SECTION 2.

05
CRANKCASE COMPONENT REMOVAL

PISTON/CONNECTING ROD REMOVAL Do not cut down into the

ring travel zone when re-
moving the carbon ridge from the cylinder sleeve
bore. Disregarding this information could result in
This procedure is a two person operation. To product damage.
perform this procedure alone is dangerous and can
result in severe personal injury or death. 2. Use a suitable carbon scraper to remove carbon
ridge from cylinder sleeve bore (see Figure 2.05-2).
Ridge is confined to area above upper range of top
Remove only one piston piston ring travel.
and connecting rod as-
sembly at a time. Removing more than one cylinder
may cause damage to equipment. CARBON RIDGE

NOTE: Drain all engine oil before proceeding. Engine

coolant should already be drained.

1. Remove connecting rod cap (four ferryhead caps-

crews) (see Figure 2.05-1).

CAPSCREWS

Figure 2.05-2. Carbon Ridge

3. Install a piston puller (P/N 474019 -- 9-3/8 in. bore or

P/N 474018 -- 8-1/2 in. bore) onto piston crown (see
CONNECTING
Figure 2.05-3). Use a suitable refacing tool to unplug
ROD CAPS holes and clean hardened carbon from threads without
causing damage to bore. Install a lifting chain to piston
Figure 2.05-1. Capscrews -- Connecting Rod Caps puller.

To ensure removal of
the entire carbon ridge
and to avoid nicking or scratching the piston with
the carbon scraper, bar the engine over to move
each piston to its lowest point of travel.

FORM 6296 First Edition 2.05 -- 1

CRANKCASE COMPONENT REMOVAL

INCORRECT

PISTON
PULLER

Figure 2.05-3. Install Piston Puller

CORRECT

Each piston and connecting rod assembly weighs

approximately 90 lb. (41 kg). Use a suitable lifting
device and exercise caution during removal or
Figure 2.05-4. Piston/Connecting Rod Assembly
installation to avoid severe personal injury or death.

Do not allow the Connecting rods and

connecting rod to con- caps are matched sets.
tact the crankshaft after the bearing halves have Do not mix connecting rods and caps. Do not mix
been removed. Wrap a shop rag around the end of bearing halves. Tag bearing halves to identify them
the connecting rod to prevent it from scraping the during wear analysis. Disregarding this information
cylinder liner. could result in product damage.

NOTE: The piston slides out of the cylinder block with 5. Remove bearing halves from connecting rod cap and
relative ease until the lower part of the skirt reaches the connecting rod (see Figure 2.05-5 and Figure 2.05-7).
upper portion of the liner. At this point, the piston may
become cocked, causing it to bind in the liner. To prevent CONNECTING
this from happening, lightly jiggle the piston back and ROD
forth as it is raised.

4. Pull piston and connecting rod assembly out of

cylinder block. Maintain correct angle (see
Figure 2.05-4).

BEARING

Figure 2.05-5. Connecting Rod

2.05 -- 2 FORM 6296 First Edition

 CRANKCASE COMPONENT REMOVAL

WAUKESHA
PART NUMBER

CYLINDER
LOCATION

CAP AND BLADE

MATCH NUMBERS
WEIGHT CLASSIFICATION
“A”, “B”, OR “C”

Figure 2.05-6. Connecting Rods

6. Install connecting rod cap to connecting rod. Verify
BEARING rod and cap are marked with same cylinder location
numbers (see Figure 2.05-6).

If the piston and connect-

ing rod are loose in the
cylinder liner, do not bar the crankshaft over more
than necessary. It is preferable to completely
remove the piston and connecting rod assembly
before barring over the engine. Disregarding this
information could result in product damage.
CONNECTING 7. Repeat procedure to remove remaining pistons and
ROD CAP connecting rods. Use engine barring device as neces-
sary when removing piston and connecting rod.
Figure 2.05-7. Bearing Cap
8. Remove any rod bearings that have fallen into oil
sump during removal process. Note original location
and tag each bearing.

FORM 6296 First Edition 2.05 -- 3

CRANKCASE COMPONENT REMOVAL

CYLINDER LINER REMOVAL 4. Repeat this procedure for each cylinder liner being
removed.

5. Remove upper and middle O-rings, and lower O-ring

from cylinder liner (see Figure 2.05-10).
The cylinder liner weighs approximately 63 lb.
(28 kg). Use the aid of an assistant, and exercise 6. Store cylinder liners upright on end.
caution during removal or installation to avoid
severe personal injury or death.

Ensure that all engine

coolant was drained be-
fore proceeding. Use proper procedures to ensure
that the oil sump is not contaminated with coolant.
Protect all electrical components to ensure coolant
does not enter. Disregarding this information could
result in product damage.
CYLINDER
NOTE: Piston and connecting rods should already be LINER
removed from the engine.

1. Mark cylinder liners parallel and perpendicular to

crankshaft (use grease pencil). These will be used as
reference points when measuring cylinder liner ID.

BOTTOM PLATE

CYLINDER Figure 2.05-9. Cylinder Liner Puller

LINER CYLINDER
LINER

GREASE
PENCIL MARK
Figure 2.05-8. Cylinder Liners

NOTE: Use the correct bottom plate for the Waukesha

cylinder liner remover. The 8-1/2 in. bore bottom plate is
P/N 494284 and the 9-3/8 in. bore bottom plate is
P/N 494286.

2. Install cylinder liner remover (P/N 499233) and pull

liner upward about 2 -- 3 in. (51 -- 76 mm) (see
Figure 2.05-9). Assembly can be lifted out by hand once
liner seal clears lower bore of crankcase. UPPER AND
MIDDLE O-RINGS
NEVER reuse a cylinder
liner that has been
dropped. A dropped cylinder liner can have unseen
damage resulting in severe engine damage.
LOWER O-RING
3. If cylinder liners are to be reused, mark each cylinder
liner with position it came from on engine; for example,
#2LB, #3RB, etc. During reassembly, a reused liner Figure 2.05-10. Cylinder Liner
must be installed in same cylinder position.

2.05 -- 4 FORM 6296 First Edition

 CRANKCASE COMPONENT REMOVAL

REAR PULLEY SPACER

PULLEY SLEEVE

SPACER (INSTALLED WITH

OPTIONAL FRONT PULLEY)

VIBRATION DAMPER

REAR CRANKSHAFT SPACER (INSTALLED WITH

PULLEY OPTIONAL FRONT PULLEY)

FRONT PULLEY (OPTIONAL)

FRONT PULLEY SLEEVE

END PLATE

Figure 2.05-11. Vibration Dampers/Crankshaft Pulleys

VIBRATION DAMPER REMOVAL

Do not pull the vibration damper past the ends of the

guide pins when installing lifting straps and lifting
This procedure is a two person operation. To device. Allowing the vibration damper to slide past
perform this procedure alone is dangerous and can the ends of the guide pins without proper lifting
result in severe personal injury or death. devices attached could cause severe personal
injury or death.
NOTE: Different combinations of pulleys and spacers
may be installed on the engine. Engine may have a stub 3. Attach lifting eyes to two threaded holes in vibration
shaft installed in place of front pulley. Remove all damper and a suitable lifting device to lifting eyes.
applicable components.
4. Ensuring vibration damper is against rear crankshaft
1. Remove three capscrews from 12, 9 and 3 o’clock pulley, remove remaining eight capscrews, washers,
positions on front pulley (see Figure 2.05-11). spacer, and front drive pulley from vibration damper.
2. Install three guide pins in 12, 9 and 3 o’clock 5. Using a suitable lifting device remove vibration
positions (guide pins may be fabricated from damper from crankshaft.
1/2 in.--13 x 6-1/2 in. capscrews). Capscrews must be
threaded approximately 2 in. (51 mm) on one end. 6. Remove three capscrews (7/8 in.--14 x 2-1/2 in.), lock
washers, washers, crankshaft endplate and crankshaft
front pulley sleeve from crankshaft.

The vibration damper weighs approximately 303 lb.

(137 kg). Use a suitable lifting device and exercise
caution during removal or installation to avoid
severe personal injury or death.

FORM 6296 First Edition 2.05 -- 5

CRANKCASE COMPONENT REMOVAL

FRONT GEAR COVER REMOVAL

The special removal tool (stop sleeve) must be

used, and the crankshaft endplate re-installed,
when removing the rear crankshaft pulley. This will This procedure is a two person operation. To
keep the crankshaft pulley from springing off the perform this procedure alone is dangerous. Failure
tapered sleeve during the removal process and also to use at least two people for this operation can
will separate the tapered sleeve from the pulley. result in serious personal injury or death. See other
Failure to follow this procedure could cause severe warnings and cautions at the beginning of this
personal injury or death. section.

7. Install stop sleeve (P/N 474005) on crankshaft end NOTE: Engine oil and coolant should already be
(see Figure 2.05-12). drained.

1. Remove capscrews, lock washers, two circular

STOP SLEEVE TAPERED covers and gaskets from gear housing cover (six
SLEEVE
capscrews per cover, 3/8 in.--16 x 7/8 in.) (see
CAPSCREW Figure 2.05-13).

6² DIAMETER
COVER PLATE

1/4²
MINIMUM

CRANKSHAFT
ENDPLATE
PULLEY

Figure 2.05-12. Crankshaft Pulley Stop Sleeve

8. Re-install crankshaft endplate and three capscrews

(see Figure 2.05-12).
5-1/4² DIAMETER
9. Using a puller and a portable hydraulic press, COVER PLATE
remove rear crankshaft pulley from crankshaft.
Figure 2.05-13. Gear Cover Plates -- Front Left
10. Remove puller and stop sleeve.
2. Remove six nuts, lock washers, cover and gasket
11. Remove tapered crankshaft pulley sleeve and
from rear left side of gear housing (see Figure 2.05-14).
crankshaft rear pulley spacer from crankshaft.

2.05 -- 6 FORM 6296 First Edition

 CRANKCASE COMPONENT REMOVAL

4. Remove 18 capscrews (1/2 in.--13 x 3 in.) from right

COVER and left sides of rear gear housing cover.

5. Remove 6 capscrews (1/2 in.--13 x 1-3/4 in.) and

washers from bottom flange of gear housing cover and
oil sump.

6. Remove 15 capscrews (1/2 in.--13 x 1-3/4 in.) and

lock washers from perimeter of gear housing cover.

Front gear housing cover weighs approximately

157 lb. (71 kg). Use a suitable lifting device and
exercise caution during removal or installation to
avoid severe personal injury or death.

7. Place lifting straps through upper right and left

Figure 2.05-14. Rear Gear Housing Cover -- Front Left
inspection holes and attach lifting device.

NOTE: There are dowel pins between the gear housing

and gear housing cover, these pins do not have to be
removed.
Always wear safety glasses when removing retain-
ing rings. Verify the correct retaining ring pliers is 8. Pry apart gear housing and cover.
used and it is in good condition. If the retaining ring
9. Using a lifting device remove gear housing cover
slips off the pliers when being installed or removed,
from gear housing.
it can be propelled with enough force to cause a
serious eye injury. Disregarding this information 10. Remove oil seal from front gear cover (see
could result in severe personal injury. Figure 2.05-16).

3. Remove retaining ring and ball bearing from acces-

sory (magneto) drive shaft (see Figure 2.05-15). FRONT OIL
SEAL

BALL BEARING ACCESSORY

(MAGNETO) DRIVE
GEAR SHAFT

Figure 2.05-16. Front Oil Seal

RETAINING
RING

Figure 2.05-15. Ball Bearing

FORM 6296 First Edition 2.05 -- 7

CRANKCASE COMPONENT REMOVAL

11. Remove O-ring and oil slinger from crankshaft end

(see Figure 2.05-17).

OIL
SLINGER

DRIVE SHAFT

Figure 2.05-19. Drive Shaft

4. Disconnect oil supply tube and remove six nuts and

CRANKSHAFT O-RING lock washers that secure magneto drive to front gear
housing (see Figure 2.05-20). Remove capscrews that
Figure 2.05-17. Oil Slinger And O-Ring secure support bracket.

MAGNETO DRIVE GEAR REMOVAL OIL SUPPLY TUBE

1. Remove key from shaft keyway.

2. Remove six capscrews and lock washers from drive

gear (see Figure 2.05-18).

SUPPORT NUTS AND

BRACKET LOCK WASHERS

Figure 2.05-20. Magneto Drive

CAPSCREWS

Figure 2.05-18. Magneto Drive Gear

3. Remove drive gear from shaft (see Figure 2.05-19).

2.05 -- 8 FORM 6296 First Edition

 CRANKCASE COMPONENT REMOVAL

IDLER GEAR REMOVAL CAMSHAFT GEAR REMOVAL

1. Bend back tab locks on idler gear capscrews (see 1. Loosen camshaft lock nut, and turn set screw until
Figure 2.05-21). contact with camshaft is made, then back out 1/4 turn so
cam is free to rotate (see Figure 2.05-23).
TAB LOCK
CAMSHAFT SET
SCREW

VALVE LIFTER
TAB LOCK HOUSING COVER

Figure 2.05-21. Lock Idler Gear Capscrews Figure 2.05-23. Valve Lifter Housing Plate

2. Remove two capscrews (1/2 in.--13 x 1-1/4 in.), NOTE: The lock washer is no longer required. Do not
capscrew locks and idler gear washers from each idler install the lock washer during assembly.
gear.
2. Bend back tab on washer that secures gear nut (see
3. Remove idler gears from idler gear spindles. Figure 2.05-24).

NOTE: Perform Step 4 only if required.

LOCK WASHER
4. Remove six Nyloc capscrews (3/8 in.--16 x 1 in.), ball
bearing retainer, front ball bearing, spacer and rear ball
bearing from idler gear (see Figure 2.05-22).

BALL BEARING
RETAINER

CAMSHAFT
GEAR NUT

Figure 2.05-24. Camshaft Gear Nut And Washer

NOTE: The engine may be prevented from rotating by

placing a clean shop rag between the camshaft and idler
gear teeth.

3. Remove camshaft gear nut.

Figure 2.05-22. Camshaft Idler Gear -- Upper 4. Using two threaded holes in camshaft gear install a
bar-type gear puller on to camshaft gear.

FORM 6296 First Edition 2.05 -- 9

CRANKCASE COMPONENT REMOVAL

3. Remove capscrews and lock washers from front of

valve lifter housing and front gear housing (see
Heated parts can cause serious burns. Use caution Figure 2.05-26).
when heating parts to prevent severe personal
injury or death.

Gears excessively
heated with a torch
should not be reinstalled. The nitrating on the gear
will not withstand the excessive heat generated by
the torch. Penetration of the case-hardening will
also result in brittle teeth leading to premature gear
failure. Uneven expansion also can lead to gear or
crankshaft damage during installation.
NOTE: The camshaft gear is shrink fit to the camshaft.
If required, apply heat to the camshaft gear to assist in
removal of the gear.
CAPSCREWS
5. Remove camshaft gear and key.
Figure 2.05-26. Valve Lifter Housing -- Front
FRONT GEAR HOUSING REMOVAL
NOTE: The gears, with the exception of the crankshaft 4. Remove 16 capscrews (1/2 in.--13 x 1-1/2 in.) and
and oil pump gear, must be removed before removing lock washers from front gear housing cover (see
the front gear housing. Figure 2.05-27).

1. Remove two capscrews and washers from bottom

CAPSCREWS
flange of front gear housing cover and oil sump (see
Figure 2.05-25).

OIL PAN CAPSCREW

Figure 2.05-27. Front Gear Housing

OIL PAN
Be careful not to bend or
damage the oil tubes
Figure 2.05-25. Oil Pan Capscrew when removing the front gear housing cover.

5. Pry front gear housing cover from crankcase and

dowel pins.
The front gear housing weighs approximately
6. Using a suitable lifting device remove gear housing
138 lb. (63 kg). Use a suitable lifting device and
from crankcase.
exercise caution during removal or installation to
avoid severe personal injury or death. 7. Remove gasket from crankcase and front gear
2. Attach lifting straps and lifting device to front gear housing.
housing.

2.05 -- 10 FORM 6296 First Edition

 CRANKCASE COMPONENT REMOVAL

ROCKER ARM OIL HEADER REMOVAL

VALVE LIFTER
1. Remove four capscrews (3/8 in.--16 x 1-1/2 in.), GUIDE
1/4 in. spacers and the rocker arm oil header (see
Figure 2.05-28).

ROCKER ARM
OIL HEADER

ROUND END

Figure 2.05-30. Previous Valve Lifter Guides

VALVE LIFTER
TUBE CLAMP GUIDE

Figure 2.05-28. Rocker Arm Oil Header

VALVE LIFTER HOUSING REMOVAL

The valve lifter guides and valve lifter housing on VHP
Series Four GSI engines has been redesigned. The new
lifter housing has slotted oil drains on every other lifter
guide mounting flange (see Figure 2.05-29).

FLAT END CAPSCREW

Figure 2.05-31. Current Valve Lifter Guides

The valve lifters may fall

out of the lifter guides
during removal. Use caution during removal to
prevent damage to the valve lifters.

NOTE: Return each valve lifter and lifter guide to its

original location facing in the proper direction. Always
SLOTTED
OIL DRAIN retain the established wear patterns to minimize roller
and cam lobe wear.
Figure 2.05-29. Valve Lifter Housing (P/N 200034E)
1. Remove 3/8 in.--16 x 1-1/8 in. capscrews and lock
Current valve lifter guides (P/N 153003D) have a washers that secure valve lifter guides to valve lifter
protrusion with a flat end, previous lifter guides had a housing.
round end (see Figure 2.05-30 and Figure 2.05-31).
Do not mix and match. New lifter guides must be used 2. Remove valve lifters from slotted lower bore of valve
with the new housing (P/N 200034E) and gaskets. lifter guides (see Figure 2.05-32). Remove lifter guide
gaskets.
NOTE: Replace all valve lifters if a new camshaft is
needed. Waukesha will not warrant the new shaft if used
followers are installed.

FORM 6296 First Edition 2.05 -- 11

CRANKCASE COMPONENT REMOVAL

VALVE LIFTER VALVE LIFTER

GUIDE ROLLER

Figure 2.05-32. Valve Lifter Guide Figure 2.05-34. Valve Lifter Housing

3. If not already removed, remove five ferryhead 6. Remove 3/8 in.--16 x 1-1/2 in. capscrews and lock
capscrews and lock washers from front flange of valve washers that secure valve lifter housing cover to
lifter housing (see Figure 2.05-33). crankcase (see Figure 2.05-35).

4. Remove two ferryhead capscrews, (3/8 in. x

1-1/2 in.) and lock washers from flanges of upper and
lower valve lifter housing covers (see Figure 2.05-33).

UPPER
HOUSING COVER

CAPSCREWS

Figure 2.05-35. Valve Lifter Housing -- Rear

SET SCREW
7. Carefully pry valve lifter housing from crankcase.
Figure 2.05-33. Valve Lifter Housing Cover
Valve lifter guides and
lifters must be removed
prior to Step 8, or severe engine damage may occur.

The valve lifter housing weighs approximately 8. Use a suitable lifting device remove valve lifter
198 lb. (90 kg). Use a suitable lifting device and housing from crankcase.
exercise caution during removal or installation to
avoid severe personal injury or death. 9. Clean gasket material from valve lifter housing and
crankcase mating surfaces.
5. Attach lifting eyes, lifting straps and a suitable lifting
device to valve lifter housing (see Figure 2.05-34). 10. Remove five capscrews and lock washers [3 ferry-
head capscrews (3/8 in.--16 x 1-1/2 in.) with lock
washers and hex nuts; 2 ferryhead capscrews
(3/8 in.--16 x 1-1/4 in.) with lock washers] and separate
front and rear sections of valve lifter housing (see
Figure 2.05-36).

2.05 -- 12 FORM 6296 First Edition

 CRANKCASE COMPONENT REMOVAL

3/8² X 1-1/4² CONNECTOR TUBE

FERRYHEAD CAPSCREWS FITTINGS

3/8² X 1-1/2²
FERRYHEAD CAPSCREWS

Figure 2.05-36. Valve Lifter Housing Assembly Figure 2.05-38. Valve Lifter Housing -- Rear

11. Clean gasket material from valve lifter housing front 14. Remove four capscrews, lock washers, lower valve
and rear sections. lifter housing cover and gasket from crankcase (see
Figure 2.05-39).
12. If required, remove cover. Loosen hex jam nut and
remove jam nut and set screw from rear face of valve
lifter housing (see Figure 2.05-37).

UPPER
HOUSING COVER

LOWER COVER

SET SCREW
Figure 2.05-39. Lifter Housing Lower Cover

Figure 2.05-37. Camshaft Set Screw

13. If required, remove two male connector tube

fittings. Remove tube fittings located at rear of valve lifter
housing (see Figure 2.05-38).

FORM 6296 First Edition 2.05 -- 13

CRANKCASE COMPONENT REMOVAL

CAMSHAFT REMOVAL 2. Remove 16 ferryhead capscrews and lock washers

from camshaft bearing caps (see Figure 2.05-42).
1. Remove thrust washer, shims and outer thrust ring
from camshaft end (see Figure 2.05-40 and
Figure 2.05-41). O-RING BEARING CAP

THRUST
WASHER

CAPSCREW

Figure 2.05-42. Cam Bearing Cap

Figure 2.05-40. Thrust Washer Do not mix or cross mate

the camshaft bearing
shells. Bearings are matched sets. Mixing the
THRUST RING camshaft bearings may cause damage to
equipment.

3. Remove camshaft bearing caps and bearings.

4. Remove and discard O-rings located at top of

camshaft bearing caps.

5. Mark position of bearing shells to aid in assembly.

Camshaft weighs approximately 114 lb. (52 kg). Use

a suitable lifting device and exercise caution during
SHIM
removal or installation to avoid severe personal
injury or death.
Figure 2.05-41. Shim Pack
6. Attach a suitable lifting device to camshaft and
Install the camshaft remove camshaft.
bearing caps in their
7. Remove lower camshaft bearing shells. Mark bear-
proper position. The camshaft bearing caps are
ing position to aid in assembly (see Figure 2.05-43).
marked for their proper location #1 -- #7 (front to
rear). The camshaft bearing saddles are precision
align bored with all camshaft bearing caps torqued
in place. Installing the camshaft bearing caps in the
wrong positions will result in camshaft bearing
and/or camshaft failure.

2.05 -- 14 FORM 6296 First Edition

 CRANKCASE COMPONENT REMOVAL

2. Remove 16 capscrews (1/2 in.--13 x 1-1/2 in.) and

lock washers from the rear flywheel housing section
(see Figure 2.05-45).

3. Carefully pry rear flywheel housing section from the

front flywheel housing section. Remove rear flywheel
housing section.

BEARING

Figure 2.05-43. Valve Lifter Housing Gasket -- Front

BARRING DEVICE REMOVAL

1. Remove barring device located on left front flywheel
housing (3 capscrews 5/8 in.--11 x 1-1/4 in. with lock
washers) (see Figure 2.05-44).
REAR FLYWHEEL
HOUSING

Figure 2.05-45. Rear Flywheel Housing

4. Attach flywheel lifting bracket, chains and a suitable

lifting device to the flywheel.

LIFTING
BRACKET

BARRING
DEVICE

Figure 2.05-44. Front Flywheel Housing -- Rear Left

FLYWHEEL REMOVAL

Rear flywheel housing section weighs approximate-

ly 107 lb. (49 kg). Use a suitable lifting device and
exercise caution during removal or installation to
avoid severe personal injury or death.
Figure 2.05-46. Flywheel Lifting Bracket
1. Attach a suitable lifting bracket, lifting straps and
lifting device to rear flywheel housing section. A lifting
bracket (see Figure 2.05-46) should be devised to
properly handle the flywheel.

FORM 6296 First Edition 2.05 -- 15

CRANKCASE COMPONENT REMOVAL

5. Remove two capscrews and lock washers from nine

o’clock and three o’clock positions (see Figure 2.05-47). CAPSCREW

9 O’CLOCK POSITION 3 O’CLOCK POSITION

Figure 2.05-48. Front Flywheel Section
Figure 2.05-47. Remove Flywheel
OIL PICKUP SCREEN REMOVAL
6. Install two guide pins 6 in. (152 mm) long, threaded
approximately 1/2 in. (13 mm) on one end, into the nine Do not bar over engine
o’clock and three o’clock positions. with the oil pickup screen
assembly loose in the crankcase. Failure to remove
the oil pickup screen assembly prior to barring the
engine over will cause damage to the connecting
The flywheel weighs approximately 878 lb. (398 kg). rods and crankshaft.
Use a suitable lifting device and lifting bracket, and
1. Remove capscrews and lock washers from oil elbow
exercise caution during removal or installation to
inlet flanges (2 capscrews per elbow 3/8 x 2 in. with lock
avoid severe personal injury or death.
washers) and pickup screen assembly (see
Figure 2.05-49).
7. Remove remaining flywheel bolts and washers.
2. Remove capscrews and lock washers from oil elbow
8. Using a suitable lifting device remove flywheel. outlet flanges (2 capscrews per elbow 3/8 in. x 1-1/8 in.
9. Remove guide pins. with lock washers) and the front of the oil pan.

3. Remove oil pickup screen assembly and elbows

from oil pan. Replace baffle if damaged.

The front flywheel housing section weighs approxi- 4. Separate baffle and oil pickup screen.
mately 202 lb. (97 kg). Use a suitable lifting device
and exercise caution during removal or installation 5. Remove oil tubes from screening element.
to avoid severe personal injury or death.
NOTE: Gasket material may stick to the oil pan surface
and oil pickup screen assembly as well as the oil elbow
10. Attach suitable lifting eyes, chains and lifting device
flanges.
to the front flywheel housing section.
6. Remove gaskets from the oil elbow inlet and outlet
11. Remove 14 capscrews 5/8 in.--11 x 1-1/2 in. and
flanges.
lock washers from front flywheel housing section (see
Figure 2.05-48). 7. Remove gaskets from oil tube flanges.
12. Carefully pry front flywheel housing section from
crankcase.

13. Using a suitable lifting device, remove front flywheel

housing section.

2.05 -- 16 FORM 6296 First Edition

 CRANKCASE COMPONENT REMOVAL

The oil pan weighs approximately 1790 lb. (812 kg).

Use extreme caution when removing this compo-
nent. Plan ahead on how this piece, as well as the
crankcase, will be handled. Make sure that the oil
pan is properly supported by blocks or cribbing.
Also make sure that properly rated lifting equipment
OIL and rigging are used. The crankcase weighs
ELBOW approximately 6793 lb. (3081 kg) with the crank-
shaft installed, but completely stripped of all other
components. If ANY components are still attached,
the crankcase will be heavier by the amount of the
GASKET
components weight. Failure to take adequate pre-
cautions can result in severe personal injury or
death.

Always lift the engine using the approved lifting

BAFFLE eyes. The 12 cylinder VHP Series Four engine is
equipped with two pairs of lifting eyes, one pair at
GASKET
the front, the other pair at the rear. Lifting eyes are
meant for lifting the engine only. They must not be
OIL TUBE used to lift driven or auxiliary equipment that may be
attached to the engine. Follow approved rigging
procedures. Always use the proper spreader bar to
ensure that no undue strain is placed on the lifting
eyes and hoisting chains. Disregarding this in-
formation could result in severe personal injury or
death.

1. Attach a suitable lifting device to lifting eyes located

on crankcase.

SCREEN NOTE: The front gear housing, along with two caps-
crews and washers that connect the bottom flanges of
Figure 2.05-49. Oil Pickup Screen Assembly the front gear housing to the crankcase, should already
be removed.
OIL PAN REMOVAL
2. Remove 28 capscrews and washers that secure oil
1. Ensure engine is positioned upright with oil pan pan to crankcase. These capscrew heads are located
supported on suitable blocks. inside the crankcase. They are accessible through side
access plates (see Figure 2.05-50).

Never raise the crankcase more than an inch or two

off the floor (except to remove it from the hot tank, Make sure that the crankcase lifts away from the oil
install it in the rollover stand or position it on the oil pan. Do not raise the crankcase if the oil pan
pan). While the block is suspended, do not put does not separate from the crankcase immediately
hands, arms, feet or any other body parts beneath it. as it is raised. The oil pan must stay in contact with
Stand back as far as possible and exercise extreme the supporting blocks or cribbing at all times.
caution. Disregarding this information could result Failure to take adequate precautions can result in
in severe personal injury or death. severe personal injury or death.

FORM 6296 First Edition 2.05 -- 17

CRANKCASE COMPONENT REMOVAL

This procedure is a two person operation. To

perform this procedure alone is dangerous. The
only recommended way to remove the crankshaft
from the crankcase is with an engine rollover stand
with the crankcase oriented so that the crankshaft is
on top. Use the proper attachment fixtures certified
to handle the weights involved with the VHP Series
Four engine. Failure to use at least two people for
this operation and a proper engine rollover stand,
and properly rated lifting and moving equipment
can result in severe personal injury or death. See
other warnings and cautions at the beginning of this
OIL PAN CAPSCREWS
(LOCATED UNDER FLANGE) section.

Figure 2.05-50. Bolt Holes In Engine Block

3. Carefully lift crankcase away from oil pan. Always lift the engine using the approved lifting
eyes. The 12 cylinder VHP Series Four engine is
4. Install crankcase onto suitable engine rollover stand. equipped with two pairs of lifting eyes, one pair at
the front, the other pair at the rear. Lifting eyes are
5. Remove oil pan seal (see Figure 2.05-51).
meant for lifting the engine only. They must not be
used to lift driven or auxiliary equipment that may be
LOCATING DOWEL
attached to the engine. Follow approved rigging
procedures. Always use the proper spreader bar to
ensure that no undue strain is placed on the lifting
eyes and hoisting chains. Disregarding this in-
formation could result in severe personal injury or
death.

Never raise the crankcase more than an inch or two

off the floor (except to remove it from the hot tank,
install it in the rollover stand or position it on the oil
pan). While the block is suspended, do not put
OIL PAN SEAL
hands, arms, feet or any other body parts beneath it.
Stand back as far as possible and exercise extreme
Figure 2.05-51. Oil Pan Seal caution. Disregarding this information could result
in severe personal injury or death.
CRANKSHAFT REMOVAL
1. Install crankcase in a suitable rollover stand. Orient
crankcase with crankshaft on top (see Figure 2.05-52).

The crankcase weighs approximately 6793 lb.

(3081 kg) with the crankshaft installed, but com-
pletely stripped of all other components. If ANY
components are still attached, the crankcase will be
heavier by the amount of the components weight.
Failure to take adequate precautions can result in
severe personal injury or death.

2.05 -- 18 FORM 6296 First Edition

 CRANKCASE COMPONENT REMOVAL

4. Crankshaft gear is a shrink fit to crankshaft. Apply

OIL PUMP GEAR heat to crankshaft gear to assist in removal. Remove
gear.

NOTE: Previous design crankshaft gears had threaded

holes.

5. Attach a bar-type puller to threaded holes in thrust

washer (see Figure 2.05-54).

6. Remove crankshaft gear from crankshaft.

7. Remove thrust washer, shims (if present) and outer

thrust rings from crankshaft end (see Figure 2.05-54).

NOTE: The pistons, connecting rods, and the oil pan

NUT
should already be removed.
Figure 2.05-52. Oil Pump Gear
THRUST WASHER FRONT MAIN
2. Remove nut and washer from oil pump gear bolt (see BEARING CAP
Figure 2.05-52).

3. Remove oil pump gear capscrew, gear and idler gear

spindle from front main housing (see Figure 2.05-53)
Separate capscrew, front washer and idler gear spindle.
If required, press out bushing from idler gear spindle.
Note position of recess on front washer.

FRONT WASHER WASHER NUT

DOWEL PIN

Figure 2.05-54. Crankshaft Gear Mount

The crankcase weighs approximately 6793 lb.

(3081 kg) with the crankshaft installed, but com-
CAPSCREW
OIL PUMP pletely stripped of all other components. If ANY
IDLER GEAR SPINDLE GEAR components are still attached, the crankcase will be
heavier by the amount of the components weight.
Figure 2.05-53. Oil Pump Gear Assembly The crankshaft weighs approximately 1828 lb.
(829 kg) with the counterweights attached. Each
main bearing cap weighs 46 lb. (21 kg). Use extreme
caution when removing this component. Plan ahead
on how this piece, as well as the crankcase it is
Heated parts can cause serious burns. Use caution attached to, will be handled. Make sure that the
when heating parts to prevent severe personal crankcase and the crankshaft are properly sup-
injury or death. ported and that properly rated lifting equipment and
rigging are used. Failure to take adequate precau-
tions can result in severe personal injury or death.
Gears excessively
heated with a torch
8. Remove four capscrews and lock washers from rear
should not be reinstalled. The nitrating on the gear
of lower oil retainer plate at rear of engine (see
will not withstand the excessive heat generated by
Figure 2.05-55).
the torch. Penetration of the case-hardening will
also result in brittle teeth leading to premature gear
failure. Uneven expansion also can lead to gear or
crankshaft damage during installation.

FORM 6296 First Edition 2.05 -- 19

CRANKCASE COMPONENT REMOVAL

CAPSCREWS AND Once the main bearing caps are removed, the
LOCK WASHERS engine rollover stand cannot be moved. If the
rollover stand is moved the crankshaft may fall from
the crankcase, causing severe personal injury or
death.

Main bearing caps weigh approximately 46 lb.

(21 kg). Use the aid of an assistant and use suitable
lifting devices when removing or installing the main
bearing caps or severe personal injury or death may
result.
LOWER OIL
RETAINER PLATE
Do not mix or cross mate
crankshaft bearing caps.
Figure 2.05-55. Lower Oil Retainer Plate The crankshaft bearing saddles are precision
matched with the caps (numbered 1 through 7, front
9. Remove two capscrews and lock washers from to rear). Installing the crankshaft bearing caps in the
flanges between upper and lower shells of oil retainer wrong positions will result in crankshaft bearing
plates. and/or crankshaft failure.
10. Remove lower oil retainer plate from crankcase.
While it is not recom-
11. Remove and discard seal from lower oil retainer mended to reuse bear-
plate (see Figure 2.05-56). Remove two cross-tie bolts ings, do not mix or cross mate the crankshaft
and washers from each main bearing cap. bearing shells if they are to be reused. Tag bearings
to ensure they are installed in the same position.
WICK TYPE SEAL Note the difference between upper and lower
bearings and differences in bearing width. Mixing
the crankshaft bearings may cause damage to
equipment.

12. Remove four lock nuts and washers from each main
bearing cap (see Figure 2.05-57).

MAIN BEARING CAP

Figure 2.05-56. Wick Seal

Figure 2.05-57. Main Bearing Cap

2.05 -- 20 FORM 6296 First Edition

 CRANKCASE COMPONENT REMOVAL

13. Remove main bearing caps and upper main When removing the
bearings from crankcase. Alternately pry up at end of crankshaft, be sure the
bearing caps. lifting straps distribute the weight of the crankshaft
14. Remove thrust ring from #1 main bearing cap (see evenly. The crankshaft should not be subjected to
Figure 2.05-58). Mark thrust ring using a tag for any excessive bending or flexing. Use care during
identification. handling and prevent scratching or marring the
machined surfaces, especially the connecting rod
and main bearing journals.
BEARING

17. Attach suitable lifting device to crankshaft.

18. Using suitable lifting devices, remove crankshaft

from crankcase and lower it to a suitable cradle (see
Figure 2.05-60).

THRUST RING

Figure 2.05-58. #1 Main Bearing Cap

15. Remove remaining inner thrust ring segment from

crankshaft (see Figure 2.05-59). Mark thrust ring using
a tag for identification.

Figure 2.05-60. Crankshaft

19. Remove main bearings from bearing saddles (see

Figure 2.05-61). Mark bearing shells with a tag for easy
identification.

BEARING
SADDLE

THRUST RING

Figure 2.05-59. Thrust Ring

16. Remove each main bearing. Mark bearings with a

tag for easy identification.

The crankshaft weighs 1828 lb. (829 kg). Use the aid
of an assistant and use suitable lifting devices when
removing or installing the crankshaft or severe
personal injury or death may result. BEARING

Figure 2.05-61. Bearings

FORM 6296 First Edition 2.05 -- 21

CRANKCASE COMPONENT REMOVAL

CRANKCASE COMPONENTS Use caution when heat-

ing the area around the
1. If required remove oil tubes from front of crankcase idler gear spindles. Applying too much heat could
(see Figure 2.05-62). cause damage to the crankcase or idler gear
spindle.
OIL TUBES
4. Apply heat to area around idler gear spindle.

5. Remove idler gear spindles from crankcase.

6. Remove five capscrews, lock washers and upper

retainer plate from crankcase (see Figure 2.05-64).

7. Remove seal from retainer plate (see

Figure 2.05-64).

SEAL

Figure 2.05-62. Oil Tubes

NOTE: A collet-type stud driver grips the threads of the

studs. This will prevent scratching and gouging of the
studs, causing weak spots to be created.

2. Using collet stud driver, remove main bearing studs

from crankcase (see Figure 2.05-63).

MAIN BEARING FRONT MAIN CAPSCREW AND UPPER RETAINER

STUDS BEARING SADDLE LOCK WASHER PLATE

Figure 2.05-64. Upper Retainer Plate

CRANKSHAFT #1 MAIN BEARING

REMOVAL IN FIELD CONDITIONS
NOTE: This procedure applies to the #1 main bearing
with current “T” Drilled crankshaft. Procedures for the
remaining main bearings are similar, with the exception
IDLER GEAR that steps to remove the oil pump, oil pickup screen and
SPINDLE NUTS oil pump drive gear, do not apply. Refer to “Crankshaft
Main Bearings Removal In Field Conditions” in this
Figure 2.05-63. Crankcase -- Inside Front section for procedures to remove the other main
bearings. Refer to Service Bulletin 5-2328F (or latest
NOTE: The idler gear spindle nut is a left-hand thread.
revision) for all previous crankshaft and bearing configu-
The idler gear spindle is a shrink fit to the crankcase.
rations.
3. If required, remove nut and washer from idler gear
spindles.

Each main bearing cap weighs 46 lb. (21 kg). The

bearing must be supported from underneath while
Heated parts can cause serious burns. Use caution removing or installing to avoid severe personal
when heating parts to prevent severe personal injury or death.
injury or death.

2.05 -- 22 FORM 6296 First Edition

 CRANKCASE COMPONENT REMOVAL

Do not subject the crank-

shaft to any excessive
bending or flexing. Keep high heat sources, such as
cutting torches and welders, away from the crank-
shaft. Use care during handling. Prevent scratching
or marring the machined surfaces, especially the
rod and main bearing journals. Disregarding this
information could result in product damage.

The main bearings con-

sist of two half shells,
fitted in the bearing saddle and bearing cap, CROSS--TIE BOLTS
respectively. The shells are precision machined.
Do not file the joint faces, and do not scrape the
running layer in any way. Disregarding this informa-
tion could result in product damage. Figure 2.05-65. Cross--Tie Bolts

NUT

The crankshaft weighs 1828 lb. (829 kg). To provide

the crankshaft with adequate support, never re-
move more than two main bearing caps at the same
time. The only exception to this is when the
crankshaft is removed from the crankcase and both
are properly supported with adequate lifting de-
vices. Failure to take adequate precautions can
result in severe personal injury or death.

NOTE: The oil pan doors should already be off. If not,

remove the doors adjacent to the main bearing to be
replaced. EYE SCREW
INSTALLATION LOCK NUT
1. Refer to Section 5.30 Lubrication System and
remove the oil pump assembly. Figure 2.05-66. #1 Main Bearing

Do not leave an unat- 6. Place a block of wood under gear so when bearing
tached oil pickup screen cap and oil pump gear drop down, gear will rest on wood.
beneath any rod journals if the engine is to be barred
7. Carefully pry (using a pipe in eye screw) bearing cap
over. Disregarding this information could result in
off (see Figure 2.05-66). Mark thrust bearing position
product damage.
with a tag to aid in reassembly.
2. Refer to Section 5.30 Lubrication System and 8. While holding oil pump bolt, remove self-locking
remove the oil pickup screen from the oil sump. marsden nut and washer from spindle (see
Figure 2.05-66).
3. Remove two cross-tie bolts from #1 main bearing
(see Figure 2.05-65). 9. Remove oil pump bolt and washer from oil pump
gear.
4. Loosen four lock nuts on bottom of bearing cap (see
Figure 2.05-66). 10. Mark gear spindle front side and remove spindle
through oil pump opening.
5. Install eye screw in center of main bearing cap (see
Figure 2.05-66).

FORM 6296 First Edition 2.05 -- 23

CRANKCASE COMPONENT REMOVAL

11. Remove four lock nuts and washers from lower

bearing cap. BEARING
SHELL

12. Slide cap out from under studs.

BEARING
ROLLOUT TOOL
The eye screw is not re-
quired for installation.
The eye screw must be removed from the bearing
cap prior to installation or damage to equipment will
result.

13. Remove eye screw from bearing cap.

14. Mark position of thrust bearings if they are to be

reused.
FRONT MAIN
Watch for the position of BEARING SADDLE
the upper bearing tang COUNTERWEIGHT
before rolling out the upper bearing. The bearing LOCATING TANG
must be rolled in the proper direction. If the tang is
accidently rolled through the upper bearing seat, Figure 2.05-67. Bearing Rollout
damage to the seat and crankshaft will result.
16. Inspect roll pins on front of bearing cap, ensure that
15. Using a bearing rollout tool (P/N 494366), roll out split of roll pins are assembled as shown (see
the upper main bearing and thrust bearing (see Figure 2.05-68).
Figure 2.05-67). Mark bearings with tag to ensure
17. Thoroughly clean all parts as required.
proper reassembly.

ROLL PIN 0.188 ± 0.015²

SPLIT ANGLE (4.775 ± 0.381 mm)
BOTH SIDES

FRONT MAIN
BEARING CAP

Figure 2.05-68. Roll Pin Installation

2.05 -- 24 FORM 6296 First Edition

 CRANKCASE COMPONENT REMOVAL

CRANKSHAFT #1 MAIN BEARING 4. Generously apply engine oil to main bearing cap
INSTALLATION IN FIELD CONDITIONS studs, nuts and washers before installing them.

NOTE: This procedure applies to the #1 main bearing 5. Install lower bearing shell and thrust bearing on
with current “T” Drilled crankshaft. Procedures for all bearing cap (see Figure 2.05-67).
other main bearings are similar, with the exception that
steps to install the oil pump, oil pickup screen and oil
pump drive gear, do not apply. Refer to “Crankshaft Main
Bearings Installation In Field Conditions” for procedures Each main bearing cap weighs 46 lb. (21 kg). The
to install the other main bearings. bearing must be supported from underneath while
removing or installing to avoid severe personal
Thrust bearings come in injury or death.
matched sets. Always
install the thrust bearings in the same position. NOTE: Each main bearing cap is matched to a main
Failure to install thrust bearings in the correct bearing saddle. Check the stamped number on the
position can cause damage to equipment. bearing cap before installing the cap (see
Figure 2.05-70).
1. Lubricate running side of upper main bearing.

Watch position of upper

bearing tang before rol-
ling in the upper bearing. The bearing must be rolled
in the proper direction. If the tang is accidently
rolled through the upper bearing seat, damage to
the bearing seat and crankshaft will result.

2. Using bearing rollout tool (P/N 494366) (see

Figure 2.05-67) install upper bearing (grooved with
elongated oil hole) and thrust bearing (grease thrust
bearing to help hold it in place).
BEARING CAP
NUMBERS
Ensure the ungrooved
lower bearing shell is
installed on the bearing cap. Failure to follow proper Figure 2.05-70. Main Bearing Cap Stamped
procedures could cause damage to equipment. Identification Numbers

3. Lubricate running surface of lower bearing. Apply 6. Start front main bearing cap on stud. Place a 2 x 6 in.
grease to thrust bearing roll pins to help hold thrust (51 x 152 mm) wood block underneath bearing cap to
bearing on bearing cap (see Figure 2.05-69). hold in place.

7. Use reference mark on oil pump gear and secure

gear onto lower main bearing cap using outer washer, oil
pump bolt, washer and marsden nut (see
Figure 2.05-71 and Figure 2.05-72).

8. Apply a small amount of Loctiteâ 271 Adhesive

Sealant (High Strength) to threads of spindle screw.

9. Install spindle screw hex nut (Grade 8, 3/4 in.--16)

with large chamfer facing outside, smaller chamfer in
toward bearing cap. Tighten nut to 300 -- 325 ft-lb (406 --
440 N×m).

THRUST RING

Figure 2.05-69. #1 Main Bearing Cap

FORM 6296 First Edition 2.05 -- 25

CRANKCASE COMPONENT REMOVAL

NOTE: Verify crankshaft rotates freely after each

FRONT WASHER WASHER NUT bearing cap is tightened.

12. Tighten hex nuts and cross-tie bolts in proper

sequence listed in Figure 2.05-74.

A. Tighten hex nuts 1 through 4 (in that order) to

75 ft-lb (102 N×m). If installing replacement caps
that will be aligned bored, tighten to only 30 ft-lb
(40 N×m). When installing more than one cap,
IDLER GEAR OIL PUMP tighten nuts 1 through 4 to 75 ft-lb (102 N×m) on
SPINDLE CAPSCREW GEAR
all caps before tightening side bolts.
Figure 2.05-71. Oil Pump Gear Assembly B. Tighten all full dowel (left side) cross-tie bolts
(five) to 250 ft-lb (339 N×m) starting from front of
10. Apply 3M Scotch-Gripâ 847 Rubber and Gasket engine.
Adhesive to both sides of cross-tie bolt washers to
prevent oil leaks. Install one washer on each cross-tie C. Tighten all diamond dowel (right side) cross-tie
bolt. bolts (six) to 250 ft-lb (339 N×m) starting from
front of engine.
11. Install front main bearing cap using four washers,
lock nuts, cross-tie bolts and washers (see D. Tighten hex nuts 1 through 4 to 275 ft-lb
Figure 2.05-72 and Figure 2.05-73). (373 N×m) in two steps: first 175 ft-lb (237 N×m),
and then 275 ft-lb (373 N×m).
LOCK NUT
-- FULL DOWEL PIN -- DIAMOND DOWEL PIN
WASHER FULL DOWEL SIDE

3 2

1 4

MARSDEN
NUT
VIEW OF BEARING CAP (FROM BOTTOM)

Figure 2.05-72. #1 Main Bearing

Figure 2.05-74. Main Bearing Cap Tightening Pattern

13. Refer to Section 5.30 Lubrication System and install

oil pump assembly.

14. Refer to Section 5.30 Lubrication System and install

oil pickup screen.

CROSS--TIE BOLTS

Figure 2.05-73. Cross--Tie Bolts

2.05 -- 26 FORM 6296 First Edition

 CRANKCASE COMPONENT REMOVAL

CRANKSHAFT MAIN BEARINGS 3. To assist in removal, install an eye screw

REMOVAL IN FIELD CONDITIONS (1/2 in.-13 UNC) in center drilling of main bearing cap
(see Figure 2.05-75).
NOTE: This procedure applies to the main bearings
with current “T” Drilled crankshaft, with the exception of
the #1 main bearing. For procedures for the #1 main
bearing refer to “Crankshaft #1 Main Bearing Removal
In Field Conditions” in this section.

Each main bearing cap weighs 46 lb. (21 kg). The

bearing must be supported from underneath while
removing or installing to avoid severe personal
injury or death.

Do not subject the crank-

shaft to any excessive CENTER DRILLING
bending or flexing. Keep high heat sources, such as
cutting torches and welders, away from the crank- Figure 2.05-75. Main Bearing Cap
shaft. Use care during handling. Prevent scratching
or marring the machined surfaces, especially the 4. Carefully pry with pipe in eye screw to loosen cap.
rod and main bearing journals. Disregarding this
information could result in product damage.

The main bearings con- Each main bearing cap weighs 46 lb. (21 kg). The
bearing must be supported from underneath while
sist of two half shells,
fitted in the bearing saddle and bearing cap, removing or installing avoid severe personal injury.
respectively. The shells are precision machined.
5. While supporting lower main bearing cap, remove
Do not file the joint faces, and do not scrape the
running layer in any way. Disregarding this informa- four lock nuts and washers from lower bearing cap (see
tion could result in product damage. Figure 2.05-75).

NOTE: Do not handle the bearing running surfaces with

bare hands.

The crankshaft weighs 1828 lb. (829 kg). To provide 6. Slide main bearing cap and lower bearing shell out
the crankshaft with adequate support, never re- from under studs.
move more than two main bearing caps at the same
time. The only exception to this is when the The eye screw is not re-
crankshaft is removed from the crankcase and both quired for installation.
are properly supported with adequate lifting de- The eye screw must be removed from the bearing
vices. Failure to take adequate precautions can cap prior to installation, or damage to equipment
result in severe personal injury or death. will result.

NOTE: The oil pan doors should already be off. If not, 7. Remove eye screw from main bearing cap.
remove the doors adjacent to the main bearing to be
replaced. Watch for the position of
the upper bearing tang
1. Remove two cross-tie bolts from main bearing (see
before rolling out the upper bearing. The bearing
Figure 2.05-73).
must be rolled in the proper direction. If the tang is
2. Loosen four lock nuts (see Figure 2.05-75) on accidently rolled through the upper bearing seat,
bottom of bearing cap. damage to the bearing seat and crankshaft will
result.

FORM 6296 First Edition 2.05 -- 27

CRANKCASE COMPONENT REMOVAL

8. Using a bearing rollout tool, roll out upper bearing

shell (see Figure 2.05-76).

9. Thoroughly clean all parts as required. Each main bearing cap weighs 46 lb. (21 kg). The
bearing must be supported from underneath while
MAIN BEARING BEARING
removing or installing to avoid severe personal
JOURNAL SHELL injury or death.

BEARING NOTE: Each main bearing cap is matched to a main

ROLLOUT TOOL
bearing saddle. Check the stamped number on the
bearing cap before installing the cap (see
Figure 2.05-77).

GEAR MOUNT

BEARING
SADDLE

LOCATING TANG COUNTERWEIGHT

Figure 2.05-76. Bearing Rollout

CRANKSHAFT MAIN BEARINGS

INSTALLATION IN FIELD CONDITIONS BEARING CAP
NUMBERS
NOTE: This procedure applies to the main bearings
with current “T” Drilled crankshaft, with the exception of Figure 2.05-77. Main Bearing Cap Stamped
the #1 main bearing. For procedures for the #1 main Identification Numbers
bearing refer to “Crankshaft #1 Main Bearing Installation
In Field Conditions” in this section. 5. Install bearing cap on studs. Place 2 in. x 6 in.
(51 x 152 mm) wood block underneath bearing cap to
1. Lubricate running side of upper main bearing shell. hold in place.

Watch for the position of 6. Apply 3M Scotch-Gripâ 847 Rubber and Gasket
the upper bearing tang Adhesive to both sides of each cross-tie bolt washer to
before rolling in the upper bearing. The bearing prevent oil leaks. Install one washer on each cross-tie
must be rolled in the proper direction. If the tang is bolt.
accidently rolled through the upper bearing seat,
7. Secure main bearing caps with four washers, lock
damage to the bearing seat and crankshaft will
nuts, cross-tie bolts and washers (see Figure 2.05-78).
result.
NOTE: Verify crankshaft rotates freely after each
2. Using bearing rollout tool, install upper bearing shell bearing cap is tightened.
(grooved with elongated oil hole) (see Figure 2.05-76).

3. Lubricate running surface of lower bearing shell.

Ensure the ungrooved

lower bearing shell is
installed on the bearing cap. Failure to follow proper
procedures could cause damage to equipment.

4. Install lower bearing shell on main bearing cap.

2.05 -- 28 FORM 6296 First Edition

 CRANKCASE COMPONENT REMOVAL

CAMSHAFT BEARING REMOVAL IN

FIELD CONDITIONS
1. Remove capscrews and lock washers from bearing
cap (see Figure 2.05-80). Replace one bearing at a
time.

CAMSHAFT
BEARING CAP

CROSS--TIE BOLTS

Figure 2.05-78. Cross--Tie Bolts

8. Tighten hex nuts and cross-tie bolts in proper

sequence listed in Figure 2.05-79.

A. Tighten hex nuts 1 through 4 (in that order) to

75 ft-lb (102 N×m). If installing replacement caps
that will be aligned bored, tighten to only 30 ft-lb Figure 2.05-80. Cam Bearing Cap
(40 N×m). When installing more than one cap,
tighten nuts 1 through 4 to 75 ft-lb (102 N×m) on 2. Remove bearing cap and upper bearing shell.
all caps before tightening side bolts.
3. Remove and discard O-ring from bearing cap.
B. Tighten all full dowel (left side) cross-tie bolts
(five) to 250 ft-lb (339 N×m) starting from front of The camshaft bearings
engine. consist of two half shells,
fitted in the bearing saddle and bearing cap,
C. Tighten all diamond dowel (right side) cross-tie
respectively. The shells are precision machined.
bolts (six) to 250 ft-lb (339 N×m) starting from
Do not file the joint faces, and do not scrape the
front of engine.
running layer in any way. Disregarding this informa-
D. Tighten hex nuts 1 through 4 to 275 ft-lb tion could result in product damage.
(373 N×m) in two steps: first 175 ft-lb (237 N×m),
and then 275 ft-lb (373 N×m). Watch for the position of
the lower bearing tang
before rolling out the lower bearing. The bearing
-- FULL DOWEL PIN -- DIAMOND DOWEL PIN must be rolled in the proper direction. If the tang is
FULL DOWEL SIDE accidently rolled through the lower bearing seat,
damage to the bearing seat and camshaft will result.

3 2 4. Using proper bearing rollout tool, P/N 474001,

carefully roll out lower camshaft bearing in proper
direction.

1 4

VIEW OF BEARING CAP (FROM BOTTOM)

Figure 2.05-79. Main Bearing Cap Tightening Pattern

FORM 6296 First Edition 2.05 -- 29

CRANKCASE COMPONENT REMOVAL

CAMSHAFT BEARING INSTALLATION IN

FIELD CONDITIONS

Verify position of lower

bearing tang before rol-
ling in the lower bearing. The bearing must be rolled
in the proper direction. If the tang is accidently
rolled through the lower bearing seat, damage to the
bearing seat and camshaft will result.

1. Lubricate bearing shells.

2. Using bearing rollout tool (P/N 474001) carefully roll

in lower bearing shell.

3. Install a new O-ring in bearing cap.

4. Secure bearing cap and upper bearing shell with

ferry head capscrews and lock washers (see Section
4.00 Camshaft and Bearing Installation).

5. Refer to Section 4.00 Crankcase Assembly for

procedures on replacing valve lifter cover.

2.05 -- 30 FORM 6296 First Edition