning 

Scrape the carbon from the carbon groove in the dome, ring grooves 
in the piston, and from the dome. Remove all foreign matter from the 
oil holes in the oil ring (bottom) groove. Clean all parts in dry- 
cleaning solvent or volatile mineral spirits paint thinner. 

50. Inspection and Repairs 

Pistons with cracks, scores, or damage of any kind must be replaced. 
Determine the wear on the skirt of each piston at the bottom at right 
angles to the piston pin. If the wear is 0.010 inch less than the original 
size (par. 152), or if the piston is out-of -round more than 0.005 inch, 
the piston must be replaced. Check the width of the ring grooves with 
new rings and a feeler gage (fig, 52) . If the piston ring to piston 
groove clearance exceeds dimension given in serviceability standards 
the piston must be replaced. Measure the piston pin hole. If the 
inside diameter of the piston pin hole is more than wear limit in serv- 
iceability standards (par. 152), the piston must be replaced. Piston 
pins worn to less than wear limit in serviceability standards (par. 
153), must be replaced. Check the connecting rods for alinement, 
using aliner connecting rod (figs. 55 and 56) . Bent or twisted con- 
necting rods (par. 151) must be correctly alined. Damaged connecting 
rod bolts must be replaced. Excessively worn, scored, discolored, or 
pitted connecting rod bearings must be replaced. 

51. Fitting Pistons 

(fig. 58) 

The normal clearance of the piston to the cylinder bore is approxi- 
mately 0.003 inch, see serviceability standards (par. 152). Place a 
feeler gage %-inch wide and 0.003-inch thick into the cylinder bore, 
making sure the feeler gage is long enough to extend down into the 
bore the entire length of a piston. Attach piston fitting scale to 
feeler gage. Push a piston into the cylinder bore with the T-slot in 



62 



the piston opposite the feeler gage. Pull up on the tension scale; if 
more than ten pounds is required to pull the feeler gage from the 
cylinder bore, the piston is too tight. Select a smaller piston. If 
less than five pounds pull is required to remove the gage, the piston 
is too loose. Select a larger piston. Mark the cylinder number on 
each piston after fitting. 



mno, PISTON ^ wo 1 %MU 




.;fA.-l»D:: 
Figure 52. Checking piston ring to groove clearance. 



63 




Figure 53. Fitting piston pin. 



64 



RING, PISTON " WO.d37042 



mtON -7372873 




Figure 54. Checking piston ring fit. 



65 



ROD, CONNECTING™ 
7743/5) OR 7743752 




PIN, PISTON -7371144 



AMNER, CONNeCTtNG ROD 



kAPD 357952 



Figure 55. Checking connecting rod alinement for twist. 



66 



PIN, PiSTON 



:Mmsy OR 7743752 




ALINER, CONNECTING mo 



kAPDZSnm!: 



Figure od. Checking connvctifig rod alhiciitcnt for hcnd. 



67 



VAIVF, CHAmCA%t VfiNTtlATtNO - Al 3^6400 
Hirni, PIP!:, \/4 n 3/4 192466 
VAlVf, VENTiUltNC ■ 7%7S)7i 
%Cm:W, COVKR wo- 445094 

GASm WO-'$H75' 

COVfcR, VAiVfc SPNiHC COMPARTMENT ?3?)?37 






GA$KfT, COVIR 




ELBOW, 1/4 JN 
MALE, mm fND 



OANKCAS£-8013}2 



GASKIT, VINT mm TO 
VAiy£ $PRiWG COMPARTMENT 

covts 7Z-n777 

BODY, V«NT, CKANKCASE ■^737121^ 



SC!«EW, COVER WO 6'*5093 



figure 51. Valvc-spring-compartment cover and ventilating valves. 



68 




SCALE™ ^1-5-498 




Figure 58. Fitthig piston in cylinder hore^ using scale and feeler gage. 



69 



^ 




06ir ■ 


HHHitt:^.' m 


;^BS 


^ : ;.|iM/ ;.'^^^^te:i^.''''' * ■■^^^* W^ 






^^^^o^MJSS^I 


\ ...:■■'.:,..■ '^'^Bite... ^■■■^^^"' 


V 


. ,|«^^ 


''""■■*!*-. 


■« J 'frN 




« P ^>**-""'*'''"'^''*^^^^^: \ 


IHBB 


^^^■HH 




.^^ .:if|^^;iw-?»pr^^^;^^ / 


'^SESSS^ZI 


s.^^ ■■-" ^^.-^^■"' ^,^.^,_i..., . 




^^^'^'^'^•--— ^^ .^i^^fe 



Figure 59. Measuring piston-ring end cap using feeler gage. 



70 



52. Assemble Piston, Piston Pin, and Connecting Rod 

When installing- connecting rods on piston, make sure the oil squirt 
hole in the connecting rod is opposite the T-slot in the piston. If 
assembled in this manner, the off -set on the connecting rods will be 
in the correct position when installed in the cylinder block (par. 84). 
Select a piston pin which can be installed in the piston with a light 
"push" fit (piston temperature at 70° F.). Push the pin part way 
into the piston pin hold (fig. 53), with the groove in the piston pin 
facing downward. Hold the connecting rod in line with the piston 
pin hole, and push the pin through the connecting rod into the other 
side of piston. Install and tighten the piston pin lock bolt in the 
connecting rod. 

Note. The slot in the piston pin should be centered with the piston-pin-lock 
bolt, to prevent piston pin from scoring cylinder side walls. 

53. Fit and Install Piston Rings 

Using a connecting rod with piston attached as a rammer, so the 
ring will be square with the cylinder wall, insert a new piston ring in 
the cylinder bore, a distance equal to the length of a piston. Measure 
the piston ring end gap with a feeler gage (fig. 59) . If the gap is less 
than minimum specified in serviceability standards (par. 152), remove 
the ring and file with a fine cut file until the correct gap is obtained 
(par. 152) . If end gap exceeds maximum specified (par. 152) , use an 
oversize ring. Repeat the same procedure for all piston rings. KoU 
the new piston ring around its particular groove in the piston (fig. 
54) . The ring should roll freely and not have a clearance greater than 
specified in serviceability standards (par. 152) (fig. 52). Repeat the 
above procedures on each piston ring. Install the piston rings on the 
piston using a piston ring applier (fig. 60), making sure that edge 
marked "TOP" on both compression rings are toward the top of piston, 
and ring having beveled edge is installed in the top groove. 

Section VIII. REBUILD OF CAMSHAFT 

54. Cleaning 

Clean the camshaft, camshaft gear, camshaft gear washer, camshaft 
thrust washer and thrust plate in dry-cleaning solvent or volatile 
mineral spirits paint thinner. 



71 



APPUER, PISTON R!NG^ 41 -A- 3 29-500 

RING, PISTON- WO- 11661 6 



PiSTON ™7372873 




RAPD 357957 



Figure 60. Installing piston rings. 



55. Inspection and Repair 

A camshaft with excessively scored or damaged cams, or with worn, 
corroded, scored, or discolored journals must be replaced. Inspect 
the camshaft oil pump drive gear. If the teeth are worn, broken, or 
chipped, the camshaft must be replaced. Measure the four camshaft 
journals (fig. 37), and record the readings. If readings do not con- 
form to size specified in serviceability standards (par. 154), the cam- 
shaft must be replaced. Should it be necessary to replace the gears, 
due attention must be given to both the end float of the shafts and 
running clearance of the gears. End float of the camshaft is deter- 
mined by the running clearance between the face of the camshaft gear 
and the thrust plate (fig. 37) , mounted on the crankcase. The stand- 
ard clearance is 0.004r-0.007 inch which is determined by the thickness 
of the thrust plate spacer. Generally this clearance will change little 
through wear or even when a new gear is installed. Should a check 
indicate too little end float, place a shim of suitable thickness between 
the gear hub and the spacer. Too much end float may be corrected 
by dressing off the spacer until required thickness is obtained. Use 
a micrometer to measure the thickness of both the thrust plate and the 
thrust plate spacer. The thickness of the washer should be approxi- 
mately 0.006 inch greater than that of the thrust plate. When the 
gear and washer are mounted on the shaft and drawn up solidly with 
the mounting screw, the parts will be drawn together to provide the 
correct end float of 0.004 inch. When the spacer is installed, be sure 
that the face having the beveled edge is placed toward the cylinder 
block. 



72 



Section IX. REBUILD OF VALVES AND VALVE SPRINGS 

56. Rotator-Type Exhaust Valve 

(%. 61) 

The rotator type exhaust valve used on this vehicle consists of a 
special valve spring retainer, valve cap, two retainer locks, a spring 
seat, and a special hard faced valve. A standard valve spring is used. 

57. Operation of Rotator-Type Exhaust Valves 

At the beginning of the valve lift, the valve tappet first pushes the 
valve cap (fig. 61) through the nominal clearance, taking the spring 
load off the valve before it opens. This action results in the valve 
being free once it starts to open and remaining free until it closes, 
permittin,g the possibility of slight valve rotation during each cycle. 

58. Cleaning 

Scrape the carbon off the valve heads and stems. Clean the valves 
and valve springs thoroughly in dry-cleaning solvent or volatile 

mineral spirits paint thinner, 

59. Inspection and Repair 

Yalves with bent or scored stems must be replaced. Measure the 
outside diameter of each valve stem. If measurement is less than 
specified in serviceability standards (pars. 155 and 156) replace 
valves. Pitted, corroded, or burned valves must be refaced. Valves 
that are burned, warped, or pitted, and will not clean up with a slight 
cut of the grinding wheel, must be replaced. When the rotator-type 
exhaust valves are removed for rebuild, always keep each exhaust 
valve and keeper assembly (valves spring retainer, locks, and valve 
cap) together to minimize the amount of refitting necessary when 
measuring the valve-cap-to-valve clearance. If part of one assembly 
is worn or damaged or lost, it can be replaced with a new one, but 
clearance must be checked. Valve-spring-retainer locks in general 
are the only parts which may have to be replaced because of wear. 
However, since the wear is normally light and only on one side, they 
may be re-used. If re-used, they should be installed, with the worn 
side away from the valve tip, so that the unworn surface is used for 
subsequent running. If due to excessive wear or breakage, valve- 
spring-retainer locks must be replaced ; always install two new locks. 
Measure the free length of each valve spring ; if less than 2% inches 
in length the spring must be replaced. Check the tension of each 
valve spring (fig. 63) using tester 41-T-1600. If the valve spring 
tension registers less than 50 pounds when the valve spring is com- 

73 



pressed to Qi/ig inches or 116 pounds when compressed to 1% inches 
in length, it must be replaced. Measure valve-cap- to- valve clearance 
using valve cap clearance gage 41-G-500-90 (fig. 62). Assemble 
the exhaust valve, spring, retainer, locks, and cap in the tester, with 
the cap seating against the end vertical surface of tester. Push cam 
handle down toward base of ga^e, this will cause rotator valve-cap to 
force valve keys away from the valve-stem lock-groove allowing valve 
to rotate freely. Adjust dial gage so that the prong contacts the top 
of valve. Push the valve stem into the cap until it seats, note reading 
on indicator. Pull the valve stem forward (out of cap) until the 
lock groove on the stem contacts the locks and note reading. The 
difference between the two readings is the valve-cap-to-valve clear- 
ance. If clearance is less than 0,003 inch, grind off the valve stem 
end. If clearance is more than 0.003 inch, polish off the rim of the 
valve cap using abrasive cloth. When correct clearance is attained, 
remove valve from gage and keep the parts together until installed in 
the engine. 

Section X. REBUILD OF VALVE TAPPETS 

60. Cleaning 

Clean the valve tappets thoroughly with dry-cleaning solvent or 
volatile mineral spirits paint thinner. 

61. Inspection and Repair 

Cracked, scored, or excessively w^orn valve tappets (fig. 61) must be 
replaced. Valve tappets, or valve tappet adjusting screws (fig. 61) 
with worn or damaged threads, must be replaced. 

62. Disassembly 

Unscrew the valve tappet adjusting screw from the tappet. 

63. Assembly 

Screw the valve tappet adjusting screw approximately three- 
quarters of the way into the valve tappet. 



74 






■iii 








^iiM::3i: 



Figure 61. Rotator-type exhaust valve— eicploded view. 




IHifcfilii 

.;:/;;,^j;';-;;./:.::::;:;fr-;v;:..';:^ 

Fiuure 62. Checking ei hamt valve4o-vulve cap clearance with gage 41-0^500-90. 



75 



STONO, SfAlVi ..-737123 5 




ir^lffi ■■■ -^i rl^OO 



mm 3S7f$^ 

Figure GS. ChecMny teiiKion of valve spring. 

Section XI. REBUILD OF OIL PUMP AND OIL STRAINER 

64. Disassembly 

d. Oil Pump. Remove the cap screw and lock washer that secures 
the oil pump assembly to the cylinder block, and remove the oil pump 
assembly (fig. 32). File either side of the driven-gear pin (fig. 64), 
until the pin is flush with the driven-gear hub. Drive the pin out of 
the sleeve and shaft using a small punch and remove gear. Remove 
the relief -valve-spring retainer, gasket, spring, and plunger from the 
housing. Remove the five cap screws that hold the cover to the hous- 
ing and remove the cover. Remove the cover gasket, rotor, and shaft 
assembly. 



76 



I H {2| t^ N MTi 



GASKET, Oil PUMP TO CYUNDER BlOCK> 7372587 
GEAR, DRIVE, PUMP ~« 7744333 
BODY, Oil POMP - WO-649872 



I^SCRHW, EXT-TEfTH lOCX WASHER, ™ 420992 

SHAFT, W/R0T08S. ASSY -~ W064 1742 






PIN, 5/32 X- 31/32 
-7371279 



PLUNGER, PRESSURE REUEF 
VALVE ^7371 275 

SPRING, PLUNGER - 7372586 
GASKET/ RETAINER - 7371 270 



RETAINEI?, SPRING -^7371271 




^ 



RAPD 357394 



Figure 64. Oil pump — exploded view. 



h. Oil Strainer. Eemove the cotter pin that secures the oil strainer 
to the support, and remove the strainer (fig. 38) . Straighten the four 
tabs on the strainer, and remove the screen. 

65. Cleaning 

Clean all parts and drilled passages thoroughly with dry-cleaning 
solvent or volatile mineral spirits paint thinner, and blow the oil 
strainer screen and all oil passages in the oil pump and oil strainer. 

66. Inspection and Repair 

A cracked or damaged oil pump housing or cover must be replaced. 
Match the rotors together with one lobe of the inner rotor pushed as 
far as possible into the notch of the other rotor (fig. 64) ; if the clear- 
ance between the lobes of the rotors (fig. 65) is greater than wear limit 
specified in serviceability standards (par. 157), replace both rotors. 
Measure the clearance between the outer rotor and the pump housing 
(fig. %%). If the clearance is greater than wear limit specified in 
serviceability standards (par. 157) , replace the pump housing. Check 
the cover to be sure the inner surface is not rough or scored and that it 
is flat within 0.001 inch, tested with feeler gage (fig. 67). Measure 
length of the rotors, which must be within 0.001 inch of each other. 
An oil pump driven gear with broken or chipped teeth must be re- 
placed. Compress the relief -valve spring to ly^g inches (fig. 63) , using 
tester 41-T-1600. If the tension is less than 71/2 pounds (par. 157), 
the spring must be replaced. Replace a broken, distorted or cracked 
oil-strainer support (fig. 38). 

67. Assembly 

a. Oil Strainer. Place the screen in the oil strainer (fig. 38). 
Place the sump on the strainer, and bend the four tabs to lock the 
sump in place. Slide the support onto the strainer, making sure the 
tongue on the support is in the recess. Install a cotter pin in the 
support. 

h. Oil Pump. Assemble the rotors in the pump housing and in- 
stall the cover without the gasket. When the cover screws are tight- 
ened to normal tension, there should be interference between the rotors 
and the cover making it impossible to turn the pump shaft by hand. 
Remove the cover and replace it with the gasket in position which 
should free the rotors and shaft. Tap the driven gear onto the shaft 
with the gear toward the oil pump until there is a 0.0313-inch clearance 
between the gear and the pump housing. If installing a new shaft, 
drill a hole for the pin. Install a new driven gear pin through the 
gear and shaft. Peen both ends of the driven gear pin. After as- 
sembling the gear on the shaft, check the running clearance between 

78 



the gear and pump housing with a feeler gage (fig. ^6). This clear- 
ance should be from 0.003 to 0.010 inch. Drop the oil relief plunger 
and spring into the opening in the oil pump housing (fig. 64). Place 
a new gasket on the oil relief spring retainer, and install and tighten 
the retainer. 




^BODY, Oil PUMP 
WO-801761 



RA PD 357949 



Figure 65. Checking clearance hetween lohes of rotors. 



79 




SNAfT W/ROTORS"' ^1 
^ WOh$41742 



SODY, OIL PUMP 
~~WO-649a72 



tA.PD. 35796^. 



Figure 66. Checking rotor-to-pump-housing clearance. 



80 



GAG'S. f^LEt 



COV£lt SO^Y . ™77 4 4 33.2 







Figure 67. Checking oil pump cover for flatness. 

Section XII. REBUILD OF CRANKSHAFT 

68. Cleaning 

Clean out the drilled holes on the crankshaft journals with a piece 
of wire. Clean the crankshaft thoroughly with dry-cleaning solvent 
or volatile mineral spirits paint thinner. 

69. Inspect Crankshaft Main Bearing Journals 

(fig. 43) 

If worn or scored, the crankshaft must be replaced or journals re- 
ground. Measure the outside diameter of each main bearing journal. 
If the diameter is less than that specified in serviceability standards 
(par. 150) , the crankshaft must be reground to 0.010-, 0.020-, or 0.030- 
inch undersize, whichever the case may be. Light scores and scratches 



1 1 _i J ii i:„i»_j ,„:j.i„ «, — „i^+i^ 

call ue iiuiiba mux liikhi poiisiieu. witii i;iui;us (jiuuii. 



jLj. mam u^^tiAxxxg 



81 



journals will not clean up at 0.030-inch undersize the crankshaft must 
be replaced. If a new crankshaft or flywheel is being used, it must 
be fitted as outlined in paragraph 74. 

Section XIIL REBUILD OF FLYWHEEL 

70. Cleaning 

Wash the flywheel thoroughly in dry-cleaning solvent or volatile 
mineral spirits paint thinner. 

71. Inspection and Repair 

A flywheel (fig. 68) with an excessively scored or worn friction 
face must be replaced. A flywheel ring gear (fig. 68) with broken, 
chipped, or excessively worn teeth must be replaced (pars. 73 and 74). 
Measure the inside diameter of the main drive gear pilot bushing. 
If more than 0.632 inch, it must be replaced (pars. 73 and 74). If a 
new crankshaft or flywheel is being used, it must be fitted as outlined 
in paragraph 74. 










mn>--^^$$\ 



Figure 68. Flywheel, ring gear, and Maring. 



82 



72. Disassembly 

Drive the main gear pilot bushing out of the flywheel. Heat the 
flywheel ring gear until it can be driven off the flywheel. 

73. Assembly 

Clean the flywheel ring gear recess on the flywheel. Apply heat 
evenly to the ring gear. When the ring gear is thoroughly heated, 
place it on the cold flywheel, making sure it is firmly seated in its 
recess. Drive a main gear pilot bushing in place with a fiber block. 

74. Fit Crankshaft to Flywheel When Either Part Is New 

Install the flywheel onto the crankshaft with the four flywheel bolts, 
lock washers and nuts. Drill the tw^o tapered (stud) holes with a 
3%4-inch drill, and ream the two holes with a %6-"i^li (0.5625 inch) 
straight reamer. Install the two bolts that are supplied w^ith each 
crankshaft and/or flywheel. 

Section XIV. REBUILD OF INTAKE AND EXHAUST MANIFOLDS 

75. Disassembly 

Eemove the four cap screws that secure the intake manifold to the 
exhaust manifold and separate the two manifolds. Kemove the nut 
and screw that secure the heat-control- valve shaft (fig. 69) . Remove 
the counterweight lever, heat-control-valve lever, w^asher, and spring 
off the shaft. Remove the crankcase ventilating and control valves 
and primer line (fig. 32). 

76. Cleaning 

Scrape all the old gaskets and carbon from the manifolds. Wash 
the manifold and parts in dry-cleaning solvent or volatile mineral 
spirits paint thinner. 

77. Inspection and Repair 

Cracked or broken manifolds must be replaced. Damaged or 
broken studs must be replaced (par. 43). An exhaust manifold with 
a damaged heat control valve or shaft must be replaced. If the crank- 
case ventilating valve fails to seat properly, it must be replaced. If 
the ^-inch pipe threads are worn or stripped on the intake manifold, 
causing a leak at this joint, replace the manifold. 



83 



78. Assembly 

Install the crankcase ventilating and control valves on the intake 
manifold (iigs. 32 and 57) . Slide the heat control valve spring onto 
the shaft (fig. 69), making sure the end of the spring is resting on 
top of the stop. Slide the washer, counterweight, and control level 
onto the shaft ; install the nut and screw through the counterweight. 
Place a new gasket between the two manifolds and install the four 
cap screws and spring stop. Install primer fuel line. 




A »- SCREW, lEVER, COUNTERWBGHT- WO'5272 

B^-KEY, HEAT CONTROl VAlVE LEVER -737 1396 

C- SHAFT, HEAT COHTSOl VAiVE~-737l391 

0- WASHER, H£AT COHTtOL VAlVg SPmNG -7371 390 

i-lEVER, COUNTER WSGHT, HEAT CONTROL VALVE -7371392 

F -SPRING, HEAT CONTROL VAiVE- 7372565 

G-STOP, HEAT CONTROL VALVE SPRING -737 1 395 ^^ ^^ 358006 

Figure 09. Manifold heat control valve. 



84 



Section XV. ASSEMBLY OF ENGINE FROM SUBASSEMBLIES 

79. Install Valves 

Place a valve tappet and tappet adjusting screw in each valve tappet 
bore. Slide the camshaft into the cylinder block. Install a valve 
spring and valve spring retainer on each tappet (fig. 61), making 
sure the closed coils of the valve springs are against the cylinder 
block and properly seated. Install the valves in their respective valve 
guides. Compress the valve springs on all valves that are in closed 
position, using valve lifter, and install the valve spring retainer locks 
{&g. 70). Turn the camshaft to close the other valves, and install 
the valve spring retainer locks on the rest of the valves. 



A ~~ TAPPET, VAtVE - 7372585 
B - SCREW, ADJUSTING, VALVE CIEARANCS 
C - RETAINER, VAIV6 SPRING -7371236 
D ™ UFTER, VAtVE ^ 4M-1410 
£ ™ SPRING, VAIVE - 7371235 
F - BLOCK, CYDNDER - WO-800100 
G - REPLACES ~ 4]'k-2^P^'$4 



7371258 




m-rt>-nm^;^ 



Figure 10. Installing valve spring retainer locks, using lifter 41~L-1410 and 

replacer Jfl-R~2398 

Note. Install the valve cap on rotator-type-exhaust-valve stems (fig. 61) 
while the spring is compressed. 



85 



80. Adjust Valve Tappets 

Turn the camshaft until No. 1 valve is in the closed position, and 
the tappet is on the heel of the cam. Hold the valve tappet with one 
wrench and turn the valve tappet adjusting screw with another 
wrench (fig. 71) clockwise or counterclockwise until 0.016-inch clear- 
ance is established between the valve and the valve tappet adjusting 
screw (pars. 155 and 156) . Repeat the same procedure on each valve. 
Install valve-spring-compartment cover and vent body. Connect 
crankcase vent line to cover and to ventilating valve elbow. 




iiiliiiiii^iiSiiiiiiiSiliiiiMii^ 

W§ggg§Sig§M$l^ '.':■'■■ ^^ ^^ 358003 ■ 

Future 11. Adjusting valve tappets, 

81. Install Crankshaft 

If a new crankshaft or flywheel is being used, refer to paragraph 
74 and 85. Install the three upper halves of the main bearings in the 
cylinder block (fig. 41). Press the crankshaft rear-main-bearing 
packing into the recess provided at the rear main bearing (fig. 72) 
and in the rear-main-bearing cap (fig. 72) . Cut the ends of the crank- 
shaft packing flush with the crankcase and with the bearing cap. In- 
stall the four bolts and the two tapered studs in the flywheel flange 
on the crankshaft. Install the three lower halves of the main bearings 



86 



in the three main bearing caps. Oil the main bearing inserts with 
a light oil. Position the crankshaft in the cylinder block. Install 
the front and center bearing caps, and tighten the bolts until they 
are just snug. Coat the rear-bearing cap with joint sealing compound 
on both sides and top. Install the rear-bearing cap in the cylinder 
block. Tighten the six main-bearing bolts with a torque wrench (65 
to 70 Ib-ft) . Slip the rear-bearing-cap packing into the hole on each 
side of the rear-main-bearing cap, leaving i/4-inch of the packing to 
protrude from the crankcase (fig. 72) (par. 143) . 




RAK> Z57902 



Figure 12. Installing rear-hearing-nap pacMng. 



B7 



82. Fit Crankshaft 

After installation of crankshaft, check the running clearance. Place 
an 0.002-inch test shim between the shaft and the shell. With the 
bearing cap nuts drawn up to the recommended 65-70 Ib-ft torque, 
the shaft should either be locked or there should be a drag when it 
is turned by hand proving that the clearance is correct. 

Caution: Do not overlook removing the test shim. 

83. Check Crankshaft End Play 

The standard end play of the crankshaft is 0.004 to 0.006 inch which 
is adjusted by shims placed between the crankshaft thrust washer 
and the face of the front main bearing. Check clearance with feeler 
gage (fig. 73). To adjust end play, it is necessary to remove the 
crankshaft gear using puller 41-P-2956-4 (fig. 40), and the thrust 
washer. When installing the washer, be sure the side with the inner 
beveled edge faces the front bearing. 

Caution: Never file a main bearing cap or install shims between the 
cap and block as roundness and alinement of bearings will be 
destroyed. 

84. Install Connecting Rods and Pistons 

Piston assemblies must be installed in the cylinders to which they 
are fitted (par. 51). Oil the piston rings and install a ring com- 
pressor on the piston rings (^g. 74). Place the No. 1 connecting rod 
and piston assembly in the No. 1 cylinder so that the short end of 
the offset (fig. 75) on the connecting rod is toward the nearest main 
bearing. With the T-slot of the piston facing toward the camshaft 
side of the engine, and the oil squirt hole in the connecting rod facing 
toward the oil-filler-pipe side of the engine, tap the piston down into 
the cylinder with the handle end of a hammer (fig. 74). Place one- 
half of a connecting rod bearing in the connecting rod, and the other 
half in the connecting-rod-bearing cap. Coat the connecting rod 
bearings with a light film of oil. Connect the rod to the crankshaft 
and install, but do not tighten the two connecting rod nuts. Repeat 
the same procedure when installing the other rods, making sure the 
short end of the offset (fig. 76) on each connecting rod is toward 
the nearest main bearing and the oil squirt hole faces toward the oil- 
filler-pipe side of the engine with the T-slot of the piston facing to- 
ward the camshaft side of the engine. Tighten all the connecting-rod 
nuts to 50 to 55 lb- ft torque using a torque wrench. Install a jam 
nut on each connecting rod bolt. Turn the jam nut down on the bolt 
until seated against the connecting rod nut, then turn one complete 
turn. 

88 




Mgure 73. Checking crankshaft end play, 

85. Install Flywheel 

If installing a new flywheel or crankshaftj fit the crankshaft to the 
flywheel, as outlined in paragraphs 74 and 82. Fasten the engine rear 
plate temporarily to the engine with two bolts. Turn the crankshaft 
until the No. 1 and No. 4 pistons are at top center. Place the flywheel 
on the crankshaft flange so that the letters "TC" on the flywheel are 
alined with the index mark at the center of the timing hole (fig. 76) in 
the engine rear plate. Install the timing gears, and position them so 



89 



that the indent marks on the gears are opposite each other (fig. 77) . 
Install and tighten the six lock washers and nuts on the flywheel with a 
torque wrench to 36-40 Ib-ft. Check run-out on the flywheel with a 
dial gage. If the run-out exceeds 0.008 inch at the outer edge, the 
flywheel or crankshaft flange must be ref aced. 




Figure 74. Installing piston and connecting rod asseniMy in cylinder J>locTc. 



90 




Figure 15. Position of connecting rod offset and oil squirt hole when installed. 

86. Install Clutch Disk and Pressure Plate 

(fig. 78) 

Apply a good coating of No. 2 general purpose lubricating grease on 
flywheel pilot bearing. Hold the clutch disk on the flywheel with short 
side of hub toward flywheel and install a clutch pilot tool in the flywheel 
and the disk. Hold the pressure plate on the flyw^heel and install, but 
do not tighten six lock washers and cap screws. Tighten the six lock 
washers and cap screws evenly to prevent bending the pressure plate 
cover. Remove the clutch pilot tool. 



91 




Figure 76. Ignition timing marks on fiijtvheel. 

87. Install Camshaft Timing Gear 

Eemove the camshaft gear. Place a gasket and the engine front 
plate on the engine and install the three cap screws and two nuts and 
lock washers. Turn the crankshaft until No. 1 piston is at top center 
(fig. 36) . Install the thrust plate and spacer (fig. 40) , making certain 
the beveled edge of the spacer faces the camshaft. Place the camshaft 
timing gear on the camshaft, making certain the zero "0" marks on the 
camshaft and crankshaft timing gears are opposite each other (fig. 7), 
Insert the camshaft timing gear washer, lock nut, and retaining bolt. 
Tighten bolt. 



92 



88. Install Timing-Gear Cover and Crankshaft Pulley 

(fig. 41) 

Place a gasket on the timing-gear cover ; install oil seal in recess pro- 
vided in cover. Place spacer and oil slinger on shaft. Install the 
cover on the engine. 

Note. Do not tighten nuts down tight as this may interfere with installation 
of crankshaft pulley. 

Place crankshaft and fan belt pulley on shaft and tighten retaining 
nut. Evenly tighten all engine front cover cap screws. 



PIATE ENOiHE, FRONT -- 7372578 



GEAR, CAMSHAFT -^774141^ 




€5EAIt>CRAHKSH^ "-7^41415 VfiMIHO GEAR MARKS RAH) 3^7913 | 

■,.: . ■ . . ■ ........ ' . ■ ■ ■ . '.i 

Figure 77. Timing gears. 



953383—51- 



93 



PUTE, EHGtm SEAf? ~ 7375029 



fLYWHEBL, W/R>NG GEAft^/^372582 



PlATe, PRESSURE 
7375073 




SHAFT, INPUT ™ 7697566 



COYER, TIMING HOIE » 737 ISO'S 

'""^ir RAFD 357S9S 

Figure 78. Installing clutch disk and pressure plate on flywheel. 

89. Install Oil Pan 

Hold a gasket and the oil strainer in place (fig, 38) and in>stall the 
two lock washers and cap screws. Coat the bottom ( machined surface ) 
of the crankcase wdth grease, and install the oil pan gasket. Hold the 
oil pan in place, and install all the lock washers and cap screws except 
the six front cap screws. Hold the generator and fan pulley guard in 
place and install the remaining six lock washers, gaskets, and cap 
screws. Tighten all the oil-pan cap screws. 

90. Install Cylinder Head 

(%. 41) 

Install a cylinder-head gasket on the cylinder block, making sure 
trade mark on gasket faces cylinder head. Make sure there is no 
foreign matter in the cylinders, and place head on cylinder block. 
Install lifting eye on studs Nos. 1, 2, and 7 (fig. 79) . Install air intake 
pipe on stud No. 5 (fig. 79) . Install oil filter bracket on studs Nos. 9, 



94 



10, and 15 (fig. 79). Install distributor-to-fuel-pump-vent-line hold- 
down clip on stud No. 12 (fig. 79). Tighten the cylinder-head bolts 
with a torque wrench from 65 to 75 lb- ft following tightening sequence 
(fig. 79). 

91. Install Intake and Exhaust Manifold 

Place an intake and exhaust manifold gasket in place on the cylinder 
block. Position the intake and exhaust manifold on the cylinder block. 
Install nuts. Connect the crankcase ventilating valves (fig. 57) to the 
intake manifold. Connect one end of the crankcase ventilation line to 
the valve spring compartment cover and the other end to the ventilat- 
ing valve elbow (fig. 57) . 




^AH) SST969 

Figure 79. Cylinder head-holts tightewmg sequettec. 

92. Install Oil Pump 

Place a finger on No. 1 spark plug hole, and turn the crankshaft 
until No. 1 piston is coming up on compression stroke. Continue 
turning the crankshaft until the timing mark "5°" on the flywheel 
is alined with the index mark in the center of the timing hole on 
the engine rear plate (fig. 76). Install the distributor in the cylinder 
block (par. 98), temporarily. Set the rotor on No. 1 firing position 
with the ignition points just breaking. Immerse the oil pump in a 
container of oil (same grade as used in the engine), and turn the 
inner rotor and shaft until the oil flows from the outlet hole in the 
oil pump housing. Place a gasket on the oil pump and, with the wide 
side of the slotted end of the shaft assembly up, install the oil pump 
on the engine, making sure the slot in the oil-pump shaft engages with 
the distributor shaft while the rotor is on No, 1 firing position with 
ignition points just breaking. Install the three %6-inch cap screws 
that secure the oil pump to block. Remove distributor. 



95 



93. Install Water-Outlet Elbow and Thermostat 

(fig. 32) 

Install the thermostat and retainer in the water-outlet elbow with 
the bellows of the thermostat facing downward. Place a gasket on 
the cylinder head and install the water-outlet elbow, lock washers, 
and cap screws. 

Section XVI. INSTALLATION OF ACCESSORIES 

94. Install Water Pump 

(figs. 27 and 32) 

Hold a gasket and the water pump in place on the engine and 
install the three lock washers and cap screws. Connect by-pass tube 
between cylinder head and water pump. 

95. Install Carburetor 

(figs. 31 and 32) 

Place a carburetor gasket and diffuser on the intake manifold 
and install the carburetor, accelerator-return- spring clip, lock 
washers, ventilating- valve -control-cable clip, and nuts. Install hose 
between carburetor and air intake pipe. Install air-intake-pipe-to- 
carburetor vent line. 

96. Install Oil Filter 

(figs. 2 and 27) 

Hold the oil filter in place, and install and tighten the two cap 
screws. Connect the oil-filler-pipe bracket to the oil-filter bracket 
with a cap screw. Connect inlet line to the elbow fitting located on 
the left side of the engine in front of the fuel pump opening. Connect 
outlet line to timing gear cover. Connect oil filler pipe to ventilating 
valve hose (fig. 38). 

97. Install Fuel and Vacuum Pump 

(fig. 30) 

Insert two mounting screws and washer in fuel pump mounting 
flange holes, using screws as a guide place gasket on fuel pump ; in- 
stall rocker arm link spacer and gasket. Hold the entire fuel pump 
in place on engine, making sure the fuel pump rocker arm is on top 
of camshaft. Tighten the mounting screws that secure the fuel 
pump to cylinder block. Install carburetor to fuel pump line. Install 
two vacuum lines on lower portion of pump. 



96 



98. Install Distributor 

(fig. 33) 

Place a thumb over No. 1 spark plug hole, and turn the crankshaft 
until No. 1 piston is coming up on compression stroke, and the timing 
mark "5°" on the flywheel is alined with the index line on the engine 
rear plate. Install the distributor on the engine, and rotate the rotor 
until the distributor shaft engages with the oil pump shaft. Install 
the cap screw in the distributor hold- down clamp, and turn the dis- 
tributor until the points are just breaking. Tighten the bolt in the 
distributor hold-down clamp. 

99. Install Pin 

(fig. 32) 

Hold the fan in place on the w^ater pump pulley, and install the 
four lock washers and cap screws. 

100. Install Generator 

(fig. 33) 

Install the generator bracket on the cylinder block with two lock 
washers and cap screws. Install the generator on the engine, making 
sure there is a flat washer on each side of the rubber bushing in the 
generator bracket and engine front plate. Install a flat washer, lock 
washer, and nut on the generator front mount. Install a flat washer, 
lock washer, and nut on the generator rear mount. Install belts and 
adjust tension. 

2Vo^e. Never install a new and an old hclt. 

101. Install Starter 

(figs. 26 and 33) 

Hold the starter in place on the clutch housing and install and 
tighten the two cap screws on the clutch housing. Hold the starter 
mounting bracket in place on the engine and install a lock washer, flat 
washer, and cap screw. 

Note. Do not tighten the cap screw. 
Install and tighten a lock washer, flat washer, and cap screw in the 
starter and starter support bracket. Tighten the cap screw in the 
starter support bracket. 

102. Install Spark Plugs and Cable 

Install the distributor cap on the distributor. Install the spark 
plugs and new spark-plug gaskets in the cylinder head. Connect the 
spark-plug cables. 



97 



103. Install Accelerator Linkage 

(fig. 31) 

Install the accelerator (throttle linkage) on the engine with two 
lock washers and cap screws. Connect the accelerator linkage to the 
carburetor throttle lever with a cotter pin, making sure flat washer is 
in place. Connect the accelerator return spring to the accelerator 
return spring clip. 

Section XVII. RUN-IN TESTS AND ADJUSTMENTS 

104. Accessories 

Tests and adjustments of accessories are outlined in the pertinent 
operator's manual and pertinent maintenance technical manuals 
(par. 1). 

105. Preparation for Run-in 

Install the engine to a dynamometer. Pre-oil the engine, forcing 
oil under pressure into the oil system. This insures adequate lubri- 
cation to the engine parts until the engine pump supply reaches them. 
If no pre-oiling equipment is available, fill all external oil lines with 
the proper grade of oil. 

106. Engine Run-in 

a. General. A rebuilt engine will be started and run-in in accord- 
ance with table II listed in / below and with instructions given in TB 
OKD 215. 

h. Warm-up Eun Before Adjustments. Fill the engine with oil 
to the "Full" mark on the bayonet-type oil gage using OE-10 engine 
oil. Eun the engine for 15 minutes at 1,000 rpm, no load, to warm up 
engine. Stop the engine and perform operations in c and d below. 

c. Distributor Adjustment. 

(1) Adjust breaker point gap to 0.020 inch. 

(2) Adjust ignition timing to 5° BTDC at 600 rpm. 

d. Carburetor Adjustment. 

(1) Adjust idle adjusting screw for engine speed of 600 rpm. 

(2) Adjust idle mixture to leanest setting for a smooth 600 rpm 
idle (TM 9-801). 

e. Warm-up Run After Adjustments. Start engine and run for 
perio'd of time and load as indicated in period 1 of table II (/ below) . 
Eecord the oil and w^ater temperature, at the conclusion of this run, 
on the test log (TB ORD 215) . Water temperature must be at least 
120° F. and oil temperature at least 100° F. before starting period 2 
run. 



98 



/. RiTN-iN Schedule. 

Ifote, See TB ORD 215 for conversion of brake horsepower (BHP) to dy- 
namometer scale readings. Dynamometers have various constants "K" or means 
for determining load. The manufacturer's Instructions furnished with the 
dynamometer will be followed. 

Table II. Run-In Schedule 



Period 


Time minutes 


Engine EPM 


BHP load 


1 . ^- 


20 
20 
20 
20 
20 
20 
20 
20 
20 
5 
15 
10 


1,200 
1,200 
1,360 
1,600 
1,880 
2,080 
2,400 
2,760 
3,320 
4,000 
2,000 
1,200 





2 


9 


3 


15 


4 - 


21 


5 


26 


6 . - 


32 


7 _ 


38 


8 -_- ^ 


44 


9 


55 


10 


57 


11 


24 


12 







3 hr3. 30 min. 





g. Water and Oil Temperatures While Running in Engine. 

(1) Water temperature should not exceed 160'^ F. 

(2) Oil temperature should not exceed 220° F. 
h. Record Readings at End of Each Test Period. 

(1) Engine rpnu 

(2) Dynamometer load reading. 

(3) Brake horsepower (BHP). 

(4) Oil pressure. 
(6) Fuel pressure. 

(6) Oil temperature, 

(7) Water temperature. 

(8) Cylinder head temperature. 

(9) Manifold vacuum. 

(10) Scale reading of oil weighing equipment if used. 

i. Check: and Add Oil if Necessary. If oil weighing equipment 
is not used, check the oil level at end of periods 3 and 7, table II. 
Make the necessary additions in one pint increments. At the con- 
clusion of run-in test complete and record on log the total amount of 
oil used. 

;. Record Air Temperature and Pressure Readings. Record ba- 
rometer reading and wet and dry bulb temperature at end of period 
5, table 11. Produced by Military Media, Inc. 

Copyright 1999 

99 




RA f D 358020 

Figure 80. Horsepoiver curve for Willys-Overlcmd model MG engine. 

Section XVIII. ASSEMBLY OF POWER PLANT 

107. Assembly of Clutch Housing to Transmission 

(fig. 29) 

Install the four lock washers and cap screws that hold the clutch 
housing to the transmission. Working tlirough tlie large end of the 
clutch housing, install the clutch control lever on the clutch release 
bearing carrier, and on the ball joint located on the main drive gear 
bearing retainer. Slide the lever cable through the hole in the hous- 
ing, and connect the lever cable yoke end to the lever and tube assem- 
bly with a clevis pin and cotter piu. Press the ball and socket joint 
end of the lever inward, and slide the lever cable in place on the control 
lever. 

108. Installation of Clutch Housing and Transmission 

i^g. 29) 
Working with an assistant, assemble transmission and clutch hous- 
ing to engine by sliding clutch housing onto dowel bolts on right and 
left of engine rear plate ; install lock washers and nuts. Install re- 
maining six bolts, lock washers and nuts, and tighten. 

109. Installation of Transfer to Transmission 

(fig. 29) 

Place the transfer in position on the transmission. Install the bolts 



100 



that secure the transmission to the transfer case. Slide the mainshaf t 
gear on the transmission mainshaft through the rear cover opening 
on the transfer case. Install the flat washer, castellated nut, and 
cotter pin that secure the gear to the mainshaft. Install a new gas- 
ket and the rear cover on the transfer case. 

110. Installation of Radiator 

Insert radiator retaining rods on right and left sides of radiator. 
With the help of an assistant, insert the rods in corresponding slots 
on the engine (fig. 25). Install the radiator hoses and tighten hose 
clamps. 

111. Installation of Power Plant in Vehicle 

(fig. 23) 

Place radiator pads in place on frame. Install a suitable lifting 
hook in the front lifting eye, mounted on the cylinder block. Lift 
the power plant into the vehicle with a hoist, and lower it until trans- 
mission and transfer case rest on the frame cross member. Force the 
rear of the engine to the left to connect the clutch linkage at the ball 
stud. Kemove lifting hook. 

112. Installation of Transmission to Frame 

(fig. 21) 

Install the transmission hold-down bolt, nut, and lock washer se- 
curing the right side of transmission and transfer case to the frame 
cross member. Tighten the two nuts on the right and left sides of 
the transmission, noting that the slotted brackets are secure. Tighten 
the two hold-down bolts in each front engine support mounting 
bracket. 

113. Installation of Hand Brake Cable, Clutch Cable, and 

Engine Stay Cable 

Slide the engine stay cable through the bracket on the engine rear 
plate (fig. 25) and into the ball socket connection; when tension is 
even, tighten the bolts. Install the clevis that secures the clutch 
release fork cable to the clutch shaft. Install the clevis pin that se- 
cures the hand brake cable to the hand brake control lever at rear of 
transfer case. Install the cap screw that secures the hand brake cable 
clamp to the engine support plate. 

114. Connect Speedometer Cable 

Connect the speedometer cable at the transfer case (fig. 22), 

101 



115. Installation of Front and Rear Propeller Shafts 

(fig. 21) 

Install and tighten the U bolts, lock washers, and nuts that secure 
the front propeller shaft to the driving flange on the transfer. Insert 
rear spline shaft into universal joint sleeve and tighten seal and collar. 

116. Installation of Poor Pan and Shift Levers 

(fig. 17) 

Hold the transfer shift levers in place and secure with fulcrum 
pin (D, Q.g. 20). Insert the gear shift lever, gear shift lever spring, 
and lever spring washer into the gear shift housing. Tighten the 
gear shift housing cap. Slide rubber boot down into position on gear 
shift housing. Tighten the 24 cap screws and internal toothed wash- 
ers. Install and tighten the clamps on the gearshift lever rubber 
boot. 

1 1 7. Installation of Electrical Cables 

Connect the starter cable, auxiliary power receptacle cable, and 
starter-to-regulator cable to the starter. Connect the field, armature, 
and ground cable plug to the generator. 

118. Installation of Air Cleaner 

Place the air cleaner in place on the mounting bracket ; secure the 
four wing screws in place. Slide the air cleaner hoses onto the metal 
tubes and tighten the hose clamps. Connect windshield wiper and 
fuel-tank-to-air-cleaner vent lines at air cleaner. Connect air-cleaner- 
to-dash- tee line at air cleaner. 

119. Installation of Ventilating Valve Control Cables 

Slide the valve-control-cable conduit through the hold- down 
bracket, and the valve control cables through the collars on the valve 
control arms (figs. 13 and 15). Push in the valve control handle 
on the instrument panel. Pull the valve control levers forward as 
far as possible, and tighten the set screws in the collars. Tighten the 
bolt and nut securing the ventilating valve-control-cable conduit into 
the bracket. 

120. InstaHation of Choke and Throttle Controls 

(fig. 31) 

Slide the choke control conduit through the conduit clamp on the 
carburetor, and the cable through the choke lever swivel screw. Push 
in the choke control button on the instrument panel. Pull the choke 
lever forward as far as possible, and tighten the swivel screw in the 

102 



collar. Slide the throttle control conduit through the conduit clamp 
on the carburetor. Run the throttle control cable and conduit to the 
left of the carburetor choke link and the carburetor. Run the throttle 
control cable through the carburetor throttle shaft arm and screw as- 
sembly. Push the throttle control cable on the instrument panel 
all the way in. Tighten the screw on the carburetor throttle shaft 
arm. 

121 . Installation of Oil Pressure and Water Temperature Gage 

Sending Units 

Connect the water temperature gage sending unit at the right side 
of the engine (fig. 11) . Connect the oil pressure gage line at the send- 
ing unit on the left side of the engine (fig. 7) . 

122. Installation of Radiator to Frame Cross Member 

(fig. 10) 

Install and tighten a lock washer and nut on each radiator mounting 
stud. 

123. Installation of Hinged Radiator Guard 

(fig. 9) 

Place radiator guard on front bumper and slide into hinged sockets. 
Raise radiator guard to proper position and tighten the three nuts on 
each side of radiator guard grill and connect the three head light 
connectors at left head light (fig. 8) . 

124. Installation of Radiator Brace Rod 

i^g- T) 

Install radiator brace rod in slot on rear of radiator and tighten 
wing nut securing brace rod. 

125. Installation of Battery 

{^g- 6) 

Install battery ground cable and close and fasten cover on battery 
box. 

126. Final Operations 

Make sure the radiator and engine drain cocks are closed, and install 
the specified coolant. Tighten the oil pan drain plug and fill the 
engine with the specified amount and grade of oil. Start the engine. 
If the oil pressure does not register immediately on the oil pressure 
gage, stop the engine. Remove the oil pump relief valve retainer 
and prime the oil pump. 

103 



CHAPTER 5 
CLUTCH 



Section I. DESCRIPTION AND DATA 

127. Description 

The clutch is of the single plate automotive type, composed of two 
major units (fig. 81) ; the pressure plate assembly and the driven plate 
or disk. The pressure plate is adjusted at the factory, and requires no 
other adjustments, except where it is necessary to install new clutch 
pressure springs, clutch springs, clutch fingers, or pressure plate 
(fig. 82), 

128. Data 

Type Single dry plate 

Torque capacity 144 Ib-ft 

Clutch disk : 

Make Borg and Beck 

Facings 2, molded asbestos 

Facing diameter Inside 5% in 

Facing diameter Outside SVa in 

Facing thickness 0.138 in 

Pressure plate : 

Make Auburn 

Number of springs _ 6 

Spring pressure at 1 9/16-in compressed length 180-195 lbs 

Auxiliary spring pressure at 1.518-in compressed length 60 lbs 

Section II. DISASSEMBLY OF PRESSURE PLATE 

129. Removal of Clutch Adjusting Screw 

Place the pressure plate and cover assembly in a press. Place a 
wood block 2y2 inches square on top of the clutch levers (fig. 83) . De- 
press the clutch levers, and remove the three clutch adjusting screws, 
lock nuts, and washers (fig. 82). Kelease the pressure on the levers 
slowly to prevent the pressure springs from flying out from under 
the lever. 



104 



pi$K>; ; w/h:u.b/: assy;;- ;i^p-2d6f ; p: 




f LAfI, PRESSUtg J 



Figure 81. Clutch dWc and pressure plate. 



RAPD 357914 



130. 



Removal of Clutch Pressure Spring Cups and Springs 

(fig. 82) 



Push the clutch pressure spring cups, springs, and spring retainers 
from the pressure plate cover with a screwdriver or punch. Remove 
the clutch pressure plate return clips from the cover. 

131. Cleaning, Inspection, and Repair of Clutch 

a. Cleaning. Clean all parts thoroughly using dry-cleaning solvent 
or volatile mineral spirits paint thinner. 
h. Inspection and Repair. 

(1) Clutch pressure plate (fig, 82). A ridged, scored, radial 
cracked, or burned pressure plate must be replaced. 

(2) Pressure plate cover (fig. 82). A distorted pressure plate 
cover or one with worn clutch levers must be replaced. 

(3) Clutch pressure springs (fig. 82). Place each clutch pres- 
sure spring (large) in a tension scale, and depress it to 1 9/16 
inches (fig. 84) . If the spring tension is less than 180 pounds, 



105 




JNCHgS 



e-coves wo-649971 

C~-CUP, PRESSURE SPRING WO-800728 
0-SPftiNG, Pg£SSUftE W0^649975 
E-SPRING, AUXtliARY hi£5SUft£ WO~a02380 
F-RETAJNER, AUXiUARY SPRING WO-802381 
O-SCMW, ADJUSTING W0^64^976 
H-CLIP, RETAiNER WO401698 
i~.HUT, LOCK WO'649W2 
K-WASHER WO-801641 

Figure 82. Pressure plate diJ<ass<'mMed, 



RAPD 357897 



it must be replaced. The auxiliary pressure springs should 
be depressed to 1.518 inches. If tension is less than 60 
pounds, it must be replaced. 

Section III. ASSEMBLY OF PRESSURE PLATE 

132. Installation of Clutch Pressure Spring Cups and Springs 

Install the clutch pressure spring cups and pressure springs in the 
cover (%. 82), making sure the indentation of each cup is toward the 
center of the cover. 

133. Installation of Pressure Plate on Pressure Plate Cover 

Slide a pressure plate return clip in place under each clutch lever 
on the pressure plate cover. Place the cover in a press, blocking it up 
as shown in figure 83. Place a wood block 2i^ inches square on top 
of the clutch levers, and depress the levers (fig. 83) . Install the three 
clutch adjusting screws, pressure plate return clips, lock nuts, and flat 
washers in the pressure plate. 



106 



^Od(, 2'A *NC^«S SQUA«g 



PIATC, PRESSURE 
W/COV^ ~ 7372^64 




RAJ»D 357898 
Figure 83. Pressure plate Mocked up in precis for disassembling or assembling. 



134. Adjustment of Pressure Plate 

Install the clutch disk and pressure plate onto the flywheel (par. 86) . 
Hold a straightedge across and against the edges of 2 clutch levers 
where the release bearing normally makes contact. Turn the adjust- 
ing screws until a distance of 27^2 inch is established between the 
straightedge and the face of the pressure plate cover. When adjust- 
ment is completed, hold the adjusting screws and tighten the lock nuts, 
using wrenches. Hold straightedge across and against the edge of the 
unadjusted lever and one which is adjusted. Turn adjusting screw 
until 2%2 inch is established and tighten lock nut. Check previous 
adjustment. 



107 




SPRING, ClUTCH PRESSURE ^WO-649975 



TESTER ™ 4 M- 1600 



RAPD 35789« 
Figure S//. Making compression test on clutch pressure spring. 



108 



CHAPTER 6 

ENGINE VENTILATION FOR DEEP WATER FORDING 

OPERATION 



Section I. DESCRIPTION AND DATA 

135. Description of Underwater Ventilation System 

(%• 4) 

Operation of the vehicle underwater is made possible by the sealing, 
at time of manufacture, of all parts or assemblies which are affected 
immediately by the entrance of water. Watertight housings are 
provided as standard equipment for all instruments, switches, starter^ 
generator, regulator, battery vents, ignition filter, and distributor, in- 
cluding cables. The majority of these parts require venting to at- 
mospheric pressure either to operate or to prevent damage due to 
condensation. A series of ventilating lines, which are shown in figure 
4, are provided for this purpose. 

136. Carburetor Float Chamber Vent 

The carburetor float chamber is vented to the air horn by an internal 
passage and is extended to the air intake pipe by an external line, F. 

137. Brake Master Cylinder Vent 

(fig. 4) 

The brake master cylinder is vented through line E which extends 
up between the foot pedals to dash elbow D, mounted on the dash, and 
line C to dash tee Q, and line P to air cleaner. 

138. Fuel Tank Vent 

(%. 4) 

The fuel tank is vented through line B, which connects to the air 
cleaner. 



953383—51 8 109 



139. Transmission, Transfer Vent 

The transmission and transfer are vented through line N connected 
to the top of the transfer to the air cleaner through dash tee Q and 

140. Distributor Housing Vent 

(%• 4) 

Positive circulation of air through the distributor housing is as- 
sured through lines L and M. One tube from the air cleaner L, pro- 
vides an air intake for the venting ; the other, M, is connected to tee H 
in the windshield wiper vacuum line. This vacuum connection pro- 
vides positive ventilation and will draw off any water which might 
possibly enter or collect in the distributor. 

141. Crankcase Ventilation 

(fig. 4) 

The standard crankcase oil filler tube is used to ventilate the engine. 
Air circulates from the air intake pipe into the oil filler tube and 
►crankcase through line K. Circulation is completed through crank- 
case vent outlet line J and a ventilating valve mounted in the intake 
manifold. Ventilating control valves G, which are operated from 
the instrument panel, are provided to block off the system when the 
vehicle is submerged. This causes a pressure to build up in the crank- 
case, thus preventing the entrance of water. 

Section If. INSPECTION AND REPAIR OF ENGINE VENTILATION 

SYSTEM 

Caution: It is important that all personnel servicing the vehicle 
understand the importance of using extreme caution and care when 
making adjustments and replacements to guard against inadvertently 
leaving vent lines or hose connections loose. Check all rubber hoses 
for leakage due to deterioration. When replacing tubes, use sealer 
as a safeguard against leakage. Replace all air ventilating lines that 
are broken, pinched, or distorted. Check all connection points to as- 
sure airtight connections. 

142. Crankshaft Rear Bearing Seal 

The crankshaft seals must be checked periodically as they are wear- 
ing parts and must be sufficiently tight to maintain the necessary crank- 
case internal pressure to prevent entrance of water should the engine 
be submerged. For information covering method of checking, see 
"Crankcase Internal Pressure" in section III. 



110 



143. Rear Main Bearing Seal 

If inspection of the rear main bearing seal indicates leakage of oil 
or entrance of water, this seal must be replaced. To install a new seal 
in the bearing cap„ first clean the groove, dip the seal in engine oil to 
provide initial lubrication and insert it in the groove. Press it into 
the groove until seated and be sure that it is centered to allow from 
0.020 to 0.030 inch to extend above the face of the cap at each side to 
allow this amount of crush when the cap is installed. The same pro- 
cedure should be followed when installing a crankcase seal. The 
rubber packings (fig, 72) , between the bearing cap and the case are 
cut to a given length and will protrude approximately % inch from 
the case (par. 81). When the oil pan is installed, it will force this 
packing tightly into the holes and will effectively seal any opening 
between the bearing cap and the crankcase. 

Section III. TEST OF INTERNAL CRANKCASE PRESSURE 

144. General 

When the vehicle is submerged, water is prevented from entering 
the engine by internal crankcase pressure which builds up due to seal- 
ing the engine ventilating system by closing valves "G" figure 4 and 
ventilated as shown in figure 84. The amount of internal pressure 
which develops depends upon piston and ring fits and also upon the 
amount of leakage by engine gaskets and especially through the crank- 
shaft front and rear seals discussed in paragraph 143 of this manual. 
Ordinarily, two pounds pressure will prevent the entrance of water. 

145. Lack of Pressure 

Should pressure fail to build up, the fault may usually be traced to 
leakage through the crankshaft seals, for they are subject to wear. 
These should be checked periodically, for they may function perfectly 
for highway use but fail when the vehicle is submerged. 

146. Various Leakage Points 

a. Gasket between the cylinder block and distributor. 

&. Fuel pump gasket. 

G. Timing gear cover gasket. 

d. Valve cover plate gasket. 

e. Crankcase ventilating line connections and gaskets. 
/. Oil pan gasket. 

g. Ventilating system ventilating control valves. 



Ill 



147. Internal Pressure Gage 

A satisfactory gage may be readily made for checking internal 
pressure. Secure a suitable pressure gage which must be calibrated 
for low pressure. Install the gage on a spare oil filler tube cap with 
the mounting airtight. To check the pressure, install the gage 
mounted cap on the oil filler tube, using a gasket satisfactory for an 
airtight mounting. Seal the crankcase ventilating system by pulling 
out the control handle mounted on the instrument panel (fig. 86). 
Start the engine and allow it to run until operating temperature is 
reached (TM 9-804). If the engine is sufficiently tight to operate 
satisfactorily when submerged, at least two pounds pressure will be 
indicated on the gage. 




VALVE CIOS5C 



mm js7^u 



Figure 85. Crankcase ventilation. 



112 




RA m 357926 



Figure 86. Fording control valve plate. 



113 




Figure 87. ServiceaUlity standards points of measurement. 



114 




ftA Pl> 356014 

Figure 88. i^crricca'bilitjj Htnndardi^ points of meamiremcnt. 



115 




Figure 89. ServiceaMUty standards points of measurement. 



116 




Figure 90. ServiceaMUty standards 'joints of measurement. 



117 




Figure 91. ServicealiUtv standards points of measurement. 




Figure 92. ServiceaMlitp standards points of measurement. 



118 



^'AMAIXB. OF CIHiet 
SiOl^ la CiNTit i^^ 




amz 



Figure 93. 



w^^ m cfmmm. 



mm^m^l 



ServiceaMlity standards points of measurement. 



CAMSHAFT SUSPENDED AT POINTS A AND D 

IN "V" BLOCKS ON SURFACE PUtE 

MEASURED AT POINTS 8 AND C 



RAPD 3$i022 



Figure 94. ScrviceaMlity standards points of measurem^ent 



120 



CHAPTER 7 
SERVICEABILITY STANDARDS 



148. General 

The serviceability standards listed in the following paragraphs give 
the minimum, maximum, and key clearances of new or rebuilt parts 
as well as wear limits which indicate that point to which a part or 
parts may be worn before replacement, in order to receive maximum 
service with minimum replacement. Normally, all parts which have 
not been worn beyond the dimensions shown in the "Wear Limits" 
column or damaged from corrosion will be approved for service. An 
asterisk (*) in the "Wear Limits" column indicates that the part or 
parts should be replaced when worn beyond the maximum size given 
in the "Sizes and fits of new parts" column. 

149. Cylinder Block 

(par. 43) 

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



Fig. No. 


Ref. Itr. 


Point of measurement 


Sizes and fits of new parts 


Wear limits 


Min. 


Max. 


87 


c 

F 
B 
B 
K 
K 


Diameter at top of ring travel 

Diameter at bottom of ring travel 
Piston to block clearance.- 


3. 125 

3. 125 

0. 0021 


3. 127 

3. 127 

0. 0029 


3. 137 
3. 129 
0.005 




Rebore for next oversize at - _ 


0. 005 




Max taper - _ - _ 






0.010 




Out of round 


0. 0003 


0. 0005 


0. 003 









121 



h. Valve Tappet Bores. 



Fig. No. 


Ref. Itr. 






Sizes and fits of new parts 


Wear limits 




Min. 


Max. 


90 


B 
A 

A 


Dii 

Ta 
Re 


imeter of tappet bore - - 


O: 625 
0. 0005 


0.626 
0.002 


0. 6295 




ppet to block clearance 


■ 0. 003 




bore for oversize at 


0.003 












c. Valve Seats. 


Fig. No. 


Ref. Itr. 


Point of measurement 


Sizes and fits of new parts 


Wear limits 


Min. 


Max. 


90 


J-K 


Va 


Ive seat angle 


45° 














JVoie. Valve tappets are available in 0.004-tnch oversize. 

1 50. Crankshaft 

(pars. 69 and 83) 

a. Crankshaet. 


Fig. No. 


Ref. Itr. 


Point of measurement 


Sizes and fits of new 
parts 


Wear limits 




Min. 


Max. 




88 -_ 


E 
A 


Run out — (Crankshaft sus- 
pended at points 
B& G). 

End play 






0.001 




0.004 


0.006 




h. Main Bearing Journals. 




Fig. No. 


Ref. Itr. 


Point of measurement 


Sizes and fits of new 
parts 


Wear limits 




Min. 


Max. 




88 


B-D-G 

C 
B-D-G 
B-D-G 
B-D-G 


Diameter ^ _ - 


2. 3335 
0. 0005 


2. 3340 
0.001 


2. 3330 




Bearing to journal clearance- __ 
Regrind for next undersize at _ 


0.002 
2. 3330 




Max out of round. - 






0.001 




Max taper 






0. 001 

















122 



c. Connecting Rod Bearing Journals. 



Fig. No. 



Ref. Itr. 



Point of measurement 



Sizes and fits of new- 
parts 



Min. 



Ma.\. 



Wear limits 



88 



Diameter 

Bearing to journal clearance.. 
Regrind for next undersize at. 

Max out of round 

Max taper 



1. 9372 
0. 0005 



1. 9377 
0.001 



1. 9367 

0. 002 

1. 9367 
0.002 
0.002 



Note. Main bearings and connecting rod bearings are available in 0.010-, 0.020-, and 0.030-inch undersize. 



151. Connecting Rod 

(par. 50) 



Fig. No. 


Ref. Itr. 


Point of measurement 


Sizes and fits of new- 
parts 


Wear limits 




Min. 


Max, 




88 


F-H 


Side clearance 


0. 005 


0. 009 


0. 013 


93 


Allowable twist at 5 inches _ 


0.004 




Allowable bend_ 






0.002 













152. Pistons and Rings 

(pars. 50, 51, and 53) 

a. Pistons. 



Fig. No. 


Ref. Itr. 


Point of measurement 


Sizes and fits of new 
parts 


Wear limits 




Min. 


Max. 




93 

86 
58 


I ^ 


Diameter of piston at top of 
skirt (90 deg to piston pin) „ _ 

Diameter of piston at bottom 
of skirt (90 deg to piston pin) _ 

Piston to block clearance 


3. 1245 

3. 1245 
0. 0021 


3. 1255 

3. 1255 
0. 0029 


0. 005 



123 



&. Rings. 









Sizes and fits of new 










parts 




Fig. No. 


Bef. Ur. 


Point of measurement 






Wear limits 




Min. 


Max. 




87 


D-J 


Thickness of compression rings 
(2). 


0.093 


0. 0935 




86 


H 


Thickness of oil ring (1) 


0. 186 


0. 1865 




93 




Top ring to groove clearance___ 


0.002 


0.004 


0.005 






Center ring to groove clearance _ 


0. 0015 


0. 0035 


0. 0045 






Bottom ring to groove clear- 


0. 0015 


0.004 


0. 0045 






ance. 












Ring gap in cylinder block 


0.008 


0.013 


0.020 



c. Piston Pin Bores. 



Fig. No. 


Ref. Itr. 


Point of measurement 


Sizes and fits of new 
parts 


Wear limits 




Min. 


Max. 




87 


A 
A 

E 


Diameter __ 


0. 8120 
0. 8150 

0. 0001 


0. 8122 
0. 8152 

0. 0005 


0. 8137 




Ream for 0.003-inch oversize 

pin to. 
Pin to piston clearance 


0. 8167 
0.001 



Note: Pistons and rings are available in 0.020, 0.030, and 0. 040-Inch oversize. 

153. Piston Pin 

(pars. 50 and 52) 



Fig. No. 


Ref. Itr. 


Point of measurement 


Sizes and fits of new 
parts 


Wear limits 




Min. 


Max. 




87 


G 
E 


Diameter _ 


0.8117 
0. 0001 


0.8119 
0. 0005 






Pin to piston clearance 


0.001 



JVtrftf.— Piston pins are available in 0.003-ineh oversize. 



124 



154. Camshaft 

(par. 55) 

a. Camshapt. 



Fig. No. 


Ref. Itr. 


Point 0/ measurement 


Sizes and fits of new 
parts 


Wear limits 




Min. 


Max. 




94 


B-C 
A 


Run out „ 






0.001 


89 


Camshaft gear to thrust plate 
clearance. 


0.004 


0.007 


0.004 



J). Bearing Journal Diameters. 



Fig. No. 



89 
92 



Ref. Itr. 



Point of measurement 



Front 

Front intermediate 
Rear intermediate. 
Rear 



Sizes and fits of new 
parts 


Min. 


Max. 


2. 186 
2. 125 
2. 0625 
1.625 


2. 1855 
2. 126 
2. 0635 
1.626 



Wear limits 



2. 182 
2. 121 
2. 0585 
1.621 



c. Bearing to Journal Clearances. 



Fig. No. 


Ref. Itr. 


Point of measurement 


Sizes and fits of new 
parts 


Wear limits 




Min. 


Max. 




89 


B 
B 
E 
H 


Front- __ __-_,_ - 


0.001 
0. 0025 
0.002 


0. 0025 
0. 0045 
a 0035 


0.004 


92 


Front Intermediate - _ 


0. 004 




Rear intermediate 


0. 004 




Rear 















958383—5] — -i) 



125 



155. Intake Valve 

(par. 59) 

a. Valves . 



Fig. No. 


Ref. Itr. 


Point of measurement 


Sizes and fits of new 
parts 


Wear limits 




Min. 


Max. 




90 


K 

N 

Q 


Seat angle 




45 deg _ 
0.373 






Diameter stem _ 


0. 3623 
0.116 


0. 3608 




Valve to tappet clearance 











&. Valve Gtjides. 



Fig. No. 


Ref. Itr. 


Point of measurement 


Sizes and fits of new- 
parts 


Wear limits 




Min. 


Max. 




90 


L 
P 
M 


Inside diameter 


0. 3745 
0. 0015 
0. 0565 


0. 3755 
0. 0132 
0. 6575 


0. 3785 




Valve to guide clearance 

Outside diameter ^ , _ 


0. 0192 









c. Valve Tappets. 



Fig. No. 


Ref. Itr. 


Point of measurement 


Sizes and fits of new 
parts 


Wear limns 




Min. 


Max. 




90 


B 
F 
A 


Diameter.^ 


0. 6240 
0. 0005 


0. 6245 
0-002 


0. 6236 


92 
90 
92 


Tappet to cylinder block clear- 
ance. 


0.003 



126 



156. Exhaust Valve 

(par. 59) 

a. Valves. 



Fig. No. 


Ref. Itr. 


Point of measurement 


Sizes and fits of new 
parts 


Wear limits 




Min. 


Max. 




90 


J 
G 
C 
D 


Seat angle __ 


45° 
0.371 






90 .. 


Diameter stem 


0.372 
0.016 
0.004 


0. 3685 


90 


Valve cap to tappet clearance 




90_„. 


Valve to valve cap clearance--- 


0.000 


0.005 



&. Valve Guides. 



Fig. No. 


Ref. Itr. 


Point of measurement 


Sizes and fits of new- 
parts 


Wear limits 




Min. 


Max. 




90 


H 
E 
F 


Inside diameter 


0. 3745 
0. 0025 
0. 6565 


0. 3755 
0. 0045 
0. 6575 


0. 3785 


90 
90 


Valve to guide clearence 

Outside diameter 


0.010 









c. Valve Tappets. 



Fig. No. 


Ref. Itr. 


Point of measuoemet 


Sizes and flts of new 
parts 


Wear limits 




Min. 


Max. 




90 


B 

A 


Diameter . 


0. 6240 
0. 0005 


0. 6245 
0.002 


0. 6285 


90 


Tappet to cylinder block clear- 
ance. 


0.003 



127 



157. Oil Pump 

(par. 66) 



Fig. No. 


Ref. Itr. 


Point of measurement 


Sizes and fits ol new- 
parts 


Wear limits 




Min. 


Max. 




91 
65 
91 
66 
91 


A-B 

C-D 

E 
F 


Outer rotor lobe to inner rotor 

lobe clearance. 
Outer rotor to pump body 

clearance. 
Free length of plunger springs. 


0.006 
0.009 


0. 0005 
0.005 

1. 8594 


0.010 
0.012 


91 


Plunger spring length when 
load of V/i lb applied. 


1. 0625 











128 



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 SB 310-20-5 

Army Regulations, Special Regulations, Readjustment Regulations, 
Joint Army-Air Force Adjustment Regulations, General Orders, 
Bulletins, Circulars, Commercial Traffic Bulletins, Joint Procure- 
ment Circulars, Department of the Army Pamphlets, and ASF 
Manuals. 

Index of Army Motion Pictures and Film Strips SR 110- 1-1 

Index of Army Training Publications SR 810-20-3 

Field Manuals, Training Circulars, Firing Tables and Charts, Army 
Training Programs, Mobilization Training Programs, Graphic 
Training Aids, Joint Army- Navy Air Force Publications, and Com- 
bined Communications Board Publications. 
Index of Blank Forms and Army Personnel Classification 

Tests SR 310-20-6 

Index of Technical Manuals SR 310-20-4 

Technical Regulations, Technical Bulletins, Supply Bulletins, 
Lubrication Orders, Modification Work Orders, Tables of Organi- 
zation and Equipment, Reduction Tables, Tables of Allowances, 
Tables of Organization, and Tables of Equipment. 

Introduction and Index (supply catalogs) ORD 1 

Military Training Aids FM 21-8 

Ordnance Major Items and Combinations and Pertinent Publi- 
cations SB 9-1 

2. Supply Catologs 

The following catalogs of the Department of the Army Supply 
Catalog pertain to this materiel : 

a. Maintenance and Repair. 
Cleaners, Preservatives, Lubricants, Recoil Fluids, Special Oils, and 

Related Maintenance Materials ORD 8 SNL K-1 



129 



Items of Soldering, Metallizing, Brazing and Welding Materials: 
Gases and Eelated Items ORD 3 SNL K-2 

Lubricating Equipment, Accessories and Related Dispensers 

ORD (*) SNL K-3 
Tool-sets (common), Specialists' and Organizational 

ORD 6 SNL G-27, Sec 2 
h. Vehicle. 
Truck, 14-Ton, 4x4, Utility, M38 ORD (*) SNL G-740 

3. Forms 

The following forms are applicable to this materiel : 
WD AGO Form 9-71, Locator and Inventory Control Card 
WD AGO Form 9-72, Ordnance Stock Record Card 
WD AGO Form 9-76, Request for Work Order 
WD AGO Form 9-77, Job Order Register 
WD AGO Form 9-78, Job Order 
DA AGO 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 AGO Form 461-5, Limited Technical Inspection 
DA AGO Form 468, Unsatisfactory Equipment Report 
WD AGO Form 865, Work Order 
WD AGO Form 866, Consolidation of Parts 
WD AGO Form 867, Status of Modification Work Order 
DD Form 6, Report of Damaged or Improper Shipment 

4. Other Publications 

The following explanatory publications contain information perti- 
nent to this materiel and associated equipment : 

a. Camouflage. 

Camouflage — TM 6-267 

Camouflage, Basic Principles FM 5-20 

Camouflage of Vehicles FM 5-20B 

h. Decontamination. 

Decontamination TM 3-220 

Defense Against Chemical Attack FM 21^0 

c. Demolition To Prevent Enemy Use. 

Ammunition, General TM 9-1900 

Explosives and Demolitions FM 5-25 

Qualification in Arms and Ammunition Training 

Allowances AR 775-10 

Regulations for Firing Ammunition for Training, Target Practice, 

and Combat SR 385-^10-1 

*See ORD 1, Introduction and Index, for published catalogs of the 0rdna,nce section 
of the Department of the Army Supply Catalog. 



130 



d. General. 

Cooling Systems: Vehicles and Powdered Ground Equipment 

TM 9^2858 

Fuels and Carburetion TM 10-550 

Ordnance Service in the Field FM ^~f> 

Precautions in Handling Gasoline AR 850-20 

Principles of Automotive Vehicles -- TM 9-2700 

Storage Batteries, Lead-Acid Type TM 9-2857 

e. Maintenance and Repair. 

Cleaning, Preserving, Sealing, and Related Materials Issued for 
Ordnance Materiel TM 9-850 

Hand, Measuring, and Power Tools TM 10-590 

Instruction Guide: Welding Theory and Application TM 9-2852 

Lubrication TM 9-2835 

Maintenance and Care of Hand Tools TM 9-867 

Maintenance of Supplies and Equipment : Maintenance Responsibili- 
ties and Shop Operation AR 750-5 

Motor Vehicle Inspection and Preventive Maintenance Services 

TM 37-2810 

Ordnance Maintenance : Carburetors (Carter) TM 9-1826A 

Ordnance Maintenance : Electrical Equipment (Auto-Lite) 

TM 9-1825B 

Ordnance Maintenance: Fuel Pumps TM 9-1828A 

Ordnance Maintenance : Vehicular Maintenance Equipment : Grind- 
ing, Boring, Valve Reseating Machines and Lathes— TM 9-1834 A 

Painting Instructions for Field Use TM 9-2861 

Uneconomically Repairable Ordnance Vehicles SR 755-105-5 

/. Operation. 

i/i-Ton, 4 X 4, Utility Truck TM 9-804 

g. Shipment and Standbt or Long Term Storage. 

Army Marking Directive TM 38-414 

Army Shipping Document — TM 38-705 

Instruction Guide : Ordnance Packaging and Shipping (Posts, Camps, 
and Stations) TM 9-2864 

Ordnance Storage and Shipment Chart— Group G— TB 9-OSSC-G 
Protection of Ordnance General Supplies in Open Storage 

TB ORD 379 
Standards for Oversea Shipment and Domestic Issue of Ordnance 
Materiel Other Than Ammunition and Army Aircraft 

TB ORD 385 



131 



INDEX 



Accelerator linkage: Paragraph Page 

Connect 103 98 

Disconnect 20/i 21 

Accidents, field report 3c 2 

Adjustments: 

Accessories 104 98 

Engine 106 98 

Pressure plate 134 107 

Valve clearance 80 86 

Air cleaner: 

Installation 118 102 

Removal 20j 21 

Assembly : 

Connecting rods 51 62 

Flywheel 73 83 

Manifolds. 78 84 

Oil pump , 67 78 

Oil strainer . ^ 67 78 

Pistons 52 71 

Pressure plate 132, 133 106 

Valve tappets 63 74 

Water pu[rip 47 59 

Block, cylinder {See Cylinder block) 

Cables: 

Clutch cable: 

Connect 113 101 

Disconnect - 20o 17 

Hand brake cable: 

Connect 113 101 

Disconnect 20o 17 

Throttle Control cable: 

Connect 120 102 

Disconnect 20/i 21 

Camshaft and gear: 

Cleaning 54 71 

Inspection and repair 55 72 

Installation 79 85 

Removal 39 47 

Serviceability standards 156 127 

Camshaft bearings: 

Serviceability standards 156 127 

Carburetor: 

Installation ^ 95 96 

Removal 25 38 

Choke control cable: 

Connect 120 102 

Disconnect. 20/i 21 



132 



Cleaning: Paragraph Page 

Clutch pressure springs 131 105 

Connecting rods 49 62 

Crankshaft 68 81 

Cylinder block 42 53 

Cylinderhead 42 53 

Flywheel 70 82 

Manifolds 76 83 

Oil pan 42 53 

Oil pump 65 78 

Oil strainer 65 78 

Pistons 49 62 

Pressure plate - . — 131 105 

Valves 58 73 

Valve tappets 60 74 

Water pump 45 58 

Clearances : 

Crankshaft 82 88 

Pistons -- 51 62 

Valves -^ 59,80 73,86 

Clutch: 

Cleaning 131 105 

Connect linkage 107 100 

Data -- 128 104 

Description 4, 127 3, 104 

Disconnect linkage 20s 23 

Inspection and repair 131 105 

Clutch cable: 

Connect 113 101 

Disconnect 20o 22 

Clutch disk: 

Installation 86 91 

Removal 34 43 

Clutch pressure springs: 

Cleaning 131 105 

Inspection and repair 131 105 

Installation 132 106 

Removal 130 105 

Compression ratio 18 16 

Connecting rods: 

Assembly 51 62 

Bent or twisted 50 62 

Cleaning 49 62 

Disassembly 48 62 

Inspection and repair 50 62 

Installation 84 88 

Removal 40 49 

Serviceability standards 153 124 

Crankshaft: 

Cleaning 68 81 

Clearance 82 88 

End play 83 88 

Fitting crankshaft to flywheel 74, 82 83,88 

Inspection 69 81 

Installation 81 86 



133 



Crankshaft— Continued Paragraph Page 

Removal 41 52 

Serviceability standards 152 123 

Crankshaft bearings {See Main bearings) 

Crankshaft pulley: 

Installation 88 93 

Removal 39 47 

Cylinder block: 

Cleaning 42 53 

Inspection and repair 43c 54 

Serviceability standards 151 123 

Cylinder head: 

Cleaning 42 53 

Inspection and repair 43& 54 

Installation 90 94 

Removal 36 44 

Damaged studs: 

Replacement 43d 54 

Deep-water fording {See Ventilation system) 

Disassembly: 

Connecting rods 48 62 

Flywheel 74 83 

Manifolds 75 83 

Oil pump 64 76 

Oil strainer 64 76 

Pistons 48 62 

Pressure plate 129, 130 104, 105 

Valve tappets 62 74 

Water pump 44 58 

Distributor: 

Installation 98 97 

Removal 29 38 

Dynamometer test 105 98 

Electrical cables: 

Connect 117 102 

Disconnect 20k 22 

Engine : 

Cleaning (See Cleaning) 

Data 5, 18 3, 16 

Description 4 3 

Electrical system, description 15 16 

Final operations (after installation) 126 103 

General 13 15 

Installation in vehicle 111 101 

Lubrication 14 15 

Removal from vehicle 20 17 

Run-in test '_ 106 98 

Trouble shooting 11, 12 12 

Ventilation system 16, 135 15, 109 

Engine stay cable: 

Connect 113 101 

Disconnect -_._ 20o 22 

Exhaust manifold (See Manifolds) 

Exhaust valves (See Valves) 



134 



Paragraph Page 

Expansion plugs 43 53 

Fan: 

Installation 99 97 

Removal 30 40 

Field and depot maintenance allocation 2 1 

Field report of accidents _ 3 2 

Filters: oil {See Oil filter) 

Flywheel: 

Assembly 73 83 

Cleaning 70 82 

Disassembly 72 83 

Fitting crankshaft to flywheel 74 83 

Inspection and repair 71 82 

Installation 85 89 

Pilot bearing 71 82 

Removal 35 43 

Timing marks 85 89 

Floor pan : 

Installation 116 102 

Removal 201 22 

Forms, records, and reports 3 2 

Fuel pump: 

Installation 97 96 

Removal 26 38 

Gap, spark plug 18 16 

Gears: 

Camshaft (See Camshaft gear) 

Crankshaft {See Crankshaft gear) 

Timing {See Crankshaft gear and Camshaft gear) 
Generator: 

Installation 100 97 

Removal 27 38 

Hand brake cable: 

Connect 113 101 

Disconnect 20o 22 

Ignition timing 18, 87 16, 92 

Inspection and repair: 

Camshaft and gear 54 71 

Clutch 131 105 

Clutch pressure springs 131 105 

Connecting rods 50 62 

Crankshaft 69 81 

Cylinder block 43c 54 

Cylinder head 436 54 

Flywheel 71 82 

Manifolds 77 83 

Oil pan 43o 53 

Oilpump 66 78 

Oil strainer 65 78 

Pistons 50 62 

Pressure plate 131 105 

Valve guides 43/ 56 



135 



Inspection and repair — Continued Paragraph Page 

Valves 59 73 

Valve springs S9 73 

Valve tappets 61 74 

Water pump 46 58 

Installation: 

Air cleaner 118 102 

Camshaft and gear 79 85 

Carburetor i^5 96 

Clutch disk 86 91 

Connecting rods _ 84 88 

Crankshaft 81 86 

Cylinderhead 90 94 

Distributor 98 97 

Engine HI 101 

Fan 99 97 

Flywheel 85 89 

Fuel pump 97 96 

Generator 100 97 

Manifolds 91 95 

Oil filter 97 96 

Oil pan 89 94 

Oil pump 67,92 78,95 

Oil strainer 67 78 

Pistons 84 88 

Radiator 110, 122, 123, 124 101, 

103 

Starter 101 97 

Thermostat 93 96 

Transfer 104 98 

Transmission 108, 112 100, 

101 

Valves 79 85 

Water pump 94 96 

Intake manifold (See Manifolds) 

Intake valves (See Valves) 

Main bearings: 

Serviceability standards 152 123 

Manifolds : 

Assembly 78 84 

Cleaning 76 83 

Disassembly 75 83 

Inspection and repair 77 83 

Installation 91 95 

Removal 32 43 

Oil filter: 

Installation 97 96 

Removal 28 38 

Oil pan : 

Cleaning 42 53 

Inspection and repair 43a 53 

Installation 89 94 

Removal 38 47 



136 



Oil pump: Paragraph Page 

Assembly 67 78 

Cleaning 65 78 

Clearances 66, 67 78 

Disassembly 64 76 

Inspection and repair 66 78 

Installation . 67,92 78,95 

Removal 64 76 

Serviceability standards 160 121 

Oil strainer: 

Assembly 67 78 

Cleaning 65 78 

Disassembly 64 76 

Inspection and repair 65 78 

Installation 67 78 

Removal 38,64 47,76 

Parts, special tools and equipment: 
Field and depot maintenance: 

General 6 8 

Parts --- 7 8 

Special tools and equipment 8 8 

Piston pins (See also, Pistons) 

Serviceability standards 155 126 

Piston rings {See also, Pistons) 

Installation 53,84 71,88 

Removal 48 62 

Serviceability standards 154 125 

Pistons : 

Assembly 52 71 

Checking clearance 51 62 

Cleaning 49 62 

Disassembly 48 62 

Inspection and repair 50 62 

Installation 84 88 

Removal 40 49 

Serviceability standards 154 125 

Plugs, expansion 43 53 

Power plant (See also, Engine) 

General 17, 19 16 

Installation in vehicle HI 1^1 

Removal from vehicle 20 17 

Pressure plate: 

Adjustment 134 107 

Assembly 132, 133 106 

Disassembly 129, 130 104, 

105 

Installation 86 91 

Removal 34 43 

Propeller shafts : 

Connect 115 102 

Disconnect 20w( 22 

Pumps : 

Fuel (See Fuel pump) 
Oil (See Oil pump) 
Water (See Water pinnp) 

137 



Radiator: Paragraph Page 

110, 122 101, 

Installation \ 103 

123, 124 103 

Removal 22 30 

Records {See Forms, Records, and Reports) 

References Appendix 129 

Removal : 

Air cleaner — 20j 21 

Camshaft and gear 39 40 

Carburetor 25 38 

Clutchdisk 34 43 

Connectingrod 40 49 

Crankshaft 41 52 

Cylinder head 36 44 

Distributor 29 38 

Engine 20 17 

Fan 30 40 

Flywheel - 35 43 

Fuel pump 26 38 

Generator 27 38 

Manifolds 32 43 

Oil filter 28 38 

Oil pan 38 47 

Oil pump 64 76 

Oil strainer 38 47 

Pistons 40 49 

Radiator 22 30 

Starter 2? 30 

Thermostat 33 43 

Transfer 24 32 

Transmission 24 32 

Valves 37 44 

Water pump 31 43 

Repair (See Inspection and Repair) 

Ring, piston (See Piston rings) 

Rod, connecting (See Connecting rod) 

Run-in test: 

Preparation 105 98 

Engine run-in test 106 98 

Sending units; 

Connect 121 103 

Disconnect 20e 17 

Serviceability standards: 

Camshaft 156 127 

Camshaft bearings 156 127 

Connecting rods 153 124 

Crankshaft 152 123 

Cvlinder block 151 123 

General 150 122 

Main bearings 152 123 

Oil pump 157 128 

Piston pins 155 126 

Piston rings 154 125 

Pistons 154 125 

138 



Paragraph Page 

Spark plug gap 18 16 

Spark plugs and cables; 

Installation 102 97 

Removal 29 38 

Special tools (See Parts, Special Tools and Equipment) . 

Speedometer cable: 

Connect 114 101 

Disconnect 20n 22 

Starter: 

Installation 101 97 

Removal 23 30 

Studs: 

Inspection, repair, and replacement 43d 54 

Tests: 

Accessories 104 98 

Engine run-in 106 98 

Ventilation system 144, 145, 146, 147 111, 

112 

Thermostat: 

Installation 93 96 

Removal 33 43 

Throttle control cable: 

Connect 120 102 

Disconnect 20A 21 

Timing gears (See also. Crankshaft gear and camshaft gear). 

Ignition timing 87 92 

Timing marks 87 92 

Torque specifications 148, 149 121 

Transfer: 

Installation 109 100 

Removal 24 32 

Transmission : 

Installation 108, 112 100, 

101 

Removal 24 32 

Trouble shooting: 

Engine 12 12 

General instructions and procedures 10, 11 1 1, 12 

Purpose 9 11 

Unsatisfactory equipment or materiel, report Sd 2 

Valve guides: 

Removal 43/ 55 

Inspection and repair 43/ 55 

Installation 43/" 55 

Valves: 

Adjustment 80 86 

Cleaning 58 73 

Clearance ■ ^ .. 59 73 

Events 18 16 

Inspection and repair 59 73 

Installation 79 85 

Removal . 37 44 

Rotator-type (exhaust) ^-- - 56,57 73 

139 



Valves — Cootinued Paraerapk Pate 

ServiwMibiUty standwds 155 126 

Stem-to-oap clearance (exhaust) 5S 73 

Timing --- 18 1<5 

Valve springB: 

Inspection 59 73 

Installation - - 79 86 

Removal - - 37 44 

Serviceability standards 159 121 

Vaive tappets: 

Assembly 63 74 

Cleaning - - -- 60 74 

Disassembly - - 62 74 

Inspection and repair _-.--. 61 74 

Ventilation system, deep-water fording: 

Data. . ..136,137.138,139.140,141 109, 

110 

Description - 136 109 

Inspection and repair » 142,143 110, 

111 

Test__ - 144,146,146,147 111, 

112 

Water pump: 

Assembly - -- 47 59 

Cleaning - ---^ *6 58 

Disassembly 44 68 

Inspection and repair ^ — 46 68 

Inatallation ---. - — 94 96 

Removal 31 48 



140