Document bZYj6DXyvp47R7Jr2NobOvX3

BULLET) I' AUGUST 15, 1980 No. Q104 under BRAKES POR branches, distributors and CUSTOMERS. / s/ CHASSIS AFFECTED ALLENTOWN0 HAYWARDS OAKVILLE0 BRAKE LINING SERVICE KITS (All With 16-1/2 x 7 Cam Type Rear Axle Brakes) PURPOSE material. To inform the field of new service linings made of non-asbestos RECOMMENDATION Install non-asbestos lining kits if improved lining and drum life and/or quieter operation is desired. INFORMATION The non-asbestos linings provide longer drum and lining life along with reduced noise levels. They are directly interchangeable with standard and combination service kits on axles rated at 20,000 pounds (40,000 per bogie) or less. They can also be used on axles rated up to and including 23,000 pounds (44,000 per bogie) if type 30 brake chambers and six inch slack adjusters are installed. Lining kits currently available Standard Combination Service Kits Service Kits 202SMI1204 202SMH204-P2 not available 202SMH210 202SMH220 202SMH220 are: Non-Asbestos Service Kits 202SMM204N 202SMM210N 202SMM220N ADDlication Rockwell Pand Q Rockwell P-44,000 lb. Eaton bogie : END 3 CIRCULATION Service Manager Shop Foramen Night Foreman Night Foreman Inapector leadman Inapector Laadman Inapactor laadman Unit Over haul Room Service Operations, Allentown, Pa., U.S.A. Shop Olflca ,9 Figure 2-12. Valve Spring Figure 2-14. Torquing Sequence tn-t Valve Rocker Arm and Shaft Assembly The valve rocker arm features a bushing. When the bushing is installed, the split must locate on the horizontal plane and face the slipper side of the arm. See Figure 2-15. Figure 2-13. Installing Valve Keys Installing Cylinder Heads New cylinder head gaskets are installed on the cylinder block with "Top" markup. Check cylinder head studs for secureness in the block; also threads for damage that may cause binding of the stud nuts. Fit cylinder heads over studs lowering on to cylinder head gasket carefully to avoid damage. Install cylinder head stud washers and nuts. Torque nuts in sequence shown with a calibrated torque wrench in progressive steps of 50, 100 and finally 140 lb. ft. (Stud threads oiled). See Figure 2-14. Install the two water connection flanges, with gaskets, to cylinder head (connecting heads together to permit cooling water circulation through the three cylinder heads), and install thermostat housing (outlet) and gasket to the front head. A blank plate and gasket are used at the rear head. Figure 2-15. Rocker Arm Assembly Press the bushing in so that it will come flush with the side of the hub which contacts the rocker arm shaft bracket. Two oil holes must be drilled in the bushing. They must be in alignment with the two oil holes pro vided on top of the arm to feed the slipper and the rocker arm to pushrod adjusting screw with lube oil. Ream bushing I. D. 0.8661 to 0.8669 in., to allow for proper running clearance with a new rocker arm shaft diameter. Check shaft O. D. at unworn area for size, before reaming new bushings to be used with old shaft. Running clearance, 0.0005 to 0.0015 in. 2-34 The valve rocker arm shaft is hollow. Two large holes are drilled through the shaft, vertically, at locations where the bracketto-cylinder head screws are installed. Four positions on the shaft are drilled through the shaftfrom one side to the other, on a horizon tal plane. This provides eight oil feed holes, two for each of four rocker arms. Theyfeed the bushing with lube oil at the 3 and 9 o'clock positions. The valve rocker arm and shaft assembly must be installed only after the cylinder heads have been properly torqued down. The valve lifters must be installed with the camshaft in place. The pushrods must then be installed. See Figure 2-16. Figure 2-16. Installing Valve Lifter The rocker arms, shaft, springs and brackets are assembled and secured at each end with large hex head type plugs. The two bracketto-cylinder head bolts must also be in place before installing the assembly to the head. The bolts are drilled up through the center, and a feed hole drilled on side of the bolt locates inside the rocker arm shaft, on the assembly, to admit lube oil which originates (under pressure) from a passage directed to the bottom of the tapped hole (in the cylinder head) to feed the bracket bolt. A heavy paper disc type gasket is used bet ween the brackets and cylinder head to pre vent oil leakage. Before installing new gas kets, remove any part of the old gaskets that may be adhering to the bracket or head to assure solid seating. Tighten the bolts equally and finally torque to 40 lbs. ft. maximum. See Figure 2-17. NHl Figure 2-17. Rocker Arm and Shaft Assy. When the rocker arm and shaft assembly is installed on the engine, carefully check outer rocker arms for possible binding between bracket andhex head plug. Rap opposite end of shaft with hammer to free. Naturally Aspirated Diesel (END475) Adjust valve clearance (cold engine setting); inlet valve, 0.014 in. and exhaust valve, 0.018 in. Turbocharged Diesel (ENDT475) Inlet valve, 0. 014 in. andexhaust valve 0. 028 in. Squirt engine oil over valve mechanism and at valve stems for initial protection. NOTE As soon as engine is running, ob serve to be sure lubricating oil is flowing from all rocker arms. CYLINDER BLOCK Description The cylinder and upper crankcase is an in tegral casting of alloy cast iron. See Fig ure 2-18. It features replaceable wet-type cylinder sleeves flanged at the top to fit in the counterbores on the cylinder block deck. Three O-ring type seals are employed to seal the lower areas of the sleeve at the water jacket. The O-rings are resistant to oil and heat. The standard cylinder sleeve I. D. is 4.527. This is the only size available. A worn or scored sleeve must be replaced with a new sleeve because the piston and piston rings are also only available in standard size. Cylinder sleeves may be removed by using puller J-21376 and sleeve puller shoe J21587. See Figure 2-19. > '#*. ' -SttiPj-c * '&*!* - f f r r tjfo 'A *- i. ; * 2-35 to 1.457 Inch (37mm) Is 147.84 lbs. (660N). See Figure 2-19. tt } Figure 2-19.Checking Valve Springs Position inner and outer valve springs over the inlet and exhaust valve stems and Install washers, valve stem keys and caps using a suitable spring compressing tool. See Fig ure 2-20. Figure 2-21 .Cylinder Head Gasket (Note: Fire Ring Formed in Left Gasket) 1. Clean the cylinder block deck thoroughly. 2. Check cylinder sleeve height above the deck. (SeeFigure 2-31.)Install new cylinder head gasket on deck. NOTE Do not use a sealing compound or soak cylinder head gasket. 3. Check gasket position. Be sure that all passages are open and not blocked by the gasket. See Figure 2-22. Installing Cylinder Heads NOTE A fire ring is formed in the cyl inder head gasket when the cyl inder head is torqued on the cyl inder block; therefore, a new gasket must be used when instal ling the cylinder head. See Fig ure 2-21. 2-72 Figure2-22.Gasket and Cylinder Head Over Cylinder Block k 9. Install impeller lockwasher and nut and secure. THERMOSTAT The thermostat is located above and to the right of the injection pump. See Figure 2-91. Removal To remove the thermostat, first drain the coolant and then remove the outlet housing. See Figure 2-92. CASKET Figure2-92.Thermostat Housing Exploded View 121.10 TURBOCHARGER Preliminary Inspect external and visible internal areas for contamination or damage before install ing the unit on the engine. Check the con dition of the turbine and exhaust manifold mating flanges for uneven surfaces. The smooth surface is required to assure good gasket clamping for dependable sealing and for longer gasket life. Make certain that the air cleaner and air tubes are clean, to avoid restricted air flow. New hose connections and dependable clamps should be used and properly secured. 2-99 Insert the proper timing gear cover alignment sleeve in the cover, (J-26583 for 4.250 inch nominal O.D. oil seal, and J-24230, with handle J-8092, for 4.00 inch nominal O.D. seal). The sleeve also protects the seal when installing the timing gear cover. Install two suitable guide studs and position the timing gear cover on the engine using a new gasket. Install two timing gear cover screws, finger tight. Then tap the cover with a soft-faced hammer, using a straight edge to align the timing cover with the oil pan rail. See Figure 2-129. After timing gear cover has been aligned, remove the guide studs. In stall the remaining capscrews and torque to specifications. To adjust the thrust button, rotate the button clockwise until it is snug against the shaft, (camshaft and auxiliary shaft). Then back out the thrust button 1/4 turn and tighten jam nut. The resulting end-play will then be within specifications-. See Figure 2-130. Figure 2-129. Aligning Timing Gear Cover Figure 2-130. Positioning Thrust Button After thrust buttons have been ad justed, remove the centering sleeve. 2-194 Lubricate oil pump drive and driven gears and mount the oil pump assembly to engine. See Figure 2-150. back lash between gears to make certain that gears are not tight. Place new gasket on oil pump inlet tube flange and assemble to oil pump. See Figure 2-151. Figure 2-150. Assembly of Oil Pump to Engine Assemble the oil pump mounting screws and torque to specifications. Check Figure 2-151. Assembling Oil Pump Inlet Tube To assist in readily identifying the different cap and spring combinations, refer to Table 4. TABLE 4 OIL PRESSURE RELIEF VAVLE CAP AND SPRINGS (In Oil Pump) TYPE OF FILTERING SYSTEM By-Pass Filter Full-Flow By-Pass (Pre-ESI) ESI (With 100 PSI Oil Pressure Gage in Cab) ESI (With 150 PSI Oil Pressure Gage in Cab) ESI Plus RELIEF VALVE CAP * RELIEF VALVE SPRING SPRING INSPECTION LIMITS 226GB121 572GC11 25.0 lbs.+ 1.8 lbs. at 2-3/4 in. 226GB122 572GC114 40.0 lbs.+ 4.0 lbs. at 3-5/64 in. 226GB147 572GC114 40.0 lbs.+ 4.0 lbs. at 3-5/64 in. 226GB122 572GC114 40.0 lbs.+ 4.0 lbs. at 3-5/64 in. 226GB122 572GC114 40.0 lbs.+ 4.0 lbs. at 3-5/64 in. * The last three digits of the part number (such as "121") are stamped on the end of the cap for identification. 2-201 CYLINDER HEAD Make certain that cylinder head as sembly is in satisfactory condition. (Refer to "Cylinder Head Recondition ing Procedure" on Page 2-225 .) Assemble the correct type of cylinder head gasket to engine. The "foldedsteel" type gasket is used with the "flat-flange" type cylinder liner, and the "Maxidyne" type is used with the beaded-flange type liner. See *1 Page 2-155. All gaskets are pre-coated and do not require any type of sealing com pound . Assemble gasket in cylinder block lo Figure 2-155. Oil Pan for ESI-Plus cating gasket over guide pins. Make Engines (51 Quart Capacity) cerain that surface of gasket marked "Top" is on the top side. With the NOTE "Maxidyne" type gasket, carefully fit a new fire ring over the circular Because of the low mileage bead on each cylinder liner flange. normally incurred with on See Figure 2-156. A.-. and off highway type vehic les, and also because of ground clearance problems, the new "ESI-Plus" engines are not used in models such 5^' as the DM600 or 800, DMM, RD,RM and MB. Basic Engine Assembly - Oil Pan Applications v . Current Basic Engine Assemblies (for . >i Service) are built with the 28 quart capacity oil pan which is required ,tfr for ESI engines. When this assembly is used to replace an engine not hav ing ESI features, it is recommended Figure 2-156. Installing Maxidyne that the ESI retrofit kit be in Fire Ring stalled. Position the cylinder heads (com If the original oil filter arrange pletely assembled) over the cylinder ment is retained, there are two block, locating the guide holes in options: the head over the pins in the cylin der block. See Figure 2-157. 1. Use the new oil pan and add 9 quarts of oil to provide proper If engine has cylinder head studs, oil level in the 28 quart pan. check for condition of threads and straightness of shank. Apply a light 2. Use oil pan from replaced engine, coat of lubricating oil to threads of (19 quart capacity). studs and install * them in cylinder block finger tight, then back off 1/3 If an "ESI-Plus" engine is being re turn. Apply a light coat of oil to placed, the 28 quart capacity oil pan cylinder head stud washers and nuts on the new assembly must be replaced and install in position and hand by a 51 quart capacity oil pan. tighten. 2-203 6. Continuing adjusting valve lash for the remaining cylinders, in fir ing order, placing each piston at TDC with respective turning of the engine crankshaft. NOTE Engines equipped with the Hack Dynatard* engine brake system will have hydraulic valve lash adjusters in the exhaust rocker arms. Adjust exhaust lash (cold static) using special exhaust valve adjusting tool UVT-36-6. When using tool press down ward with hand on exhaust valve adjuster so that the internal clearance in the ad juster is eliminated. Fail ure to press down on the ad juster will result in unsat isfactory engine performance and unsatisfactory perform ance of the engine brake. The MVT-36-6 Exhaust Valve Adjusting Tool is available from: Automatic Aids 1618 Willow Avenue La Mott, Philadelphia, Pennsylvania 19126 For a detailed explanation of the en gine brake operation, refer to "Dyna tard Engine Brake" section. CYLINDER HEAD COVER Check cylinder head covers to make certain that mounting surfaces are flat and clean. Also make certain that gasket surfaces are dry and free from dust. Apply a thin layer of "Scotch Grip" 3M Co., No. 1711, (or equivalent) contact-type cement to both cover mounting surface and gasket. Let stand for several minutes then assem ble adhesive side of gasket to cover. Allow several minutes for gasket to bond to cover, then assemble covers to engine. Torque capscrews to spec ifications. See Figure 2-167. Figure 2-167. Torquing Cylinder Head Cover Capscrews NOTE Use of the adhesive between the cover and the gasket will prevent the gasket from sque ezing out from under the cover. Cylinder Head Cover (with Mack Dynatard Engine Brake) There are two types of terminals assembled to the cylinder head cover. Type No. 1 has a spring steel strip (approximately 3/8 inch wide) which contacts the terminal on the center valve rocker arm shaft bracket. Type No. 2 has a circular contactor spring (approximately 1-5/16 inch in diameter). The circular spring eliminates the need to position the contactor in the horizontal plane. Type No. 1 Assembly (Non-Current) 1. Assemble insulating washers and/or insulating adapter in terminal hole in cylinder head. See Figure 2-168. 2. Position strip on terminal in cylinder head toward center of engine so that it will come in contact with terminal on center valve rocker arm shaft bracket. Use Loctite and torque nut as specified in Figure 2-168. 3. Loosen nuts holding center screw and adjust screw to obtain dimension shown in Figure 2-168. 2-208 12 To correct this condition, clean the contact surfaces with emery cloth. See Figure 2-170. 1. Terminal 2. One Drop Loctite 242 3. Cylinder Head Cover 4. Bracket 5. Terminal 6. Torque 15-17 lbs. in. Figure 2-168. Engine Brake Terminal Arrancement (End View) Non-Current 4. Position terminal blade length wise, tighten upper nut, and apply Loctite as shown in Figure 2-169. NOTE When tightening nuts on term inal make certain that ad justing screw and terminal strip are not moved out of position. 5. Apply gasket to cover with adhe sive and assemble cover to engine as previously described on Page 2-208. NOTE Poor Dynatard engine brake performance can result from any film or residue on the contact surfaces of the en gine brake terminals and switch, which prevents ade quate current flow to operate Dynatard engine brake. 1. One Drop Loctite 290 After Assembled 2. Lockwasher 3. Insulator 4. Cylinder Head Cover 5. Terminal Blade Figure 2-169. Engine Brake Terminal and Solenoid Arrangement (Side View) Non-Current Figure 2-170. Contact Surfaces to be Cleaned Type No. 2 Assembly (Current) Assembly arrangement of engine brake terminal parts is shown in Figure 2-171. 2-209 m ..ijj KAMrt 1. Nut 8. Contactor 2. Lock Washer Spring 3. Terminal Blade 9. Lock Washer 4. Lock Washer 10. Cylinder Head 5. Plain Washer Cover Boss 6. Nut 11. Adapter(Brass) 7. Screw 12; Insulator (Nylon) Figure 2-171. Engine Brake Terminal Parts Arrangement Current To assemble terminal, proceed as fol lows: its-toi 1. Apply one drop of Loctite 290 in threads after assembly. (Three Places). 2. Apply Permatex No. 2 to joint between nylon insert and screw. Figure 2-172. Engine Brake Terminal Assembly Arrangement (End View) Current VALVE LIFTER COVER Check valve lifter covers for flat ness. Use new gaskets and assemble front and rear valve lifter covers. See Figure 2-173. 1. Assemble contactor spring to screw with lock washer and nut. Tighten nut. 2. Install the adapter into the cyl inder head cover boss, using sealant as specified in Figure 2-172. 3. Assemble screw through the adap ter insulator, using sealant. Adjust to dimension as shown in Figure 2-172. 4. Assemble flat washer, lock washer and nut (with sealant) on top side of screw to lock screw at dimension shown in Figure 2-172. Tighten nut. 5. Assemble terminal blade, lock washer, and nut (with sealant), as shown in Figure 2-172. Tighten nut. 2-210 Figure 2-173. Assembling Valve Lifter Covers NOTE If any instruction plates are fastened to the original valve lifter cover, make certain that they are replaced when rebuilding engines. lii INJECTION PUMP (American Bosch and Robert Bosch) Bar the engine, in normal direction of rotation, until the number 1 cyl inder is on the compression stroke, and the damper and/or flywheel timing mark indicates correct number of de grees BTC as specified on instruction plate attached to engine. Coupling Ring Drive Arrangement Grease front (non-counterbored) face of coupling ring and mount on pump driveshaft flange, with long end of offset indexing pin pointing rear ward, and center the coupling ring laterally. See Figure 2-177. Figure 2-177. Assembling Coupling Ring Assemble the injection support mounting bracket to the injection pump capscrews. pump upper (where used) and tighten Rotate the pump coupling drive flange until the indexing hole is in-line with the pin on the coupling ring. See Figure 2-178. Position new gasket to injection pump mounting surface and mount pump as sembly to engine. As pump moves into position, indexing pin can be observ ed through adapter inspection hole. See Figure 2-179; Figure 2-179. Installing Injection Pump Assemble the injection pump mounting capscrews to cylinder block and tighten. Assemble the injection pump lower support bracket to the cylinder block and tighten screws lightly. Install and tighten the capscrew connecting the upper and lower support brackets. Then tighten the lower support brac ket to cylinder block screws. Celeron Coupling Drive This drive arrangement includes a multiple-tooth type drive shaft in stead of the tang-type. There is a locating pin in the space between two teeth on the drive shaft to mate with a notched out tooth on the injection pump coupling. This method is used to provide proper timing alignment of the drive shaft with the Celeron coupling. 2-212 TACHOMETER DRIVE ASSEMBLY Figure 2-183. Fuel Transfer Pump Mounted to Injection Pump There are two types of tachometer drive assemblies in use. One assem bly is used solely to drive the tach ometer, while the other is a combina tion fuel transfer pump and tach ometer drive. (The combination drive assembly is covered in the preceding section of this manual.) Lubricate tachometer shaft and gear. Install tachometer drive assembly in cylinder block, using new gaskets and flat washers under mounting cap screws. Tighten capscrews. See Fig ure 2-185. Figure 2-184. Combination Fuel Transfer Pump and Tachometer Drive This unit is assembled at the tach ometer drive hole location. Lubri cate shaft and gear. Always use a new gasket when installing pump. Use flat washers and capscrews for secur ing pump to block. Tighten cap screws. Figure 2-185. Installing Tachometer Drive Assembly Assemble fuel inlet line to transfer pump inlet. NOTE For complete details on the two types of transfer pumps, refer to the "Fuel Section" in this manual. 2-214 A exhaust manifold After checking exhaust manifold for restrictions, cracks or wear, assem ble on cylinder head exhaust manifold mounting studs, using new gaskets. Position plain washer and nut locking tab over studs, and assemble nuts to studs. Torque nuts to specifica tions. See Figure 2-190. CAUTION Failure to use the proper gasket could result in insuf ficient oil pressure, and cause engine damage. NOTE If in doubt as to the proper gasket, refer to the in structions for installation of service blocks, which is included in this manual. See Page 2-275. Assemble housing to cylinder block using lockwashers and capscrews. Snug capscrews. Install two new 0-rings on top coun terbore of housing. See Figure 2-192. Figure 2-190. Torquing Exhaust Manifold Stud Nuts After nuts are torqued, bend locking tab to secure nut. One-half of tab is bent against flat on nut and the other half is bent against side of manifold flange. OIL PRESSURE RELIEF VALVE Refer to "Lubrication System" on Page 2-256 for correct oil pressure relief valve housing. Align gasket on mounting flange of relief housing to ensure that proper gasket is used. See Figure 2-191. Figure 2-192. Installing 0-Rings Assemble capscrews through lube oil fitting into oil filter adapter, and into oil pressure relief valve hous ing. Snug capscrews. Figure 2-191. Checking Oil Pressure Relief Valve Housing Gasket After the oil cooler, oil filter fit ting, oil filter adapter, valve hous ing, and oil inlet tube are in posi tion, make certain that all capscrews are "snugged". Then tighten screws to specifica tions. Start with oil pressure re lief valve housing mounting screws. Then tighten cooler water inlet fit ting to water pump screws. Finally, tighten all remaining screws and hose clamps. 2-217 OIL COOLER Make certain that oil cooler is in satisfactory condition. (Refer to "Oil Cooler Rebuild" on Page 2-246.) Assemble the oil cooler and oil fil ter lube oil fitting to the oil cool er, using a new O-ring gasket. Snug capscrews. WATER PUMP Make certain that watefr pump is in satisfactory condition. (Refer to "Water Pump Rebuild" on Page 2-250.) Assemble water pump to cylinder block using new gasket. Install capscrews and lockwashers, and torque to scificatlons. See Figure 2-194. Assemble thermostat by-pass tube, hoses, and clamps, at the cooler water inlet fitting. Assemble oil cooler to engine, using new gasket between cooler inlet fit ting and water pump. Snug capscrews. See Figure 2-193. Figure 2-193. Assembling Oil Cooler to Engine Assemble oil cooler oil inlet tube to cooler, using new O-ring. Before fastening inlet tube to cooler, lub ricate O-ring in oil filter fitting and insert tube into fitting. Snug capscrews. Figure 2-194. Water Pump Installation WATER MANIFOLDS Non-Intercooled Engines Inspect the water manifolds for re strictions, cracks, and flange wear. Assemble hose and clamps at center section of front inlet manifold. Us ing lockwashers, proper length cap screws, and new gaskets, assemble manifold to engine. Assemble rear water manifold to engine and tighten all capscrews. Position hose to suitable cover front and rear section for proper clamping area. Tighten hose clamps. Intercooled Engines On intercooled engines assemble rear section of water outlet manifold after intercooler manifold is in position. Use new gaskets and rubber hose connection. Tighten capscrews to specifications. Tighten hose clamps. See Figure 2-195. '4 '4 *T~ '^ 3 3 ytM* NOTE The snugged capscrews are tightened when the oil pres sure relief valve housing is assembled to the engine. This will permit alignment of all connecting parts. i 2-218 Figure 2-195. Assembling Rear Water Outlet Manifold C` ' INLET MANIFOLD Check inlet manifold to make certain flanges are flat and there are no cracks or foreign material in mani fold. NOTE On engines equipped with tur bochargers , assemble turbo oil feed line to oil filter adapter before assembling in let manifold. INTERCOOLER AND TIP TURBINE FAN (ON ENGINES SO EQUIPPED) The intercooler assembly is designed to remove heat from the turbocharged air by air after cooling. The assem bly consists of a tip turbine fan, air flow valve, intercooler header, intercooler manifold, and intercooler core. See Figure 2-196. To install the intercooler manifold, assemble two locating guide pins to the cylinder head to help in posi tioning manifold. Assemble gasket over guide pins and position inter cooler manifold over pins. Install mounting capscrews. Remove guide pins and replace with capscrews. Tighten all capscrews to specifica tions. See Figure 2-197. CAUTION If turbocharger oil feed check valve is in system on ESI engines, it should be re moved, since field tests in dicate it is not required. Assemble intercooler manifold support bracket to cylinder head studs with three plain washers and capscrews. Snug capscrews. Assemble two plain washers and capscrews to intercooler manifold and snug capscrews. Finally tighten all capscrews to specifica tions . Position lockwasher on capscrew and insert in flange holes. Using new gaskets, assemble manifold to engine. Tighten capscrews to specifications. ~Y Visually inspect the bond between the upper and lower gaskets of the inter cooler core. Make certain that gas ket is firmly attached all the way around. If any gaps are found, fill with Silastic compound. Also check the vertical end seals. If they are damaged, they must be replaced. See Figure 2-198. NOTE Some installations use a "Patch-Lock" capscrew for mounting the inlet manifolds. With these screws, lockwashers are not required. On intercooled engines, assemble rear half of inlet manifold after inter cooler header is in position. Use new gaskets and rubber hose connec tion. Tighten capscrews to specifi cations. Tighten hose clamps. For detailed procedure in assembling gaskets to intercooler core, refer to rebuild section in this manual. CAUTION If intercooler core gasket is not properly sealed, lack of air boost pressure and low power can result. Also dirt could be entering past seals, causing premature engine damage. 2-219 To prevent gasket sticking to mani fold, wipe the manifold and gasket surfaces with talcum power or Dow Corning 44 silicone grease before installiQg core. DO NOT use petroleum base grease or oil for this purpose. install the core in the manifold as indicated by the air flow arrows. See Figure 2-199. Attach cross over tube to inlet mani fold using new hoses. Tighten clamps. Assemble rubber hose to tip turbine fan air inlet and position fan to in tercooler manifold. 2-201. See Figure NOTE If the directional air flow arrows are missing, install the core with the wide fins toward the tip turbine fan. Figure 2-201. Assembling Tip Turbine .Fan Assemble rubber hose to air outlet on intercooler header. Tighten hose clamps. Tighten hose clamps. Tight en V-band clamp to specifications. Assemble intercooler header on mani fold and tighten capscrews and center stud nut to specifications. See Fig ure 2-200. There are two basic types of tip tur bine fans in use. Initial production tip turbine fans had a separate air valve assembly and an oil feed and oil return lice. See Figure 2-196. If this type is being replaced by the same type, make certain that the oil lines are reinstalled and the air valve assembly is installed properly. (The arrow on the valve assembly should be pointing towards the tip turbine fan.) Figure 2-200. Torquing Intercooler Header to Manifold Capscrews and Stud Nut The current production tip turbine fan uses permanently lubricated seal ed bearings, therefore, it does not require an oil feed or return line. Also, the air valve has been made part of the tip turbine fan assembly. See Figure 2-202. 2-221 THERMOSTAT install new thermostat seal in water outlet fitting using tool J-26637. See Figure 2-205. the valve should be located in the direction of the arrows. The ball checks are located so that they are unseated by the direction of coolant flow. Figure 2-205. Installing Thermostat Seal Using new thermostat and gasket, as semble fitting to water outlet mani fold. Attach hose from thermostat by-pass tube to water outlet fitting and tighten hose clamps. COOLANT CONDITIONER There are two basic types of coolant conditioner arrangements in use. Type I. - Engines equipped with 150F. (or 170F.) thermostats hav ing a higher opening temperature shutterstat. Type II. - Engines equipped with a 170F. thermostat and no shutterstat or a lower opening shutterstat. rigure 2-206 Type II Coolant Conditioner Adapter Engines equipped with the 170F. thermostat and no shutterstat (or an optional shutterstat which operates at a lower temperature), have an ex ternal coolant feed line. This sys tem eliminates the inlet check valve that was in the adapter. Instead, the inlet check valve is included with the water inlet fitting which is assembled into the adapter. When assembling adapter to thermostat housing, always use new 0-ring in check valve counterbore. See Figure 2-207. Type I With this arrangement, two ball check valves are assembled in the coolant conditioner adapter. The direction of the coolant flow into the adapter is indicated by cast arrows shown on top of the adapter. See Figure 2-206. Take note of the direction of the arrows so that check valves can be properly installed. The open end of Figure 2-207. Assembling Coolant Conditioner Adapter Before assembling coolant conditioner to adapter, apply a film of oil to the sealing gasket. Tighten con ditioner one full turn after gasket contacts adapter. 2-223 Figure 2-267 . Inspect Relief Valve Seat a. If the seat surface has burrs or nicks, it must be lapped. Place valve lapping compound on plunger seat. See Figure 2-268 . Figure 2-269 . Lapping Oil Pressure Relief Valve Seat 10. Remove driven gear with shaft from housing. See Figure 2-266 , (13). 11. Remove oil pump inlet flange cover and gasket from housing. See Figure 2-266 , (11 and 12). Figure 2-268 . Applying Lapping Compound b. Seat plunger in relief valve housing and oscillate. See Figure 2269. Inspecting the Oil Pump Housing NOTE <* After removing all parts from the oil pump housing, thoroughly clean the housing. Inspect the housing for scoring or other damage. If the housing is damaged, it must be replaced. 6. Slide oil pump idler gear off shaft. See Figure 2-266 , (5). 7. Turn pump upside down and remove the oil pump driving shaft nut. See Figure 2-266 , (8). 8. Pull oil pump drive gear off of shaft. See Figure 2-266 , (7). 9. Remove driving gear key. Figure 2-266 , (9). See 1. Check the bushings in the oil pump housing for burrs, nicks, or cracks. See Figure 2-270 . NOTE The bushings are an integral part of the oil pump housing. If they are damaged, they must be replaced. 2-240 OIL COOLER REBUILD Oil Cooler Disassembly 1. Remove water inlet and outlet end caps. See Figures 2-287 and 2-288. 3. Scrape off end cover gaskets. See Figure 2-290 . Figure 2-287. Removing Water Inlet End Cap Figure 2-290. Scraping End Cover Gasket 4. Remove oil supply line gasket. See Figure 2-291. Figure 2-288. Removing Water Outlet End Cap 2. Remove bundle from housing. Figure 2-289. See Figure 2-291. Scraping Oil Supply Line Gasket 5. Remove 0-ring from housing. Figure 2-292 . See Figure 2-289 . Removing Bundle 2-246 Figure 2-292 . Removing 0-Ring NOTE Visually inspect the housing for cracks which could lead to a leak. If the housing is damaged, replace with new. 6. The oil cooler bundle should be checked for leaks by pressurizing with 80 PSI air pressure and submerg ing in water. If leaks develop, re place bundle with new. See Figure 2293. Figure 2-295. Installing 0-Ring 3. Spread Perma-Tex gasket sealer on inlet water flange before installing gasket. See Figure 2-296. Figure 2-293. Water Testing Bundle Oil Cooler Assembly 1. Lubricate 0-ring. 294. See Figure 2- Figure 2-296. Applying Gasket Sealer to Hou&ing 4. Install gasket on water inlet end of housing. See Figure 2-297. 2. Install 0-ring in groove at water outlet end of the oil cooler. See Figure 2-295 . 2-247 5. Spread Perma-Tex gasket sealer on top of gasket. See Figure 2-298. 7. Spread Perma-Tex gasket sealer on bundle end. See Figure 2-301. Figure 2-298 . Applying Gasket Sealer on Gasket 6. Install bundle. Tap last 1/2 inch with a soft-faced hammer to seat bundle past O-ring. See Figures 2299 and 2-300 . Figure 2-301. Applying Gasket Sealer on Bundle 8. Place gasket on bundle end. Figure 2-302. See Figure 2-299. Installing Bundle Figure 2-302 . Placing Gasket on Bundle 9. Spread Perma-Tex gasket sealer on top of gasket before installing the end cap. See Figure 2-303. ' c --.afr t r-v ! - Figure 2-300. Tapping Bundle into Housing 2-248 Figure 2-303. Applying Gasket Sealer on Gasket 18. Torque- pulley nut to 100 lb.ft. See Figure 2-334. 20. Place gasket on sealer making sure to line up the holes. See Figure 2-336. Figure 2-334 . Torquing Pulley Nut Figure 2-336. Applying Gasket 21. Position housing cover assembly over housing. See Figure 2-337. NOTE When torquing the pulley nut on the shaft, it is necessary to use a strap wrench to keep the pulley and shaft from turning while tightening the pulley nut. 19. Place gasket sealer on the gasket seating surface of the housing. See Figure 2-335. Figure 2-337. Positioning Housing Cover 22. Coat housing cover capscrew threads with sealing compound and tighten. See Figure 2-338 . Figure 2-338. Applying Sealer to Capscrews 2-255 cylinder head gaskets Two (2) types of cylinder head gaskets are currently being used during engine rebuild. The "folded-steel" type gasket (see Figure 11) is used with the "flat-flange" type cyl inder liner (see Figure 12). Figure 13. Maxidyne-Type Gasket (with Fire Rings) Figure 12. Flat-Flange Type Cylinder Liner Figure 14. Beaded-Type Cylinder Liner (4-7/8 In. Bore) The "Maxidyne-Type" gasket (consisting of a one-piece composition gasket and three (3) fire rings as shown in Figure 13 must be used with the beaded-type liners as shown in Fig ures 14 and 15. NOTE Before assembly of cylinder head, always check the circular grooves in the head surface di rectly opposite the liner bead. They must be 0. 008 in. deep and absolutely clean to assure a good fire ring seal. Figure 15. Beaded-Type Cylinder Liner (5 In. Bore-END707 and END711 Engines) CAUTION Always use new gaskets and fire rings when assembling engines. 2-281 OIL FILTERS Early engine models had by-pass type oil filters. The quantity of oil going through this type of filter is controlled by a metering orifice. See Figure 65. 1. Oil Pressure Feed Holes 2. Oil Drain Hole Figure 66. Top View of Oil Filter Pad Cover 1. Metering Orifice 2. Oil Inlet 3. Oil Outlet Figure 65. By-Pass Type Filter Figure 67. Bottom View of Oil Filter Pad Cover This filter used flexible lines for oil supply to filter and oil return to engine. The oil lines are connected to a cover which is as sembled to the oil filter pad on the left-hand side of the engine. Because of revisions that have been made to the cast contours of the pad on the current cylinder blocks, oil filter pad cover, 368GB29D, and gasket, 590GB1152B, must be used with a by-pass filter installation. See Figures 66, 67, and 68. 1H< Figure 68. Oil Filter Pad Cover Gasket CAUTION Failure to use the correct cover and gasket, on current cylinder blocks, will result in low oil pressure and possible engine damage. If the replaced engine has a full-flow by-pass type of filter, as shown in Figure 69 or a spin-on type filter, as shown in Figure 70, use the adapters or housings from the orig inal engine. 2-296 f t < * Provisions have been made on both sides of the case to install buttress screws which fit into the main bearing cap. The buttress screws are used on both sides of all main bearing caps. They must be removed in order to remove the main bearing caps. Block Preparation 1. Check the cylinder block deck surface for warpage. If warpage is excessive be sure that the maximum amount of material removal limit is not exceeded. Figure 2-9 Cylinder Sleeve Bore Measuring Tool CAUTION The piston travel above the cylinder block deck is critical and must be checked during assembly to insure proper clearance of piston with cylinder head and valve. 2. Remove all core plugs and fittings from the cylinder block and remove any accumulation of rust and sludges. 3. Check block for cracks, the condition of threaded holes and the straightness of the mating flanges. 4. Thoroughly inspect the upper edge of the cylinder sleeve counterbore in the block for signs of pitting or errosion. Rework as required. Shims are available to obtain correct sleeve height at reassembly. 5. Blow all passages thoroughly with compressed air. 6. Coat new O-ring with sealant, place on core plugs and install plugs in block. 7. Install all oil gallery plugs and gaskets using Permatex sealant or equivalent to insure positive sealing. Cylinder Sleeve The cylinder sleeves are wet type, centrifugal cast iron and are available in standard size. A bead is provided around top of seating flange for using a fire ring type cylinder head gasket. Clean sleeve flanges using a brass wire rotary brush to be sure of effective fire ring sealing. Check cylinder sleeve for out-of-round and taper. Use tool J5347-01 and measure each sleeve I.D. See Figure 2-9. Take readings in two directions at each ofthree levels: top, center, and bottom. Check the sleeve height above the cylinder block deck. Use gage J26948. See Figure 2-10. Figure 2-10. Checking Sleeve Height Above Block Deck Honing If sleeve bore when in place does not exceed out-of-round and taper limit, clean up I.D. with a suitable hone, 150 to 220 grit, to produce a diamond criss-cross pattern surface finish of 25 to 40 micro-inch rms. Wash liner bore with a solution of household laundry detergent and air blow dry. Wipe liner bore with a clean oil soaked cloth. Sleeve Rebore If sleeve exceeds out-of-round and taper limit, the sleeve may be resized using boring bar equipment to receive the next applicable oversize piston. After re-sizing, hone 150 to 220 grit to produce a diamond criss-cross pattern surface finish of 25 to 40 micro-inch rms. 2-321 Figure 2-13.InstallingCylinder Sleeve Figure 2-14. Installing Camshaft Bushing CAUTION If for any reason the sleeve is backed out even as little as 1/8 inch, it may roll the top seal over the relief edge damaging the seal. Remove sleeve and replace seals. 8. Secure cylinder sleeve in pairs using keeper washer and capscrew at center cylinder head capscrew hole until pistons, rings and cylinder heads are installed. Expand the front oil gallery plug to offer resistance upon entering bore. The front oil gallery plug is further secured by installing the camshaft thrust washer which partially covers the plug. Paichlock countersunk Allenhead capscrews are used to secure the thrust washer in place. It is imperative that the mating surfaces be clean and new Paichlock screws are used. See Figure 2-15. Camshaft Bushings There are two camshaft bushing widths. The front camshaft bushing is the wider bushing; the remaining bushings are of a narrower width. All bushings are located at set distances measured from the forward machined surface of the camshaft thrust washer recess to the forward edge of subsequent bushing. Use special tool kit J-21428 to install or remove bushings. Coat outer surface of the bushings with engine oil before installation. The oil supply hole in the bushing should be located to the right as viewed from above and standing to the rear of the engine. The camshaft bushing interlocking split should be installed upward. See Figure 2-14. Figure 2-15.Installing Camshaft Thrust Washer NOTE The rear camshaft bushing can be removed, using special tool J-21385, without removing the flywheel housing. Apply a coat of Permatex to the rear oil gallery plug and gasket and install in rear oil gallery. See Figure 2-16. 2-323 4. Remove front bearing retainer and drive front bearing and spacer from housing out through the front. 5. Reverse housing and drive rear bearing from housing out through the rear. Inspection 1. Inspect the water pump drive gear for wear pattern and condition of teeth. 2. Inspect and check shaft for journal wear and condition of internal spline. 3. Inspect and check condition of the bearings. Assembly 1. Install front bearing (double row ball bearing) in housing from the front. 2. Install retaining ring, tapered side outward, in housing groove. 3. Start water pump drive gear and shaft assembly into the bearing bore. Do not completely install. 4. Rotate gear and tap with a soft face hammer until gear rotates concentric with the bearing. 5. Press gear and shaft assembly into bearing until it bottoms on shoulder on shaft. 6. Invert housing and gear and install spacer. 7. Install rear bearing with seal side outward in housing. 8. Clamp assembly in a suitable clamping fixture to hold gear and install water pump drive shaft screw. Tighten to recommended torque. 50 lb. ft. 9. Install O-ring in the groove on outer periphery of the housing. 10. Lubricate O-ring seal generously and install drive assembly in cylinder block recess with flat side of housing toward camshaft gear. NOTE It is important to generously lubricate O-ring seal before installing in block. This will prevent the O-ring from rolling on upper surface and restricting oil supply to the water pump bearings. 11. Install three water pump housing capscrews securing assembly in position. Tighten to recommended torque. 26 lb. ft. TIMING GEAR COVER Inspection Inspect timing gear cover for dents, condition of threaded holes and straightness of flanges. Installation 1. Install crankshaft front oil seal into the cover using tool J-21375. 2. Install the adjustable camshaft thrust button from the inside and position the washer and jam nut on the outside of the cover. 3. Adjust camshaft thrust button to its retracted position. 4. Install six guide studs. Two guide studs are used at the lowest point, highest point and one adjacent to the water pump drive and the final stud adjacent to the drive provision directly opposite the water pump drive. 5. Install the timing gear gasket over guide studs. 6. Install the timing gear cover over the guide studs and push cover into position. 7. Install all cover capscrews loosely. 8. Install water pump drive alignment tool J-21382 and crankshaft oil seal alignment tool J-21381. Torque all capscrews. CRANKSHAFT VIBRATION DAMPER AND HUB Inspection 1. Inspect crankshaft vibration damper hub for scoring, condition of flange, threaded holes and keyway. 2. Inspect the vibration damper for general condition, mounting threaded holes and housing. Installation 1. Position crankshaft keyway UP and install key. 2. Heat crankshaft vibration damper hub in hot oil to 250 degrees F. 3. Align crankshaft hub on key and install hub. See Figure 2-49. 2-341 2. Inspect and check the bolt holes for elongation and baffle for security. 3. Inspect and check drain hole for condition of threads. Installation 1. Position gasket on oil pan and position oil pan on cylinder block. 2. Install and tighten oil pan retaining capscrews evenly to prevent oil leakage. AUXILIARY DRIVE ASSEMBLY NON-CURRENT (Figure 2-50) Prior to following: Engine ENDT(B)865 ENDT(B)865C ENDT(B)866 ENDT(B)866C Serial Number TB865 5F 9380 T865C 5M 5045 T866 5F 8981 T866C 5M 4357 t 7t * Not required on Current Production Engines Figure 2-49. Vibration Damper and Hub Arrangement 4. Install hub washer and retaining screws. Torque screws. 5. Install vibration damper, spacer and timing disc on crankshaft hub; the holes will only line up one way. 6. Install retaining capscrews securing assembly. NOTE When all parts are assembled on the crankshaft, keyway up, the scribe mark on the damper rim must be up. The TDC mark must align with the timing indicator 30 degrees to the left of the engine centerline. OIL PAN Inspection 1. Inspect oil pan for dents, cracks and condition of flange. Figure 2-50. Auxiliary Drive Assembly Description The auxiliary drive is a complete unit sub-assembly located between the cylinder heads on the front of the engine. The auxiliary drive consists of a drive housing, idler shaft and gear assembly and drive shaft. It is gear driven from the camshaft. DRIVE HOUSING Description The auxiliary drive housing is an alloy casting and supports the drives for the injection pump, air compressor, tachometer drive and hydraulic steering pump. Installation 1. Time auxiliary drive to camshaft gear. Install both push rods in No. 6 cylinder location. Bar engine over until movement is felt in both push rods simultaneously and the timing indicator pointer indicates TDC for No. 1 and 6 cylinders. The single punch mark on the camshaft gear will be in the upright position. 2. Install O-ring in oil passage port at right hand front top edge of cylinder block. 3. Apply a bead of 243SX32 gasket compound or equivalent to mating surfaces of the auxiliary drive housing.. 4. Place auxiliary housing assembly on top of the block carefully. NOTE Be sure timing gear cover gasket is properly positioned and the single timing mark on the camshaft gear alignes with the single timing mark on the auxiliary drive gear. 5. Install all nine capscrews and washers hand tight. 6. Torque the two lower timing gear cover to auxiliary housing capscrews. 7. Torque all auxiliary housing to cylinder block capscrews. 8. Release the torque on the two timing gear cover to auxiliary housing capscrews then retorque the same capscrews. NOTE This procedure will align auxiliary housing to front face of the cylinder block and permit block surface to butt fully to mating surface of auxiliary housing. 9. Check backlash between camshaft gear and auxiliary drive gear. If backlash is not within limits, loosen auxiliary housing capscrews and reposition housing by tapping with a soft faced mallet. Retorque capscrews and recheck backlash. NOTE Care must be taken at this time to have all pipe plugs in the auxiliary drive oil gallery passages. Access to these plugs becomes increasingly difficult at later assembly points. VALVE LIFTER COVERS The center valve lifter cover is a steel stamping and requires a new gasket at assembly. The rear valve lifter cover is cast aluminum. At assembly apply a bead of gasket compound 243SX32 to the cover and cylinder block mating area. INJECTION PUMP Installation 1. Bar engine over in the normal direction of rotation until the No. 1 cylinder piston is at TDC, as indicated by the timing indicator, and the timing marks on the auxiliary drive shaft gear aligns with the timing mark on the auxiliary drive idler. The pin hole location will be at the five o'clock position and the coupling tangs are at 12 degrees 36 minutes off the horizontal. See Figure 48. 2. Bar engine back approximately 40 degrees. 3. Bar engine over in the normal direction of rotation until timing indicator reads the B.T.C. setting as specified on the injection pump name plate. In this position the tangs on the drive coupling will be approximately horizontal and the drive coupling pin hole will be approximately at the 4:30 o'clock position. The gear marks will be approximately 15 degrees 30 minutes to the right. See Figure 2-55. 2-345 NOTE End play is controlledby the drive shaft thrust washers. Check the following if the end play does not fall within the correct specifica tion. Make corrections as re quired. 1. Worn thrust washers. 2. Worn thrust journals. 3. Shaft bushings not properly installed. 1U-7* Figure 2-79. Auxiliary Drive Gear 13. Install auxiliary drive gear retaining ring. See Figure 2-80. INSTALLATION 1. Thoroughly clean the auxiliary housing mounting surface on the engine block and remove the exposed portion of the timing gear cover gasket. 2. Carefully cut a new timing gear cover gasket to. the exact size of the removed portion and install on the timing gear cover using a good grade gasket sealer. NOTE Apply an extra bead of gasket sealer where the new gasket meets the old gasket. 3. Install a new O-ring seal in the engine block to auxiliary oil supply port. 4. Apply a bead of Silastic to the mounting surface of the block. Use extreme care not to allow the Silastic to enter/block the oil supply port. See Figure 2-81. Figure 2-80. Installing Retaining Ring 14. Place the auxiliary housing on end and check end play with a dial indicator. Figure 2-81. Applying Silastic 5. Install the auxiliary housing on the engine block. 2-355 CYLINDER head installation NOTE New cylinder head gaskets and fire rings must be installed each time cylinder heads are removed. 1. Clean the cylinder block deck thoroughly. 2. Install new cylinder head gasket on deck. Position of gasket is determined by guide pins in the upper deck. NOTE Do not use a sealing compound or soak cylinder head gaskets. They are all pre-coated. 3. Install new fire ring carefully fitted over circular bead on cylinder sleeve flange. See Figure 2-102. 6. Install cylinder head on block. 7. Install fourteen cylinder head capscrews. 8. Torque capscrews on each head progressively in steps of 50 to 100 to 175, and finally to 225 lb. ft. in sequence as shown. See Figure 2-103. 105*7) Figure 2-103. Cylinder Head Tightening Sequence Figure 2-102. Cylinder Head Installation 4. Clean the surface of the cylinder head and ciruclar groove for the fire ring. 5. Carefully position the cylinder head assembly over the cylinder block deck aligning the guide pins in the block with the guide holes in cylinder head. PUSH RODS Description The push rods for the intake and exhaust valve rocker arms, are tubular steel with spherical ends. Engines not fitted with the Dynatard engine brake feature identical 1/2 inch O.D. x 14-17/64 " push rods; however, when the engine is fitted with the Dynatard engine brake system the exhaust valve rocker arm push rod is a solid steel rod 5/8 inch 0.D. x 14 inches long. Inspection 1. Inspect and check the push rods for length and straightness. Replace any that are bent. 2. Inspect and check the spherical surfaces for wear and tightness to tube. Installation Apply a light coat of lubricating oil to the spherical ends and install the push rods in the valve lifters. 2-363 4. Continue adjusting valve lash for the remaining cylinder pistons in firing order placing each cylinder piston at TDC with respective 1/4 turns of the engine crankshaft. 5. Properly secure aduusting screw locknut after each cylinder piston valve lash adjustment. INLET MANIFOLD Inspection 1. Inspect and check the inlet manifolds for restrictions. 2. Inspect and check mounting flanges for erosion, cracks and straightness. Installation 1. Place new gaskets between the inlet manifold and cylinder head. 2. Install right and left hand inlet manifolds and lifting eyes. Secure to cylinder head by installing attaching capscrews and tighten to the recommended torque. 3. Place a new inlet manifold fitting gasket on the top of each inlet manifold and install inlet manifold inlet fitting. 4. Install tee fitting and complete inlet manifold assembly. WATER OUTLET MANIFOLD Inspection 1. Inspect water outlet manifold for restrictions. 2. Inspect and check mounting flanges for cracks and straightness. Installation 1. Place new gasket between right bank and left bank water manifold and the mating cylinder heads. 2. Install and tighten attaching capscrews to the proper torque. 3. Install thermostats in the right and left bank water manifolds. 4. Install thermostat gaskets, water outlet fittings, thermostat seals and water outlet by-pass elbows. 5. Secure assembly to the water manifold by installing the attaching capscrews. 2-366 EXHAUST MANIFOLD Inspection 1. Inspect and check the exhaust manifold for restrictions. 2. Inspect and check the mounting flanges for erosion, cracks and straightness. Installation 1. Place new gaskets between exhaust manifold and cylinder head. 2. Install and tighten the attaching capscrews and washers to the proper torque. CYLINDER HEAD COVERS Inspection 1. Inspect and check the cylinder head covers for cleanliness, dents and straightness of flange. 2. Inspect and check breather in cover, if applicable, to be sure it is not plugged. Installation 1. Cement a new gasket to the mounting flange of the cylinder head cover. 2. Position the cylinder head cover over rocker arms. 3. Install and torque cover retaining capscrews. TURBOCHARGER Description The turbocharger is an exhaust gas driven air compressor. See Figure2-106The purpose of the turbocharger is to increase the supply of air to the cylinders and thus bum more fuel which in turn produces more power. flows around the turbine housing and radially inward causing the turbine wheel to rotate. The exhaust gas is then discharged through the center of the turbine housing into the exhaust pipe. The bearing housing contains the through-shaft, bearings, seals, and oil passages. The bearings are of the floating sleeve type and are pressure lubricated from the engine oil supply system. Piston ring type oil seals are used at each end of the shaft to effectively seal off the oil. The compressor housing contains the compressor wheel and air enters at the center of the compressor wheel and flows radially outward. intothe compressor wheel and flows radially outward into the compressor housing. The air leaves through a tangential outlet on the outside of the compressor housing and is ducted to the inlet manifold. Checks Before Removal If turbocharger malfunction is suspected, make the following checks before removal of turbocharger from the engine. Figure 2-106. Exhaust Driven Turbocharger The turbocharger consists of three main parts; the turbine housing, the bearing housing and the compressor housing. The turbine housing is located at one end of the bearing housing and the compressor housing is located at the other end. A common shaft connects the turbine wheel and compressor wheel. The turbine end of the turbocharger uses exhaust gas energy normally discharged to the atmosphere. The exhaust gas enters the turbocharger through the flange connection on the exhaust manifold. The exhaust gas 1. Start engine and check for unusual noise or vibration from- turbocharger. This will idicate out-of-balance, rubbing or damage to compressor or turbine wheels. 2. Check for leaks in the air system from turbocharger to intake manifold and from intake manifold to cylinder block. Be sure all bolts, clamps and connections are tight and gaskets are not blown and are in proper location. 3. Check air cleaner and air intake system, from the air cleaner to turbocharger, for restrictions to air flow or leaks. 4. Check exhaust system from cylinder block to turbocharger for exhaust leaks. Be sure all bolts, clamps and connections are tight and gaskets are not blown and are in proper location. 5. Check exhaust system from turbocharger to outlet for restrictions. 2-367 11. Place housing assembly on a suitable adaptor in vise and install hub retaining washer and locknut. See Figure 2-111. 12. Install grease vent. (Install auxiliary driveshaft extension, if removed). Figure 2-109. Installing Fan Drive Shaft V-8 Series 9. Invert housing on press stand and sup port coupling end of shaft on press base. Install long housing capscrew and lockwasher before installing fan drive pulley. 10. Install long key in shaft, align, and using a suitable tool to engage inner part of hub, press hub on shaft. See Figure 2-110. Figure 2-111. Installing Hub Retaining Washer and Locknut Installation 1. Place new gasket on housing and install housing, grease vent at top, aligning coupling with auxiliary driveshaft extension. 2. Assemble fan to hub. Be sure bolts are proper length, 3/8-16 x 7/8 inch. CAUTIONNJ Longer bolts will engage inner member and cancel out vibration absorbing effect of elastic insu lator and shorten service life of fan drive assembly. 3. Install fan belt. Refer to Fan Belts for proper tensioning. 2-371